description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a simplified sound reproducing device and, more particularly, to a sound reproducing device having a reproduction selection mechanism in which a record disc having a plurality of record grooves and an indexing portion showing respective recorded items on the disc is mounted in a record holder tiltably attached to a casing so that any one desired recorded item can be selected on the record disc.
2. Description of the Prior Art
There have been provided simplified sound reproducing devices carrying a record holder which include a casing having a window, a tone arm having a swingable sound reproducing stylus projecting toward the window supported by a sound transmitting member which is normally biasing toward a starting point of sound reproduction on the record disc, a speaker diaphragm attached to a face of the record disc opposite to which the tone arm is engageable, a turn table supported in the casing by a center pin so as to be rotatably driven by a motor, a record holder swingably attached to the margin of a window-like aperture on the casing and having on its end portion a record disc fixing portion which is resiliently ejected by an opening spring to move tiltably away from the window and is swingably moved back, in parallel, to the turn table when it is pushed against the force of the spring, and a record disc having a plurality of record grooves, each starting point of which is spaced apart along the circumference of the record disc, and an indexing portion showing each of the recorded items wherein the record face can be engaged with the reproducing stylus when the record holder is pushed against the spring, while the record disc can be set in the record holder with the indexing portion being visible from outside of the casing.
Also, there have been disclosed a simplified sound reproducing device including a reproduction selection means that can temporarily stop the reproduction stylus at a position where the stylus can engage the selected recorded groove on the record disc by manipulating selection poles corresponding in number to the number of the record grooves.
The prior art also discloses a simplified sound reproducing device capable of performing selective reproduction by utilizing contiguous spring energizing pieces which extend radially outward with respect to each other and urge the selection poles normally toward the outside of the casing of the sound reproducing device. However, such a sound reproducing device has yet been constructed with a record holder that receives and holds a record disc having a plurality of record grooves in which any desired item recorded on the record disc can be selected by the selection poles.
The problems of a complicated construction required in combining the use of a selection pole for selecting a recorded item or items to be reproduced with the provision for holding the record disc by a record holder in order to obtain a sound reproducing device which holds in its record holder a record disc carrying a plurality of record grooves, and yet can select and reproduce any desired recorded items by means of selection poles has not been fully and satisfactorily addressed by the prior art. Accordingly, such devices have necessitated high production costs, together with insufficient operability in reproduction.
This invention aims to obviate such problems as mentioned above. Accordingly, an object of the present invention is to provide a sound reproducing device of simplified construction which is capable of holding a record disc carrying a plurality of recorded grooves and yet is able to select and reproduce any desired record groove by manipulating selection poles. Another object of the present invention is to provide a selective reproducing means of precise performance for a simplified sound reproducing device. A still further object of the invention is to provide a simplified reproducing device consisting of a minimum number of components which result in an attendant lower manufacturing cost.
SUMMARY OF THE INVENTION
In order to accomplish the above-mentioned objects, the present invention adopts a construction, namely, the device consists of a simplified sound reproducing device which includes: a casing having a window or aperture, a tone arm carrying a sound reproducing stylus projecting toward the window 1 and which is swingably attached to the casing and normally urged toward the starting point of sound reproduction while on the record disc supported by a sound transmitting member. A speaker diaphragm is attached to a portion opposite to the face of the record disc where the tone arm is swingably attached. A turn table is supported by a center pin in the casing so as to be rotatably driven by a motor. A record holder is swingably attached at one end to the rim of the casing and has a record disc fixing portion formed at its other end which is capable of being resiliently ejected by an opening spring so that the record disc fixing portion can be tiltably moved away from the rim of the window. At the same time, the record disc fixing portion can be returned to a parallel position with the turn table when it is pushed against the force imparted by the opening spring. A record disc having a plurality of record grooves each of their starting points being circumferentially spaced apart on the disc and an indexing portion is arranged such that any record groove can be engaged by the reproducing stylus when the record holder is pushed against the opening spring and the record disc is being held in the record disc fixing portion with the indexing portion of the record disc being visible from outside of the casing. This type of simplified sound reproducing device is combined with a selective reproduction mechanism which can temporarily stop the reproducing stylus at a position where it can engage a specific record groove containing the selected item among all the items on the record disc.
In order to attain the aforesaid objects, the device of the present invention includes a stopper which radially projects from the outer periphery of the turn table and selection poles which are positioned so as to project on the rotational locus of the stopper when any one of the selection poles is depressed from the outside of the casing. A plurality of energizing pieces corresponding in number to the selection poles are connected to the selection poles and are electrically connected with each other. A metal spring which normally urges each of the selection poles toward the outside of the casing are arranged to face a metal guide place disposed along the periphery of the turn table so as to hold the selection poles within the casing and to guide one of the selection poles to the locus of rotation of the stopper provided on the turn table. A plurality of projections, one provided on each selection pole and urge the spring to contact the metal guide plate when one of the selection poles is depressed. In addition, the spring and the guide plate are connected in a circuit between the motor and an electric power source so as to make these two parts play a role as an electrical contact for a selection switch.
Since each selection pole of the present invention is normally urged by the spring which also acts as a switch contact, toward the outside of the casing and is also guided by the guide plate which also acts as a switch contact, so as to be projected onto the locus of rotation of the stopper, the simplified sound reproducing device coupled with a swingably tiltably record holder can be constructed as a simplified sound reproducing device capable of effecting selective sound reproduction without requiring any particular switching means for selective sound reproduction, other than the mechanism for actuating the selection poles.
According to the present invention, a sound reproduction device of simplified construction can be provided; the record holder of which can hold a record disc having a plurality of record grooves and yet is capable of selectively reproducing any desired record groove by the operating selection poles. Moreover, the sound reproducing device of the present invention can function exactly, and yet can be made with minimum number of parts resulting in a lower manufacturing cost.
BRIEF DESCRIPTION OF THE DRAWING
The various features, advantages and other uses of the present invention will become more apparent by referring to the following detailed description and drawing in which:
FIG. 1 is a top, plan view of a preferred embodiment of the present invention;
FIG. 2 is a bottom view of the embodiment shown in FIG. 1;
FIG. 3 is a rear, perspective view of the embodiment shown in FIG. 1;
FIG. 4 is a front perspective view thereof;
FIG. 5 is a top perspective view thereof with the housing removed;
FIG. 6 is a plan view of the turn table;
FIG. 7 is a schematic and partial perspective view showing the electric circuit of the sound reproducing device; and
FIG. 8 is an enlarged, sectional view showing a major part of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1-5, a casing 2 in a preferred embodiment of the present invention, as a whole, has a rectangular configuration formed of a chassis 2a covered by a housing 2b. The chassis 2a is formed with a motor holder 23 of circular configuration in plan view and a sound outlet projection 24. The circular outer face of the sound outlet projection 24 has a number of sound outlets 25 extending therethrough.
A square window 1 is formed on the top face of the housing 2b into which a record holder 12 is swingably attached at one end to the window 1 so as to be swingably urged into or swingably moved away from the window 1. The record holder 12 has, at one side face a slit-like opening which constitutes a record disc fixing portion 10 which is normally positioned at the top of the housing 2b.
A record disc 15 is insertable through the slit-like opening in the direction shown by a thick arrow line in FIG. 3 into the record disc fixing portion 10, when the record holder 12 is tilted and moved away from the window 1. The record disc is set and held in a fixed position in the record holder 12 when the record holder 12 is swung back into the window 1.
Moreover, the record disc 15 has on one side surface a plurality, preferably record grooves 13 each carrying different recorded items, and on its periphery an indexing portion 14 depicting the content of recorded items on the recorded grooves.
FIG. 5 shows the sound reproducing device in perspective with its housing 2b removed in order that the construction of the sound reproducing device can be clearly observed.
The chassis 2a is provided with a recessed portion which constitutes a sound outlet projection 24 and, at the central part thereof, an upright center pin 8. A turn table 9 is supported around the center pin 8 for free rotation. The manner by which the turn table 9 is supported by said center pin, is shown in FIG. 8 in a partially enlarged, side sectional view.
A motor holder 23, as shown in FIGS. 2 and 3, is formed in the chassis 2 in the same manner of the sound outlet projection 24. A motor 7 is fitted and held tightly within the motor holder 23. In this embodiment, the motor 7 and the turn table 9 are connected by a belt B. However, alternatively, the motor 7 and the turn table 9 can be coupled by a rim drive means with each other in which the output shaft of the motor 7 directly engages the rim of the turn table 9.
An opening spring denoted by reference numeral 11 in FIG. 5 is disposed upright in the chassis 2a and resiliently biases the record holder 12 which is journally supported by a trunnion pin 27 at a pair of bearings 26 disposed at one side of the chassis 2a. Due to this construction, the record holder 12 is normally urged to move in a direction away from the window 1. In FIG. 5, reference numeral 28 depicts a post mounted on the record holder 12 for receiving the opening spring 11.
As particularly shown in FIG. 8, the inlet margin of the recessed portion of the chassis 2a is circular in shape. Along the periphery of the turn table 9, a plurality of projections 29 are equally spaced apart along the inner periphery of the inlet margin, onto which a metal guide plate 20 is fixedly disposed. The guide plate 20 is formed as an annular ring having an outside diameter larger than the outside diameter of the turn table 9 and an inner diameter smaller than the outside diameter of the turn table 9. A plurality of guide holes are equally spaced apart along the ring and at a position exteriorly of the outside diameter of the turn table 9 through which a selection pole 16 passes. The selection poles 16 pass through apertures formed in the bearing 30 so as to be movable in an axial direction.
As can be clearly seen from FIGS. 7 and 8, a metal spring 19 consisting of a central mounting portion fixed around the center pin 8 and a plurality of energizing pieces 18 radially extending from the central mounting portion is received within the recess of the sound outlet projection 24. The metal spring 19 is formed to contact the confronting face of the metal guide plate 20 when it is bent at the tip end of each energizing piece 18 against its inherent resilient force and is moved toward the metal guide plate 20.
At each tip portion of the metal spring 19, there is also formed an oblong hole 31 which extends in a lengthwise direction and through which each selection pole 16 is inserted. Each selection pole 16 has, at the portion adjacent to the bottom of the recessed sound outlet portion 24, a flange-like projection 21 having a diameter larger than the width of each oblong hole 31 and is normally biased by the energizing piece through the projection 21 toward the sound outlet portion 24. Therefore, when the selection pole 16 is advanced into the casing 2 it would push the energizing piece 18 against its resilient force in a direction to contact the mating face of the metal guide plate 20.
As mentioned above, when the selection pole 16 is advanced into the casing 2, the forward tip end of each selection pole 16 will take a position parallel with the peripheral side face of the turn table 9.
On the other hand, the turn table 9 is provided with a stopper 17 projecting rapidly outward at the lower part of the side periphery. The stopper 17 will rotate together with the turn table 9, and tracks a circular locus of rotation at the outer periphery of the turn table 9. The tip end of the selection pole 16, when it is pushed into the casing 2, will advance to the circular locus drawn by the rotation of the stopper 17.
In addition, rotational side periphery of the turn table 9 also acts as a pulley at all portions where it is not provided with the stopper 17.
The turn table 9, as particularly clearly shown in FIG. 8, is formed as a hollow cylinder with a bottom end and its lower part being opened, into which a downwardly directed speaker diaphragm 6 is concentrically fixed with its continuously expanding periphery being attached to the lower end rim of the turn table 9. At the central part of the speaker diaphragm 6 an acoustic cylinder 34 having flanges at both the upper and lower ends is fixed through the center pin 8 which also passes through the acoustic cylinder 34 to the central part of the speaker diaphragm 6. Thus, the turn table 9 is supported by the acoustic cylinder 34 around the center pin 8 for free rotation. The flange at the upper end of the acoustic cylinder 34 is disposed above the turn table 9 to which the free end of the bar shaped sound transmitting member 4 supported as a cantilever is attached with its free end supported.
The center pin 8 also carries a cylindrical shaft 33 having a flange at its lower end, such that the acoustic cylinder 34 is disposed co-axially above the cylindrical shaft 33 so as to be co-axially aligned with and spaced apart at a slight distance from the cylindrical shaft 33. Between the flange at the lower end of the acoustic cylinder 34 and the flange formed on the lower end of the cylindrical shaft 33, a stylus pressure spring 35 is disposed to resiliently support the turn table 9 through the acoustic cylinder 34.
As can be seen in FIGS. 5 and 6, the sound transmitting member 4 is supported above the turn table 9 received for relative slidable motion, the forward end of the tone arm 5, which is swingably supported at its rear end so as to be swung along the upper face of the turn table 9. On the upper face of the forward end of the tone arm 5, there is provided a sound reproducing stylus 3 projecting toward the recorded face of the record disc 3, and forming a pickup. FIG. 6, reference numeral 36, depicts a return spring, by which the portion of the pickup is normally urged toward the starting point of sound reproduction on the record grooves of the record disc.
The rear end of the tone arms is slightly extended to constitute a cancel lever 37. This cancel lever 37, as particularly shown in FIG. 6, projects radially outward from the upper face of the turn table 9 when the pickup approaches the central part of the record disc 15, such as upon arrival of the turn table 9 at the end point of reproduction located near the central part of the turn table 9. On the other hand, when the pickup is located at the radially outer portion of the turn table 9, the cancel lever 37 remains within the upper face of the turn table 9.
Alongside the turn table 9 within the chassis 2a, a holder locking lever 38 is supported to be swingably moved in a direction transverse to the axis of rotation of the turn table 9. The holder locking lever 38 has, at its one end, a downwardly facing hook 38a, and at the opposite end across the swivel point, a driven piece 38b upstanding up to the upper face of the turn table 9, and at the swivel point, a spring 38c is attached so that the hook 38a can be urged toward a locking piece 32 mounted on one side wall of the record holder 12.
Thus, when the record holder 12 is pushed and fixed in the window 1 as shown in FIG. 4, the hook 38a engages the locking piece 32 provided on the record holder 12, thereby holding the record holder 12 in a position such that the record disc 15 can be held within the record fixing portion 10 in engagement with the reproduction stylus 3 as shown by a dash and dot lines shown in FIG. 8.
On the other hand, when the pickup of the tone arm 5 arrives at the end point of sound reproduction and the cancel lever 37 projects radially outside the turn table 9 as shown in FIG. 6, the cancel lever 37 will engage the driven piece 38b due to the rotation of the turn table as shown in FIG. 5, and push the driven piece 38b.
By this movement, the hook 38a will rotate against the urging of the spring 38c to move away from the locking piece 32, thereby releasing the locking piece 32 from its locking action and the record holder 12 will be swingably moved by the opening spring 11 to move away from the window 1, so the record disc 15 can also be released from engagement with the reproducing stylus 3.
Reference numeral 39 shown in FIGS. 5 and 7 depicts a start switch button, reference numeral 40 denotes one contact of the start switch and reference numeral 41 the other contact of the start switch button 39 is disposed above the contact 40 and is normally maintained in an OFF position. The start switch button 39 is disposed above the contact 41 so as to be freely advanced or retracted. When the record holder 12 is pushed into the window 1 as shown in FIG. 1, the upper part of the start switch button 39 will advance into the record fixing portion 10 by the resilient force of the contact 41 and acts as an inhibitor to prevent the record disc 15 from being inserted into the record disc fixing portion 10. Accordingly, the record disc 15 can be inserted and held in the record holder 12 only when the record holder 12 has been swingably moved away from the window 1 as shown in FIG. 3. Also, when the record holder 12 is inserted into the window 1 with its fixing portion 10 containing a record disc 15, the record disc 15 will naturally be at the set position engageable with the reproduction stylus 3. Then the record disc 15 will push the upper end of the start switch button 39 before the record holder 12 arrives at the completely depressed position so that the contact 40 now being pushed by the start switch button 39 will engage the contact 41, thereby placing the start switch in an ON position. By this action, the motor 7 is energized and the turn table 9 is driven for sound reproduction.
Now, an explanation will be made of the electrical circuit of the present invention.
As shown in FIG. 5, reference numeral 42 denotes a battery case which receives a battery as a power source 22. Also, in FIG. 5, reference numeral 43 denotes a variable resistor, which is connected between the power source 22 and the motor 7 to drive the motor 7 at a suitable voltage. In the electrical circuit shown in FIG. 7, the contact 40 is connected to the metal guide plate 20, while the contact 41 is connected to the motor 7 and the metal spring 19, respectively. The other terminal of the motor 7 is serially connected via the power source 22 to the variable resistor 43 and the metal guide plate 20.
In operating the present sound reproducing device, the record disc 15 is initially inserted in the record fixing portion 10 of the record holder 12 as shown in FIG. 3. Then any desired recorded item shown in the indexing portion 14 of the record disc 15 is selected and the selection pole 16 corresponding to the selected recorded item is depressed. The selected selection pole 16 as shown, for example, in FIG. 8, will make one of the energizing pieces 18 of the metal spring 19 contact the metal guide plate 20. Thereby, as shown in FIG. 7, an electric circuit between the motor 7, the power source 22, the variable resistor 43, the metal guide plate 20 and the contact 41 of the start switch 7 can be established to start rotation of the motor 7 and the turn table 9. However, the stopper 17 is projecting radially outwardly from outer rotational periphery of the turn table 9 and rotates with the turn table 9. Since the forward tip end of the selected selection pole 16 has entered up to the circular locus of the stopper 17, the stopper 17 will strike the selection pole 16 in its advanced position and temporarily stop further rotation of the turn table 9. At this moment, the belt B slips relative to the rotating side periphery of the turn table 9. The position at which the turn table 9 has stopped is pre-selected so that the reproduction stylus 3 formed on the tone arm 5 on the turn table 9 can engage the selected groove on the record disc.
Next, release of the selection pole 16, will allow the selection pole 16 to return to its original position under the bias of the energizing piece 18 of the metal spring 19. At the same time, since the energizing piece 18 also moves away from the metal guide plate 20, electrical conduction between the metal guide plate 20 and the metal spring 19 is interrupted thereby stopping rotation of the motor 7. When the record disc 15 is engaged by the reproducing stylus 3 by swingably moving the record holder 12 into the window 1, the record disc 15 will push the start button 39. Thus, the contact 41 of the start switch engages the contact 40 and establishes an electrical circuit through the motor 7, the power source 22, the variable resistor 43, the metal guide plate 20, the contact 40 of the start switch and the contact 41 of the start switch to again cause rotation of the motor 7 and the turn table 9. Since the sound reproducing stylus 3 has already been positioned at the location where it can engage the selected record groove 13, the selected item on the record disc can be reproduced.
When the pickup arrives at the end point of sound reproduction, the cancel lever 37 will project radially outward from the upper face of the turn table 9 and urge the holder locking lever 38 to remove the hook 38a from the locking piece 32. In this way, the record holder 12 is tilted away from the window 1 and releases the record disc 15 from the applied stylus pressure, thereby enabling the record holder 12 to be removed from the window 1. | A stopper projects radially outward from the periphery of a rotary turn table and a plurality of selection poles are disposed such that any one of the selection poles, when depressed, projects into the locus of rotation of the stopper. A spring fabricated to have energizing pieces, the same in number as the number of selection poles, is positioned within a casing so that two mating parts can engage with each other. Each energizing piece is made electrically conductive and the spring also urges each selection pole toward the outside of the casing. A metal guide plate holds the selection poles 16 which are disposed along the periphery of the turn table within the casing and further guides the selected selection pole into the locus of rotation of the stopper. The selected selection pole will urge corresponding spring into engagement with the guide plate. Each selection pole is provided with a projection which urges the spring into contact with the metal guide plate when any one of the selection poles is depressed from outside of the casing. Furthermore, a circuit between a motor and a power source is connected to both the metal spring and the metal guide plate to cause these two parts to act as a pair of mating contacts in a selection switch. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a switch device of a double-function sewing machine which is provided with two different stitch-forming mechanisms.
SUMMARY OF THE INVENTION
A first object of the invention is to use, in common, a driving source and a flywheel for the two aforementioned mechanisms, to thereby make the whole body of the sewing machine compact.
A second object of the invention is to manually switch the two stitch-forming mechanisms while the sewing machine is stopped, to thereby avoid danger occurring in the prior art sewing machines, that a main shaft of a non-selected mechanism is rotated less than one rotation before a mechanical switch is finished. It is a further object of the invention to avoid a possible shock to the mechanism and to prevent the upper thread of the non-selected mechanism from slipping out from the thread path.
Yet another object of the invention is to make an exact connection between the selected stitch-forming mechanism and the driving source, and to exactly break a connection between the non-selected mechanism and the driving source and to engage it with a switching phase for keeping safety during the driving.
A still further object of the invention is to drive the selected mechanism by the drive source and also to carry out a rotational operation thereof in two opposite directions by manual operation of the flywheel, so that the flywheel may be manually adjusted during the stitch formation.
Still another object of the invention is to stop the selected mechanism together with the flywheel during coiling the thread on a thread supply.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, 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 drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a double-function sewing machine;
FIG. 2 shows an exploded view of a main part of a swtich device;
FIG. 3 shows an exploded view of the main part of the switch device, not seen in FIG. 2;
FIGS. 4 and 5 are vertical cross sectional views of the main part of the switch device, wherein FIG. 4 shows a selection of a lock stitch mechanism and FIG. 5 shows a selection of an overlock stitching mechanism;
FIG. 6 is a view showing the main part seen from arrow C in FIG. 4; and
FIG. 7 is a view showing the main part seen from arrow D in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments according to the invention will be explained in reference to the attached drawings. In FIG. 1, the reference numeral 1 is a double-function sewing machine, 2 is a stitching portion of a lock stitch-forming mechanism (called as "lock stitch mechanism"), and numeral 3 is a stitching portion of an overlock stitch-forming mechanism (called as "overlock stitch mechanism"). These stitching mechanisms are alternatively driven as later mentioned by one driving motor (not shown) via transmission mechanisms and switching mechanisms. The reference numeral 4 is a window formed on the side of the lock stitching mechanism, and the other window (not shown) is formed at the opposite side for the overlock stitching mechanism in order to indicate either selected one.
An explanation will be made in reference to FIGS. 2, 4 and 5. The reference numeral 5 designates a flywheel shaft which is pivoted by a flywheel bearing 7 secured on a machine frame 6 and is stopped by a ring 11 which is secured by a ring 9 and a screw 10 fixed to the flywheel shaft 5 by a screw 8.
The flywheel shaft 5 is formed with a couple of fitting grooves 5a and 5b. The respective fitting grooves 5a and 5b formed on the opposite side of the shaft are not seen. A key groove 5c and a slot 5d are also formed in shaft 5. Within the key groove 5c, a switch key 12 is slidably guided at its connector 12a, while within the slot 5d, a communicating plate 13 is slidably guided. A groove 13a of the communicating plate 13 is engaged with a communicating portion 12b of the switch key 12.
The communicating plate 13 is fixedly fitted in a groove 14a of an element 14 by means of a pin 15 which passes through a hole 14b formed in the element 14 and a hole 13b of the plate 13. While element 14 is secured via a switching spring 16 with a flywheel 18 by screws 17, it is also secured via the other switching spring 16' with a switch transmission plate 20 by means of screws 19.
The numeral 21 is a cover for the flywheel 18, and a projection 21a thereof is elastically fitted into a plurality of grooves 18a.
The spring portions 16a of the respective springs 16 and 16' are engaged in respective grooves 14c of the element 14 and projections 16b of those springs alternatively engage one of the couple of the grooves 5a and 5b provided at the opposite sides of shaft 5.
The numeral 22 shows a belt wheel bush (note that "22" shows the belt wheel bush in two places for convenience to illustrate opposite sides of this bush). A boss 22a of bush 22 is formed with a screw passing hole 22b, and a screw 23 is screwed into a screw hole 5e so that the bush 22 is secured to the flywheel shaft 5. Screw hole 5e does not pass through the key groove 5c of the shaft 5. The boss 22a is rotatably mounted with an overbelt wheel 24 on its outer circumference, and said overbelt wheel is engaged by a washer 26 which is secured to the face of the boss 22a. The belt wheel bush 22 is defined with a declutch seat 22e extended over a large diameter part 22c and a flange part 22d. The flange part 22d has mounted thereon a stopper cam 27, and the large diameter part 22c has mounted thereon a belt wheel 28 and is engaged with a washer 30 secured to the belt wheel bush 22 by screws 29. The belt wheel bush 22 is formed with a groove 22f. The switching portion 12c of the switching key 12 may slide between said groove 22f and key groove 35a of a lock stitching upper shaft 35 by external operation.
The overbelt wheel 24 is formed with a belt gear 24c, an engaging groove 24a and a groove 24b, and is connected with the overlock mechanism 3 via a belt 47 mounted on the belt gear 24c.
The stopper cam 27 is biased in the clockwise direction in FIG. 2 with respect to the belt wheel bush 22 by means of a twisted coil spring 31 which is positioned between the stopper cam 27 and the belt wheel bush 22. A guide member 27a is positioned at a space between an auxiliary plate 32 mounted on the declutch seat 22e and an inner circumference 28a of the belt wheel 28, and guides a roller 33 to a narrower space than said space formed by means of the guide groove 27b.
The belt wheel 28 is formed with a knurl 28b and a belt gear 28c, and is connected with a motor (not shown) via a belt 34 mounted on the belt gear 28c. The knurl 28b is connected with a driving wheel (not shown) which is provided on a thread stand 48 (FIG. 1) of thread winding mechanism so that the thread stand 48 is driven by the knurl.
The lock stitching upper shaft 35 is formed with the key groove 35a and a guide hole 35b, and is secured to the machine frame 6 and supported by a metal bush 36. A lock key spring 37 is guided within a guide hole 35b at its fitting portion 37a. A lock key 38 having an engaging portion 38a is slidably guided within the key groove 35a, and is biased toward the right side in FIG. 4 by a spring portion 37b of the lock key spring 37. The lock key 38 is pushed rightward in FIG. 2 within the key groove 35a by the lock key spring 37 at its spring portion 37b in the switching phase of the flywheel 18, so that engaging portion 38a of key 38 is engaged with an engaging groove 36a of the metal bush 36.
A further explanation will be made in reference to FIGS. 3, 4, 5 and 7. The numeral 39a is a main body of a switching pawl 39, which is formed with an engaging face 39b and a fitting portion 39c bent at a center part thereof, and extended bent indicators 39d and 39e. In the present embodiment, the indicator 39d has a red colored end portion (A) and a blue colored base portion (B), and the indicator 39e, though not shown, has a blue colored end portion (A) and a red colored base portion (B), so that the switching condition is shown at the lock stitching window 4 and the overlock stitching window (not shown). The main body 39a has an extended sliding part 39f whose end 39g is bent downwardly, on which a pawl 41 is secured by a screw 40. In setting up, a switch transmission plate 20 (FIG. 4) is positioned between an outer face of a working portion 39g and an inner face of the pawl 41.
A switching pawl bed 43 is secured to the machine frame 6 by a screw 42, and is formed with an engaging projection 43a, an engaging piece 43c having a hole 43b holding a toggle spring 44 and a hole 43d releasing it. The switching pawl 39 is positioned at its sliding part 39f slidably lengthwise between a lower face of the switching pawl bed 43 and a groove 46a of a guide plate 46 secured to the switching pawl bed 43. Said toggle spring 44 is held at its one end in the hole 43b and in a holding hole 39h via the releasing hole 43d.
With respect to the toggle spring 44, FIG. 7 shows that if the holding hole 39h is positioned at the left in regard to a segment E running along the shortest distance between the holding hole 43b and the holding hole 39h, the spring 44 biases a switching pawl 39 leftward so that the fitting portion 39c is engaged with a fitting groove 24a of an overbelt wheel 24, and if the holding hole 39h is positioned at the right, the spring 44 biases the switching pawl 39 rightward so that the engaging face 39b of the switching pawl 39 contacts the engaging projection 43a of the switching pawl bed 43.
At a phase where the fitting groove 24a of the overbelt wheel 24 engages the fitting portion 39c of the switching pawl 39, the engaging portion 38a of the lock key 38 guided within the lock stitching upper shaft 35 may engage the engaging groove 36a of the metal bush 36. At this phase, the switching key 12 is slidable between the key groove 5c of the flywheel shaft 5 and the key groove 35a of the lock stitching upper shaft 35, and by this movement the switching part 12c of the switching key 12 moves between the groove 22f of the belt wheel bush 22 and the groove 24b of the overbelt wheel 24.
A further reference will be made to the operation of the present invention. FIG. 4 shows the selection of the lock stitching mechanism, in which the switching portion 12c of the switching key 12 is engaged within the groove 22f of the belt wheel bush 22 and the key groove 35a of the lock stitching upper shaft 35. The engaging portion 39c of the switching pawl 39 which is biased leftward in FIG. 4 by the toggle spring 44 is engaged within the engaging groove 24a of the overbelt wheel 24.
Under this condition, if the belt wheel bush 22 is rotated by the driving source through the belt 34, the belt wheel 28 and the roller 33, the lock stitching upper shaft 35 is driven, which is connected to the lock stitching mechanism 2 via the groove 22f, the switching portion 12c and the key groove 35a, and the flywheel 18 is driven via the switching key 12, the transmission plate 13 and element 14.
Under the selecting condition of the lock stitching mechanism, since the switching portion 12c of the switching key 12 comes out of the groove 24b of the overbelt wheel 24, rotation of the belt wheel bush 22 is not transmitted to the overbelt wheel 24, and since the engaging groove 24a is held by the fitting portion 39c of the switching pawl 39, the non-selected overlock stitching mechanism 3 connected to the overbelt wheel 24 via the belt 47 is maintained stopped with safety.
The lock stitching mechanism is switched to the overlock stitching mechanism by manually rotating the flywheel 18 during the stopping of the sewing machine and meeting an indicator line 18b and an indicator line 6a (FIG. 1) of the machine frame 6. This rotating position corresponds to a switching phase of the flywheel 18, and at this phase the groove 22f of the belt wheel 22 and the groove 24b of the overbelt wheel 24 meet each other, and if the flywheel 18 is moved rightward in FIG. 4, the projection 16b of the switching spring 16 comes out of the engaging groove 5a of the flywheel shaft 5 and engages the groove 5b, to set the position of the flywheel 18 for the flywheel shaft 5. By this moving operation, the switching key 12 is moved rightward via the pin 15, the transmission plate 13 and the transmission part 12b of the switch key 12. FIG. 5 shows that the switching portion 12c of the switching key 12 comes out of the groove 22f of the belt wheel bush 22 and the key groove 35a of the lock stitching upper shaft 35 engages the groove 24b of the overbelt wheel 24 and moves in the key groove 35a the lock key 38 by biasing force of the lock key spring 37. The engaging portion 38a engages the groove 36a of the metal bush 36, and the switching pawl 39 is moved rightward by said movement through the switch transmission plate 20 and the pawl 41. The switching pawl 39 contacts at the engaging face 39b the projection 43a of the switching pawl bed 43 so that the engaging part 39c comes out of the groove 24a of the overbelt wheel 24. Thus, the switching is completed from the lock stitching mechanism 2 to the overlock stitching mechanism 3.
Under the condition of selecting the overlock stitching mechanism 3, when the belt wheel bush 22 is rotated via the driving source, the belt 34, the belt wheel 28 and the roller 33, the overbelt wheel 24 is rotated via the groove 22f, the switching portion 12c and the groove 24b, and the overlock stitching mechanism 3 is driven via the belt 47, and the flywheel 18 is rotated via the switching key 12, the transmission plate 13 and the element 14.
Under the condition of selecting the overlock stitching mechanism 3, the rotation of the belt wheel bush 22 is not transmitted to the lock stitching upper shaft 35, and since the lock stitching upper shaft 35 is engaged to the machine frame 6 via the lock key 38 and the metal bush 36, the non-selected lock stitching mechanism 2 is maintained stopped with safety.
The overlock stitching mechanism 3 is switched to the lock stitching mechanism 2 by manually moving the flywheel 18 to the switching phase of the flywheel 18 during the stopping of the sewing machine. If the flywheel 18 is moved leftward at said phase, the projection 16b of the switching spring 16 comes out of the groove 5b of the flywheel shaft 5 and is engaged with the groove 5a, and the flywheel 18 is positioned to the flywheel shaft 5. By this movement the switching ke6 12 is moved leftward, and the switching portion 12c engages the groove 22f of the belt wheel bush 22 and the key groove 35a of the lock stitching upper shaft 35. The engaging portion 39c of the switching pawl 39 is engaged with the groove 24a of the overbelt wheel, and the lock key 38 is moved leftward against the biasing force of the lock key spring 37. The engaging portion 38a comes out from the groove 36a of the metal bush 36. Thus the switching from the overlock stitching mechanism 3 to the lock stitching mechanism 2 is completed.
As mentioned above, the switching is completed by the manual operation by axially moving the flywheel 18 after having rotated it to the switching phase, to thereby avoid danger occurring in the prior art sewing machines that the main shaft of the non-selected mechanism is rotated less than one rotation before the mechanical switch is finished, to prevent shocks to which the mechanism is usually subjected or to prevent the upper thread of the non-selected mechanism from slipping out from the thread path.
The stitching mechanism selected under the selecting condition can not only be driven by the drive source but can also be rotated in the forward and backward directions by the manual operation of the flywheel 18, so that the flywheel may be manually adjusted during the stitch formation, if required.
Coiling of the thread will be now explained. When a lower thread bobbin (not shown) is set on a thread stand 48, and the thread stand is switched from a releasing side to a coiling side, a driving wheel (not shown) is pressed to the knurl 28b of the belt wheel 28. Under this condition, when a lever (not shown) cooperating with the thread stand 48 enters the moving locus of the engaging face 27c of the stopper cam 27 and the belt wheel 28 is rotated by the driving source via the belt 34 while the stopper cam 27 is prevented from the rotation in the clockwise direction as viewed from the flywheel 18, and since the roller 33 is pushed to the space wider than the space between the plate 32 and the inner circumference 28a of the belt wheel 28, the belt wheel 28 is idle with respect to the belt wheel bush 22, and the thread stand 48 is rotated by the knurl 28b via the driving wheel. Thus, the thread is coiled. During this period, the flywheel 18 and the selected stitching mechanism are maintained stopped, since the belt wheel bush 22 serves as the driving source therefor. The non-selected mechanism is, of course, stopped.
When the thread stand 48 is released from the thread coiling side after the completion of the thread coiling, the driving wheel separates from the knurl 28b of the belt wheel 28, and said lever (not shown) cooperating with the thread stand 48 is moved outside of the moving locus of the engaging face 27c of the stopper cam 27, and the stopper cam 27 returns the roller 33 to the initial position. Therefore the roller 33 again transmits the driving force from the belt wheel 28 to the belt wheel bush 22, and the selected stitching mechanism is driven together with the flywheel 18.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of double-function sewing machines differing from the types described above.
While the invention has been illustrated and described as embodied in a switching device of a double-function sewing machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A double-function sewing machine, which is provided with a lock stitch forming mechanism and an overlock stitch forming mechanism, has a common driving source and a common flywheel for the two mechanisms. The sewing machine is provided with a switching device which includes a switch key connected to the flywheel of the machine. The switch key is selectively switchable to engage the shaft of the lock stitch-forming mechanism or a drive of the overlock stitch-forming mechanism. The switching device further includes a switching pawl which is engageable with and disengageable from the drive of the overlock stitch forming mechanism to hold the latter when the lock stitch forming mechanism is operated. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention relates to bis-o-aminophenols and processes for their preparation. The bis-o-aminophenols are suitable for the preparation of poly-o-hydroxyamides which, after conversion into the corresponding polybenzoxazoles, can be used as a dielectric in microchips.
[0002] In order to avoid an inductive disturbance of signals that is caused by capacitive coupling, conductor tracks adjacent one another in microchips are insulated from one another by a dielectric disposed between the conductor tracks. Compounds that are to be used as a dielectric must meet various requirements. Thus, the signal transit time in microchips depends both on the material of the conductor track and on the dielectric which is disposed between the conductor tracks. The lower the dielectric constant of the dielectric, the shorter, too, is the signal transit time. The silica-based dielectrics used to date have a dielectric constant of about 4. These materials are gradually being replaced by organic dielectrics that have a substantially lower dielectric constant. The dielectric constant of these materials is generally below 3.
[0003] In microchips customary at present, the conductor tracks preferably are made of aluminum, AlCu, or-AlCuSi. With increasing integration density of the memory chips, there is a changeover to copper as conductor track material, owing to its lower electrical resistance in comparison with aluminum. Copper permits shorter signal transit times and hence a reduction in the conductor track cross section. In contrast to the techniques customary to date in which the dielectric is filled into the trenches between the conductor tracks, in the copper damascene technique, the dielectric is first structured. The-resulting trenches are first coated with a very thin barrier that, for example, includes titanium, titanium nitride, tantalum, tantalum nitride, silicon carbide, silicon nitride, or silicon carbonitride. This barrier is necessary to avoid metal atoms diffusing out of the conductor track into the surrounding dielectric when the production of the microchips includes production stages that require temperatures of 400° C. or higher. Thereafter, the trenches are first filled with copper and then excess copper is mechanically ground away. The dielectric must therefore be stable to the materials used for grinding and must have sufficient adhesion to the substrate in order to avoid becoming detached during the mechanical grinding process. Furthermore, the dielectric must have sufficient stability in the subsequent process steps in which further components of the microchip are produced. For this purpose, it must have, for example, sufficient thermal stability and must not undergo decomposition even at temperatures of more than 400° C. Moreover, the dielectric must be stable to process chemicals, such as solvents, strippers, bases, acids, or aggressive gases. Further requirements are good solubility and a sufficient shelf-life of the precursors from which the dielectrics are produced.
[0004] Polybenzoxazoles (PBOs) are polymers that have very high heat resistance. The substances are already used for the production of protective and insulating layers. Polybenzoxazoles can be prepared by cyclization of poly-o-hydroxyamides. The poly-o-hydroxyamides have good solubility in organic solvents and good film formation properties. They can be applied to electronic components in a simple manner by using the spin-coating technique. After a thermal treatment in which the poly-o-hydroxyamide is cyclized to give the polybenzoxazole, a polymer that has the desired properties is obtained. Polybenzoxazoles also can be processed directly in their cyclized form. In this case, however, there are as a rule difficulties with the solubility of the polymer. The mechanism taking place in the cyclization of poly-o-hydroxyamides to polybenzoxazoles is shown schematically below:
[0005] On heating, the o-hydroxyamide cyclizes to give the oxazole. Water is liberated.
[0006] The poly-o-hydroxyamides are prepared by reacting bis-o-aminophenols with dicarboxylic acids. The properties of the poly-o-aminophenol and of the polybenzoxazole prepared therefrom are substantially determined by the monomers used as starting material. Thus, not only the thermal, electrical and mechanical behavior but also the solubility, stability to hydrolysis, storability and numerous other properties of the polymers are influenced by the type of aminophenol used in the preparation. In order to be able to provide polybenzoxazoles that can be used in microelectronics as a dielectric between two metal planes, for example in multi-chip modules, memory chips and logic chips, or as a buffer layer between the chip and its housing, it is necessary to provide starting materials which impart good electrical, chemical, mechanical, and thermal properties to the polymer. Monomers for the preparation of readily soluble polybenzoxazole precursors are described, for example, in U.S. Pat. No. 4,525,539 to Feiring or European Patent No. EP 317 942. Owing to the constantly growing requirements with regard to the efficiency of the microchips and the associated miniaturization of the semiconductor components, however, a constant further development of the polymer materials is necessary in order to be able to fulfill the mechanical, electrical and chemical properties required for the polymers even with decreasing dimensions of the components. This in turn requires further development of the available monomers for the preparation of polybenzoxazoles or their soluble precursors.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the invention to provide bis-o-aminophenols and processes for producing bis-o-aminophenols that overcome the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that provide novel starting materials that permit the preparation of insulating polymers that have a low dielectric constant and high heat stability and stability to chemicals. With the foregoing and other objects in view, there are provided, in accordance with the invention, bis-o-aminophenols of the formula I
[0008] G is oxygen or sulfur.
[0009] M is
[0010] R 1 , R 2 , in each case independently, are
[0011] T is
[0012] n is an integer from 0 to 5.
[0013] The bis-o-aminophenols of the formula I, according to the invention, are suitable for the preparation of poly-o-hydroxyamides, from which polymeric dielectrics which have a dielectric constant of k≦2.7 can be obtained. These polymers are very suitable for filling narrow trenches. After the cyclization of the poly-o-hydroxyamide, polybenzoxazoles which have high resistance to process chemicals, such as solvents, strippers, bases, acids or aggressive gases, are obtained. These polymers are also outstandingly suitable for the copper damascene technique. During the grinding process in which excess copper is removed, no disadvantageous effects, such as delamination, cracking, or bubble formation, occur. The adhesion of such dielectrics to the surfaces relevant for chip technology, such as silicon, silicon carbide, silicon carbonitride, silicon nitride, silica, titanium, tantalum, titanium nitride, tantalum nitride, or silicon oxynitride, is very good. The polymers prepared from the bis-o-aminophenols according to the invention are very soluble in many organic solvents. Suitable solvents are, for example, acetone, cyclohexanone, diethylene mono- and diethyl ether, N-methylpyrrolidone, γ-butyrolactone, ethyl lactate, methoxymethyl acetate, tetrahydrofuran, or ethyl acetate. They can be readily processed by spin coating, spraying or dipping techniques and give films of very good quality. The polybenzoxazoles derived from the bis-o-aminophenols according to the invention moreover have very high thermal stability.
[0014] Bis-o-aminophenols of the formula II
[0015] in which M and G have the abovementioned meaning, are particularly preferred. The bis-o-aminophenols of the formula II can be prepared in high yields and high isomer purity, which substantially simplifies the purification of the products. The bis-o-aminophenols of the formula II can therefore be made available economically.
[0016] The bis-o-aminophenols according to the invention are divided into bis-o-aminothiophenols (G=S) and bis-o-aminophenols (G=O). For the sake of simplicity, both classes of compound are combined under the term “bis-o-aminophenols”. Although polymers having advantageous properties can also be prepared using bis-o-aminothiophenols, the bis-o-aminophenols (G=O) are of greater importance since, owing to their higher stability to oxidation, they can be more easily processed. Among the bis-o-aminophenols of the formula I, the compounds in which G is an oxygen atom are therefore preferred.
[0017] In order to be suitable for industrial use, it is important that the bis-o-aminophenols of the formula I be obtainable in a simple and economical manner. The invention therefore also relates to a process for the preparation of bis-o-aminophenols of the formula I, wherein a diol of the formula III
[0018] in which M has the meaning previously, is nitrosated with a nitrosating agent to give the nitroso compound, and the nitroso compound is then reduced to the bis-o-aminophenol of the formula I.
[0019] For the preparation of the bis-o-aminophenols of the formula I, the diol of the formula III is first dissolved in a suitable inert solvent at room temperature. Suitable solvents are, for example, alcohols, such as ethanol, isopropanol or butanol, acetonitrile, esters, such as ethyl acetate or propyl acetate, ketones, such as acetone, methyl ethyl ketone or diethyl ketone, or chlorinated hydrocarbons, such as chloroform, dichloromethane or methylene chloride. The solution preferably contains from 5 to 30% by weight of the diol of the formula III which is used as a starting material. Thereafter, a suitable nitrosating agent is added and the mixture obtained is stirred at temperatures of, preferably, from −15 to 40° C., in particular from 5 to 15° C., until virtually complete conversion of the starting material has taken place. Suitable reaction times are in general in the range of 1-10 hours, in particular 2-4 hours. In order to separate off the resulting nitroso compound, the solvent is first evaporated, preferably under reduced pressure. The nitroso compound can then be purified by recrystallization from a suitable solvent or by separation by column chromatography using a suitable eluent.
[0020] The advantage of the process according to the invention is firstly that the diol of the formula III, which is used as a starting material, has sufficient reactivity to achieve substantially complete conversion of the dihydroxy compound within periods of interest for industrial use. Furthermore, the hydroxyl groups of the dihydroxy compound of the formula III need not be protected by a protective group, so that operations for introduction and elimination of a protective group are dispensed with. If the hydroxyl group is in the para position relative to the group M, the nitroso group is selectively introduced into the phenyl ring in the ortho position relative to the hydroxyl group, so that, in the subsequent purification, no removal of undesired isomers is required. This too contributes to the economical preparation of the bis-ortho-aminophenols of the formula I.
[0021] All customary nitrosating agents can be used for the nitrosation. For example, isoamyl nitrite, alkyl nitrites and a mixture of sodium nitrite and concentrated sulfuric acid are suitable.
[0022] The purified bis-o-nitroso compound is then reduced to the bis-o-amino compound. For this purpose, the nitroso compound is first dissolved in a suitable solvent. For example, ethers, such as tetrahydrofuran or dioxane, are suitable. The reduction to the amino group is preferably effected with hydrogen under catalysis by a suitable catalyst. In order to accelerate the reaction, the hydrogenation is advantageously effected at elevated hydrogen pressure. A suitable catalyst is, for example, palladium on active carbon.
[0023] The bis-o-aminophenols of the formula I can also be prepared via the corresponding nitro compounds. The invention therefore also relates to a process for the preparation of bis-o-aminophenols of the formula I, wherein a diol of the formula IV
[0024] in which M and G have the meanings stated previously and R S is a protective group, is nitrated with a nitrating agent to give the nitro compound, and the nitro compound is then reduced to the bis-o-aminophenol of the formula I.
[0025] The nitration of the protected diol of the formula IV is effected using customary nitrating reagents, for example nitric acid, nitric acid/sulfuric acid mixtures, dinitrogen pentoxide, or acetyl nitrate. In this reaction, however, it is necessary for the hydroxyl groups of the starting material to be protected by corresponding protective groups R S . After a purification of the bisnitro compound, the nitro group is reduced to the amino group. For this purpose, the bisnitro compound is dissolved in a suitable solvent, for example tetrahydrofuran, a catalyst is added, for example palladium on active carbon, and hydrogenation is effected with hydrogen in an autoclave.
[0026] The protective group R S is suitably chosen so that it is reductively eliminated during the reduction of the nitro group to the amino group. In this case, the elimination of the protective group R S requires no additional production step. A benzyl group is particularly suitably used as the protective group R S .
[0027] The bis-o-aminophenols of the formula I can be reacted with dicarboxylic acids or their activated derivatives to give the desired poly-o-hydroxyamides. For this purpose, the bis-o-aminophenols of the formula I are reacted with a dicarboxylic acid or an activated dicarboxylic acid derivative of the formula V
[0028] in which L is a hydroxyl group or an activating group and Y is in principle any divalent hydrocarbon radical. For example, acid chlorides or activated esters, for example sulfonic esters, can be used as an activating group for the dicarboxylic acid derivatives of the formula V. The reaction of the bis-o-aminophenols of the formula I and of the dicarboxylic acids of the formula V can, however, also be effected in the presence of a compound which activates the carboxylic acid, such as, for example, carbonyldiimidazole or dicyclohexylcarbodiimide. In principle, all reagents that bind the water formed in the reaction to themselves are suitable. For the preparation of the poly-o-hydroxyamides, the bis-o-aminophenols of the formula I and the dicarboxylic acid or optionally the dicarboxylic acid derivative of the formula V are reacted in an organic solvent at from −20 to isooc in the course of from 5 to 20 hours. If required, the terminal groups of the polymer can be blocked with a suitable reagent. The poly-o-hydroxyamide formed after the reaction is precipitated by dropwise-addition of the reaction solution to a precipitating agent, washed and dried. Suitable precipitating agents are water and alcohols, such as isopropanol, butanol or ethanol. Mixtures of these precipitating agents can also be used. The precipitating agent-can also suitably contain from 0.1 to 10% of ammonia. The precipitated polymer can be directly further processed by filtration and drying and, for example, dissolved in one of the solvents mentioned further above for application to a semiconductor substrate.
[0029] The polymerization to give the poly-o-hydroxyamide can be carried out in the presence of a base in order to trap acid liberated. Suitable basic acid acceptors are, for example, pyridine, triethylamine, diazabicyclo-octane, or polyvinylpyridine. However, other basic acid acceptors also may be used. Compounds that are readily soluble in the solvent used for the synthesis, for example N-methylpyrrolidone, and in the precipitating agent, for example water or water/alcohol mixtures, or those which are completely insoluble in the solvent, such as, for example, crosslinked polyvinylpyridine, are particularly preferred. The acid acceptors can then readily be separated from the resulting poly-o-hydroxyamide during the working-up of the reaction product.
[0030] Particularly suitable solvents for the polymer synthesis are γ-butyrolactone, tetrahydrofuran, N-methylpyrrolidone and dimethylacetamide. However, in principle any solvent in which the starting components are readily soluble can be used.
[0031] The poly-o-hydroxyamides prepared in this manner can be converted into the desired polybenzoxazoles by heating with cyclization according to the mechanism explained above. Owing to their good electrical, mechanical and chemical properties, the polybenzoxazoles are very suitable for use in microelectronics.
[0032] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0033] Although the invention is illustrated and described herein as embodied in bis-o-aminophenols and processes for producing bis-o-aminophenols, 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.
[0034] 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 examples.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The invention is explained in more detail on the basis of examples.
EXAMPLE 1
Synthesis of 3,3′-Diamino-4,4′-dihydroxytetraphenylmethane
[0036] Synthesis Route:
[0037] Stage 1: Nitrosation
[0038] 20.07 g (0.057 mol) of 4,4′-dihydroxytetraphenylmethane are dissolved in 100 ml of glacial acetic acid, and 20 ml of isoamyl nitrite are added dropwise at RT. The course of the reaction is monitored by thin-layer chromatography until starting material is no longer detectable. 100-200 ml of water are added, and the precipitated solid is filtered off. This is triturated with methanol and allowed to stand for several hours. After filtration with suction and drying, the product is taken up in hot toluene and subjected to fractional crystallization.
[0039] Yield: 21.27 g (91% of theory)
[0040] Stage 2: Hydrogenation and Isolation as Hydrochloride
[0041] The hydrogenation is effected according to known methods for the hydrogenation of nitro compounds, as described, for example, in European Patent Application No. EP 905 121 (which corresponds to U.S. Pat. No. 6,320,081), example 8.
[0042] 20.5 g (0.05 mol) of 4,4′-dihydroxy-3,3′-dinitroso-tetraphenylmethane are dissolved in 250 ml of tetra-hydrofuran (THF), and 2.00 g of 5% Pd-C are added under inert gas. The suspension is introduced under Ar inert gas into a previously heated hydrogenation reactor and is hydrogenated at room temperature for 24 h and 2 bar H 2 pressure. After a hydrogenation time of 24 h, the suspension is transferred under inert gas into 150 ml of analytical-grade ethanol. 10 ml of concentrated HCl are added to the mixture while stirring, and, when the product has completely dissolved, the mixture is filtered three times over a Buchner funnel to remove the Pd catalyst. The solution thus obtained is evaporated down at 70° C. and 300 mbar until about 20 ml of ethanol remain and is added with rapid stirring to a solution of 700 ml of diethyl ether and 30 ml of acetone (Selectipur). The suspension is stored for 24 h at −18° C. The solid is then filtered off with suction and dried.
[0043] Yield: 21.39 g (94% of theory)
EXAMPLE 2
Synthesis of 9,10-Bis(3-amino-4-hydroxyphenyl)anthracene
[0044] Synthesis Route:
[0045] Stage 1: 9,10-Bis(4-methoxy-3-nitrophenyl)anthracene
[0046] 23.43 g (60mmol) of 9,10-bis(4-methoxy)anthracene in 250 ml of acetic anhydride are initially introduced and dissolved. A solution of 18.7 ml (0.184 mol) of nitric acid (62% strength) in 100 ml of acetic anhydride is then added dropwise in the course of 30 min to the solution at 0° C. At the same temperature, stirring is effected for 4 h and the precipitated solid is filtered off with suction on a frit. After the end of the reaction, the mixture is carefully poured into 500 ml of ice water and thoroughly stirred. The product is filtered off with suction, washed thoroughly with water and recrystallized. For this purpose, the crude product is dissolved at room temperature in toluene (2 ml/g) and heated to 90° C., and petroleum ether (4 ml/g) is added until crystallization begins. The mixture is then slowly cooled to RT. The suspension is stored for 4 h in a freezer at −18° C. and then filtered. The product is dried for 24 h at 200 mbar and 55° C.
[0047] Yield: 21.9 g (766 of theory)
[0048] Stage 2: 9,10-Bis(4-hydroxy-3-nitrophenyl)anthracene
[0049] 19.2 g (0.04 mol) of 9,10-bis(4-methoxy-3-nitrophenyl)-anthracene in a mixture of 200 ml of butanone and 200 ml of concentrated HBr are refluxed for 24 h while stirring. After the end of the reaction, the suspension is evaporated down to half its volume in a rotary evaporator and the product is filtered off with suction. Recrystallization from toluene is then effected.
[0050] Yield: 16.64 g (92% of theory)
[0051] Stage 3: 9,10-Bis(3-amino-4-hydroxyphenyl)anthracene The hydrogenation is effected according to the known methods for hydrogenating nitro compounds, as described, for example, in European Patent Application No. EP 905121, example 8.
[0052] 13.56 g (30 mmol) of 9,10-bis(4-hydroxy-3-nitrophenyl)-anthracene are dissolved in 300 ml of THF, and 3.00 g of 50 Pd-C are added under inert gas. The suspension is introduced under Ar inert gas into a previously heated hydrogenation reactor and hydrogenated at room temperature for 24 h and at 2 bar H 2 pressure. After a hydrogenation time of 24 h, the suspension is transferred under inert gas into 100 ml of analytical-grade ethanol. 10 ml of concentrated HCl are added to the mixture while stirring and, when the product has completely dissolved, the mixture is filtered 3 times over a Buchner funnel in order to remove the Pd catalyst. The solution thus obtained is evaporated down at 70° C. and 300 mbar until about 20 ml of ethanol remain and is added to a solution of 500 ml of diethyl ether and 20 ml of acetone (Selectipur) with rapid stirring. The product is precipitated in the form of dark violet crystals. The suspension is stored for 24 h at −18° C. The solid is then filtered off with suction and dried.
[0053] Yield: 12.37 g (89% of theory)
EXAMPLE 3
Synthesis of 4,4′-Di(3-amino-4-hydroxyphenoxy)tetraphenylmethane
[0054] Synthesis Route:
[0055] Stage 1: 3-Benzyloxy-4-nitrofluorobenzene
[0056] 157 g (1.00 mol) of 3-fluoro-6-nitrophenol are initially taken in 500 ml of acetonitrile in a three-necked flask (KPG stirrer, reflux condenser, inert gas connection), and 174 g (1.02 mol) of benzyl bromide and 345 g (2.50 mol) of potassium carbonate are added in this sequence under inert gas. The mixture is refluxed for 3 hours at 90° C. After cooling to room temperature, the mixture is filtered with suction and the remaining solid is rinsed twice with 100 ml of acetonitrile each time. The solution is evaporated down until it crystallizes, and the crude product is filtered off with suction. The crude product is dissolved at room temperature in ethyl acetate (1 ml/g of crude product) and precipitated with hexane (3.6 ml/g of crude product). The mixture is stored overnight at T<−10° C. for complete crystallization.
[0057] Yield: 194 g.(80% of theory),
[0058] Melting point: 58° C.
[0059] Stage 2: 4,4′-Di(4-benzyloxy-3-nitrophenoxy)-tetraphenylmethane
[0060] 30.74 g (87.3 mmol) of 4,4′-dihydroxytetraphenylmethane and 43.65 g (176 mmol) of 3-fluoro-6-nitrobenzyloxy-phenol are initially taken in a three-necked stirred flask equipped with an inert gas connection, KPG stirrer and reflux condenser. 350 ml of N,N-dimethyl-formamide are added to this mixture at room temperature. 61.0 g (354 mmol) of K 2 CO 3 are added to the solution under inert gas and the solution is refluxed at 135° C. for 4 h. The progress of the reaction is checked hourly by thin-layer chromatography (eluent: petroleum ether (fraction 80-120° C.): ethyl acetate=2:1 (R f,product =0.49)). After complete conversion, the suspension is cooled to room temperature and poured into aqueous KOH solution (350 ml of H 2 O/7.2 g of KOH/100 g of ice). The product is precipitated in the form of yellow crystals. The precipitation is accelerated by adding about 20 ml of ethyl acetate. The product is filtered off, rinsed once with 200 ml of H 2 O and then poured into 350 ml of acetic acid solution (320 ml of H 2 O/30 ml of concentrated glacial acetic acid). The solution is stirred for 30 min and the product is filtered off and additionally washed twice with 200 ml of H 2 O.
[0061] 60 g of the crude product are dissolved in 350 ml of tetrahydrofuran and heated to the boil. The solution is kept at the boiling point for 30 min and then filtered. The solution is heated again to the boil and stirred for a further 30 min. Petroleum naphtha (boiling range 60-80° C.) is added dropwise until precipitation of the product begins at 65° C. The solution is allowed to cool to room temperature and is stored for 24 h in a refrigerator at 4° C. The product is separated off by filtration and rinsed with twice 100 ml of petroleum naphtha (fraction 60-80° C.). The recrystallized product is dried at 50° C./200 mbar for 24 h.
[0062] Yield: 63.35 g (90% of theory)
[0063] Stage 3: 4,4′-Di(3-amino-4-hydroxyphenoxy)tetraphenyl-methane as the Hydrochloride
[0064] The hydrogenation is effected according to known methods with the hydrogenation of nitro compounds, as described, for example, in European Patent No. EP 905121, example 8.
[0065] 54.48 g (67.57 mmol) of 4,4′-di(4-benzyloxy-3-nitro-phenoxy)tetraphenylmethane are dissolved in 600 ml of THF, and 5.00 g of 5% Pd-C are added under inert gas. The suspension is introduced under Ar inert gas into a previously heated hydrogenation reactor and hydrogenated at room temperature for 24 h and at 2 bar H 2 pressure. After a hydrogenation time of 24 h, the suspension is transferred under inert gas into 200 ml of analytical-grade ethanol. 10 ml of concentrated HCl are added while stirring. After the product has completely dissolved, the mixture is filtered three times over a Buchner funnel to remove the Pd catalyst. The solution thus obtained is evaporated down at 70° C. and 300 mbar until about 30 ml of ethanol remain and is added to a solution of 700 ml of diethyl ether and 30 ml of acetone (Selectipur) with rapid stirring. The product is precipitated in the form of dark violet crystals. The suspension is stored for 24 h at −18° C. and the solid is then filtered off with suction and dried.
[0066] Yield: 37.46 g (87% of theory). | A bis-o-aminophenol has a formula I
These bis-o-aminophenols permit the preparation of polybenzoxazoles stabilized at high temperatures. The bis-o-aminophenols are preferably prepared from the corresponding diols, which are first nitrosated. The nitroso compound is then reduced to the amino compound by hydrogenation with Pd/C and H 2 . | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a null monitoring system and more particularly to a null monitoring system for digital incremental scales.
It is desirable in any commercial weighing operation, but particularly in retail food operations, that strict accuracy and equity be maintained. Consumers are concerned that they receive full weight and value. Merchants wish to avoid embarrassment and possible prosecution for short weight but yet must be assured of full legitimate profit to survive. Analog weighing devices as heretofore used in the retail trade did provide through analog indices and means at least for virtual absolute zero resolution and definitive full range calibration. In recent digital devices without supplementary analog provision or other means, neither reference zero nor calibration over the weighing range can readily be resolved to less than plus or minus one-half of the minimum weight which is digitally indicated or recorded. Since net profit in retail operations today may sometimes not exceed one-half of 1%, a minus resolution error of that order may totally or substantially offset minimal and dissipated profits, or result in short weight publicity and prosecution. The monitoring system of the present invention heredisclosed is a novel and unique means for absolute resolution at zero and for the purpose of definitive calibration through the weighing range and yet permits the use of relatively inexpensive low-resolution encoders The monitoring system of the present invention is particularly valuable for use in conjunction with simple functional in-store check procedures insuring better than regulatory or common maintenance tolerances in use and as incorporated in several of assignee's present digital devices.
One form of digital scale utilizes a weighing platform and a reticle assembly including one or more light sources and light sensors and a displaceable reticle which is mechanically linked to the weighing platform for displacement proportional to the weighing platform displacement and ultimately to the weight of the load being weighed. Such reticles include light transmissive areas and opaque areas and cooperate with the light sources and light sensors to derive a plurality of counting pulses. When a load is placed onto the weighing platform, the scale weighing platform moves up and down in oscillating movement to cause the reticle assembly to provide the counting pulses. As the weighing platform moves in the down direction the counting pulses are added and as the weighing platform moves in the up direction the counting pulses are subtracted to ultimately obtain a net number of pulses when the weighing platform comes to rest.
Because the counting pulses are generated digitally, the position of the weighing platform can only be determined to within the least significant digit of the scale. For calibration purposes, it would be advantageous to determine the exact position of the weighing platform within the scale least significant digit.
It is therefore an object of the present invention to provide a null monitoring system for a digital scale for monitoring the exact position of the scale weighing platform within the scale least significant digit.
It is also an object of the present invention to provide a null monitoring system which generates an analog signal the magnitude of which is indicative of the scale weighing platform position within the scale least significant digit increment.
It is a still further object of the present invention to provide a null monitoring system which provides means for determining the exact position of the digital scale weighing platform within its least significant digit when the platform comes to rest.
SUMMARY OF THE INVENTION
The invention provides a null monitoring system for use in a digital incremental scale of the type which includes a weighing platform, a reticle assembly comprising a reticle having a plurality of light transmissive areas and opaque areas and displaceable by an amount proportional to the weighing platform load, a light source on one side of the reticle, and first and second light sensors on the other side of the reticle, the first and second light sensors being aligned in relation to the light source for operation with the light transmissive areas and the opaque areas and being spaced apart by approximately one-fourth the distance between adjacent light transmissive areas to generate first and second sinusoidal outputs which are approximately 90° out of phase with one another to thereby derive four counting pulses as the reticle is displaced by a distance equal to the distance between adjacent transmissive areas for indicating the extent and direction of reticle displacement accurate to a single digital increment of the scale. The null monitoring system monitors the position of the scale weighing platform within the digital increments and comprises combining means coupled to the first and second light sensors for combining the first and second sinusoidal outputs for providing first, second, third and fourth combined sinusoidal outputs, each of the combined sinusoidal outputs having a 90° quadrant the magnitude of which is indicative of the position of the scale weighing platform within the digital increments, monitoring means coupled to the combining means for monitoring the magnitude of the first, second, third and fourth combined sinusoidal outputs, and counting means coupled to the combining means and responsive to the counting pulses for acting upon the combining means to select individual ones of the first, second, third and fourth combined sinusoidal outputs during 90° quadrants thereof one at a time to derive an analog signal indicative of the instantaneous position of the weighing platform within the digital increments to be monitored by the monitoring means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with the objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, and the several figures of which like reference numerals identify like elements, and in which:
FIG. 1 is a perspective view showing the weighing platform and reticle assembly of a digital scale which may be utilized in practicing the present invention;
FIG. 2 is an exploded partial view of the reticle assembly of FIG. 1;
FIG. 3 is a schematic circuit diagram of a null monitoring system embodying the present invention;
FIG. 4 is a graphical representation of an ideal waveform to be utilized by the null monitoring means of the present invention;
FIG. 5 shows graphical representations of the sinusoidal outputs provided by the reticle assembly of FIG. 1 which may be utilized in practicing the present invention;
FIGS. 6a-6d are graphical representations of combined sinusoidal outputs resulting from the combination of the sinusoidal outputs of FIG. 5 which are utilized by the null monitoring means of the present invention; and
FIG. 7 is a graphical representation of another waveform obtainable in accordance with an alternate embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a perspective representation of a weighing platform 10 and reticle assembly 11 of a digital scale which may be utilized in practicing the present invention. The reticle assembly 11 comprises a reticle 12 having a plurality of light transmissive areas 13, a plurality of light opaque areas 14, a light source 16 and first and second sensors 17 and 18 on the side of the reticle opposite the light source. The reticle assembly has lever arm 19 pivotably mounted at point 20 to impart arcuate movement or displacement to the reticle 12. The lever arm 19 is coupled to the weighing platform 10 by linkage 21 to thereby displace the reticle by an amount proportional to the displacement of the weighing platform and ultimately the weight of the load placed onto the weighing platform.
Sensors 17 and 18 are aligned relative to the light transmissive and opaque areas and to the light source 16 to provide first and second outputs which approximate sinusoids, sinusoid A and sinusoid B. While sinusoids A and B are not true sinusoids, they are close enough to being truly sinusoidal for purposes of this preferred embodiment to be considered as such. Therefore, they and any other signals derived from their combination will hereinafter be referred to as sinusoids. Sinusoid A is generated by light sensor 17 and sinusoid B is generated by light sensor 18. The light sensors are spaced apart by one-fourth the distance between adjacent transmissive areas resulting in sinusoid A and sinusoid B being 90° out of phase with each other. Sinusoid A and sinusoid B are graphically shown in FIG. 5.
FIG. 2 shows the reticle and associated light source and light sensors in greater detail. The light transmissive areas and opaque areas are of a width which approximates the relative magnitude of the diameters of the light sensors. This assures that the outputs of the light sensors are a close approximation to a sinusoidal signal.
Referring now to FIG. 3, there is shown a circuit diagram partially in block form of a null monitoring system embodying the present invention. It comprises a two-bit up/down counter 30, operational amplifiers 31-34, inverting amplifiers 35 and 36, and a null monitor comprising a null volt meter 37.
The two-bit up/down counter 30 is of the type well known in the art and has a pair of inputs 40 and 41 which are coupled to the encoder interface of the digital scale which provides up counting pulses at input 40 and down counting pulses at input 41. Referring to FIG. 5 for a moment, FIG. 5 shows the sinusoidal output A of sensor 17 and the sinusoidal output B of sensor 18 as the reticle moves. The encoder interface includes a threshold detector and transforms the sinusoidal outputs to square waves which are then examined by the encoder interface to generate a counting pulse whenever one of the square waves makes a transition. Logic within the encoder interface determines from the condition of the square waves at any point in time along with the particular transition monitored to determine if the reticle is moving in the upward or downward direction. If a transition occurs and the reticle is moving in the downward direction the encoder will provide an up pulse and if the reticle is moving in the upward direction the encoder will provide a down pulse. Because the sinusoidal outputs are 90° out of phase, as the reticle is displaced by a distance equal to the distance between adjacent transmissive areas four counting pulses will be provided. This is commonly referred to as four-times logic and is well known in the art. A reset pulse is applied at the start of the reticle movement to synchronize the two-bit counter with the sinusoidal signals so that the first count corresponds to the 0° to 90° quadrant, the second corresponds to 90° to 180° etc.
Referring back to FIG. 3, operational amplifiers 31, 32, 33 and 34 and inverting amplifiers 35 and 36 comprise a combining means wherein the sinusoidal outputs are combined to provide first, second, third and fourth combined sinusoidal outputs. Operational amplifier 34 has an input 42 coupled to light sensor 17 for receiving sinusoid A and input 43 coupled to light sensor 18 for receiving sinusoid B. Operational amplifier 34 adds sinusoid A to sinusoid B and provides an output at output 44 which comprises the combination of sinusoid A and B. This is the first combined sinusoidal output and is graphically illustrated in FIG. 6a and is labeled A+B.
Operational amplifier 33 has an input 45 coupled to output 46 of inverting amplifier 35 is coupled to light sensor 17 and provides at output 46 a signal which is the inversion of sinusoid A and provides the inverted sinusoid A at input 45 of operational amplifier 35. Operational amplifier 33 also has input 48 coupled to the light sensor 18 for receiving sinusoid B. Therefore, operational amplifier 33 provides at output 49 the second combined sinusoidal output which comprises the summation of the inverted sinusoid A and the uninverted sinusoid B. The second combined sinusoidal output is graphically illustrated in FIG. 6b and is labeled -A+B.
Operational amplifier 32 has an input 50 coupled to output 46 of inverting amplifier 35 to receive the inverted sinusoid A. Operational amplifier 32 also has an input 51 coupled to output 52 of inverting amplifier 36. Inverting amplifier 36 has an input 53 coupled to light sensor 18 for providing at output 52 the inversion of sinusoid B. Operational amplifier 32 has at its inputs 50 and 51 the inverted sinusoid A and inverted sinusoid B respectively to provide at output 54 the third combined sinusoidal output which comprises the difference between the inverted sinusoid A and the inverted sinusoid B. It is graphically illustrated in FIG. 6c and is labeled -A-B.
Lastly, operational amplifier 31 has an input 55 coupled to light sensor 17 for receiving sinusoid A and an input 56 coupled to output 52 of inverting amplifier 36 for receiving the inverted sinusoid B. Operational amplifier 31 therefore provides at output 57 the fourth combined sinusoidal output which comprises the difference between the sinusoid A and the inverted sinusoid B. It is graphically illustrated in FIG. 6d and is labeled A-B.
Null meter 37 is coupled to each of the operational amplifier outputs 57, 54, 49 and 44 for receiving the combined sinusoidal outputs. Each of the operational amplifiers 31, 32, 33 and 34 is coupled to the two-bit up/down counter which selects the operational amplifiers one at a time responsive to the counting pulses received upon its inputs 40 and 41. It receives the up pulses at input 40 and down pulses at input 41. The two-bit up/down counter derives from its input conditions, a two-bit binary word which is decoded to select one of the operational amplifiers in response to the particular two-bit binary word present as a result of counting the up and down input pulses. In practicing the present invention, counter 30 preferably may include a 7473 integrated circuit and 7400 quad two-input gate arranged in a well known fashion to form a binary up/down counter. For decoding the binary words thereby produced, counter 30 may preferably include a 2405 Harris Semiconductor decoder integrated circuit which accepts the two-bit binary words, decodes them, and provides a signal at one of the four outputs of counter 30. Which output provides the signal is dependent upon the logic levels of the two bits within the counter. The 2405 integrated circuit is particularly suited for practicing the present invention because it includes operational amplifiers which may be used for operational amplifiers 31, 32, 33 and 34. All of these integrated circuits are commercially available and their applications are well known. Also, inasmuch as two-bit up/down counters and one of four decoders are well known in the art, their functions have been combined in counter 30 as shown in FIG. 3 for purposes of simplicity. Each of the operational amplifiers 31, 32, 33 and 34 includes a power input enable gate 71, 72, 73 and 74 respectively and is selected by being coupled to its power supply voltage by its gate responsive to signals from the two-bit up/down counter 30. When it is activated, it provides the null meter with its respective combined sinusoidal output 90° quadrant which is indicative of the position of the weighing platform within the scale least significant digit.
Referring now to the graphical illustration of FIG. 4, it shows the ideal waveform which may be provided to the null meter 37. Within each significant digit of the weighing scale, the waveform of FIG. 4 provides an analog signal which is representative of the position of the weighing platform at any instant of time within the scale least significant digit. In other words, because the scale is digital and therefore must derive the weight of an item by counting individual and discrete digital increments of weight (i.e. .01 pb. increments), an individual increment can only be added or subtracted after the weighing platform has physically passed by a transition point. The waveform of FIG. 4 allows the instantaneous position of the platform between increments and thus between transition points to be determined. For ease of interpretation, the null meter should ideally have its null point in the center of its scale and move from left to right with increasing weight. Thus, readings to the left of the null would correspond to a weight just less than the displayed weight and readings to the right of the null will indicate a weight greater than the displayed weight but all within one count of the least significant increment of the digital display. Observation will show that the ideal waveform of FIG. 4 can be constructed by selecting individual 90° quadrants of the combined sinusoidal outputs which correspond to individual 90° quadrants of sinusoid A. For example, the first combined sinusoidal output (A+B) between the 0° to 90° quadrant of sinusoid A corresponds to the desired signal for the null meter. Similarly, the second, third and fourth combined sinusoidal outputs satisfy the null meter waveform requirements between 90°-180°, 180°-270° and 270°-360° quadrants respectively of sinusoid A. The output signals from counter 30 sequentially enable one of the amplifiers in the previously described operational sequence for providing the null meter with an analog signal indicative of the position of the weighing platform within its least significant digit. A reset pulse is applied at the start of the reticle movement to synchronize the two-bit counter with the sinusoidal signals so that the first count corresponds to the 0° to 90° quadrants, the second to 90° to 180° etc.
Practice has shown that as the weighing platform comes to rest the null meter needle will jump rapidly as it tracks the combined sinusoidal outputs. This effect can be minimized by damping the meter to lower its response. Alternately the sequence of selection can be altered by rearranging the connections between the counter and the amplifiers to operate in the sequence A+B, A-B, -A-B, -A+B. This produces a waveform without discontinuities but in the direction of the waveform fed to null meter 37 for the even numbered signals, i.e. from 90° to 180° and 270° to 360°, is reversed as shown in FIG. 7.
A still further modification may be made which includes a two position switch, where in one position of the switch the null monitoring system is operative for all positions of the weighing platform and in the other position, the null monitoring system is operative for only the zero weight or unloaded position of the weighing platform. For the first switch position the null monitoring system may be operated in accordance with any of the embodiments previously described. The second switch position may be used to activate a gate associated with a separate zero reference sensor and light transmissive area for deactivating all of the operational amplifiers when the scale weighing platform is displaced away from the zero reference position. With this modification, the scale operator need only be concerned with absolute zero while a service technician would have means affording exact calibration for all weighing platform positions.
While particular embodiments of the invention have been shown and described, modifications may be made, and it is intended in the appended claims to cover all such modifications as may fall within the true spirit and scope of the invention. | The disclosure relates to a null monitoring system for a digital incremental scale of the type including a weighing platform and a reticle assembly which provides first and second sinusoidal outputs 90° out of phase for deriving counting pulses indicative of the weight of the load and the weighing platform position accurate to a single digital increment of the scale and the direction of movement of the weighing platform. The null monitoring system provides an analog indication of the actual position of the weighing platform within the digital increments for zero reference and calibration purposes.
The null monitoring system includes combining means for combining the first and second sinusoidal outputs for providing first, second, third and fourth combined sinusoidal outputs, each having a 90° quadrant with an instantaneous magnitude indicative of the position of the weighing platform within the digital increments, monitoring means for monitoring the magnitudes of the combined sinusoidal outputs, and counting means responsive to the counting pulses for selecting individual ones of the combined sinusoidal outputs during 90° quadrants thereof to be monitored by the monitoring means. | 7 |
BACKGROUND OF THE INVENTION
This invention pertains generally to dairy equipment and more particularly to milking apparatus for milking cows and conveying the milk to a storage tank. Apparatus of this general character is shown in several United States patents where the milk lines, receivers, and control equipment are secured in the milking parlor and/or in the milk room. These installations are permanent and generally quite expensive due to the milk lines and other apparatus which is required and furthermore these prior art apparatus are inflexible, somewhat inefficient, and expensive to produce and maintain. Examples of such prior art apparatus is shown in U.S. Pat. Nos. 3,273,514 which issued Sept. 20, 1966 and entitled "Fluid Conveying Apparatus"; 3,310,061 which issued Mar. 21, 1967 and entitled "Milk Line Equipment"; 3,352,248 which issued Nov. 14, 1967 and entitled "Fluid Conveying Apparatus"; 3,531,217 which issued Sept. 27, 1970 entitled " Vacuum Operated Timing Device for Fluid Conveying Apparatus"; and U.S. Pat. 3,658,441 issued Apr. 25, 1972 entitled "Fluid Line Releaser and Washer".
SUMMARY OF THE INVENTION
The present invention provides a mobile, complete milking unit for milking cows, collecting the milk, and periodically transferring the collected milk to a storage tank, all of which is accomplished in an automatic and timed manner. The portable unit can be used in the barn where the cows are brought to be milked or the unit may be transported to the barn yard or out in the field where the cows are located, thus avoiding the necessity of bringing the cows into the barn or into a particular milking area and the latter procedure is especially desirable in countries or climates where such a system lends itself to that method of milking.
The mobile milking unit contemplated by the present invention can be mounted on a portable cart having ground engaging wheels, it can be mounted on an overhead trolley for being moved along a milking parlor, or it can be mounted on a self-propelled vehicle, such as a truck, the truck having an internal combustion engine for driving a generator and which thus provides the necessary electrical energy.
The invention provides electrical control means for periodically conveying the collected milk from a milk receiver and to the bulk storage tank.
The present invention provides a highly efficient and complete milking unit which operates with no loss or milk and is otherwise efficient in operation; it is sanitary and complies with the various sanitation codes; it is flexible in operation and requires no permanently attached milk lines or other components which would otherwise limit its use.
These and other objects and advantages of the present invention will appear hereinafter as this disclosure progresses, reference being had to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of one embodiment of the invention and showing it as applied to a portable, manually pushed cart having the necessary ground wheels;
FIG. 2 is a plan view of the portable unit shown in FIG. 1, certain parts being removed for the sake of clarity;
FIG. 3 is a schematic diagram of certain of the parts shown in FIGS. 1 and 2 and also including an electric control circuit and components for the various parts;
FIGS. 4 and 5 show embodiments of the invention wherein the portable unit is mounted on an overhead track for being conveyed along a milking area, FIG. 4 being an elevational view of the unit and FIG. 5 being another elevational view of the unit and taken generally along the line 4--4 of FIG. 5; and
FIG. 6 is another embodiment of the invention and showing the unit as mounted on a self-propelled vehicle, such as a truck and which truck also has a trailer attached thereto containing a storage tank.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1, 2 and 3, the mobile unit is in the form of a cart C, having a mobile frame F which is generally comprised of a steel vacuum tank 1 which acts as a base of the unit and to which are attached a pair of rubber tired wheels 2 and caster wheel means 3. The mobile frame also has a series, for example four, of swing arms 4 swingably mounted thereon. Any number of swing arms can be mounted on the frame and each is adapted to support a conventional teat claw 6 and the flexible lines 7 and 8 extending therefrom. Line 8 is a lower vacuum line having an on/off valve 9, and extends from the interior liner 14 of the teat cups 12 through an enclosed pan 10 of the claw, and to a receiver manifold 11. Only one such teat claw has been illustrated in FIGS. 1 and 3, but it is understood that other numbers can also be simultaneously used and the manifold 11 has a series of attached nipples 13 for the reception of said other vacuum lines and claw assemblies.
The mobile frame also has a milk receiver 16 mounted thereon and this milk receiver is generally formed of transparent material such as glass and acts to receive the milk from the teat claw assemblies 6. Vacuum means are provided for continually drawing a vacuum in the interior of the receiver 16 and this vacuum means includes a vacuum pump 20 which is connected via line 21 to the vacuum tank 1. The vacuum pump is driven by the pump motor 22 which in turn is connected by electrical lines 23 with the electric power lines 24. Power lines 24 are connected via an on/off switch 25 to an electrical source, not shown. The vacuum tank is connected by vacuum conduits 28 and 29, respectively, to the receiver 16 and to a solenoid pulsator 30 to be later referred to. The vacuum pump is continually operated to produce a vacuum in the tank 1 which thus in turn continually draws a vacuum from the receiver 16, via the moisture trap 32. The vacuum tank also continually draws a vacuum from the solenoid pulsator through line 29.
A milk pump 40 is connected to an outlet 41 of the receiver and is driven by the milk pump electric motor 42. A bulk storage tank 44 is provided and the milk pump periodically is actuated to pump the milk from the receiver 16 through a one-way check valve 46, milk filter 48, and through a flexible tubing 50 and into the bulk storage tank. The flexible tubing 50 is preferably of plastic material and can be coiled for storage on the flexible tubing storage frame 52 which is carried by the mobile frame. As the mobile frame is moved from one milking area to another, the coil of flexible tubing 50 is unwound so that the unit can convey the milk to the bulk storage tank 44 which can be located elsewhere.
Means are provided in the receiver 16 for sensing when the receiver is sufficiently full of milk from the claw assemblies so that it should be emptied by actuating the milk pump 40 and pumping the milk from the receiver to the storage tank 44. This milk level sensing means located in the receiver takes the form of three electrical probes A, B and C which extend upwardly therefrom, the bottom end of the probes being located at different levels in the receiver. These probes in turn are connected to milk level control means 60, to be referred to in detail, and which control the milk pump 40 in a timed manner. The milk probes sense the level of the milk, both the low and high extremes thereof in the receiver jar and insure that the receiver will never over-flow and that the milk pump 40 will not be damaged by running dry. The arrangement of the probes is such that when the milk level rises sufficiently in the receiver so as to contact the shortest probe A, the milk level control 60 activates a contacter 64 which closes its normally open contacts to apply electrical energy to the milk pump motor 42 from the lines 24, thus emptying the receiver when the level rises as indicated. More specifically, when milk enters the receiver 16 and submerges the top probe A, enough current flows through the milk to be sensed by a solid state amplifier 61 which provides enough gate signal to trigger a silicon controlled rectifier (SCR). The output of the SCR operates the control relay 62. Once the control relay 62 is activated the SCR and the control relay 62 are latched through closure of the normally open contacts 62a between lines 65 and 66. Activation of control relay 62 effects closure of the normally open contacts 62b to activate the milk pump contactor 64. Probe B extends downwardly in the receiver farther than probe A and when the liquid level falls below this probe B, the milk level control means 60 deenergizes contactor 64 and disconnects the milk pump motor 42 from the lines 24 thereby deenergizing motor 42 and causing the pumping action of the pump 40 to cease, and consequently permitting the receiver 16 to again fill with milk from the continuous vacuum line 8. Probe C is a ground probe. The milk level control 60 may, for example, take the form of a Model LCS10 device manufactured by Curtis Industries, Inc., 8000 West Tower Avenue, Milwaukee, Wisconsin 53223.
Referring to the claw assemblies 6, they are subjected alternately to vacuum and/or atmospheric pressure thereby causing the teat cup liners 14 (FIG. 3) or inflations to open or collapse on the cow's teat in the known manner. Intermitted high vacuum is supplied to the teat cups 12 by the vacuum line 7, which is connected to the manifold 15 of the solenoid 30. When the solenoid permits air to enter the line 7, shutting off vacuum, the air fills the space between the teat cup outer shell 12a and the cup liner and thus causes inflation of the cup to collapse, thereby massaging the teats. When the solenoid applies the high vacuum to line 7, the teat cups are inflated, in the known manner. Conduitsor lines 8 lead directly from the interior of the teat cups 12 that is directly from the teat of the cow and the conduits 8 thus convey the milk to the manifold 11 and thus to the receiver 16. The vacuum in lines 8 is a lower vacuum than that in line 7, all as is conventional, thus milk and vacuum are drawn into the receiver 16.
The pulsator 30 is connected to the pulsator timer 80 which may be operated at 60 cycles per minute and which is in turn connected to the power lines 24. The pulsator timer 80 has a 60-40 duty cycle alternating vacuum and atmospheric pressure. The purpose of the pulsator timer 80 is to control the on/off time of the solenoid operated pulsator 30 which in turn alternates between vacuum and atmosphere pressure to effect the teat cup operations as described. The pulsator timer 80 comprises an astable multivibrator (timer) 81 which operates at a frequency of 1 Hz, with 0.6 seconds on time and 0.4 seconds off time. The pulsator timer 80 also includes a light activated silicon control rectifier (LASCR) which is used to provide isolation between the output circuits and the timer circuit so the frequency will stay constant. Additionally, the LASCR provides sufficient gating current to trigger the TRIAC circuit which acts as a single pole normally open relay for controlling the pulsator solenoid 30.
During the 0.6 seconds on time voltage is applied to the three-way solenoid 30 and vacuum is applied via line 7 to the outer side of the teat cup inflator causing them to open and milk flows from the cow's teat. During the 0.4 seconds off time the solenoid 30 reverts to its static condition and allows atmospheric pressure to the other side of the inflator allowing it to collapse and massage the cows' teat. The pulsator timer 80 is a solid state timing device using a three-way solenoid valve.
The embodiment of the invention shows in FIGS. 4 and 5 is the same as that shown in connection with FIGS. 1, 2 and 3, except that the mobile frame is mounted as previously indicated on an overhead trolley track 90 by the wheels 91 fixed to the upwardly extending frame members 92. Thus, the mobile frame is suspended for overhead movement rather than movement along the floor.
FIG. 6 shows another modification wherein the mobile unit is mounted on a self-propelled vehicle, such as a truck 100 which includes an internal combustion engine 101 that drives an electric generator 102. The generator thus acts as a source of electrical energy for the power lines 24. In this modification the storage tank 44a is in the form of a trailer attached to the truck 100. This embodiment of the invention can be used to go out in the field where the cows are located to thereby avoid the necessity of bringing the cows into a particular milking area. Several trailer type storage tanks 44a may be used so that they can be conveyed individually out in the field when they are full. | A mobile, complete milking unit for milking cows and transferring the milk to a storage tank, the unit having all the milk handling components mounted thereon as an integral, portable unit. The unit can be moved about in the milking area whether it is in the barn, in the barn yard, or in the field. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to an automatic clutch control apparatus used, for example, in controlling a wet-type multiple-disc clutch.
Automatic clutch control of a wet multiple-disc clutch is performed in such a manner that engine torque is not transmitted in a state where the vehicle is at rest and the accelerator pedal is not depressed. When the accelerator is in the depressed state, however, control is so effected as to transmit a torque commensurate with the engine rpm that prevails at such time.
FIG. 9 is a flowchart illustrating this conventional method of clutch control. If the shift position is the reverse, drive or low position (i.e. R, D or L, as indicated at a in the flowchart) and, moreover, the accelerator pedal is not being depressed (i.e. the accelerator is not ON, as indicated at (b), then a minimum value of solenoid current I s is outputted (c) by a control unit for providing a minimum clutch pressure P c that will turn off the clutch so that a transfer torque is not produced. If the accelerator pedal is being depressed (i.e. the accelerator is ON, as indicated at (d), on the other hand, the required value of clutch pressure P c [P c =f(N e ,d)] is calculated at step f in accordance with the prevailing engine rotational speed N e (sensed at step e) and the amount of d of accelerator pedal depression. The required value of solenoid current I s is then calculated in the control unit at step g and outputted by the unit at step h. Next, the clutch input rotational speed N o and output rotational speed N ds are sensed by suitable sensor and a clutch engagement ratio C e (=N ds /N o ) is calculated in the unit at step i. If the clutch engagement ratio C e is equal to or greater than 0.95 (meaning that synchronization has been attained), indicated at j in the flowchart, then the maximum value of solenoid current I s that will bring the clutch pressure to maximum (i.e. line pressure) is outputted at step k. If C e is less than 0.95 (i.e., synchronized), detection of engine rpm, calculation of P c [=f(N e ,d)], calculation of I s (step g), outputting of I s , calculation of C e and the decision step C e ≧0.95 are repeated (l), providing the shift position is still R, D or L and the accelerator is ON.
If the accelerator is OFF (m) and the vehicle velocity is less than a set value (n) when the solenoid current I s is maximum, the solenoid current I s is changed over at step c to the minimum value of solenoid current I s , which turns off the clutch so that a transfer torque is not generated.
When the accelerator is switched from the OFF (m) to the ON state at such time that the outputted value of solenoid current I s is minimum (c), this conventional arrangement for controlling the automatic clutch functions to increase the solenoid current I s to its maximum value through the abovementioned process a, d, e-k in order to increase the transfer torque of the clutch. Consequently, there is a time lag between depression of the accelerator pedal and transfer of the torque by the clutch. This means that if the vehicle is propelled forward from rest on an upgrade, for example, the vehicle will move backward until torque transfer begins. This is a significant problem in the prior-art arrangement described above.
SUMMARY OF THE DISCLOSURE
Accordingly, an object of the present invention is to provide an automatic clutch control apparatus which prevents an automotive vehicle from moving backward, as when the vehicle is propelled forward from rest on an upgrade, by reducing the time lag between depression of the accelerator pedal and transfer of the torque by the clutch.
Another object of the present invention is to provide an automatic clutch control apparatus capable of preventing an automatic vehicle from moving backward, as when the vehicle is propelled forward from rest on an upgrade, without undue clutch wear and vibration.
According to the present invention, the foregoing objects are attained by providing a control apparatus for an automatic clutch for use in an automotive vehicle, the control apparatus comprising a pressure regulating valve for selectively connecting clutch actuating pressure to line pressure and a drain, and control means for controlling the pressure regulating valve and including means for sensing vehicle inclination, braking torque and engine drive torque when the clutch is off, and means operative under a condition where the engine drive torque is greater than the sum of the braking torque and a torque in an adverse direction to the direction desired, which is due to vehicle inclination, attempting to move the vehicle in an adverse direction, for displacing the pressure regulating valve in a direction which will connect the clutch actuating pressure to the line pressure when the braking torque is smaller than the torque in the adverse direction to the direction desired, and in a direction which will connect the clutch actuating pressure to the drain when the braking torque is greater than the directionally adverse torque.
Assume that the vehicle is to be propelled forward from rest on an upgrade, that the clutch is off and that the drive torque of the engine is greater than the sum of the braking torque and the so-called "backward" or directionally adverse torque which attempts to move the vehicle backward due its inclination. When the braking torque is smaller than this directionally adverse torque under the above condition, the pressure regulating valve is displaced in a first direction by the control means to connect the clutch to the line pressure, whereby the clutch transfer torque is enlarged to check the backward movement of the vehicle. If the braking torque is greater than the directionally adverse torque under the above condition, then the pressure regulating valve is displaced in a second direction by the control means to connect the clutch to the drain. As a result, there is no transfer of torque by the clutch.
In accordance with the invention as set forth above, vehicle inclination, braking torque and engine drive torque are sensed. If the braking torque is smaller than the directionally adverse torque when the vehicle is propelled forward from rest on an upgrade, the control unit is operative to displace the pressure regulating valve in a direction which will connect the line pressure to the clutch, thereby increasing the clutch pressure to enlarge the clutch transfer torque. Therefore, even if the accelerator is in the off state, there is no time lag between depression of the accelerator pedal and the start of torque transfer by the clutch in response to accelerator depression. This prevents the vehicle from moving backward.
Though an automatic clutch equipped with a torque converter as in the prior art is capable of preventing backward movement of a vehicle starting forward on an upgrade by generating creep at all times, torque is constantly being transferred even when the vehicle is being held at rest by the braking torque. This results in extreme wear of the clutch friction surface and is a cause of vibration. By contrast, the control apparatus of the present invention does not permit a torque transfer by the clutch if the vehicle is being held at rest by the braking torque. This prevents undue torque wear and eliminates the abovementioned cause of vibration.
These and other characterizing features of the present invention will become clear from a description of preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view illustrating a pressure regulating valve employed in an embodiment of an automatic clutch control apparatus according to the present invention;
FIG. 2 is a flowchart illustrating the operation of control unit employed in the automatic clutch control apparatus of FIG. 1;
FIG. 3 is a view useful in describing the detection of vehicle inclination;
FIG. 4 is a graph showing the relationship between master cylinder brake pressure and braking torque in accordance with the illustrated embodiment;
FIG. 5 is a graph showing the relationship between clutch pressure and clutch transfer torque in accordance with the illustrated embodiment;
FIG. 6 is a graph showing the relationship between solenoid current and clutch pressure in accordance with the illustrating embodiment;
FIG. 7 is a graph showing the relationship between solenoid current and solenoid pressure in accordance with the illustrated embodiment;
FIG. 8 is a graph showing the relationship between solenoid pressure and clutch pressure in accordance with the illustrated embodiment; and
FIG. 9 is a flowchart illustrating the operation of automatic clutch control unit according to the prior art.
DETAILED DESCRIPTION
A preferred embodiment of the present invention will now be described in detail with reference to FIGS. 1 through 8.
FIG. 1 illustrates a pressure regulating valve 1 for regulating clutch pressure, namely clutch actuating pressure, in the clutch control apparatus of the invention. The regulating valve 1 includes a piston 2, a valve spool 3, a spring 4 interposed between the piston 2 and valve spool 3 for connecting them, and a cylinder 5 in which the piston 2 is free to slide. The cylinder 5 has an internal chamber 6 connected at all times to a hydraulic (oil pressure) line via a port 7 and connected to a drain via a port 8 the opening degree of which is regulated by a valve body 10 of a solenoid valve 9 mounted at the port 8.
Oil lines 11, 12 and 13 are connected to the hydraulic line, clutch and drain, respectively, and have respective apertures 11a, 12a, 13a arranged on the same horizontal line in the order mentioned from the left side of FIG. 1. The arrangement is such that the valve spool 3 is guided along this line by a guide 14 while undergoing sliding motion.
The peripheral portion of the valve spool 3 is formed to include an annular passageway 3a the axial width of which is large enough to communicate apertures 11a and 12a or 12a and 13a. Formed within the guide 14 is a chamber 15 communicated with the annular passageway 3a by a passageway 3b defined by the valve spool 3.
The pressure regulating valve 1 is so adapted that the piston 2 and valve spool 3 are operated under control of a solenoid current I s applied to the solenoid of the solenoid valve 9 by the control unit, thereby communicating oil lines 11 and 12 or 12 and 13. The construction of the control unit is shown only schematically in the figures as it is understood that any type of control unit typically employed in clutch control devices may be employed in the present invention. Similarly, the types of sensors employed to signal the parameters employed by the control apparatus are known per se and are not discussed further. The construction of each of these individual elements makes up no part of the present invention.
Control of the solenoid current I s will be described while referring to the flowchart of FIG. 2. The process for executing this control is inserted at point T in the flowchart of the conventional operation shown in FIG. 9.
The operation indicated by the flowchart of FIG. 2 is executed in the control unit when, as shown in FIG. 9, the solenoid current I s is raised to its maximum value at step k, the accelerator is off (m) and, moreover, the vehicle velocity is less than a set value (n). Under these conditions, and in accordance with the present invention, vehicle inclination is sensed at step o in the flowchart of FIG. 2, a torque T 1 based on this inclination is calculated in the unit at step p, brake pressure P B is sensed at step p', and braking torque T 2 is calculated at step q. Next, a checking is rendered as to the shift position. If the shift is in one of the forward positions, namely D or L, the arithmetic operation T 3 =T 2 +T 1 is performed at step r. If the shift is in the reverse position, namely R, the arithmetic operation T 3 =T 2 -T 1 is performed at step s. The rotational speed (rpm) of the engine is then sensed at step s', and drive torque T 0 is calculated at step t.
The above is followed by comparing the calculated value of T 3 with the drive torque T 0 . If -T 3 >T 0 is found to hold, then the mininum value of the solenoid current I s is outputted at step c and operation returns to the initial step of the flowchart. If -T 3 >T 0 does not hold, however, which condition is indicated at u in FIG. 2, then it is determined whether the calculated value of T 3 is negative or positive. Operation returns to the initial step of the flowchart unless T 3 <0 holds. When T 3 <0 (v) holds, the required value of clutch pressure P c is calculated at step x. The required value of solenoid current I s is then calculated at step y on the basis of the required value of clutch pressure P c , the solenoid current I s having this value is outputted at step z, and operation returns to the beginning.
If the solenoid current I s is maximum, the accelerator is off and, moreover, the vehicle velocity is less than the set value (n) in the flowchart of FIG. 2, then the vehicle will be at rest and the vehicle inclination β will be sensed at step o by an inclination sensor, G sensor or the like.
If a G sensor is used, the vehicle inclination β is sensed thereby by performing the calculation
β=sin.sup.-1 α/g
where g is acceleration due to gravity and α is the acceleration of the vehicle. Let an upwardly directed α be negative and a downwardly directed be positive. According, with reference to FIG. 3, ##EQU1## where α 1 is negative acceleration and α 2 is positive acceleration.
After the vehicle inclination β is sensed, the torque T 1 acting on the vehicle due to the vehicle inclination is calculated at the step p by performing the following arithmetic operation:
T.sub.1 =K.sub.1 ×W×sin β
where K 1 represents a constant, W the weight of the vehicle and β the sensed angle of inclination.
Let the torque acting upon the vehicle when the latter is on the upward incline be negative if it acts in a direction that moves the vehicle backward, and let the torque acting upon the vehicle when the latter is on the downward incline be negative if its acts in a direction that moves the vehicle forward. Then, in the case of the upward incline, we have ##EQU2## and in the case of the downward incline, we have ##EQU3##
This is followed by sensing the master cylinder brake pressure P B generated as a function of the amount of foot pressure applied to the brake pedal of the vehicle. The braking torque T 2 applied to the vehicle is calculated in the unit at step q on the basis of the sensed value of pressure P B . The master cylinder brake pressure P B and braking torque T 2 are related as shown by the graph of FIG. 4. It will be understood that the following holds:
T.sub.2 =f(P.sub.B)
If the result of the decision regarding the shift position is that the shift is in the D or L position, then the arithmetic operation
T.sub.3 =T.sub.2 +T.sub.1
is performed at step r. If the shift is in the R position, then the arithmetic operation
T.sub.3 =T.sub.2 -T.sub.1
is performed at step s.
On the basis of the results of the above calculation and the results of sensing the engine rpm, vehicle drive torque T 0 produced by the engine output is calculated at step t through the following arithmetic operation:
T.sub.0 =K.sub.2 ×T.sub.e
where K 2 is a constant and T e is the engine torque decided by the engine and is expressed as follows:
T.sub.e =f(θ, N.sub.e)
where is the throttle opening and N e represents the engine rotational speed.
The calculated value of T 3 and the drive torque T 0 are compared. If T 0 +T 3 >0 holds, namely if the calculated value of T 3 is greater than the drive torque T 0 , control for increasing the clutch transfer torque is not executed and the minimum value of solenoid current I s is outputted by the unit at step c until the accelerator is turned on at step d to raise the engine rpm. The purpose of this is to prevent the engine from stalling.
If T 0 +T 3 >0 holds, namely if the calculated value of T 3 is less than the drive torque T 0 (u in the flowchart of FIG. 2), and if the condition T 3 <0 also holds (v in the flowchart of FIG. 2), then the required clutch pressure P c is calculated at step x. The purpose of this is to prevent the vehicle from moving backward on an upward incline, as would be caused by inadequate braking pressure, by way of example. The required clutch pressure P c is related to the clutch transfer torque T c as shown in FIG. 5 and is calculated as follows:
P.sub.c =T.sub.c /K.sub.2 +K.sub.3
where K 2 , K 3 are constants.
It should be noted that if T 3 ≧0 holds, the vehicle will not move backward (or forward) and the clutch is in the off state.
The required value of solenoid current I s is calculated at step y on the basis of the calculated value of clutch pressure P c and this current is outputted to the solenoid valve of pressure regulating valve 1 at step z to control the same.
The relationship between the clutch pressure P c and solenoid current I s is indicated by the graph of FIG. 6, which shows that in the region I s ≧I s0 , solenoid current is calculated as follows:
I.sub.s1 =(P.sub.c -P.sub.c0)/K.sub.4 +I.sub.s0
where K 4 is a constant.
As regards the relationship between the solenoid current I s and the operation of pressure regulating valve 1, the solenid current I s is controlled on the basis of the vehicle inclination, brake pressure P B and engine drive torque T 0 , as described above. Assume that the clutch is off, that the inclination is upward as seen from the direction in which the vehicle is about to travel, and that braking torque produced by application of the vehicle brakes is so small that the vehicle is about to move backward. When such is the case, the solenoid current is increased to displace the valve body 10 of solenoid valve 9 in a direction that closes the port 8. As a result, solenoid pressure P SOL with the chamber 6 of cylinder 5 increases with the rise in the value of the solenoid current I s , as shown in FIG. 7, so that the valve spool 3 is displaced in the direction of arrow A (FIG. 1) by the piston 2 acting through the spring 4. This movement of the spool 3 brings the oil lines 11, 12 into communication via the annular groove 3a, so that line pressure is transmitted from oil line 12 to the clutch in the form of clutch pressure, whereby the torque transfer torque is increased to a torque value corresponding to the inclination of the vehicle, namely the inclination of the road. The relationship between the solenoid pressure P SOL and clutch pressure P c is shown in FIG. 8. Clutch pressure P c thus is controlled on the basis of the solenoid current I s .
When the clutch transfer torque attains the value of torque corresponding to the inclination of the vehicle, the line pressure introduced from oil line 11 to annular grove 3a is transmitted to the chamber 15 in guide 14 via the passageway 3b, whereby the valve spool 3 is urged in a direction opposite to that of arrow A. The valve spool 3 oscillates so as to maintain equilibrium between the pressure internally of chamber 15 and the force applied by the spring 4. Clutch pressure in the oil line 12 is thus held at a prescribed value.
Controlling the pressure regulating valve 1 in the above manner increases the clutch transfer torque to compensate for inadequate braking torque produced by the vehicle brakes, thereby preventing the vehicle from undergoing backward movement caused by the inclination of the vehicle. The vehicle is moved forward and accelerated by gradually increasing the clutch transfer torque in dependence upon the amount of accelerator depression. After the vehicle has starting moving forward, control is exercised by a method similar to that used in the prior art.
If the braking torque produced by the vehicle brakes is greater than the torque attempting to move the vehicle backward, the value of the solenoid current I s is reduced to displace the valve body 10 of solenoid valve 9 in a direction that opens the port 8 of the pressure regulating valve 1. As a result, the pressure internally of the chamber 6 is bled to the drain through the port 8, so that the valve spool 3 moves together with the piston 2 and spring 4 in a direction opposite to that of the arrow A, thereby communicating the oil lines 12 and 13 via the annular groove 3a. This allows the clutch pressure to bleed to the drain via the oil lines 12 and 13, as a result of which the clutch transfer torque vanishes.
In summary the following control apparatus for an automatic clutch for use in an automotive vehicle is contemplated based on the foregoing embodiment;
A control apparatus comprising:
a pressure regulating valve having a valve spool for selectively connecting clutch actuating pressure to line pressure and a drain, and
control means for controlling said pressure regulating valve and including:
sensing means for sensing vehicle inclination β, braking torque T 2 and engine drive torque T 0 when the clutch is off;
first calculating means for calculating a directionally adverse torque T 1 , which attempts to move the vehicle backward, using a signal indicative of vehicle inclination produced by said sensing means;
second calculating means for calculating the sum T 3 of the braking torque T 2 and the directionally adverse torque T 1 (T 3 =T 2 +T 1 );
first comparing means for comparing the engine drive torque T 0 and said sum T 3 ;
second comparing means for detecting if said sum T 3 is negative; and
means for displacing the valve spool of said pressure regulating valve in a direction which will connect the clutch actuating pressure to the line pressure when said first comparing means produces a signal indicative that the engine drive torque T 0 is greater than said sum T 3 and, moreover, said second comparing means produces a signal indicating that said sum T 3 is negative; and in a direction which will connect the clutch actuating pressure to the drain when said first comparing means produces signal indicating that the engine drive torque is smaller than said sum T 3 or said second comparing means produces a signal indicating that said sum T 3 is not negative.
The control apparatus includes a shift position sensing means to sense the shift position when clutch is off. When the shift position sensing means produces a signal indicative of "forward" driving, (e.g., D or L range), the second calculating means is operated regularly as hereinabove described. However, when the shift position sensor produces a signal indicative of "rearward" driving ("Reverse" range) the second calculating means calculates T 3 =T 2 -T 1 , i.e., upon summarizing T 2 and T 1 , T 1 is made negative corresponding to the "reverse" direction.
As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | A control apparatus for the automatic clutch of an automotive vehicle includes a pressure regulating valve for selectively connecting clutch actuating pressure to line pressure and a drain, and a control unit for controlling the pressure regulating valve. The control unit senses and/or calculates vehicle inclination, braking torque and engine drive torque. If the braking torque is smaller than a directionally adverse torque which attempts to move the vehicle in the adverse direction when the vehicle is propelled in the desired direction from rest on a grade, the control unit is operative to displace the pressure regulating valve in a direction which will connect the line pressure to the clutch, thereby increasing the clutch pressure to enlarge the clutch transfer torque. Therefore, even if the accelerator pedal is not being depressed when the vehicle is on the grade, there is no time lag between depression of the accelerator pedal when this done and the start of torque transfer by the clutch. This prevents the vehicle from moving in an adverse direction due to its inclination on the grade. | 1 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims priority to and the benefit of China P.R. Priority Application 201210352888.6, filed Sep. 20, 2012 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The invention is related to technology in the emergency power supply field, particularly to an emergency power supply starting system for a lithium battery with automatic preheating function.
BACKGROUND OF THE INVENTION
[0003] As a successful example of new energy resources, the lithium battery is applied extensively in a plurality of fields. However, due to its stringent demand on temperature conditions it is hard to discharge normal large current in both high and low temperature environments. Discharge performance of a lithium battery falls with decreasing temperature and its discharge performance at low temperature is far from that at room temperature. Generally, its discharging performance at −20° C. is 10%-20% of that at room temperature, and the percentage drastically drops to only 2% at about −30° C. What is worse, the required starting current for common starter of automobile increases as environmental temperature falls. The main environmental condition of an emergency power supply starting product is of low temperature or ultralow temperature, due to its properties, which limits the development of a lithium battery on emergency start-up power. From a user's perspective, it is worthwhile to transfer part of its own energy of the battery into heat energy in a certain process and heat the battery up, which would restore the capacity of the battery of its large current electro-discharge. Take the 8 AH mechanical lithium battery with discharge ratio of 80° C. for example, its discharge current at room temperature is 640 A/5 s/pause of 3 min and it could afford 10 cycles of such a discharge. Thus, its discharge performance is only as weak as about 64 A at a temperature of −20° C., which is not enough to start an automobile. However, if 1 AH or 1.5 AH of it is used to transfer into heat energy for the exchange of the temperature increase of the battery, an ideal discharge performance would be obtained. In spite of some energy loss, the discharge performance is enhanced. Basically, the discharge performance in unit time of such batteries of various capacitance remains the same at the same voltage and same discharge ratio, differing only in discharge time and number of cycles. Thus, this mode of automatic preheat could make up for the innate disadvantage of poor discharge performance of lithium battery at low temperature.
SUMMARY OF THE INVENTION
[0004] The purpose of the invention is to offer an emergency power supply starting system for a lithium battery with automatic preheating function to overcome the disadvantage of poor discharge performance of the lithium battery at low temperature and to improve the startup capability of the lithium battery at low temperature.
[0005] The invention is realized with the following technical scheme: the invention includes a lithium battery pack, an output control module, an output module, a working power supply control module, a CPU master control module, an operation panel display function module, a heater control module, a heater module, an information sampling module and a charging module, in which the heater module is disposed on the outside of the lithium battery pack, heating the lithium battery under the control of heater control module, the heater control module, receiving information from the CPU master control module, controls switching on and off of working power supply in the heater module and carries out compulsory power off protection for the heater module on condition of abnormal over current or over-temperature, the working power control module detects usage state, and controls switching on and switching off of power as well as to provide standard working power supply and sampling reference power supply for the CPU master control module, the output control module, connected with the lithium battery pack, controls switching on and switching off the power supply of the lithium battery pack for an external device, the output module, connected with and the under control of the output control module supplies electric power of the lithium battery pack to the external electric device. The information sampling module, connected with the output control module, output module, charging module, working power supply control module, and heater module, respectively collects voltage of the lithium battery pack, external connection status, real-time status in charging process, operation information and real-time temperature information of the lithium battery pack, and transfers the collected information into uniform analog quantity, which is transmitted in time to the CPU master control module. The CPU master control module receives information from the sampling module and executes: processes including estimating real-time residual capacity of lithium battery pack and when abnormal battery voltage change occurs, sending alarm information or compulsory switching off instruction in time, estimating and distinguishing the connection status of a connected external battery apparatus and sending a corresponding instruction or compulsory switching off message when an error occurs, estimating temperature of the lithium battery pack, and on condition of anomaly of battery temperature, raising an alarm or driving the heater control module to start heating and to adjust power of heating and total heating time with reference to the residual capacity of the lithium battery pack, and the charging module is employed to charge the lithium battery pack. The operation panel display function module serves as the input and output window between machine information and user, and submits the user operation information through operation buttons and then displays the processed information from the CPU master control module.
[0006] Preferably, the lithium battery pack comprises several individual lithium batteries combined together by means of series connection or combination of series and parallel connection, is employed to provide power supply to an external electric device and provides a working power supply to all the modules in the system.
[0007] Preferably, the output control module is a large-current-controlling switch and controls the master switch for an outside power supply.
[0008] Preferably, the output module, is an output connecting port, a positive, or a negative port clip, and is employed to fast transmit electric power to an external electric device.
[0009] Preferably, the working power supply control module, comprises a power supply electronic switching circuit, a voltage switching control circuit and a reference voltage switching circuit, wherein the power supply electronic switching circuit transfers all operation information to electric signal and automatically turns on the master control circuit switch of the circuit working power supply to transmit voltage of the power supply to voltage switching control circuit by means of a power supply electronic switch, which the power supply electronic switch transfers the battery voltage into working power supply stable enough for CPU master control module, and in the mean time provides working power to voltage switching circuit and takes advantage of voltage switching circuit to provide a reference voltage source with more accuracy as datum reference point of the CPU master control module and provides a working power supply for a temperature measuring and sampling circuit.
[0010] Preferably, the CPU master control module is composed of a single-chip and related peripheral circuits.
[0011] Preferably, the operation panel display function module comprises a button switch, a digital display module, an LED indicator light and an audio alarm, wherein the button switch provides an input window of user operation, transforms all the operation information of a user, together with information from the information sampling module, into an electric signal, and transfers the information to the CPU master control module, the CPU master control module processes the information and obtains an outcome, and outputs the outcome as a message displayed by the digital display module, as a signal displayed by the LED indicator light, or as an alarm signal of the audio alarm.
[0012] Preferably, the heater control module comprises an electronic switch, a fuse wire and a temperature controller, wherein the electronic switch receives instruction from the CPU master control module, and provides power turning on and off for the heater module; the fuse wire and the temperature controller provide double protection to the heater module in operation by turning-off when an abnormal over current or over-temperature occurs in the heater module or the CPU master control module is out of control.
[0013] Preferably, the heater module comprises a heater, a heat conduction insulating strip, a temperature fuse wire and a temperature detector, wherein the heater serves as a heat source of the lithium battery pack and transforms electric energy of the lithium battery pack into heat energy through a low current of the lithium battery pack. The heat conduction insulating strip electrically isolates the heater and the lithium battery pack, and in the meantime transmits heat energy evenly to the lithium battery pack. The temperature fuse wire is connected to the heater, and self-runs to turn off power on an abnormally high temperature. The temperature detector is employed to measure the real-time surface temperature of the lithium battery pack, and coordinates with the information sampling module to transform the surface temperature of the CPU master control module into an electric signal, and the electric signal is transmitted to the CPU master control module in real time.
Detailed Working Principles of the Invention
[0014] 1. Lithium battery at low temperature could discharge low current in short time, though not large current. Thus, the invention takes advantage of the low current to drive the external heater module, which then increases the temperature of the lithium battery;
[0015] 2. Heating resistor disc with good stability, connected to positive and negative electrodes of the battery by means of electronic switch, is employed in the external heater and laid out on the surface of each battery in accordance with the shape of the battery. As the low current from the battery goes through the heating resistor disc, it is transferred quickly into heat energy, which heats the surface of the lithium battery through direct conduction. Then the entire temperature is raised back in a short span, so the lithium battery will be at a relative high temperature, and its high discharge capacity restored.
Working Process of the Invention:
[0016] Before the lithium battery starts running, the real-time temperature, residual capacity and user operation status of the lithium battery pack are measured by the CPU master control module and different operations are carried out respectively according to the conditions below.
[0017] If voltage is normal but battery temperature is too high, the equipment of the invention will trigger an alarm, and in the mean time compulsorily cut off all input and output functions until the battery is cooled.
[0018] If the voltage of the battery is too low, all output function will be compulsorily turned off and restarted after battery charging.
[0019] If the voltage is normal but the battery temperature is too low, the heater control module will start the heater module to carry out a heating process with driving of low current from the lithium battery and recover temperature of lithium battery for normal use of consumer.
[0000] Compared with Prior Technology, the Invention Enjoys the Following Advantages:
[0020] 1. The invention could automatically measure real-time temperature and residual capacity and adjust the heating status for lithium according to information detected, which means whether it needs heating or the heating time on different condition.
[0021] 2. The maximum of heating temperature could be set in the invention to make sure the lithium battery could obtain ideal temperature after the heat process.
[0022] 3. The maximum of preheating time could be set in the invention to increase heat safety factor of product.
[0023] 4. The invention could automatically adjust the rate of power and time of preheating according to different environment and different battery capacity.
[0024] 5. The invention could realize man-machine interaction by transmission of real-time temperature and preheat information to a user through an operation panel.
[0025] 6. The invention has multiple safety protection and could automatically adjust heating power according to battery temperature, improve heat energy utilization and shorten the preheat latency time. Thus, the operation by a user gets safer, more convenient and more stable.
[0026] Above all, the invention has been installed with a heat source for lithium battery heating, cooperating with the control circuit, to automatically heat the lithium battery so that the emergency starting power supply could be used normally in low temperature condition.
DESCRIPTION OF THE ATTACHED DRAWINGS
[0027] FIG. 1 is the system chart of the invention;
[0028] FIG. 2 is the working process flow diagram corresponding to the system of the invention;
[0029] FIG. 3 is an electric schematic diagram of the working power supply control module circuit in the system of the invention;
[0030] FIG. 4 is an electric schematic diagram of the CPU master control module circuit in the system of the invention;
[0031] FIG. 5 is an electric schematic diagram of the temperature sampling circuit in the system of the invention;
[0032] FIG. 6 is an electric schematic diagram of a USB output and charging control circuit in the system of the invention; and
[0033] FIG. 7 is an electric schematic diagram of the heating control circuit in the system of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The following description of the embodiment is offered with attached drawings and the embodiment below is intended to implement according to the technical scheme of the invention, with detailed execution method and operation processes, but is not to limit the protection scope of the invention.
[0035] As shown in FIG. 1 , the embodiment comprises: lithium battery pack 101 , output control module 102 , output module 103 , working power supply control module 104 , CPU master control module 105 , operation panel display function module 106 , heater control module 107 , heater module 108 , information sampling module 109 and charging module 110 , in which:
[0036] The heater module is disposed on the outside of the lithium battery pack, heating the lithium battery under the control of heater control module.
[0037] The heater control module, receiving information from the CPU master control module, controls switching on and off of working power supply in the heater module and carries out compulsory power off protection for the heater module on condition in the event of abnormal over current or over-temperature.
[0038] The working power control module detects usage state, controls switching on and off of power as well as provide standard working power supply and sampling reference power supply for the CPU master control module.
[0039] The output control module, connected with the lithium battery pack, controls the switch of power supply of the lithium battery pack for external device.
[0040] The output module, connected with and under control of output control module, supplies electric power of lithium to the external electric device.
[0041] The information sampling module, connected with the output control module, output module, charging module, working power supply control module, and heater module, respectively collects information including the voltage of the lithium battery pack, external connection status, real-time status in charging process, operation information and real-time temperature information of the lithium battery pack, and transfers the collected information into uniform analog quantity, which is transmitted in time to the CPU master control module;
[0042] The CPU master control module receives information from the sampling module and executes steps including estimating real-time residual capacity of lithium battery pack and when abnormal battery voltage change occurs, sending alarm information or compulsory switching off instruction in time, estimating and distinguishing the connection status of a connected external battery apparatus and sending a corresponding instruction or compulsory switching off message when an error occurs, estimating the temperature of the lithium battery pack, and on condition of anomaly of battery temperature, raising an alarm or driving the heater control module to start heating and to adjust the power of heating and total heating time with reference to the residual capacity of the lithium battery pack.
[0043] The charging module is employed to charge the lithium battery pack.
[0044] The operation panel display function module serves as the input and output window between machine information and the user, submits the user operation information through operation buttons and then displays the processed information from the CPU master control module.
[0045] In one embodiment, the lithium battery pack comprises several individual lithium batteries combined together by means of a series connection or combination of series and parallel connection, has functions 1. to provide power supply to an external electric device; and 2. to provide working power supply to the inner control circuit;
[0046] In one embodiment, the output control module, comprises a large-current-controlling switch and output wires, and controls for the master switch for the outside power supply.
[0047] In one embodiment, the output module, comprises output wires, an output connecting port, and/or a positive, or a negative port clip, and functions mainly to establish a fast connection between the battery and an external electric device by means of the output system.
[0048] In one embodiment, the working power supply control module comprises a power supply electronic switching circuit, a voltage switching control circuit and a reference voltage switching circuit, wherein the power supply electronic switching circuit transfers all operation information to an electric signal and automatically turns on the master control circuit switch of the circuit working power supply to transmit voltage of the power supply to the voltage switching control circuit by means of the power supply electronic switch, the voltage switching control circuit transfers the battery voltage into stable working power supply required of the CPU master control module, and in the mean time provides working power to the reference voltage switching circuit, and by means of the latter provides a reference voltage source with more accuracy to serve as a reference point for the CPU master control module and a working power supply for the temperature measuring and sampling circuit.
[0049] In one embodiment, the CPU master control module is composed of a single-chip and related peripheral circuits.
[0050] In one embodiment, the operation panel display function module comprises a button switch, a digital display module, an LED indicator light and an audio alarm. The button switch provides an input window of user operation, transforms all the operation information of a user together with information from the information sampling module into an electric signal, and transfers the information to the CPU master control module. The CPU master control module processes the information and obtains an outcome, and outputs the outcome as a message displayed by the digital display module, as a signal displayed by the LED indicator light, or as an alarm signal of the audio alarm.
[0051] In one embodiment, the heater control module comprises an electronic switch, a fuse wire and a temperature controller, wherein the electronic switch receives instruction from the CPU master control module, and provides power turning on and off for the heater module; the fuse wire and the temperature controller provide double working protection to the heater module by turning-off when an abnormal over current or over-temperature occurs in the heater module or the CPU master control module is out of control.
[0052] In one embodiment, the heater module, being a core component of the system, comprises a heater, a heat conduction insulating strip, a temperature fuse wire and a temperature detector, wherein the heater serves as a heat source of the lithium battery pack and transforms electric energy of the lithium battery pack into heat energy through a low current of the lithium battery pack. The heat conduction insulating strip electrically isolates the heater and the lithium battery pack, and in the meantime transmits heat energy evenly to the lithium battery pack. The temperature fuse wire is connected to the heater, and self-runs to turn off power on an abnormally high temperature. The temperature detector is employed to measure the real-time surface temperature of the lithium battery pack, and coordinates with the information sampling module to transform the surface temperature of the CPU master control module into an electric signal, and the electric signal is transmitted to the CPU master control module in real time.
[0053] As shown in FIG. 2 , the working process of the invention is described below:
[0054] Before the lithium battery starts running, the real-time temperature, residual capacity and user operation status of the lithium battery pack are measured by the CPU master control module and different operations are carried out respectively according to the conditions below:
[0055] If the voltage is normal but battery temperature is excessive, the equipment of the invention will give off an alarm, and in the mean time compulsorily cut off all input and output functions until it is cooled;
[0056] If the voltage of battery is too low, all output function will be compulsorily turned off and restarted after battery charging;
[0057] If the voltage is normal but battery temperature is too low, the heater control module will start the heater module to carry out a heating process by driving low current from the lithium battery and recover the temperature of lithium battery for normal use by the consumer.
[0058] As shown in FIG. 2 , the detailed working process of the embodiment is described below:
[0059] Before the lithium battery starts running, the real-time temperature, residual capacity and user operation status of the lithium battery pack are measured by the CPU master control module and different operations are carried out respectively according to the conditions below:
[0060] If the voltage is normal but battery temperature is too high, the equipment of the invention will give off an alarm, and in the mean time compulsorily cut off all input and output functions until it is cooled;
[0061] If the voltage of battery is too low, all output function will be compulsorily turned off and restarted after battery charging;
[0062] If the voltage is normal but battery temperature is too low, heater control module will start the heater module to carry out a heating process by driving low current from the lithium battery and recover the temperature of the lithium battery for normal use of consumer.
[0063] As shown in FIGS. 3-7 , the fundamental diagram of the circuit corresponding to the embodiment is described below:
[0064] FIG. 3 shows a circuit diagram of the power supply control circuit. When switch SW 1 is changed from OFF position to USB-VCC position, voltage of positive port BAT+ will pass the switch, be limited by diode D 4 , current-limiting resistance R 8 and voltage-regulator diode ZD 1 and then pass current-limiting resistance R 9 to drive switch tube Q 1 so as to completely allow current flow in Q 1 . Thus, the Q 4 base electrode could obtain reversal bias voltage and the Q 4 switch tube completely allow current to flow; voltage of positive port BAT+, passing through diode D 8 , Q 4 and R 25 , enters into the input end of the three-port integrated voltage stabilizer 7805 so that port 3 provides stable 5 VDC voltage power to the CPU and other circuits. The 5 VDC voltage passes through current-limiting resistance R 26 and enters into IC 3 , so that IC 3 could provide stable 2.5V power to CPU and temperature detecting circuit as a reference voltage source.
[0065] When any port of “V1”, “CH+”, “external VCC” and so on is powered on, 7805 then will turn into normal working status. Among these ports, if “V1” is inversely connected with an external clip, the external reverse connection signal will be transferred through IC 5 into an inner positive signal, which will be transmitted to the input port of diode D 1 .
[0066] As is shown in FIG. 4 , a diagram of the master control circuit, after the CPU is powered on, it will automatically detect the AD variation of all signal input ports, which is then calculated and processed to drive the corresponding opto-acoustic alarm control circuit and the heater switch control circuit.
[0067] As is shown in FIG. 5 , a circuit diagram for battery temperature sampling, the battery temperature sampling resistance composes R 1 and RT 1 , wherein RT 1 is an NTC high-precision thermistor, processed and disposed on the surface of the battery housing. After the CPU is powered on, different voltage drop is generated by RT 1 in accordance with different resistance value responding to the battery surface temperature, and a corresponding electric signal enters into the port 11 of the single-chip. The signal processed by the single-chip represents the real time temperature, so that the temperature state of the battery could be judged to be normal, too high or too low respectively. If over-temperature occurs, an opto-acoustic alarm will ring in time; if the battery temperature is too low, an alarm will be set by flickering of the LED and the battery is heated according to the actual temperature; when heating time is over or it has reached the preset temperature, the heating process will automatically stop, and in the mean time the flickering of the LED as an alarm will go off to show the end of heating and start of a standby mode.
[0068] The inversed connected alarm signal sampling circuit is composed of IC 5 , R 39 , D 5 and R 2 , R 17 as well as C 3 . Its specific working process is described as below: the large current switch is positioned at OFF, the positive electrode clip of the machine is connected to the negative electrode of the external battery, and the negative electrode clip of the machine is connected to the positive electrode of the external battery. Then, the voltage of the external battery is current-limited by R 39 , and then transferred into an optical signal by IC 5 and D 5 , and turned back into an electric signal by IC 5 . The electric signal is divided by port 3 of IC 5 into two parts, one of which is transmitted into the power supply control circuit to start the working power supply and the other one is connected to R 2 , R 17 , C 3 and so on, so that the signal is input into the single-chip to be processed. The circuit diagram of the USB output and charging control is shown in FIG. 6 .
[0069] In the sampling circuit, the “CH/A” serves as a sample of the charging current intensity; “V2” as a sample of the working status of the inner battery; the “external BAT+” as a sample of correctness of the external battery polarity of output clip, and in the mean time as a sample of misconnection of the external battery (for example, a machine of 12V is connected to both ends of battery of 24V, which indicates misconnection of the inner and external batteries); the “CH+” as a sample of the input voltage of the charger to judge whether there is charging voltage input. If there is, the corresponding charging indicating circuit will be powered on to transmit real-time charging status to the user by an LED; the “inner BAT”″ as sampling site of the electric quantity of the inner battery. The power supply and “BSB-VCC” is connected to the same terminal and the real-time residual capacity of the battery is indicated with LED lights of various colors.
[0070] After switch SW 1 is turned on, the power supply control chip IC 1 is powered on and connected to the USB port through the peripheral sampling, voltage reduction, voltage stabilization, filtration circuits, and so on. Meanwhile, the CPU is powered on and starts to function. If voltage of the inner battery is lower than the set value, the 11 port of single-chip will output a low current, so that IC 1 will cut off output. Thus, the function of USB to automatically cut off on condition of low voltage is realized.
[0071] FIG. 7 shows a diagram of the heating control circuit and the heating circuit, wherein, LED 1 and LED 4 serve as indications of connection status of the machine with the external device. When it is connected correctly, LED 4 (green light) will light up; when the external connection is in reverse, LED 1 will fast blink (0.25 s on/0.25 s off) and beep with a continuous alarm. If voltage of the external battery is incorrect, LED 1 will slowly blink (1 s on/1 s off) and beep with a continuous alarm to indicate a misconnection of the inner and external batteries.
[0072] LED 2 , LED 5 and LED 6 serve as indications of battery electric quantity and rolling flicker indications for charging. When the battery voltage is lower than 11.5V, the LED 2 (red light) will light up; when it is higher than 11.5V but less than 12.5V, LED 6 (yellow light) will light up; when it is higher than 12.5V but lower than 15.5V, LED 5 (green light) will light up; when it is higher than 15.5V, LED 5 will fast blink and beep with a continuous alarm. When the charger is connected and the battery is in charging status, LED 2 , LED 5 and LED 6 will automatically light in rolling cycle, which indicates that it is being charged. When the charging of battery is over, LED 2 , LED 5 and LED 6 will be all in constant light-up status, which indicates that the battery is fully charged.
[0073] LED 3 serves as an indicator of the battery temperature. When battery temperature is over 60° C., LED 3 (red light) will light up and sound an alarm continuously; when battery temperature is too low, the machine will heat the battery automatically after the system is powered on, and in the mean time LED 3 will flicker (0.5 s on/0.5 s off), which indicates that the battery temperature is too low and the machine is in the heating process. When the heating process is over or battery temperature is in the normal range, LED 3 goes off automatically.
[0074] The sound alarm circuit is composed of the beeper B 1 , the control switch tube Q 3 and the resistors R 11 , R 14 . The battery heating system is composed of an electrical relay K 2 , a resettable fuse RF 1 , a heating resistor disc RtA, a protection diode D 10 , a switch tube Q 2 and resistors R 10 , R 13 . When the single-chip decides that battery temperature is too low and the battery needs heating, the 13 port of the single-chip will output a high level current to drive the switch Q 2 to be powered on, so that the electrical relay K 2 is in pull-in break-over status and the heating resistor disc obtains working power supply. Thus, the objective to heat the lithium battery is realized.
[0075] In one embodiment, the specific standards of control is described as below:
[0076] 1. The system automatically adjusts the total heating time and pause recovery time according to the real time condition of battery. Corresponding to different battery temperatures, the heating time could be 3 min, 5 min or 10 min. If battery temperature is −5° C.˜-10° C., the total heating time should be 3 min; if −10° C.˜-20° C., it is 5 min; if less than −20° C., it is 10 min, and in the mean time, there is two heating cycles per min (it means a cycle includes heating of 27 s and pause of 3 s). Thus, the battery could be quickly heated up, and in the mean time is protected timely and has time for automatic recovery;
[0077] 2. Relevant parameter setting of the heating system: upper limit of battery temperature (60° C.), upper limit of maximum heating temperature (20° C.), heating start temperature point (−5° C.), continuous heating up time 27 s (subject to the real-time voltage of the battery), pause period 3 s, longest heating up time 3 min, 5 min and 10 min (automatically adjusted according to the actual battery temperature);
[0078] In one embodiment, the heating resistor chip could serve as a heat source for the battery, as well as in the role of increasing the thermal dissipation area of the battery surface to help cooling the battery.
[0079] One embodiment fully takes advantage of the energy of the battery itself to realize automatic detection of the battery voltage, temperature and a series of actions such as heating, cutting off and so on at ultralow temperature, and the capacity of the battery to output large current at ultralow temperature.
[0080] The fundamental mechanism, main characters and advantages of the invention are described and shown above. A person of the art should be aware that the invention is not limited by the embodiment above. Contents described in the above embodiment and specifications are intended to illustrate mechanisms of the invention. Various changes and modifications may be made to the embodiment without departing from the spirit and scope of the invention, which are all included in the scope of protection of the invention. The scope of the invention is to be limited only by the appended claims and its equivalents. | An emergency power supply starting system a lithium battery with automatic preheating function, including a lithium battery pack, an output control module, an output module, a working power supply control module, a CPU master control module, an operation panel display function module, a heater control module, a heater module, an information sampling module and a charging module is disclosed. The CPU master control module, monitoring the real-time temperature, residual capacity and user operation status of the lithium battery pack, cuts off all output functions and charges the lithium battery (power supply is resumed only after charging) if the battery voltage is too low; if the voltage is normal but battery temperature is too low, the heater control module will start the heater module to initiate the heating process driven with the low current from the lithium battery and the latter is ready for use after the lithium battery temperature returns to normal. The invention arranges a heating source for heating the lithium battery the invention to realize automatic heating for the lithium battery and therefore, normal usage is possible in low temperature condition. | 8 |
BACKGROUND OF THE INVENTION
Small two band radiators for frequency bands around 900 MHz and 1800 MHz are available commercially although they are not sufficiently broadbanded to reach to frequencies of 2200 MHz. Further, very high broadband antennas are available, for instance the logarithmic periodic antennas, although these are too large and expensive for simpler applications.
Described in EP 0 613 209 A1, with the title “A two frequency impedance matching circuit” is a matching circuit for a simple whip antenna that enables roughly 50 Ohms matching at two frequencies to be achieved. In the preferred embodiment, these frequencies lie between 810 and 960 MHz. This implies that the antenna is broadbanded within this frequency band; see FIG. 7 of the patent specification.
The present invention has a different aim, as matching is strived for in two frequency bands that are widely separate from each other, of which at least one band is very wide.
SUMMARY OF THE INVENTION
The object of the invention is to provide a radio antenna that includes a matching circuit which functions on at least two different frequency bands, of which at least one is broad. Other objects are that the antenna shall be relatively small in relation to alternative solutions, and that it shall be relatively simple and economic to mass-produce. For instance, the matching circuit can be mounted on printed circuit boards. In some cases, the radiator may also be mounted on the same printed circuit board.
The invention has evolved as a result of the need to transmit and receive radio waves with a single antenna, within all of the following communications frequency band:
GSM
800-960 MHz
GSM
1710-1880 MHz
GSM
1850-1990 MHz
DECT
1880-1900 MHz
UMTS
1900-2200 MHz
The invention will be described with reference to two preferred embodiments for these frequency bands. However, the invention can be also applied for other frequency ranges and other applications, and hence the principle of the invention will be described in more generality in the accompanying claims.
The frequency ranges with which the preferred embodiments are concerned will be designated in accordance with the following:
890-960 MHz will be referred to as the “first frequency band”
1710-2200 MHz will be referred to as the “second frequency band”
In this case, the three higher frequency bands have been combined into a broader band.
A complete antenna consists of radiator ( 5 , 20 ) and matching circuit ( 8 ). The matching circuit always includes a transmission circuit ( 10 , 21 ) and, when required, a Balun transformer ( 9 ). It is assumed that the radiator has low radiation resistance within a first frequency band and a high radiation resistance within a second frequency band.
The purpose of the transmission circuit ( 10 , 21 ) is to transfer the electromagnetic wave from the antenna connection point, Port A—A, to the other end of the transmission circuit, Port F—F, so that its impedance values within both frequency bands will lie in the proximity of a common resistance value that corresponds to the impedance of the feeder, the Balun transformer, or the radio apparatus, illustrated at point O in the Smith chart of FIGS. 4 to 8 inclusive. When the antenna is balanced (e.g. dipole) and the supply line is unbalanced (e.g. a coaxial cable), the matching circuit ( 8 ) will also include a Balun transformer ( 9 ) whose Port G—G is matched to the unbalanced feeder.
The function of the transmission circuit is illustrated in the Smith chart in FIGS. 4-9, where it is shown how the impedance curve of the radiator is changed incrementally, so that the curve segment which lies in the frequency bands concerned is moved to the proximity of the centre point O in the Smith chart of FIG. 9 .
The impedance of the radiator ( 5 ) in the Smith chart (FIG. 4) shows that the curve intersects the true axis at a first point (P) within the first frequency band, and at a second point (Q) within the second frequency band. The radiator ( 5 ) is thus resonant at these frequencies. The curve is moved down in the capacitive region of the Smith chart shown in FIG. 5, with the aid of parallel capacitor ( 11 ). The inductance ( 13 ) moves the curve to the inductive region and draws the curve together to form a small loop in accordance with FIG. 6 . The curve is moved closer to the centre point (O) of the diagram in FIG. 7, with the aid of series capacitor ( 12 ), and its balance is improved in relation to the horizontal axis (X) of the diagram at the same time. The curve is then shifted through a phase angle of about 130° with the aid of a phase shift line ( 14 ), the result being shown in FIG. 8 . We see here that the markers in the first band lie in the proximity of the horizontal axis (X), whereas the markers for the second band lie on a coherent loop in the inductive part of the Smith chart. This last-mentioned loop is moved with the aid of the parallel capacitance ( 15 ), so that it will lie around the centre point (O) in the Smith chart, see FIG. 9 . The region for the first band is therewith influenced only to a small degree, as the parallel capacitance ( 15 ) influences the positions of the points in the Smith chart to a smaller degree at these low frequencies. Thus, as seen from the first port (A—A) to the second port (F—F), the transmission circuit ( 10 ) is comprised of parallel capacitor ( 11 ), series inductance ( 13 ), series capacitor ( 12 ), phase shifting line ( 14 ) and parallel capacitor ( 15 ), in that order.
The Balun transformer ( 9 ) will be described below in conjunction with the first preferred embodiment.
The Present Standpoint of Techniques
Small two band radiators for frequency bands around 900 MHz and 1800 MHz are available commercially although they are not sufficiently broadbanded to reach to frequencies of 2200 MHz. Further, very high broadband antennas are available, for instance the logarithmic periodic antennas, although these are too large and expensive for simpler applications.
Described in EP 0 613 209 A1, with the title “A two frequency impedance matching circuit” is a matching circuit for a simple whip antenna that enables roughly 50 Ohms matching at two frequencies to be achieved. In the preferred embodiment, these frequencies lie between 810 and 960 MHz. This implies that the antenna is broadbanded within this frequency band; see FIG. 7 of the patent specification. The present invention has a different aim, as matching is strived for in two frequency bands that are widely separate from each other, of which at least one band is very wide. 3
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an antenna that includes a balanced radiator and matching circuit in a first preferred embodiment.
FIG. 2 illustrates the first side of a printed circuit board.
FIG. 3 illustrates a coupling diagram for the matching circuit.
FIG. 4 is a Smith chart for the dipole at port A—A in the coupling diagram.
FIG. 5 is a Smith chart at point B—B in the coupling diagram.
FIG. 6 is a Smith chart at point C—C in the coupling diagram.
FIG. 7 is a Smith chart at point D—D in the coupling diagram
FIG. 8 is a Smith chart at point E—E in the coupling diagram.
FIG. 9 is a Smith chart at point F—F in the coupling diagram
FIG. 10 illustrates the Smith chart of the entire antenna at port G—G in the first preferred embodiment, where an unbalanced feeder from the transceiver (not shown in the figure) can be connected.
FIG. 11 illustrates an antenna with unbalanced radiator in a second preferred embodiment.
DESCRIPTION OF THE INVENTION
A first preferred embodiment with balanced radiator:
The antenna ( 1 ) shown in FIG. 1 comprises two parts:
Radiator ( 5 )
Matching circuit ( 8 )
Both components are mounted on a printed circuit board ( 2 ) that has respective first and second sides ( 3 and 4 ). Both sides are metallised and carry printed patterns.
There is chosen as the radiator ( 5 ) a dipole that has a first resonance point (P), see FIG. 4, in the first frequency band (where it functions as a half-wave dipole) and a second resonance point (Q) in the second frequency band (where it functions as a full-wave dipole). This radiator is balanced. The measurement ratio is between the width (B) of the dipole, see FIG. 2, and the length (I) is sufficiently large to cover the first frequency band. One dipole half is mounted on the first side of the printed circuit board, and the other dipole half on its other side. This enables the matching circuit and feeder (in the form of a microstrip) to be included in the pattern on said board.
The described choice of radiator means that its impedance in the gap will be approximately 60 Ohms in the first band and approximately 500 Ohms in the second band; see FIG. 4 .
The antenna is constructed for a microstrip feeder that has characteristic impedance of 50 Ohms. The imbalance must be compensated for, when a microstrip or a coaxial conductor is unbalanced (non-symmetrical), whereas a dipole is balanced (symmetrical). The impedance difference in the second band must also be compensated for, and hence a matching circuit is necessary.
The matching circuit ( 8 ) for the first preferred embodiment consists of two parts:
Balun transformer ( 9 ) of a modified Klopfenstein-Duncan type, which is described below in a separate passage.
Transmission circuit ( 10 ), which is also described separately.
The Balun transformer and the transmission circuit are connected in series. In this example, a resistance of 75 Ohms with the smallest possible reactance was taken as a choice of impedance at the connecting point (Port F—F) between the transmission circuit ( 10 ) and the Balun transformer ( 9 ). This means that the transmission circuit was constructed for transformation of the impedances to 75 Ohms; see Table:
VSWR without
Port A—A
Port F—F
transmission circuit
First band
60 Ohms
75 Ohms
1:1.25
Second band
500 Ohms
75 Ohms
1:6.67
The transmission circuit ( 10 ) transforms the impedance from Port A—A to Port F—F so that it increases slightly in the first band and decreases more in the second band. As a result, the impedance lands in the vicinity of the same value at all frequencies lying in the frequency bands in question, this value being 75 Ohms, for instance.
The Balun transformer ( 9 ) is constructed so that transformation takes place from 75 Ohms, balanced port (F—F) to 50 Ohms, unbalanced port (G—G). The modified Klopfenstein type is so broadbanded that its ports retain the same impedance within both frequency bands.
As seen from the dipole ( 5 ) through to the Balun transformer ( 9 ), the transmission circuit ( 10 ) consists of a parallel capacitor ( 11 ), two series inductances ( 13 ), two series capacitors ( 12 ), a phase shifting line ( 14 ), and a parallel capacitor ( 15 ), in that order. The reason why the series components are in pairs—something that is generally unnecessary—is because it is desired to maintain the symmetry in the structure between the dipole ( 5 ) and the Balun transformer ( 9 ). Each component in the transmission circuit changes the impedance curve in the Smith chart in its own way, as described hereinafter and illustrated to 50 Ohms.
The impedance (FIG. 4) of the dipole ( 5 ) shows that the curve intersects the real axis X at the following points: 60 Ohms in the first band (P) and 500 Ohms in the second band (Q). The dipole is thus resonant at these frequencies. The curve is moved downwards into the capacitive region of the Smith chart according to FIG. 5, with the aid of a parallel capacitor ( 11 ). The inductances ( 13 ) move the curve to the inductive region and draw the curve together to form a small loop as small loop as shown in FIG. 6 . The curve is moved closer to the centre point (O) of the chart with the aid of series capacitors ( 12 ), therewith improving the balance of the curve in relation to the horizontal axis (X), see FIG. 7 . The curve is then rotated through a phase angle of 130° (approximately) with the aid of a 75 Ohms phase-shifting line ( 14 ). The result will be apparent from FIG. 8 . It is seen here that the markers in the first band lie in the proximity of the horizontal axis (X), while the markers in the second band lie on a coherent loop in the inductive part of the Smith chart. This last-mentioned loop is moved with the aid of the parallel capacitance ( 15 ) so as to lie around the centre point (O) of the Smith chart; see FIG. 9 . The range of the first band is therewith influenced only to a small degree, since the capacitance ( 15 ) has less effect on the position of the points in the Smith chart at these lower frequencies.
It is generally known that isolated discrete elements (for instance resistances, capacitors, coils) or groups thereof can be replaced with equivalent networks of discrete and/or distributed elements (such as lines, stubs, patches) or their combinations. Similarly, distributed lines can be replaced with equivalent networks that include discrete elements. The units that can be obtained with this invention by conversions of this nature also lie within the protective scope of said invention.
Balun Transformer Theory
R. W. Klopfenstein describes a broadband Dolph-Tchebycheff circuit in the article.
A Transmission Line Taper of Improved Design. Proceedings of the IRE, pp. 31-35, 1956.
J. W. Duncan has further developed the theory, in order to obtain a broadband impedance transformer that is a Balun (balance—to unbalance converter) at the same time, according to the article:
100:1 Bandwidth Balun Transformer. Proceedings of the IRE, pp. 165-164, February 1960.
There is used for this invention a variant of the Balun transformer which is a further development of Duncan's suggestion, so that the circular structure is converted to a planar structure that can be connected directly to a microstrip.
A Second Preferred Embodiment Including an Unbalanced Radiator Over the Earth Plane
The antenna ( 16 ) shown in FIG. 11 consists of two parts:
Radiator ( 20 )
Transmission circuit ( 21 )
There is chosen as the radiator ( 20 ) a monopole over the earth plane ( 19 , 23 ), having a first resonance point in the first frequency band (here it functions as a quarter-wave monopole) and with a second resonance point in the other frequency band (where it functions as a half-wave monopole). The measurement ratio between the width (b) and the length (k) of the monopole is chosen to be large enough to cover the first frequency band.
The transmission circuit ( 21 ) is mounted on a printed circuit board ( 17 ) that has a first and a second side ( 18 and 19 respectively). Both sides are metallised and carry patterns.
The radiator is placed perpendicular to the first side of the printed circuit board ( 17 ), the metal pattern on said first side ( 18 ) being one side of the transmission circuit ( 21 ). The other side of the transmission circuit ( 21 ) and part of the earth plane are mounted on the other side ( 19 ) of the printed circuit board. The feeder ( 22 ) in the form of a microstrip can also be mounted on the printed circuit board ( 17 ).
A Balun transformer is not required for monopole radiators.
The aforedescribed choice of radiator ( 20 ) means that its impedance in the gap will be approximately 30 Ohms in the first band and approximately 300 Ohms in the second band.
The antenna is constructed for feeding with an unbalanced line that has a characteristic impedance of 50 Ohms. The transmission circuit is also needed in this case for impedance matching in the second band. No Balun transformer is required on the other hand.
The impedance at the connection point (Port F—F) between the transmission circuit ( 21 ) and the feeder ( 22 ) in this example will preferably have a resistance of 50 Ohms and the smallest possible reactance. This means that the transmission circuit is designed to transform impedances in the following manner:
VSWR without
Port A—A
Port F—F
transmissioncircuit
First band
30 Ohms
50 Ohms
1:1.67
Second band
300 Ohms
50 Ohms
1:6
The transmission circuit transforms impedance from Port A—A to Port F—F so that it increases slightly in the first band and decreases significantly in the second band. As a result, the impedance will lie in the proximity of the same value, in this example 50 Ohms, at all frequencies that lie in the frequency bands concerned.
The description of the transmission circuit for the first preferred embodiment also applies in this case, although with the difference that the serial components need not be placed in pairs, since both the radiator and the lines are unbalanced. The aforesaid concerning equivalent exchanges of discrete, distributed elements, and groups also applies here.
The principles for processing the curve in the Smith charts described in connection with the first preferred embodiment also apply here The Smith charts can suitably be normalised to 50 Ohms.
Designations
1 . The entire dipole antenna
2 . Printed circuit board for the dipole antenna
3 . First side of a printed circuit board for the dipole antenna
4 . Second side of the printed circuit board for the dipole antenna (not shown in the Figure)
5 . Radiator (dipole)
6 . One dipole half
7 . Other dipole half
8 . Dipole antenna matching circuit
9 . Dipole antenna Balun transformer
10 . Dipole antenna transmission circuit
11 . Parallel capacitor
12 . Series capacitor
13 . Series inductance
14 . Phase-shifting line
15 . Parallel capacitor
16 . The entire monopole antenna
17 . A printed circuit board for the monopole antenna
18 . First side of the printed circuit board
19 . Second side of the printed circuit board with earth plane
20 . Radiator (monopole)
21 . Transmission circuit for the single-pole antenna
22 . Feeder line
23 . Conductive surface elements
A—A
First port of the transmission circuit
F—F
Second port of the transmission circuit
G—G
Connecting port for unbalanced line
b
The width of the radiator
l
The length of the dipole
k
The length of the monopole
O
The centre of the Smith chart
X
The horizontal axis of the Smith chart
ZA
Antenna impedance
P
The resonance point of the radiator in the first band
Q
The resonance point of the radiator in the second band
ZG
Impedance of the radio apparatus or the feeder line
UG
Source voltage of the radio apparatus | Matching circuit for radio antenna that functions on a two-frequency band which are spaced approximately at a distance of one octave, wherein the upper band is broad. For instance, the first frequency band may be 890-940 MHz and the other band 1710-2200 MHz. The radiator may be a dipole or a monopole over the earth plane, whose bandwidth is sufficient for the first band. The larger bandwidth for the second band is obtained with a transmission circuit that moves and forms the frequency curve stepwise in the Smith chart. When necessary, the matching circuit includes a broadband Balun transformer in addition to said matching circuit. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] The present invention relates to a hand held scraper which utilizes suction from a vacuum to remove dust and debris generated while scraping.
[0003] 2. State of the Art
[0004] Hand-held scrapers are often used for removal of material from a surface. For example, scrapers may be used to remove material to shape a surface, to remove glue or foreign substances from a surface, to clean a surface, etc. Scrapers typically have a handle and a metal blade which is held roughly perpendicular or at an angle to the surface for use, and which scrapes material from the surface as the scraper is moved back and forth across the surface.
[0005] One drawback of using a scraper is that the material removed while scraping (dust, chips, shavings, etc.) typically remains on the surface or falls to the floor, bench, etc. Material which remains on the surface makes it difficult for the operator to see the item being scraped, and is often thrown about by subsequent scraping. The material then often ends up on the work bench, floor, etc. where it must be later removed. Often, the material removed while scraping falls on carpet or in crevices where it is difficult to remove. In many situations, such as cleaing a wall or fireplace in a finished house, it is particularly desirable to remove all of the dust and material generated while scraping without the material falling on carpet or other finished surfaces.
[0006] An attempt has been made to collect the material removed while scraping by combining a vacuum suction handle with a scraper blade, as shown in U.S. Pat. No. 6,070,292. While an improvement, the device only removes the dust, etc. from one side of the scraper blade. Scrapers are commonly used in both directions, creating dust on both sides of the blade. Dust and the like which is not removed from one side of the blade will typically be pushed about by that side of the blade and create a mess.
[0007] There is thus a need for a scraper which overcomes the limitations of available scrapers. Specifically, there is a need for a vacuum assisted scraper which removes the dust and debris generated while scraping from both sides of the blade.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide an improved vacuum assisted scraper.
[0009] According to one aspect of the invention, a scraper is provided with a vacuum hood which extends to both sides of the blade, and which provides airflow to remove debris from both sides of the blade. The vacuum shroud may be formed to have the blade mount formed on the inside of the shroud, and may have air passages formed to direct air flow from both sides of the blade and into a vacuum port.
[0010] These and other aspects of the present invention are realized in a vacuum assisted scraper as shown and described in the following figure and related description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Various embodiments of the present invention are shown and described in reference to the numbered drawings wherein:
[0012] FIG. 1 shows a perspective view of the scraper of the present invention;
[0013] FIG. 2 shows a side view of the scraper of the present invention;
[0014] FIG. 3 shows a bottom view of the scraper of the present invention;
[0015] FIG. 4 shows a partial cross-sectional view of the scraper of the present invention; and
[0016] FIG. 5 shows a partial cross-sectional view of the scraper of the present invention.
[0017] It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity.
DETAILED DESCRIPTION
[0018] The invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims.
[0019] Turning now to FIG. 1 , a perspective view of a scraper of the present invention is shown. The scraper 10 includes a handle 14 which may be formed with ridges 18 , contours, or other structures to promote a firm and comfortable grip of the scraper 10 . The handle 14 is connected to a scraper head 22 which is used to mount the blade 26 . The scraper head 22 is generally flat and is shown as generally rectangular, but can be made in various shapes. The scraper head 22 both provides a mounting surface for the blade 26 , and generally defines the area cleaned by the vacuum as the scraper is used.
[0020] The blade 26 is shown as a length of angle shaped steel. The angle shaped blade 26 provides two lateral scraping surfaces. A fastener 28 , such as a bolt or screw, is used to hold the blade to the scraper head 22 and allows the blade to be changed. The blade 26 may be held such that one side of the blade is generally parallel to the scraper head 22 and the other side (used for scraping) is held generally perpendicular to the scraper head. The scraper head 22 includes a vacuum shroud 30 which is present both in front of and behind the blade 26 .
[0021] The handle 14 is hollow, and the conduit therethrough is connected to the area enclosed by the vacuum shroud 30 via opening 34 . A front airflow passage 38 is provided between the front of the blade 26 and the front of the vacuum shroud 30 . The passage 38 allows air to flow upwardly between the blade 26 and the front portion of the vacuum shroud 30 and then above the blade 26 (between the blade 26 and shroud 30 ) towards the back portion of the vacuum shroud and towards the opening 34 . Thus, airflow is provided from in front of and behind the blade, through opening 34 into the handle, and into a vacuum. The vacuum shroud 30 directs the vacuum generated air flow around both sides of the blade so as to aid in collecting dust and debris from both sides of the blade while using the scraper 10 .
[0022] FIG. 2 shows a side view of the scraper 10 and illustrates how openings 42 may be made in the sides of the vacuum shroud 30 to increase the airflow past the back side of the blade (towards the handle). In some situations, more dust, or larger particles of dust, is generated at the back of the blade 26 while scraping.
[0023] FIG. 3 shows a bottom view of the scraper 10 . The opening 34 between the air passage in the handle 14 and the vacuum shroud 30 can be seen. Additionally, it can be seen how airflow passage 38 may extend across nearly the entire front of the blade 26 , promoting good collection of the dust and debris created in front of the blade. The scraper head 22 typically has a mount 46 used to attach the scraper blade 26 . The mount 46 may be used to elevate the blade 26 from the surface of the head 22 . The mount 46 may have a ridge 48 or other structure thereon (also visible in FIG. 4 ) to aid in preventing rotation of the blade 26 during use. The ridge 48 may also be used to cover the blade 26 adjacent the opening 34 to protect a user from cutting their finger when clearing debris from the opening 34 . The front portion of the vacuum shroud 30 may also be used to maintain the desired alignment of the blade 26 .
[0024] The portion of the mount 46 beneath the blade 26 (indicated by dashed lines) does not extend to the sides of the scraper head 22 , extending the airflow passage 38 around the sides of the mount 46 , between the blade 26 and the head 22 . Thus, a vacuum will draw air between the blade 26 and airflow shroud 30 in front of the blade through airflow passage 38 , the air passing around the sides of the mount 46 , through opening 34 , and through the handle to the vacuum. Dust and debris are thus removed from in front of the blade. Air is also drawn around the back portion of the vacuum shroud 30 and in openings 42 , through the opening 34 and through the handle 14 to the vacuum, removing dust and debris from the back side of the blade. Thus, dust and debris are removed from both sides of the blade 26 as the scraper 10 is used.
[0025] FIG. 4 shows a partial cross-sectional view of the scraper 10 taken along line A-A of FIG. 3 . The air conduit 50 through the handle 14 is clearly seen. The air conduit 50 may be formed with a socket 54 , or enlarged portion, adjacent the end of the handle 14 which receives a vacuum hose, and which is typically sized to receive an ordinary 1.25 inch vacuum hose. Opening 34 is seen as the area where the conduit 50 opens into the area enclosed by the vacuum shroud 30 . The mount 46 can be seen as a raised central portion of the head 22 , and can be seen how it elevates the blade 26 .
[0026] FIG. 5 shows a partial cross-sectional view of the scraper 10 taken along line B-B of FIG. 3 . The cross-sectional view of the scraper 10 does not pass through the mount, but runs along side thereof. It can be seen how the how the airflow passage 38 extends between the blade 26 and the head 22 , extending the airflow passage around the mount (not seen) so as to allow air flow through airflow passage 3 8 , around the sides of the mount, through opening 34 and into conduit 50 through the handle 14 , where it passes into the vacuum.
[0027] FIG. 5 and FIG. 2 both illustrate how the scraper head 22 may be mounted at a slight angle to the handle 14 so as to make the scraper easier to use. As shown, the head 22 is mounted at an angle of about 20-25 degrees from being parallel to the handle, positioning the blade 26 at a corresponding angle from being perpendicular to the handle.
[0028] The present invention thus provides a scraper 10 which is connected to a vacuum and which draws air from both in front of the behind the blade 26 to remove dust and debris from both sides of the blade. The scraper is advantageous as it keeps the area clean while the scraper is being used, promoting easier use of the scraper.
[0029] There is thus disclosed an improved vacuum assisted scraper. It will be appreciated that numerous changes may be made to the present invention without departing from the scope of the claims. | A vacuum assisted scraper draws air from both in front of and behind the scraper blade to collect dust and debris as the scraper is used. The scraper keeps the work area clean and prevents dust buildup from hindering the use of the scraper. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to the anodization of porous valve-metal anodes for capacitors and particularly to a method of forming a thin oxide layer on the outer surface thereof which has been anodized to a higher voltage than the rest of the anode to increase breakdown voltage adjacent the solid electrolyte layer.
It is known to anodize sintered valve metal electrodes in such a way that the oxide layer on the outer surface is formed (anodized) at a higher voltage than that on the inner surface of the sintered body. According to one method, described by Scheller et al in U.S. 3,415,722, issued Dec. 10, 1968, the sintered body is anodized at a normal voltage and impregnated with a material which is insoluble in the electrolyte, i.e., wax, stearin, anthracene, etc. The impregnant is extracted from the outer portion of the body, the anodization is continued at a higher voltage, and finally the impregnant is extracted from the inner portion of the body. The resulting structure has a higher breakdown voltage than prior art structures because of the thicker outer oxide layer. Alternately, Scheller et al propose to carry out the second anodization in a highly viscous electrolyte without impregnation, as such an electrolyte penetrates the inner surface slowly enough so that formation of the outer surface predominates.
SUMMARY OF THE INVENTION
Therefore, it is an object of this invention to provide an improved process for the two-stage formation of sintered valve metal electrodes.
It is a further object of this invention to provide an improved two-stage formation process which is applicable to both low- and high- voltage electrolytic capacitor electrodes.
It has been found that two-stage formation can be carried out without impregnation of the sintered body except for very low voltage electrodes. In the latter case, the impregant is such that there is no removal problem.
According to the present invention, the sintered anodes are anodized in a conventional electrolyte in the first stage, e.g. in phosphoric, sulfuric, or hydrochloric acids or salts of them, during which a very uniform film is formed throughout the pellet structure. During the second-stage, a different electrolyte is used containing a salt of a weak acid as solute in the electrolyte, so that hydronium ion concentration increases in the pores as a result of charge passage therein but not at the surface as the bath conditions are typical of a well-stirred bath or reactor. Ion transport or diffusion is such that the weak acid anion moves into the pores as necessary to balance the electrical charges. As a result, the concentration of the principal conducting species (hydronium ion) is reduced in the establishment of equilibrium between the hydronium ion, acid anion, and undissociated acid, thus forming a poorer-conducting species. Hence, it is necessary to use a different electrolyte in the second-stage, i.e., a salt of a weak acid having an ionization constant of less than 1.0×10 -4 in contrast to the stronger (more ionic) electrolyte of the first-stage having a larger ionization constant. The reduction in the concentration of the conducting species results in a relatively high voltage drop in the electrolyte which hinders further anodization in the interior while a thicker oxide layer is being built up on the outside to a higher formation voltage in the region of continued high conductivity. Such diffusion and change in electrolyte concentration within the pores is discussed by W. J. Bernard and E. J. Fresia, "Anodic Oxidation of Porous Aluminum Pellets" Electrocomponent Sci. Technol. 1, 59-64 (1974).
When forming very low voltage capacitors (10.0V), it becomes necessary to hinder or block even more the anodization within the pores, as even a slight increase in oxide film thickness will strongly affect overall capacitance. Therefore, instead of relying on the conversion of conducting species within the pores to non-conducting species, the sintered anode is impregnated with distilled water, ethylene glycol, or other poorly conducting solvent, so that by the time the weak acid ion has diffused in and formed a more conducting medium than the pure solvent, the second stage anodization to produce the additional layer at the exterior is almost or totally completed. An alternative procedure is to impregnate the anode before the second stage formation with the weak acid corresponding to the salt to be used as electrolyte solute.
By either process, the anode is finished in the usual manner and made up into capacitors with a solid electrolyte, e.g., manganese dioxide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred method which is adaptable to efficient production is as follows. Sintered valve-metal pellets are anodized in a conventional formation electrolyte, such as phosphoric acid or an ammonium chloride solution, to the desired voltage.
The pellets are thoroughly rinsed to remove all traces of the electrolyte and subjected to a second anodization in a solution of a salt of a weak acid to form an outer layer at a higher voltage than that of the interior. The preferred second-stage formation electrolyte is a salt of boric acid, such as borax, or ammonium pentaborate, although salts of weak acids having a dissociation constant of 1.0×10 -4 or less may be used. The preferred concentration of the above preferred electrolytes is 0.01-4.0 wt.% borax or pentaborate in a solution which may contain 1-5 wt % boric acid as an acid anion reservoir to permit large numbers of pellets to be anodized at the same time as in a production situation.
The pellets are rinsed of electrolyte and treated in the usual manner, e.g., impregnated with a solid electrolyte such as manganese dioxide, and made into capacitors.
When producing low-voltage capacitors (about a 10V anodization), any increase in the oxide film thickness in the interior of the pellet during the second stage anodization is undesirable. Therefore, an additional step is added of impregnating the pellets with a poorly conducting solvent, e.g., distilled water, ethylene glycol, etc. Another means of achieving a blocking action is to use a solution of the weak acid itself as the impregant prior to the second-stage formation. Since the weak acid is generated by the dissociation of the salt (at which point the conductivity drops) during the limited anodization within the pores, the introduction of that solution before anodization anticipates its eventual presence and facilitates the effect desired. While the electrolyte still will tend to diffuse into the pores under the influence of the applied field, if the second-stage anodization time is kept short, external anodization will be completed before any significant conduction, and hence anodization, occurs internally. A salt of a weak acid must still be used as electrolyte or else the current-blocking action of the solvent or acid, e.g., boric acid, in the pores will be overcome quickly.
EXAMPLE 1
This example shows the application of the present invention to high-voltage formation of tantalum pellets. Pellets weighing 2.7 g were anodized in 1% ammonium chloride solution at 25° C to 1000V. The resulting capacitance was 56.7 μF at 120 Hz. Second-stage anodization was carried out at 25° C to 180V in an ammonium borate solution having a resistivity of 4400 ohm-cm at 25° C. The charge required was only 1.3% of that for the first formation, and the capacitance was virtually unchanged, even though the pellet exterior was anodized to 180V, showing that there was little secondary anodization in the pellet interior.
EXAMPLE 2.
This example shows an application to low-voltage formation. Pellets weighing 0.13 g. were anodized in 1% ammonium chloride to 9V at 90° C, giving a capacitance of 75 μF at 120 Hz. A second-stage anodization at 90° C was carried out in 4% ammonium pentaborate with a specific resistivity of 100 Ω - cm at 25° C. The apparent formation voltage on the pellet exterior was 29V, but the total capacitance was only reduced by 10%, to a value of 67.6 μF.
The following examples demonstrate the utility of the present invention utilizing preimpregnation before second-stage anodization for the production of low voltage capacitors. The tantalum pellets were formed to 75V at constant current in the second-stage electrolyte without a first-stage formation, and, after capacitance was measured, the pellets were fractured to permit a visual determination of the formation voltage in the pores.
EXAMPLE 3
The second-stage anodization was carried out without solvent impregnation in 2% ammonium pentaborate for 4 min. The capacitance was 445 μF, and, on fracturing the pellet, a visible area of 30 V formation was evident in the interior.
EXAMPLE 4
The pellets were pre-dipped in distilled water and then anodized in 2% ammonium pentaborate for 3.17 min. The capacitance was 530 μF, and there was no interior formation.
EXAMPLE 5
The pellets were pre-dipped in ethylene glycol and then anodized in 2% ammonium pentaborate for 4.10 min. The capacitance was 540 μF, and there was no interior formation.
EXAMPLE 6
The pellets were predipped in distilled water and anodized in 0.33% phosphoric acid for 17.5 min. The capacitance was 87 μF, and the interior, like the exterior, was formed to 75 V.
Comparison of examples 3, 4, and 5 shows the blocking action of the solvent against anodization of the interior in the second stage. Example 5 demonstrates that the use of a conventional electrolyte utilizing a relatively strong acid (K I =7.5×10 31 3) results in an overall uniform oxide film formation even when the pellet has been previously impregnated with distilled water, in striking contrast to the results shown in Examples 3 and 4. This is shown by the visual observations of the oxide film color in the pellet interior upon fracturing the pellet, the low capacitance, and the long formation time.
EXAMPLE 7
Ten experimental units were made into capacitors and compared with 11 control units. For the experimental units, 2.7 g tantalum pellets were anodized in a conventional phosphoric acid electrolyte at 90° C and a formation current of 100 mA/pellet. The pellets were rinsed thoroughly and predipped in deionized water. The second stage anodization was carried out in an aqueous solution of 1% boric acid and 0.04% borax (both percentages by weight) for 120 sec., at 90° C and a formation current of 75 mA/pellet.
Table I______________________________________ Control Experimental Ratio______________________________________Formation voltage (V.sub.F) 150V 120V 1.25Second-stage V.sub.F -- 155VAfter Aging at 125° C, 35V Capacitance (μF) 29.4 36.8 1.25 Dissipation Factor 1.0 1.0 Median leakage current (μA) 0.45 0.45 I.sub.L /μF 0.015 0.012______________________________________
Since, in the production process, the anodized pellets are thoroughly rinsed with water before impregnation with the working electrolyte and assemblage into capacitors, the salt used as the second-stage electrolyte should be a salt of water-soluble weak acid.
Although tantalum is the preferred valve-metal as is shown throughout the examples, it should be understood that the process is applicable to other valve-metals such as aluminum, titanium, zirconium, hafnium, and niobium. | In a two-stage anodization process in which the outer portion of a porous valve-metal sintered body is anodized to a higher voltage than the inner portion, the second-stage anodization is carried out in an electrolyte containing a salt of a weak acid. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of co-pending U.S. patent application Ser. No. 13/195,744, filed on Aug. 1, 2011, the entirety of which is incorporated herein by reference.
FIELD
The disclosure pertains to devices and methods for storing and dispensing fluids. More particularly, the disclosure pertains to a flexible hair color bottle for mixing and applying fluid hair color chemicals using an asymmetric, bi-directional valve assembly.
BACKGROUND
The success of a hair color treatment depends on safe and controlled application of chemical dyes in a timely manner. Such chemical dyes, especially fluids, or those that contain volatile components such as solvents, may be allergenic, irritating, or even toxic if handled incorrectly. In addition, chemical dyes of the type used in hair color products can leave permanent stains if they are spilled on clothing, furniture, countertops, or floors. Moreover, skin can become stained or irritated if the color is allowed to make contact with bare skin for prolonged periods.
Hair color products are typically packaged with detailed application instructions, but it is often left up to the professional hair colorist to assemble the necessary tools for applying the product safely and consistently. For example, some instructions direct the user of the product to mix chemicals in a glass or plastic container, and to apply the chemical with a brush. If an open container such as a color bowl is used, product may be lost to evaporation and the resulting fumes may be unpleasant or even unsafe. Hair products intended for consumers are generally packaged with a color bottle or other application tools along with hair color (dye) and developer (peroxide). Consumers at home may be supplied a brush that is attached to the hair bottle to create lighter streaks in the hair or to retouch grey roots. While application with a brush typically permits better control and is appropriate for salon applications, brush application is difficult for consumers and home users of hair color almost always use a bottle having a short cone for product delivery.
The success of a hair color treatment relies on the precision of the application to the areas of the hair one desires and the speed at which one can apply the color. The color/dye is stored in a separate container from the developer/peroxide which activates the color when the two are mixed together. The dye and peroxide solutions are mixed immediately before application and as soon as the developer and color are mixed, a chemical process begins that changes the quality of the finished product. As the mixed product ages, it becomes more oxidized and less effective. In products intended to lighten hair color, the capability of the product to lighten decreases as the mixed product ages. Products intended to darken hair color, produce darker, muddier, and less attractive hair color as the mixed product ages. Consequently, the speed at which the product is applied can determine the quality of the resulting hair color. The degradation of the dye/peroxide mixture is especially problematic for home consumers who typically must rapidly, accurately, and uniformly apply the mixture to their own hair to produce satisfactory results.
Some hair color products are shipped with a small squeeze bottle having a screw cap closure with a simple cone-shaped nozzle that must be inverted to apply the product. Such a method of delivery is cumbersome for self-use, slows the delivery process, and is prone to leakage and spills. Furthermore, after initially squeezing the bottle, and upon release of manual pressure, a one-way nozzle tends to suck product back into the bottle while the air pressure is equilibrating, thus interrupting continuous flow of product during application. Also, in the case of fluids of higher viscosity or gels, some product inevitably remains in the bottom of the bottle and is wasted.
In general, fluid chemicals such as cleaning fluids or laboratory chemicals are often packaged and sold in, or may be mixed and stored by a user in, flexible squeeze bottles made from a soft, high density polyethylene. Some laboratory squeeze bottles have a wide mouth that is easy to fill, and that is covered by a screw cap having a conical tapered polypropylene nozzle coupled to a tube (pickup tube) that extends into the fluid reservoir. The tapered nozzle provides a simple way either to control the application of fluid chemical, or to use the chemical as a wash. The user controls the amount of fluid dispensed by simply squeezing the flexible bottle. Such bottles are, however, prone to dripping and chemical evaporation in response to changes in ambient air temperature and barometric pressure. Also, they must be maintained in an upright position, or the fluid will simply spill out of the dispensing cap. What is needed for safe and effective application of hair color products is a hair color delivery system suitable for mixing and storing the product in a closed container, and for applying the hair color in a continuous and controlled manner in either a salon setting or at home.
Existing vented squeeze bottle valves (for example, annular valves of the type commonly used for sports drinks or condiments) typically exhibit axial or rotational symmetry so that outside air passes through the cap around the perimeter of the dispenser as fluid chemical is squeezed out of the dispenser. Conventional dispensing bottles include those disclosed in U.S. Pat. No. 5,125,543 to Rohrbacher, U.S. Pat. No. 4,133,457 to Klassen, and U.S. Pat. No. 4,408,702 to Horvath, U.S. Pat. No. 4,474,314 to Roggenburg and U.S. Pat. No. 4,747,518 to Laauwe.
SUMMARY
The present disclosure concerns hair color bottled equipped with dispensing caps containing a bi-directional valve assembly that lacks axial or rotational symmetry. A hair color delivery system includes a flexible bottle, a dispensing cap having a tapered nozzle, an asymmetric bi-directional valve assembly situated between the flexible bottle and the dispensing cap, and a tube having a proximal end coupled to the valve and a distal end that extends into the flexible bottle. The dispensing cap is secured to the mouth of, and preferably seals, the flexible bottle, for example, by a threaded closure and using a portion of the valve assembly as a gasket situated between the bottle mouth and the dispensing cap.
According to some examples, asymmetric bi-directional valve assemblies used to dispense fluid from within a container include a platform for covering an opening to the container, an exit valve comprising a first tapered extension in the platform, and a first aperture through which fluid may be expelled from the container in an outward direction along a first axis, and an input valve comprising a second tapered extension in the platform, preferably opposing the first tapered extension, and a second aperture through which ambient air may enter the container in an inward direction along a second axis. The first and second axes are offset, or spaced apart, from each other, so that the valves are not co-axial. The tapered extensions are preferably in the shape of circular or flattened cones, having top openings that may be circular or linear slits, respectively.
Representative methods of substantially continuous delivery of a fluid to a target area include the steps of providing a flexible bottle, at least partially filling the flexible bottle with the fluid, expelling fluid from the flexible bottle, in response to application of external pressure on the flexible bottle by directing the fluid through a first tapered extension, dispensing the fluid to the target area through a tapered nozzle, and permitting air to enter into the flexible bottle through a second tapered extension spaced apart from, and opposing, the first tapered extension, so as to adjust internal and external pressures on the flexible bottle, thereby maintaining a supply of fluid in the tapered nozzle. When the fluid is a hair coloring agent, delivery of the coloring agent as disclosed results in a safe and effective hair color treatment.
There are many advantages of the disclosed methods and the disclosed systems. For example, it is easy and safe to accurately self-apply the hair color, while holding the bottle upright to reduce the chance of drips or spills. The tapered nozzle stays fully charged with product because, due to the bi-directional valve assembly, the tapered nozzle does not admit air when pressure is removed from the bottle. An opaque, closed bottle protects chemical from light and evaporation, and has a stylish appearance for use in salons. Such a bottle also protects the color product from exposure to air. A tapered nozzle also acts to cleanly part the hair, and may be used to spread the product along hair shafts. In other examples, transparent or translucent materials are used. Finally, the tube ensures that chemical remaining at the bottom of the bottle is accessible, to reduce waste.
The foregoing and other features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial side elevation view of a stylized representative example of a hair color bottle showing interior parts, including a hollow dispensing tube, a dispensing screw cap assembly that includes a tapered nozzle, and an asymmetric bi-directional valve assembly.
FIG. 2 is an exploded view of the hair color bottle of FIG. 1 .
FIG. 3 is a top plan view of the dispensing screw cap assembly shown in FIGS. 1-2 .
FIG. 4 is a side elevation view of the dispensing screw cap assembly shown in FIGS. 1-3 .
FIG. 5 is a bottom perspective view of the dispensing screw cap assembly shown in FIGS. 1-4 .
FIG. 6 is a perspective view of the asymmetric, bi-directional valve assembly shown in FIGS. 1-2 .
FIG. 7 is a bottom plan view of the asymmetric bi-directional valve assembly shown in FIG. 6 .
FIG. 8 is a schematic cross-sectional view of the asymmetric bi-directional valve assembly shown in FIGS. 6-7 .
FIG. 9 is a bottom plan view of a representative asymmetric bi-directional valve assembly in which end slits of opposing outward and inward tapered extensions are perpendicular with respect to one another.
FIG. 10 is a bottom plan view of a representative asymmetric bi-directional valve assembly in which end slits of opposing outward and inward tapered extensions are parallel and along a common axis.
FIG. 11 is a flow diagram showing steps in a method of substantially continuous delivery of fluid to a target area.
DETAILED DESCRIPTION
As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” does not exclude the presence of intermediate elements between the coupled items.
The disclosed systems, devices and methods described herein should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed systems, devices, and methods are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed systems, devices, or methods require that any one or more specific advantages be present or problems be solved. Any theories of operation are to facilitate explanation, but the disclosed systems, devices, and methods are not limited to such theories of operation. The disclosed hair color delivery system is furthermore not limited to use with hair color chemical or health and beauty products. The terms “fluid,” “chemical,” “hair color,” and “coloring agent” are meant to encompass fluids, water, mixtures, gels, slurries, pastes, and other flowing substances that may be ejected from a container by means of pressurization. The examples below are described with reference to hair colorants, but the disclosed apparatus can be used to dispense other materials as well.
According to some examples disclosed herein, a color bottle is provided for use as held in an upright position. Such an upright bottle can allow the person applying hair treatment products greater visibility and access to hard to reach areas, permitting easier application. Constant flow of color product through a delivery nozzle can provide consistent product flow, permitting more precise application. A two-way valve allows product to be applied more quickly with better results because there is no pause to allow air to depart from the chamber that retains the color product. A long tapered nozzle allows the user to cleanly part the hair before squeezing the color along the root line, and reach difficult areas more readily. In addition, the shaft of the nozzle may also be used as a tool to spread the product along the hair shaft. With such color bottles, the average home consumer may be able to reduce application time on their hair color and achieve greater accuracy. Because the color product can be less oxidized with the improved application speed that the disclosed methods and apparatus can provide, hair color results can be improved. More measured, precise application also reduces product dripping and mess, providing a more satisfactory consumer experience. The examples below pertain to a color bottle with a single nozzle assembly, but additional nozzles (such as interchangeable nozzles) can be provided as well.
With reference to FIGS. 1-2 , a representative example of a stylized hair color delivery system 100 is configured to facilitate directing and controlling the application of hair color products. Delivery system 100 comprises a flexible bottle 102 , a dispensing screw cap assembly 104 , and an asymmetric bi-directional valve assembly 106 that attaches to a proximal end 107 of a hollow delivery tube 108 having a distal end 110 that extends into the bottle 102 . According to a representative example, the bottle 102 has a circularly cylindrical shape that may feature tapered shoulders 112 and a tapered base 114 . However, the shape of the bottle 102 generally does not influence utility of the delivery system 100 and therefore containers such as the bottle 102 can be provided in arbitrary shapes. Embodiments of the bottle 102 are characterized by their flexibility, and in particular their elastic flexibility, so that when the bottle 102 is deformed by application of external pressure, the bottle 102 recovers from the compression and can return to an original shape, or at least partially return towards an initial shape or volume. Suitable elastic materials for the bottle 102 include but are not limited to low-density polyethylene-type materials commonly used for squeeze bottles. The volume capacity of the bottle 102 may reasonably be, but is not limited to, a range of volumes up to about 1 liter, wherein smaller bottles might preferably be packaged with hair color products for end user consumers, and larger bottles might preferably be sold to professional colorists or salons. Unlike conventional chemical wash bottles that are typically transparent or translucent, stylized hair color bottle 102 is preferably opaque, and available in a variety of designer colors and textures, with or without labels or indicia. However, the bottle 102 can be transparent or translucent.
Dispensing screw cap assembly 104 preferably features a tapered nozzle 115 for directing the release of hair color chemical contained in the bottle 102 and is configured to be coupled to the dispensing tube 108 . The tapered nozzle 115 is shown as part of the screw cap assembly and can be formed in a molding process with other portions of the screw cap assembly 104 , but in other examples, the tapered nozzle 115 can be a separate piece that is secured to the screw cap assembly 104 . The bottle 102 preferably has a threaded mouth 116 for accommodating corresponding threads 118 on the screw cap assembly 104 . The bottle mouth 116 has a circular cross section that fits the interior threads 118 that can be molded into an inside surface 120 of the screw cap assembly 104 . The screw cap assembly 104 may have an outer perimeter 122 of arbitrary shape, for example, egg-shaped as shown in FIG. 2 . Furthermore, the top surface 124 of the screw cap assembly 104 may be horizontal or tilted from horizontal with the bottle 102 in an upright position, and sides 126 of the screw cap assembly 104 may be vertical or tilted with the bottle 102 in an upright position, and the sides 126 can be straight or curved. As shown in FIG. 2 , apertures 127 , 128 , 129 are provided in the screw cap assembly. The aperture 128 permits gas flow in and out of the bottle 102 so as to manage pressure adjustment in the bottle 102 . The apertures 127 , 129 are configured to receive corresponding protrusions 127 A, 129 A in the valve assembly 106 so as to prevent or impede rotation of the valve assembly 106 as the dispensing cap assembly 104 is secured to the bottle 102 . The aperture 128 is generally configured to admit air to the bottle 102 .
With reference to the exploded view of delivery system 100 of FIG. 2 , the valve assembly 106 is situated between the flexible bottle 102 and the screw cap assembly 104 . The valve assembly 106 comprises a disc-shaped platform 200 , an exit valve 202 configured to extend into the screw cap assembly 104 and an input valve 204 configured to extend into the bottle 102 . The disc-shaped platform 200 may be sized to substantially match the size of the opening of mouth 116 , so that platform 200 is secured to the mouth 116 of bottle 102 preferably forming a seal between the bottle 102 and the screw cap assembly 102 . The platform 200 preferably is formed of an elastic material so as to serve as a compliant gasket.
FIGS. 3-5 illustrate additional features of the screw cap assembly 104 . In the top plan view shown in FIG. 3 , the shape of the outer perimeter 122 is visible, as are the positions of the aperture 128 that is provided to admit air or other gas into the bottle 102 when the bottle recovers from compression. The aperture 128 is situated to be coupled to the input valve 204 and the apertures 127 , 129 are configured to receive protrusions 127 A, 129 A on the valve assembly. The screw cap assembly 104 preferably includes tapered nozzle 115 as a fixed portion of the assembly, and the nozzle 115 typically includes a tapered segment 300 , a tip segment 301 , and an elbow segment 302 . As shown in FIG. 4 , the elbow segment 302 is preferably bent at an elbow angle 400 that exceeds 90 degrees so that, when the delivery system 100 is held upright, hair colorant or other product can be dispensed in a convenient direction. For delivery of hair colorant products, horizontal delivery or delivery at a slight upward angle with respect to horizontal is convenient. Typical upward angles from the horizontal are in ranges from 0 degrees to about 30 degrees, such as 0 to 30 degrees, 0 to 10 degrees, or 0 to 5 degrees. The elbow angle 400 can be selected so that an upward delivery angle of 5-45 degrees is provided with the bottle 102 held upright. This arrangement permits convenient dispensing.
The sectional view of FIG. 4 shows the interior structure of the screw cap assembly 104 , specifically, the degree of taper along the length of nozzle 115 , and the degree of taper within the tip segment 301 , where hair colorant product or other materials exit the delivery system 100 for application to a target area. The screw cap assembly 104 includes a hollow space 402 for receiving the threaded mouth 116 of the bottle 102 . Referring to the bottom perspective view of FIG. 5 , the screw cap assembly 104 also includes an aperture 500 at which elbow segment 302 joins screw cap assembly 104 and configured to receive the exit valve 202 .
A magnified perspective view in FIG. 6 illustrates details of a representative embodiment of the asymmetric bi-directional valve assembly 106 . Each of the two valves, exit valve 202 and input valve 204 , is formed by an aperture in platform 200 and a corresponding tapered extension. For example, the input valve 204 is formed by the intake aperture 128 and an inward tapered extension 601 , and the exit valve 202 is formed by an exit aperture (not visible in the view of FIG. 6 ) and an outward tapered extension 602 . The exit valve 202 includes an outward tapered extension 602 that extends along a first axis 604 to linear end slit 605 in an exit surface 606 . The exit surface 606 is configured to direct fluid from the hollow tube 108 into the tapered nozzle 115 . The slit 605 is configured to open in response to a positive pressure applied to the interior of the exit valve 202 and otherwise to remain substantially closed. Typically, the exit valve 202 is formed of a flexible, elastic material that is responsive to slight pressure provided by compression of the bottle 102 . A lower portion 607 of exit valve 202 is configured to attach snugly to the proximal (top) end 107 of the tube 108 . The exit valve 202 also includes a reinforcing collar 608 that extends outward form the platform 202 and is coupled to the outward tapered extension 602 .
As shown in FIG. 6 , the tapered extension 602 of the exit valve 202 includes opposing flat surfaces such as surface 603 A and curved or cylindrical surfaces such as surface 603 B. Surfaces such as the surface 603 A generally taper from the platform 200 to the exit surface 605 so that the exit surface 605 is approximately rectangular. Curved surfaces such as the surface 603 B can be similarly tapered. A taper angle and overall length of the tapered extension 602 can be selected as convenient, and generally so as to be accommodated by the elbow segment 302 of the nozzle 115 . If desired, an external diameter of the reinforcing collar 608 is selected to seal to the nozzle 115 as secured to the bottle 102 .
Similarly, the input valve 204 is typically configured to admit air from outside the bottle 102 via the air intake channel 600 through an inward tapered extension 601 that extends along and is tapered with respect to a second axis 609 which is offset from the first axis 604 . The axes 609 and 604 are typically but not necessarily parallel. Accordingly, the tapered extensions 601 and 602 are generally oppositely directed, but they need not be anti-parallel. Entry of air into the bottle 102 through the narrow linear end slit 608 tends to equalize internal and external air pressures exerted on bottle 102 , and maintains a headspace above the fluid reservoir within bottle 102 . To prevent or reduce twisting or rotation of valve assembly 106 in the attachment of the screw top assembly 104 to the bottle 102 , the valve assembly 106 includes the protrusions 127 A, 129 A that are configured to be inserted into corresponding apertures 127 , 129 in the screw top assembly 104 . The valve assembly 106 is preferably made of silicone or of a similar flexible elastic, chemically inert material. In some examples, the valve assembly is formed as a single piece in a molding or other process. Alternatively, input and exit valves and a suitable gasket platform can be formed separately, and retained in a suitable configuration as attached to a bottle. Input and exit valves can have the same dimensions, or can be different. Typically, neither of the valves is centered with respect to an axis of the bottle as assembled, but, if convenient, an input or exit valve can be centered.
In FIG. 7 , a bottom plan view is presented, showing the various openings in the underside of disc-shaped platform 200 that supports the valve assembly 106 . The orientation of slits 605 and 610 is understood to be substantially parallel in this representative example. An air intake channel 600 may have a different circumference than the circumference of the base of tapered extension 202 .
Referring to FIG. 8 , a cross-section of valve assembly 106 is shown, highlighting further structural asymmetries between exit valve 202 and input valve 204 . FIG. 8 shows internal dimensions of the valves 202 and 204 relative to a first tip cavity 800 and a second tip cavity 802 , respectively, that comprise valve passageways through which fluids such as hair colorants or gases such as air move in response to compression and relaxation of the bottle 102 . The volume of the tip cavities 800 , 802 can be based on desired dispense pressures or volumes, bottle sizes, or different dispense material viscosities. According to one embodiment, walls 822 , 824 of the valves 202 , 204 , respectively, meet at a junction 808 , the location of which does not coincide with the platform 200 . As shown in FIG. 8 , the thickness of the wall 822 of the valve 202 at the reinforcing collar 608 is preferably greater than that a thickness of the wall 824 of the valve 204 . The thickness of the wall 822 of the valve 202 at the reinforcing collar 608 is generally non-uniform, tapering so as to become thinner from the junction 808 in both directions. The reinforcing collar 608 also elevates the base of the outward tapered extension 602 of the valve 202 above the platform 200 whereas the location of the base of inward tapered extension 601 of the valve 204 coincides with platform 200 .
In general, valve assemblies may include a pair of opposing tapered extensions of arbitrary relative orientation. Referring to FIGS. 9-10 , additional exemplary alternative embodiments of valve assemblies are shown in which pairs of opposing tapered extensions have different orientations. For example, according to one alternative embodiment shown in FIG. 9 , a valve assembly 900 includes a first valve 902 and second valve 904 that include slits 903 , 905 , respectively, that are configured to control fluid flow. The slits 903 , 905 extend along perpendicular axes 908 and 910 , respectively. The valves 902 , 904 extend from a compliant platform 906 that can serve as a gasket. The valve 902 includes a tapered extension 912 having flat surfaces 912 A, 912 B that taper from the platform 906 to the slit 903 and curved tapered surfaces 912 C, 912 D. The valve 904 can be similarly constructed, and the valve assembly 900 can be formed as a single molded part, or constructed of separated valves and gasket.
An alternative representative valve assembly 1000 is illustrated in FIG. 10 . The valve assembly includes a gasket base 1002 configured to provide a seal between a color bottle and dispensing cap. Valves 1004 , 1006 are provided for delivery of a product such as a hair color product from the bottle and admission of air to the bottle. The valve 1004 includes a tapered portion 1008 having an approximately circular cross section at the gasket base and a substantially rectangular cross-sectional area at an exit surface 1010 . In some examples, portions of tapered extensions that define valves retain some curvature at the exit surface. For convenience, surfaces such as the exit surface 1010 are referred to as substantially rectangular as any curvature in shorter sides increase surface perimeter by less than about 20%, 10%, or 5% and when viewed, tend to appear rectangular.
As shown in FIG. 10 , sidewall sections 1011 A- 1011 B of the valve 1004 correspond approximately to portions of a conical surface, while sidewall sections 1012 A- 1012 B are defined by flat surfaces that taper to the exit surface 1010 . The sidewall sections 1011 A- 1012 B can be formed of a flexible material having a constant or variable thickness, and are conveniently formed in a molding process that includes formation of the gasket base 1002 . The valve 1006 can be similarly constructed, and in the example of FIG. 10 , includes an exit slit and exit surface 1005 situated along a common axis 1020 with the exit surface 1010 . For convenient illustration, exit slits in the valve exit surfaces are not shown in FIG. 10 . Typically two valves and the gasket base 1002 are formed as a single molded part, but one or more or all can be formed separately by a molding or other fabrication process and secured as needed.
Slits in the exit surfaces 1010 , 1005 permit fluid passage in response to a pressure difference between a pressure at the gasket base and at the exit surfaces. The valves are formed of a suitable flexible, elastic material so that such a pressure difference causes the slit to open and then to close when the pressure difference is removed. A slit length and exit surface area can be selected so as to permit ready delivery of a hair color product or other material in response to pressures available upon hand compression of a squeeze bottle. The valve assembly 1000 can also include a cylindrical extension (not shown in FIG. 10 ) that is configured for coupling to a tube that extends into a bottle to receive a hair color or other product. However, such an extension can be omitted, and the tube coupled directly to the gasket base 1002 .
The representative valve assembly 1000 is shown as a flattened, cylindrical taper, but other shapes can be used. For example, a conical taper can be used, and a circular exit surface can be provided with a rectangular slit for fluid passage. Other exit surface treatments can also be used in which exit surface can provide an aperture for fluid passage in response to pressure and remain sealed in the absence of pressure. In addition, a slit or other prospective exit surface opening need not be centered in the exit aperture, and the exit aperture need not be centered with respect to an input aperture.
As shown in the examples, the bottle cap and a delivery tube are of one piece, unitary construction, but other arrangements can be used. For example, a bottle cap can be provided with one or more apertures to be fluidically coupled to a delivery tube that is provided as a separate part and, for example, retained against the gasket when the cap is secured to the bottle.
In the examples above, fluid delivery is via a rectangular slit aligned on a rectangular exit surface, but in other examples, exit slits can be provided on circular, ovoid, polygonal exit surfaces or exit surfaces of other shapes.
With reference to FIG. 11 , a representative method 1100 by which a user may achieve substantially continuous delivery of a fluid to a target area includes a step 1102 in which a flexible bottle is provided. In a step 1104 , the bottle is at least partially filled with a fluid to be dispensed. At 1106 , a user positions the bottle so that a fluid delivery nozzle tip is situated at a suitable location (for example, a location at which hair colorant is to be applied). The bottle can be held substantially upright and external pressure is applied to the bottle at 1108 so as to expel fluid from the bottle. At 1112 , pressure can be released from the bottle so as to admit air into the bottle while retaining the fluid to be dispensed in the fluid delivery nozzle, even at the tip of the nozzle. If additional fluid such as hair colorant is to be applied, steps 1106 - 1112 can be repeated until the supply of fluid is exhausted or until selected areas are treated. The method 1100 applies generally to delivery of a fluid to a target area, for example, as an improvement in applications in which conventional squeeze bottles are used (e.g., food service, laboratory chemical use, and the like). In a specific example, the method 1100 provides steps by which a consumer can safely and effectively apply hair colorant with uniform delivery of a coloring agent without having to refill a dispensing nozzle every time a bottle is fully compressed and is allowed to return to its uncompressed shape.
In view of the many possible embodiments to which the principles of the disclosure may be applied, it should be recognized that the illustrated embodiments are only preferred examples and should not be taken as limiting the scope of the disclosure. We therefore claim all that comes within the scope and spirit of the appended claims. | A hair color delivery system includes a flexible bottle, a dispensing cap having a tapered nozzle, an asymmetric bi-directional valve assembly, and a dispensing tube. The valve assembly comprises a platform, and a pair of valves, comprising tapered extensions through which fluid may be expelled from the bottle and ambient air may enter the bottle. The valves are offset from each other so that they are not co-axial or rotationally symmetric. The delivery system enables a method of substantially continuous delivery of a fluid chemical, yielding a hair treatment that it is easy and safe to use in which the tapered nozzle stays fully charged with product as air can be admitted to a dispensing bottle through a different valve than that used for dispensing. | 0 |
This is a division of application Ser. No. 07/774,949 filed Oct. 11, 1991.
GOVERNMENT USE
The invention described herein may be manufactured, used and licensed by or for the U.S. Government for governmental purposes without payment to me of any royalty thereon.
BACKGROUND AND SUMMARY
In recent times plastic hand guns and small caliber, high pressure rifles are in some cases a viable alternative to the more traditional metal guns, the chief advantages of plastic guns being their low cost and light weight. However, the barrels of such guns can withstand only a limited number of firings before barrel wear renders the gun essentially useless. Additionally, the typical lack of longitudinal barrel stiffness limits the range and accuracy of such guns.
My invention is a composite, nonmetallic gun barrel which addresses the above problems. My gun barrel includes a tubular exterior and includes a hard inner liner to improve the wear resistance and longitudinal rigidity of the barrel. The liner is divided axially and circumferentially into liner segments to allow local elastic deformation of the barrel as a projectile is fired therethrough. The segments define spiralled channels and ridges for imparting spin to the projectile. Radial gaps between the segments contain elastomeric bodies that seal with a passing projectile to prevent escape of propellant gasses forward past the projectile.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a radial cross section of my gun barrel.
FIG. 2 is a view taken along line 2--2 in FIG. 1.
FIG. 3 is an end elevational view of a liner segment shown in FIGS. 1 and 2.
FIG. 4 is another elevational view of the liner segment shown in FIGS. 1 and 2.
FIG. 5 is a detail view of a circumferential boundary between ends of adjoining liner segments.
FIG. 6 is a radial cross section of a modified version of my gun barrel.
FIG. 7 is a detail view of a radial gap running lengthwise between the sides of neighboring liner segments.
FIG. 8 is an end elevational view of the liner segment shown in FIG. 6.
FIG. 9 is another elevational view of the liner segment shown in FIG. 6.
FIG. 10 is an end elevational view of a third embodiment of my nonmetallic gun barrel.
FIG. 11 is a view taken along line 11--11 in FIG. 10.
DETAILED DESCRIPTION
FIGS. 1 and 2 show a first embodiment of my gun barrel 10 wherein tubular barrel exterior 12 comprises a reinforced thermosetting plastic resin. The plastic can be, for example, nylon reinforced with glass, carbon or ceramic fibers. Such a nylon would typically have an elastic modulus of flexure of 1,600,000 psi, a compressive yield strength of 30,000 psi, and a Rockwell "A" hardness between 65 and 75. The plastic may also be a reinforced polycarbonate resin or an epoxy.
The barrel exterior's inner diameter 14 has a circular cross section concentric with the exterior's outer diameter 16 as shown in FIG. 1. Bonded to inner diameter 14 are ceramic liner segments such as those shown at 18, 20, 22 and 24, the liner segments together defining a plurality of shallow spiralled rifling grooves or channels 26, 28, 30 and 32 along the length of barrel 10. The degree of curvature of the inner faces of the liner segments is exaggerated for purposes of illustration in FIGS. 1 and 4. As seen in FIGS. 1 and 2, the liner segments form a smooth continuous surface. The liner segments can alternately be of similar thermosetting resin as the barrel and integral with barrel exterior 12. The segments will be reinforced more than exterior 12, preferably with ceramic particles either not found in exterior 12 or found in less quantity than in exterior 12.
It is preferred that the elongate sides of the inner segments be parallel to the channels as illustrated by sides 42 in FIG. 4. It is also preferred that the segments be all of the same curved parallelogram shape shown in FIGS. 3 and 4. Finally, it is preferred that each segment be symmetric with respect to axis 47, which itself radiates from central axis 17 of barrel 10 and passes through the center of volume of segment 28.
The longitudinal edges of the tiles can abut to form sharp ridges as shown at 34 in FIG. 1 or rounded ridges as shown at 34. A zone of the liner segment radially outward of the deepest part of the channels may be thickened by material added at the radially outer side of the liner segment, such as zone 38. Such a modification avoids interfering with the rifling function of the channels while strengthening the liner segment against imbalanced radially outward compression forces exerted by a bullet (not shown in FIGS. 1 through 5) on the barrel when the bullet is fired. Such a modification also adds to the longitudinal stiffness of the barrel. Barrel exterior 12 has sufficient elastic deformability to expand radially outward wherever the essentially incompressible liner segments are forced outward by contact with the bullet.
FIG. 5 details a typical circumferential boundary 40 between closely fit longitudinally adjacent liner segments 20 and 20A. Rearward corner 44 of segment 20 and forward corner 44A of segment 20A are slightly rounded and together form a small annular groove recessed with respect to aligned inner diametrical surfaces 32 and 32A of the liner segments. The recessed annular groove prevents rearward edge of segment 20 from catching upon the bullet as the bullet is propelled forward in the barrel. It is not strictly necessary that corner 44A be rounded, but it is advantageous to have both the forward and rearward corners of the liner segment rounded, so that either end of any liner segment may face rearward. This versatility simplifies the placement of the liner segments on a mandrel or in a mold prior to molding barrel exterior 12 around the liner segments.
In FIG. 6 is a gun barrel 50 which incorporating modifications that can be made to gun barrel 10. The first modification is to the ceramic liner segments 46, which are also detailed in FIGS. 8 and 9. As with the first embodiment, the liner segments together define a plurality of shallow spiralled rifling grooves or channels, such as channel 48, and the sides of the segments are parallel to the channels. The segments can form sharp ridges 54 or rounded ridges 56. However, the boundaries between longitudinally adjacent liner segments are at the middle of the channels and not at the channel edges as in the first embodiment. As bullet 58 passes through barrel 50 it forces segments 48 radially outward whereby gaps 52 between the segments are formed. Having the longitudinal sides of the segments at deepest part of the channels minimizes the depth of gaps 52 and thus minimizes blow by, or undesired escape, of pressurized propellant behind bullet 58. It is comtemplated that bullet 58 will be of a soft metal such as copper or a plastic such as nylon or polytetrafluorethylene.
Another optional feature shown in the right half of FIG. 6 is the presence of longitudinal reinforcing strands or fibers 60 extending the length of the barrel in at least the diametrically outer portion of plastic barrel exterior 62. These fibers would be in addition to other fibers or other reinforcing material in the barrel exterior. The fibers are preferably oriented parallel to the longitudinally axis of the barrel but may be oriented parallel to the channels. The fibers thus add longitudinally stiffness to barrel 50 but permit elastic deformation of barrel exterior 62 in radial or circumferential directions. The diametrically inner portion of barrel exterior 62 may be free of fibers, at least near gaps 52, to insure that a portion of barrel exterior 62 can flow as far as desired into gap 52 when a bullet is fired, as is explained below with reference to FIG. 7.
FIG. 7 is a detail view of gap 52 in FIG. 6 wherein the radially outward force of bullet 58 causes an intra gap body 68 of barrel exterior 62 to be squeezed further radially inward into gap 52. Dashed line 64 represents the position of the radially inward face of body in its free state, which exists before bullet 58 presses segments 48 outward of deform barrel exterior 62. Dashed line 64 is intermediate the radially outer end 74 and the radially inner end 72 of of gap 52.
Solid line 66 is the position of body 68 when bullet 68 presses segment 48 outward. Note that a rifling ridge 70 is formed on bullet 58 and that ridge 70 faces against body 68, so that blow by through gap 52 is prevented or at least minimized. Both ridge 70 and gap 52 are much smaller than the rectangularly cross sectioned rifling grooves typical of known gun barrels. The opposed edges of liner segments 48 that form gap 52 will be smooth and will not be bonded to barrel exterior 62, and zones 76 and 78 adjacent the opposed edges will also be smooth and not bonded to the exterior. The smoothness and lack of bonding permits freer movement of intra gap body 68 into and out of gap 52.
FIGS. 10 and 11 show a third embodiment of my gun barrel wherein barrel body 82 is made of a longitudinally rigid cylinder of plastic capable of limited radial elastic expansion so as to permit a projectile to be fired therethrough. Optionally barrel body may be reinforced by elongate strands or fibers as shown at 84. Embedded in barrel body 82 are elongate segments 86 aligned end to end whereby the segments form spiral shaped ceramic spines for engraving rifling grooves in the projectile as it passes through the barrel. The circumferential distance between the spines is at least three to four times the circumferential width of the spines.
The spines are triangular or sector-shaped in cross section and have tips 88 projecting radially inwardly from the inner diametrical surface of barrel body 82. The tips are shown as having sharp radially inwardly pointing edges but these edges may be rounded or flattened if desired. It is preferred that the sides 90 and 92 of the spine forming the tips define an included obtuse angle of at least 100 degrees to minimize fracturing of the tips. It is contemplated that the projectile's passage through the barrel will force the spine segments 86 slightly radially outward and elastically deform barrel body 82.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described herein since obvious modifications will occur to those skilled in the relevant arts without departing from the spirit and scope of the following claims. | The invention is a nonmetallic gun barrel having a longitudinally rigid tubular exterior capable of radial elastic deformation upon passage of a projectile therethrough. Liner segments fixed at the inner diameter of the barrel exterior are abutted end to end and form spiraled rifling structures comprised of shallow channels and ridges between the channels. Radial gaps between sides of the liners can be partly filled by radial projections of elastomeric material of the barrel exterior. The radial projections expand inwardly to seal against a projectile bearing against the inner periphery of the barrel as the projectile is fired from the barrel. | 5 |
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/454,363 filed Mar. 18, 2011, incorporated by reference in its entirety herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to solar cells, and more particularly to methods for epitaxially depositing single crystal silicon solar cells including epitaxially deposited front and back junctions.
BACKGROUND
[0003] There is a lower limit to the thickness of single crystal silicon solar cells manufactured with an aluminum back surface field (BSF), since the Al BSF fabrication process, which involves screen printing an Al paste, induces a bow in thin silicon wafers when the Al paste is fired. For 200 micron thick wafers bow starts to affect solar cell yield, and for wafers of 150 microns and less wafer bow becomes a yield killer for solar cell fabrication. The Al paste shrinks during firing causing the wafer to bow such that the Al covered surface becomes convex. This wafer bow may result in wafer breakage during subsequent processing, particularly during tabbing and stringing, and this is becoming a greater concern, as the solar industry migrates to larger wafers, from 125 mm to 156 mm square (or pseudosquare) wafers, for example. There is a need for a manufacturable alternative to an Al BSF for making thinner single crystal silicon solar cells.
[0004] The front-side p-n junction in single crystal silicon solar cells is currently manufactured using a diffusion process, which also requires a post-diffusion clean. There is a need for a more efficient manufacturing process which avoids front side diffusion and clean.
SUMMARY OF THE INVENTION
[0005] A single crystal silicon solar cell with an insitu epitaxially deposited p ++ silicon BSF (for a p-base cell) will obviate the need for the conventional Al screen printing step, thus enabling a thinner silicon solar cell because of no Al induced bow in the cell. Here the term p ++ is used to refer to very highly p-doped silicon where the dopant concentration is greater than 1×10 18 cm −3 and the resistivity is less than or equal to 20 mohm-cm. This invention is applicable to both n- and p-base silicon solar cells.
[0006] Furthermore, a single crystal silicon solar cell with insitu epitaxial p-n junction formation and n ++ front surface field (FSF) completely avoids the conventional dopant diffusion step and one screen printing step, thus enabling a cheaper manufacturing process. Here the term n ++ is used to refer to very highly n-doped silicon—with dopant concentration of greater than 1×10 18 cm −3 , where the resistivity may be less than or equal to 20 mohm-cm. This invention is applicable to both n- and p-base silicon solar cells.
[0007] According to aspects of the invention, a method of fabricating a thin epitaxial silicon solar cell may comprise: depositing an epitaxial film of highly doped p-type silicon on a porous silicon layer on a silicon wafer, the highly doped p-type silicon film having a resistivity of less than 20 mohm-cm, the highly doped p-type silicon film being a back surface field (BSF) layer; depositing an epitaxial film of p-type silicon on the BSF, the p-type silicon film being a base layer; exfoliating the BSF and the base from the silicon wafer; forming an emitter layer at the surface of the base layer; forming front contacts to the emitter layer on the front surface of the cell; and forming back contacts to the BSF on the back surface of the cell, the back contacts being patterned to cover less than fifty percent of the back surface of the cell. Furthermore, the front and back contact grids may be made of the same metal, may have the same dimensions and/or may be aligned front-to-back.
[0008] According to further aspects of the invention, a method of fabricating a thin epitaxial silicon solar cell may comprise: depositing an epitaxial film of highly doped p-type silicon on a porous silicon layer on a silicon wafer, the highly doped p-type silicon film having a resistivity of less than 20 mohm-cm, the highly doped p-type silicon film being an emitter layer; depositing an epitaxial film of n-type silicon on the emitter layer, the n-type silicon film being a base layer; depositing an epitaxial film of highly doped n-type silicon on the base layer, the highly doped n-type silicon film having a dopant density of greater than 1×10 18 cm −3 , the highly doped n-type silicon film being a front surface field (FSF) layer; exfoliating the emitter, the base and the FSF from the silicon wafer; forming front contacts to the FSF layer on the front surface of the cell; and forming back contacts to the emitter on the back surface of the cell, the back contacts being patterned to cover less than fifty percent of the back surface of the cell. Furthermore, the front and back contact grids may be made of the same metal, may have the same dimensions and/or may be aligned front-to-back.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures, wherein:
[0010] FIG. 1 is a cross-sectional view of a representation of a conventional silicon solar cell;
[0011] FIG. 2 is a cross-sectional view of a representation of an epitaxial solar cell, according to some embodiments of the present invention; and
[0012] FIG. 3 is a cross-sectional view of a representation of a further embodiment of an epitaxial silicon solar cell according to the present invention.
DETAILED DESCRIPTION
[0013] Embodiments of the present invention will now be described in detail with reference to the drawings, which are provided as illustrative examples of the invention so as to enable those skilled in the art to practice the invention. Notably, the figures and examples below are not meant to limit the scope of the present invention to a single embodiment, but other embodiments are possible by way of interchange of some or all of the described or illustrated elements. Moreover, where certain elements of the present invention can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present invention will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the invention. In the present specification, an embodiment showing a singular component should not be considered limiting; rather, the invention is intended to encompass other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present invention encompasses present and future known equivalents to the known components referred to herein by way of illustration.
[0014] FIG. 1 shows a conventional solar cell with a screen-printed aluminum back contact prior art silicon solar cell. The cell of FIG. 1 comprises an aluminum BSF and back contact 110 , a p-type base 120 , a diffusion doped n + emitter 130 , an anti-reflection coating 140 and a silver front contact grid 150 . The front surface was texture etched prior to forming the emitter.
[0015] FIG. 2 shows a thin epitaxial solar cell with a p ++ in-situ back contact, according to the present invention. FIG. 2 shows a silicon solar cell comprising a back contact grid 210 , a p ++ BSF 212 , a p-type base 220 , a diffusion doped n + emitter 230 , an anti-reflection coating 240 and silver front contact grid 250 . The front surface was texture etched prior to forming the emitter. For ease of comparison, FIG. 2 is shown below FIG. 1 which shows a conventional solar cell with a screen-printed aluminum back contact. Furthermore, due to the high conductivity of the p ++ layer, the back contacts of FIG. 2 may be patterned to cover less than fifty percent of the back surface of said cell, and preferably less than ten percent. The back contacts may be formed as a grid, for example, rather than a continuous layer, the latter being required in the conventional cell of FIG. 1 . Yet furthermore, the contacts on the front and back surfaces of FIG. 2 may be formed as matching grids and may also be formed of the same material—Ag, for example—resulting in little if any bow in the wafer. Matching grids may be grids that have the same line widths, heights and spacings and the same surface coverage; furthermore, matching grids may also be aligned front to back as shown in FIG. 2 .
[0016] An embodiment of a process flow according to the present invention for a less than 200 micron thick bifacial solar cell, such as shown in FIG. 2 includes the following steps:
1. form a porous silicon layer on a silicon substrate by anodic etching in an HF-based solution; 2. anneal the porous silicon layer in H 2 gas in an epitaxial deposition reactor; 3. deposit an epitaxial film of p ++ silicon BSF (resistivity of 1-20 mohm-cm, and preferably 1-10 mohm-cm) on the annealed surface of the porous silicon, approximately 1-10 microns thick, in the epitaxial deposition reactor; 4. deposit an epitaxial film of p-type silicon (0.5-2 ohm-cm resistivity) on the BSF, approximately 40-200 microns thick, in the epitaxial deposition reactor; 5. exfoliate the epitaxial silicon cell structure from the silicon substrate and reclaim and reuse the silicon substrate (this works for cells as thin as 80-90 microns which can be processed free standing; thinner cells require support such as a handle and/or may continue some of the front side processing prior to exfoliation—see, for example U.S. Provisional Patent Appl. No. 61/514,641, incorporated by reference herein); 6. further processing steps for the exfoliated silicon cell structure include:
a. texture etch the front side, that is the surface of the p-type silicon layer, using well known processes, using solutions containing potassium hydroxide (KOH) and isopropyl alcohol (IPA), for example; b. diffuse an n-type dopant into the texture etched surface to form a p-n junction; c. deposit a 70-90 nm thick SiN X film on the doped textured surface using a plasma-enhanced chemical vapor deposition (PECVD) or by reactive sputtering—the silicon nitride layer acts as an anti-reflection coating (ARC) and preferably has a refractive index close to 2 to give good anti-reflection performance; d. form on the front side a Ag grid with a busbar using screen printing of Ag paste followed by drying the paste (front side grids are formed so as to cover the minimum of the front surface of the solar cell and yet provide an effective electrical contact to the emitter); and e. form on the back side a Ag or Ag/Al grid with a busbar, using screen printing of metal paste followed by firing at 800 to 1,000 degrees C.—the front and back metallizations are co-fired.
[0028] Crystal Solar's epitaxial reactor, as described in U.S. Patent Application Publications Nos. 2010/0215872 and 2010/0263587, both incorporated by reference herein, provides a low cost, high throughput means for epitaxial silicon deposition which can be utilized for the above epitaxial deposition steps. The above process may also readily be adapted to make an n-base cell. Furthermore, variations on the above process flow may include alternative materials and deposition methods for the front side and back side electrical contacts. The porous silicon layer may have modulated porosity, with a lower porosity at the surface. Further variations are discussed in U.S. Patent Application Publication No. 2012/0040487 and U.S. patent application Ser. No. 13/241,112, both incorporated by reference herein. Yet further variations will be apparent to those skilled in the art after reading the disclosure of the present invention.
[0029] The epitaxial solar cell design of the present invention, as shown in FIG. 2 , is important since it completely avoids the Al screen printing step, instead using a p ++ layer in the back of the cell to allow ohmic contact to the Ag or Ag/Al grid. The epitaxial cell of the present invention may include the following advantages over a conventional cell: lower cell manufacturing cost since Al screen printing is avoided; thinner silicon (below 200 microns, and particularly below 150 microns) is enabled because Al back contact induced bow is avoided; the epitaxial cell of the present invention can be used as a bifacial cell with double glass, such as described in U.S. Patent Application Publication No. 2011/0056532 and U.S. Provisional Patent Application No. 61/514,641, both incorporated by reference herein; and the performance of a cell with an epitaxial silicon BSF is expected to be improved over a cell with an Al screen printed BSF—the former being expected to have a higher open circuit voltage, V oc .
[0030] FIG. 3 shows a schematic representation of a thin single crystal silicon solar cell with a p++ silicon emitter and an epitaxial n ++ FSF layer, according to the present invention. FIG. 3 shows a silicon solar cell comprising a back contact grid 310 , a p ++ emitter 312 , an n-type base 320 , an epitaxially deposited n ++ FSF 330 , an anti-reflection coating 340 and silver front contact grid 350 . The front surface was texture etched after depositing the FSF. Furthermore, due to the high conductivity of the p ++ layer, the back contacts of FIG. 3 may be patterned to cover less than fifty percent of the back surface of said cell, and preferably less than ten percent. The back contacts may be formed as a grid, for example, rather than a continuous layer, the latter being required in the conventional cell of FIG. 1 . Yet furthermore, the contacts on the front and back surfaces of FIG. 3 may be formed as matching grids and may also be formed of the same material—Ag, for example—resulting in little if any bow in the wafer. Matching grids may be grids that have the same line widths, heights and spacings and the same surface coverage; furthermore, matching grids may also be aligned front to back as shown in FIG. 3 .
[0031] An embodiment of a process flow according to the present invention for a less than 200 micron thin bifacial solar cell, such as shown in FIG. 3 includes the following steps:
1. form a porous silicon layer on a silicon substrate by anodic etching in an HF-based solution; 2. anneal the porous silicon layer in H 2 gas in an epitaxial deposition reactor; 3. deposit an epitaxial film of p ++ silicon emitter (resistivity of 1-20 mohm-cm, and preferably 1-10 mohm-cm) on the annealed surface of the porous silicon, approximately 0.5 microns or less in thickness, in the epitaxial deposition reactor; 4. deposit an epitaxial film of n-type silicon (0.5-2 ohm-cm resistivity) on the emitter, approximately 50-200 microns thick, in the epitaxial deposition reactor; 5. deposit an epitaxial film of n ++ silicon FSF (with dopant density of greater than 1×10 18 cm −3 , which may provide a resistivity in the range of 1-20 mohm-cm, and preferably 1-10 mohm-cm) on the n-type silicon layer, approximately 10-20 microns thick; 6. exfoliate the epitaxial silicon cell structure from the silicon substrate and reclaim and reuse the silicon substrate (this works for cells as thin as 80-90 microns which can be processed free standing; thinner cells require support such as a handle and/or may continue some of the front side processing prior to exfoliation—see, for example U.S. Provisional Patent Appl. No. 61/514,641, incorporated by reference herein); 7. further processing steps for the exfoliated silicon cell structure include:
a. texture etch the front side, that is the surface of the n ++ FSF (with p ++ junction protected), using well known processes, using solutions containing potassium hydroxide (KOH) and isopropyl alcohol (IPA), for example; b. deposit a 70-90 nm thick SiN X film on the textured surface using a plasma-enhanced chemical vapor deposition (PECVD) or by reactive sputtering—the silicon nitride layer acts as an anti-reflection coating (ARC) and preferably has a refractive index close to 2 to give good anti-reflection performance; c. form on the front side a Ag grid with a busbar using screen printing of Ag paste followed by drying the paste (front side grids are formed so as to cover the minimum of the front surface of the solar cell and yet provide an effective electrical contact to the FSF); and d. form on the back side a Ag or Ag/Al grid with a busbar, using screen printing of metal paste followed by firing at 800-1,000 degrees C.—the front and back metallizations are co-fired.
[0043] Crystal Solar's epitaxial reactor, as described in U.S. Patent Application Publications Nos. 2010/0215872 and 2010/0263587, both incorporated by reference herein, provides a low cost, high throughput means for epitaxial silicon deposition which can be utilized for the above epitaxial deposition steps.
[0044] The epitaxial solar cell design of the present invention, as shown in FIG. 3 , is important since: complete front and back junction formation in epitaxial silicon completely avoids the diffusion process and post diffusion cleans, hence has much lower cost; these cells are high efficiency n-type cells; and these cells may be made with less than 150 microns thickness, due to having no Al back contact—see discussion above with respect to the cell structure of FIG. 2 .
[0045] Further details of fabrication methods for epitaxial silicon solar cells are provided in U.S. Pat. No. 8,030,119, US Patent Application Publications Nos. 2010/0108134, 2010/0108130, 2011/0056532 and 2012/0040487 and U.S. patent application Ser. No. 13/241,112 for example, all of which are incorporated by reference.
[0046] Although methods of the present invention have been described with the monocrystalline silicon wafer of thickness less than 200 microns (preferably 100-140 microns) being formed by epitaxial deposition on a porous silicon layer on the surface of a silicon substrate followed by exfoliation, where the porous silicon layer acts as a fracture layer, other methods of forming the monocrystalline silicon wafer may be used. For example, the less than 200 micron silicon substrates may be formed by exfoliation from a silicon substrate where proton implantation to a desired depth followed by annealing at a suitable temperature can be used to exfoliate the thin silicon substrate. Furthermore, thin silicon substrates may be formed by mechanical sawing and or polishing of a silicon substrate or boule.
[0047] Although methods of the present invention have been described with the p ++ BSF being formed by epitaxial deposition, other methods for forming the BSF may be used. For example, the BSF may be formed by ion implantation of boron or by diffusion of boron into the back surface of the wafer (such as by exposing the back side of the wafer to BBr 3 or BCl 3 at a high temperature in a diffusion furnace).
[0048] Although methods of the present invention have been described with front and back contact grids formed by depositing metal paste and firing, the front and/or back contact grids may also be formed by other techniques including electroplating of metals and alloys, such as copper (using a suitable barrier metallurgy such as Ni followed by copper plate-up).
[0049] Furthermore, these alternative fabrication methods may be combined together to form solar cells such as those of FIGS. 2 & 3 . For example, a thin silicon substrate formed by mechanical sawing may have a BSF formed on the back surface by ion implantation of boron, front side processing as per the description for FIG. 2 given above, and the front and back metal contact grids may be formed by electroplating of copper to fabricate the solar cell of FIG. 2 .
[0050] The solar cells described herein are silicon-based solar cells, and the teaching and principles of the present invention apply to solar cells comprising single crystal silicon, multicrystalline silicon, and silicon heterojunctions.
[0051] Although the present invention has been particularly described with reference to certain embodiments thereof, it should be readily apparent to those of ordinary skill in the art that changes and modifications in the form and details may be made without departing from the spirit and scope of the invention. | Fabrication of a single crystal silicon solar cell with an insitu epitaxially deposited very highly doped p-type silicon back surface field obviates the need for the conventional aluminum screen printing step, thus enabling a thinner silicon solar cell because of no aluminum induced bow in the cell. Furthermore, fabrication of a single crystal silicon solar cell with insitu epitaxial p-n junction formation and very highly doped n-type silicon front surface field completely avoids the conventional dopant diffusion step and one screen printing step, thus enabling a cheaper manufacturing process. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/267,574, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to pinch sensors, particularly for vehicular closure panels where it is desirable to prevent a closure panel such as a lift gate or side door from closing if a foreign obstacle or object is detected just as the panel closes.
BACKGROUND OF THE INVENTION
It is known to apply pinch sensors to prevent a closure panel such as a lift gate or side door from closing if a foreign obstacle or object is detected just as the panel closes. The pinch sensors come in different forms, including non-contact sensors such as those based on capacitance changes, and contact sensors which rely on a physical deformation caused by contact with a foreign object.
The contact pinch sensors are typically applied in the form of a rubber strip which is routed along and adjacent to the periphery of a vehicle door. The rubber strip embeds two wires which are separated by an air gap. When the two wires contact one another, the electrical resistance therebetween drops, and a controller connected to the two wires monitors the drop in resistance, detecting an object when the drop exceeds a predetermined threshold. The fundamental problem with such conventional pinch sensors, however, is that they have a limited activation angle typically on the order of about thirty five degrees. Thus, in the event the pinch force is applied obliquely rather than head on, the wires may not contact one another.
SUMMARY OF THE INVENTION
The invention seeks to provide a resistive contact pinch sensor have a considerably wider activation range or angle. It is also desired to provide such a sensor with a low manufacturing cost.
According to one aspect of the invention a multi-lobed pinch sensor is provided. The pinch sensor includes a resiliently deformable non-conductive tubular casing having an outer wall and an inner wall that defines an internal hollow region. At least three electrically-conductive conduits are disposed along the inner wall of the casing. In section, the three electrically-conductive conduits are substantially equidistantly spaced circumferentially along the inner wall of the casing, and each electrically-conductive conduit has a periphery that extends into the hollow region. When the casing is suitably deformed, at least one of the electrically-conductive conduits comes into contact with a electrically conductive reference element to thereby lower the resistance therebetween and enable a controller to signal the detection of an obstacle.
In the pinch sensor each electrically-conductive conduit preferably comprises an elastomeric electrically-conductive skirt that envelops a low resistance electrical conductor connectable to a controller input.
In one embodiment, the casing has a cross-sectional shape of a semi-circular arch, including a base portion and a semi-circular portion. One of the electrically-conductive conduits is disposed along the base portion and functions as the reference element. The other two electrically-conductive conduits are disposed along the semi-circular portion. The internal hollow region includes two rebates that straddle the electrically-conductive reference conduit, where each rebate presents a pivot point enabling the casing to flex such that the corresponding electrically-conductive conduit disposed along the semi-circular portion is directed towards the electrically-conductive reference conduit.
In another embodiment, the conductive reference element is provided by an additional electrically-conductive core disposed within the casing inward of the three electrically-conductive conduits. The electrically-conductive core is connected to the casing by one or more non-conductive webs branching from the casing inner wall. The electrically-conductive core preferably has a tri-petal cross-sectional shape so as to trisect the internal hollow region into three air gaps. Each of the electrically-conductive conduits projects partially into one of the three individual air gaps, respectively. Each electrically-conductive conduit is preferably formed from an elastomeric electrically conductive skirt that envelopes a low resistance electrical conductor connectable to one of the controller inputs. These conductive skirts preferably have substantially similar circular cross-sectional profiles and the air gaps have substantially similar sector-shaped cross-sectional profiles of substantially uniform depth, thereby providing a substantially uniform travel for activating the sensor across an activation angle of at least 270 degrees.
According to another aspect of the invention a coaxial pinch sensor is provided. The coaxial pinch sensor includes a resiliently deformable non-conductive tubular casing. An electrically-conductive tubular conduit is disposed within the tubular casing, the tubular conduit having an inner wall defining an internal hollow region. An electrically-conductive core is disposed within the electrically-conductive tubular conduit and is normally spaced apart therefrom. When the casing is suitably deformed, the electrically-conductive tubular conduit comes into contact with the electrically-conductive core to thereby lower the resistance therebetween and enable a controller to signal the detection of an obstacle.
The coaxial pinch sensor prefereably including at least one non-conductive spacing element disposed between the electrically-conductive core and the electrically-conductive tubular conduit.
And the electrically-conductive core is preferably substantively coaxial with the electrically-conductive tubular conduit.
According to one embodiment of the coaxial pinch sensor, multiple non-conductive spacing elements are disposed between the electrically-conductive core and the electrically-conductive tubular conduit, these spacing elements being resiliently compressible. In addition, the electrically-conductive core is preferably segmented by a nonconductive divider having an end portion contacting the electrically-conductive tubular conduit. And the electrically-conductive core is preferably formed from an elastomeric electrically conductive skirt that envelops a low resistance electrical conductor.
According to another embodiment of the coaxial pinch sensor the electrically-conductive tubular conduit has a cross-sectional shape of a three-quarter cylinder having a base portion and a semi-circular portion. The spacer is connected to the base portion of the electrically-conductive tubular conduit. The electrically-conductive core has a semi-circular cross-sectional shape, and the hollow region includes an air gap that has a substantially sector-shaped cross-sectional profile of substantially uniform depth, thereby providing a substantially uniform travel for activating the sensor across an activation angle of at least 270 degrees.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects of the invention will be more readily appreciated having reference to the drawings, wherein:
FIG. 1 is a cross-sectional view of a tri-lobed pinch sensor according to a first embodiment;
FIGS. 1A , 1 B and 1 C are cross-sectional views schematically demonstrating the deformation of the pinch sensor shown in FIG. 1 under loads directed from top, left and right directions, respectively;
FIG. 2 is a cross-sectional view of a variant of the pinch sensor shown in FIG. 1 ;
FIG. 3 is a cross-sectional view of a tri-lobed pinch sensor according to a second embodiment;
FIGS. 3A , 3 B and 3 C are cross-sectional views schematically demonstrating the deformation of the pinch sensor shown in FIG. 3 under loads directed from top, left and right directions, respectively;
FIG. 4 is a cross-sectional view of a variant of the pinch sensor shown in FIG. 3 ;
FIG. 5 is a cross-sectional view of a coaxial pinch sensor according to a third embodiment;
FIGS. 5A , 5 B and 5 C are cross-sectional views schematically demonstrating the deformation of the pinch sensor shown in FIG. 5 under loads directed from top, left and right directions, respectively;
FIGS. 6A and 6B are cross-sectional views of variants of the pinch sensor shown in FIG. 5 ;
FIG. 7 is a cross-sectional view of a coaxial pinch sensor according to a third embodiment;
FIGS. 7A , 7 B and 7 C are cross-sectional views schematically demonstrating the deformation of the pinch sensor shown in FIG. 7 under loads directed from top, left and right directions, respectively; and
FIGS. 8A and 8B are cross-sectional views of variants of the pinch sensor shown in FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a tri-lobed pinch sensor 100 in cross-sectional view. The sensor 100 is configured as an elongate bendable strip, but it should be understood that the cross-sectional profile shown in FIG. 1 is substantially constant along the length of the strip (and do not follow a helical pattern). As such, the pinch sensor 100 may be relatively easily manufactured by extrusion or co-extrusion techniques as known in the art per se.
The particular pinch sensor 100 shown in FIG. 1 achieves a relatively wide activation range or angle by incorporating three electrically-conductive conduits 102 (labeled individually as 102 a , 102 b , 102 c ) within a non-conductive tubular casing 110 . In section, the electrically-conductive conduits 102 , which are alternatively referred to as conductive ‘planetary’ lobes, are substantially equidistantly spaced circumferentially along the inner wall of the tubular casing 110 about a central electrically-conductive core 112 . The planetary lobes 102 are insulated from the central conductive core 112 by a hollow region 108 but upon application of a suitable pinch force to deform the tubular casing 110 at least one of the conductive planetary lobes 102 will come into contact with the conductive central core 112 . lowering the resistance therebetween, and enabling a controller (not shown) connected to the conductive planetary lobes 102 and central core 113 to signal the presence of an obstacle. The three conductive planetary lobes 102 can be connected to one voltage polarity, and the conductive central core 112 to an opposite voltage polarity.
More particularly, each planetary lobe 102 includes a conductive skirt 104 that is preferably formed from an elastomeric conductive material, e.g., conductive rubber as known in the art per se. The conductive skirt 104 surrounds a low resistance ‘outboard’ electrical conductor 106 , discussed in greater detail below, that is connected to one of the controller inputs (all three electrical conductors being connectable to the same controller input). Each skirt 104 is preferably formed in a closed loop shape such as the illustrated circular shape so as to envelop the corresponding outboard electrical conductor 106 , although it will be understood that a complete encirclement is not essential.
The central conductive core 112 includes a conductive tri-petal or trilateral body 113 that is preferably formed from the same material as the conductive skirt 104 . The trilateral body 113 preferably surrounds a low resistance central electrical conductor 114 that is disposed along the longitudinal axis of the pinch sensor 100 and is connected to another input of the controller.
The three planetary lobes 102 are partially embedded in a resiliently deformable, non-conductive tubular casing 110 , as may be provided by rubber, that forms the outer periphery of the sensor 100 . The casing 110 encapsulates the conductive portions of the sensor, protecting it from ambient influences. The casing 110 also defines the stiffness of the section and its appearance. The casing 110 has a generally annular shaped peripheral cross-sectional profile (e.g., a three-quarter cylinder as illustrated) with three integrally formed, inwardly leading web portions 111 . The central trilateral body 113 has three corners that are each integrally connected to one of three web portions 111 to thus trisect the casing 100 and define three distinct air gaps labeled individually as 108 a , 108 b , 108 c.
In the illustrated embodiment about one half 104 j of the outer periphery of each conductive skirt 104 abuts the casing 110 , and about one half 104 k of the outer periphery of each conductive skirt 104 projects into one of the air gaps 108 a , 108 b , 108 c . Each air gap is preferably crescent or sector shaped in section with uniform depth and sized to permit about one hundred and eighty degrees of the outer periphery of the respective conductive skirt 104 to project into the air gap. The crescent or sector shape of the air gap 108 , coupled with the circular shape of the planetary conductive skirt 104 , also provides a relatively uniform depth d across the air gap 108 between the projecting portion 104 k of the planetary conductive skirt 104 and the corresponding sidewall 113 a , 113 b , 113 c of the central trilateral body 113 . The distance d is selected to achieve a selected deformation of the casing 110 before one of the planetary lobes 102 contacts the central core 112 , but in any event the preferred design ensures that the sensor 100 has a relatively constant activation travel over a wide range of pinch directions.
Each sidewall 112 a , 112 b , 112 c of the central trilateral body 112 faces one of the projecting portions 104 k of the planetary conductive skirt 104 and subtends it by an angle alpha of about one hundred twenty degrees. As the three planetary lobes 102 are angularly spaced apart from one another by about one hundred and twenty degrees, it will be seen that the pinch sensor 100 has a very wide activation angle. This can be appreciated more fully with additional reference to FIGS. 1A , 1 B, and 1 C which demonstrate how the sensor 100 reacts when a pinch force P is applied from top, left and right positions, respectively, and from which it should be appreciated that the sensor 100 has an activation angle of at least about two hundred and seventy degrees.
As shown in FIG. 1 the casing 110 features a flattened end portion 110 b in order to provide a flat surface to mount an adhesive strip 116 thereto for attaching the sensor to the contours of a support surface. It will be appreciated that in other embodiments such as shown in FIG. 2 a variant 100 ′ of the pinch sensor can have a completely circular casing 110 ′ which will thus permit an even larger activation angle.
In preferred embodiments the electrical conductors 106 and 114 are formed from multiple strands of wire such as copper combined with plastic reinforcing fiber. Such conductors can provide high elasticity in both axial (stretching) and transverse (bending) directions.
FIG. 3 shows an alternative embodiment of a tri-lobed pinch sensor 200 in cross-sectional view. The sensor 200 is configured as an elongate bendable strip, but it should be understood that the cross-sectional profile shown in FIG. 3 is substantially constant along the length of the strip (and does not follow a helical pattern), enabling the pinch sensor 200 to be relatively easily manufactured by extrusion or co-extrusion techniques.
The pinch sensor 200 achieves a relatively wide activation range or angle by incorporating three electrically-conductive conduits 202 a , 202 b , and 203 within a non-conductive tubular casing 210 . In section, the electrically-conductive conduits 102 , which are alternatively referred to as conductive lobes, are substantially equidistantly spaced circumferentially along the inner wall of the tubular casing 210 and/or about a central cylindrical axis 214 . The upper lobes 202 a , 202 b are insulated from one another by a central, common, air gap 208 , but upon application of a suitable pinch force to deform the tubular casing 210 one of the conductive upper lobes 202 , which are connected to one input of a controller (not shown), will come into contact with the conductive lower or base lobe 203 , which is connected to another input of the controller, lowering the resistance therebetween, and thus enabling the controller (not shown) to signal the presence of an obstacle.
More particularly, each conductive lobe 202 , 203 includes a conductive skirt 204 that is preferably formed from an elastomeric conductive material, e.g., conductive rubber as known in the art per se. The conductive skirt 204 surrounds a low resistance electrical conductor 206 , such as discussed above, that is connected to a controller input. Each skirt 204 is preferably formed in a closed loop shape such as the illustrated circular shape so as to envelop the corresponding electrical conductor 206 , although it will be understood that a complete encirclement is not essential. The conductive skirts 204 of the upper lobes 202 also include teardrop shaped tail sections 212 that provides a wider face (in comparison with a strict circular profile) relative to the base lobe 203 .
Each of the conductive lobes 202 is partially embedded in the resiliently deformable, non-conductive tubular casing 210 , as may be provided by rubber, that forms the outer periphery of the sensor 200 . The casing 210 encapsulates the conductive portions of the sensor, protecting it from ambient influences. The casing 210 also defines the stiffness of the section and its appearance. The particular casing 210 illustrated in FIG. 3 has a generally inverted U-shaped or semi-circular arch profile in section, including a semicircle portion 210 and a base portion 201 b . The casing 210 also includes a hollow central region that defines the air gap 208 .
In the illustrated embodiment about one half of the outer periphery of each conductive skirt 204 abuts the tubular casing 210 , and about one half of the outer periphery of each conductive skirt 204 projects into the air gap 208 . The air gap 208 includes two lower recesses or rebates 208 a , 208 b that present pivot points to allow the casing 210 to flex such that the conductive upper lobes 202 are directed towards the conductive base lobe 203 that is situated adjacent the base of inverted U-shaped casing 210 . The tri-lobed pinch sensor 200 also has a wide activation angle as will be appreciated more fully with additional reference to FIGS. 2A , 2 B, and 2 C which demonstrate how the sensor 200 reacts when a pinch force P is applied from top, left and right positions, respectively, and from which it should be appreciated that the sensor 200 has an activation angle of at least about two hundred and seventy degrees.
As shown in FIG. 3 the flattened base portion 210 b of the casing 210 provides a flat surface for mounting an adhesive strip 216 to attach the sensor to an underlying support surface. It will be appreciated that in other embodiments such as shown in FIG. 4 a variant 200 ′ of the pinch sensor can have a completely circular casing 210 ′ with three equidistantly angularly spaced circumferential conductive lobes 203 , which will thus permit an even larger activation angle.
FIG. 5 shows an embodiment of a coaxial pinch sensor 300 in cross-sectional view. The sensor 300 is also configured as an elongate bendable strip, and it will be understood that the cross-sectional profile shown in FIG. 5 is substantially constant along the length of the strip.
The coaxial pinch sensor 300 achieves a wide activation range or angle by incorporating a central electrically-conductive core 302 and a coaxial electrically-conductive tubular outer sheath 304 within a tubular casing 310 . The conductive core 302 and conductive sheath 304 are normally spaced apart by a plurality of spacers/springs 306 , but upon application of a suitable pinch force to deform the tubular casing 310 the conductive sheath 304 , which is connected to one input of a controller (not shown), will come into contact with the conductive core 302 , which is connected to another input of the controller, lowering the resistance therebetween and enabling the controller (not shown) to signal the presence of an obstacle.
More particularly, the coaxial sensor 300 includes a resiliently deformable, non-conductive tubular casing 310 , as may be provided by rubber, that forms the outer periphery of the sensor 300 . The particular casing 310 illustrated in FIG. 5 has a cylindrical inner wall and encapsulates the conductive portions of the sensor, protecting it from ambient influences. The casing 310 also defines the stiffness of the section and its appearance. The particular casing 310 illustrated in FIG. 5 has a flattened base section 310 b to which an adhesive foam strip 316 can be applied to mount the sensor to a support surface.
The casing 310 has an evacuated central region. The conductive outer sheath 304 is disposed immediately adjacent the inner wall of the casing 310 and is also preferably cylindrical to ensure a mating fit therewith. The central conductive core 302 is disposed within the outer sheath 304 , being substantially coaxial therewith. The conductive core 302 also has a smaller diameter than the outer sheath 304 so as to leave an air gap 308 therebetween.
The conductive cylindrical outer sheath 304 is preferably formed from an elastomeric material, such as conductive rubber.
The central conductive core 302 is provided as two semi-cylinders 302 a , 302 b separated by a divider 314 . Each semi-cylinder is preferably formed from an elastomeric conductive material, e.g., conductive rubber, and envelops a low resistance electrical conductor 318 , such as discussed above, that is connected to a controller input.
The divider 314 is formed from a nonconductive material, such as rubber, and has a bulbous end portion 320 that contacts the cylindrical outer sheath 304 . The divider 314 maintains a minimum spacing between the electrical conductors 318 embedded in the two semi-cylinders 302 a and prevents the collapse of the section in the event the coaxial strip sensor 300 is routed with sharp bends thereto.
The spacers/springs 306 are non-conductive resiliently deformable beads that are partially embedded in the semi-cylinders 302 a , 302 b . About half of the periphery of the spacers/springs 306 project into the air gap 308 so as to contact the conductive outer sheath 304 and prevent self activation of the sensor 300 due to sharp routing bends. The shape, quantity, position and stiffness of the spacers/springs 306 are selected to achieve a desired sensor activation force and travel.
The coaxial nature of sensor 300 enables a wide activation angle as will be appreciated more fully with additional reference to FIGS. 5A , 5 B, and 5 C which demonstrate how the sensor 300 reacts when a pinch force P is applied from top, left and right positions, respectively, and from which it should be appreciated that the sensor 300 has an activation angle of at least about two hundred and seventy degrees.
FIGS. 6A and 6B shown variants 300 ′ and 300 ″ of the coaxial pinch sensor which employ differently shaped casings 310 ′ and 310 ″.
FIG. 7 shows an alternative embodiment of a coaxial pinch sensor 400 in cross-sectional view. The sensor 400 is also configured as an elongate bendable strip, and it will be understood that the cross-sectional profile shown in FIG. 7 is substantially constant along the length of the strip.
The coaxial pinch sensor 400 achieves a wide activation range or angle by incorporating a substantially electrically-conductive central core 402 and a substantially coaxial electrically-conductive tubular outer sheath 404 encapsulated by a nonconductive tubular casing 410 . The conductive core 402 and conductive sheath 404 are normally spaced apart by an uvula-like base structure 406 projecting from the outer sheath 404 , but upon application of a suitable pinch force to deform the casing 410 the conductive outer sheath 404 , which is connected to one input of a controller (not shown), will come into contact with the conductive core 402 , which is connected to another input of the controller, lowering the resistance therebetween and enabling the controller (not shown) to signal the presence of an obstacle.
More particularly, the coaxial pinch sensor 400 includes a resiliently deformable, non-conductive tubular casing 410 , as may be provided by rubber, that forms the outer periphery of the sensor 400 . The casing 410 encapsulates the conductive portions of the sensor, protecting it from ambient influences. The casing 410 also defines the stiffness of the section and its appearance. The particular casing 410 illustrated in FIG. 7 has three-quarter cylindrical shape including a flattened base section 410 b to which an adhesive foam strip 416 can be applied to mount the sensor to a support surface.
The outer sheath 404 is disposed immediately adjacent an inner wall of the casing 410 and is also preferably shaped in the form of a three-quarter cylinder to matingly fit with the casing 410 . The conductive core 402 is disposed within the outer sheath 404 , being substantially coaxial therewith. The conductive core 402 also has a smaller diameter than the outer sheath 404 so as to leave an air gap 408 therebetween.
The conductive outer sheath 404 is preferably formed from an elastomeric material, such as conductive rubber. The outer sheath 404 includes a base portion 404 b that envelops and surrounds a low resistance electrical conductor 418 , such as discussed above, that is connected to a controller input.
The uvulate base structure 406 is a nonconductive platform disposed atop the base portion 404 b ). The conductive core 402 , which is preferably formed from an elastomeric conductive material such as conductive rubber is disposed atop the base structure 406 and envelops a low resistance electrical conductor 418 , such as discussed above, that is connected to a controller input. The base structure 406 maintains a minimum spacing between the electrical conductors 418 embedded in the core 402 and sheath 404 and prevents the collapse of the section under sharp bends in the coaxial strip sensor 400 .
In the illustrated embodiment the conductive core 402 has a substantially three-quarter circle cross-sectional profile. The air gap 408 is preferably crescent or sector shaped in section over an angular range of about two hundred and seventy degrees. The crescent or sector shape of the air gap 408 , coupled with the three-quarter circular shape of the conductive core, provides a relatively uniform depth d across the air gap 408 and thus a relatively constant activation travel over a wide range of pinch directions. This will be appreciated more fully with additional reference to FIGS. 7A , 7 B, and 7 C which demonstrate how the sensor 400 reacts when a pinch force P is applied from top, left and right positions, respectively, and from which it should be appreciated that the sensor 400 has an activation angle of at least about two hundred and seventy degrees.
FIG. 8A shows a variant 400 ′ of the coaxial pinch sensor which employs a more cylindrical casing 410 ′ and outer sheath 404 ′, along with a narrower uvulate base structure 406 ′, thereby enabling an even wider range of activation angles. FIG. 8B shows a variant 400 ″ of the coaxial pinch sensor which employs a broader uvulate base structure 406 ″, resulting in a more limited range of activation angles.
While the above describes a particular embodiment(s) of the invention, it will be appreciated that modifications and variations may be made to the detailed embodiment(s) described herein without departing from the spirit of the invention. | A resistive pinch sensor utilizing electrically conductive wires encapsulated in a resiliently deformable casing. A pinch is detected when one of the wires, which is normally separated by an air gap within the casing, contacts another wire lowering the electrical resistance therebetween. The described pinch sensors have wide activation ranges or angles. Tri-lobed designs provide wide activation range by incorporating at least three electrically-conductive conduits that are substantially equidistantly spaced circumferentially along the inner wall of a tubular casing. One of the conduits, or optionally an axially arranged electrically-conductive core may function as the reference element. Coaxial designs provide wide activation range by incorporating a central electrically-conductive core and a coaxial electrically-conductive tubular outer sheath that are normally spaced apart by at least one non-conductive spacer. | 4 |
BACKGROUND
[0001] Disclosed herein are ink jet printheads having fluorinated poly(amide-imide) copolymer front face coatings.
[0002] Ink jet systems include one or more printheads having a plurality of jets from which drops of fluid are ejected towards a recording medium. The jets of a printhead receive ink from an ink supply chamber or manifold in the printhead which, in turn, receives ink from a source, such as an ink reservoir or an ink cartridge. Each jet includes a channel having one end in fluid communication with the ink supply manifold. The other end of the ink channel has an orifice or nozzle for ejecting drops of ink. The nozzles of the jets can be formed in an aperture or nozzle plate having openings corresponding to the nozzles of the jets. During operation, drop ejecting signals activate actuators in the jets to expel drops of fluid from the jet nozzles onto the recording medium. By selectively activating the actuators of the jets to eject drops as the recording medium and/or printhead assembly are moved relative to one another, the deposited drops can be precisely patterned to form particular text and graphic images on the recording medium. An example of a full width array printhead is described in U.S. Pat. No. 7,591,535, the disclosure of which is totally incorporated herein by reference. An example of an ultra-violet curable gel ink which can be jetted in such a printhead is described in U.S. Pat. No. 7,714,040, the disclosure of which is totally incorporated herein by reference. An example of a phase change ink which can be jetted in such a printhead is the Xerox Color Qube™ cyan solid ink available from Xerox Corporation. U.S. Pat. No. 5,867,189, the disclosure of which is totally incorporated herein by reference, describes an ink jet printhead including an ink ejecting component which incorporates an electropolished ink-contacting or orifice surface on the outlet side of the printhead. Additional examples of ink jet printheads are disclosed in U.S. Pat. Nos. 7,934,815, 7,862,678, and 7,862,160, the disclosures of each of which are totally incorporated herein by reference. Thermal ink jet systems, in which the expansion of a bubble forces a droplet of ink out of the nozzle, are also known, as disclosed in, for example, U.S. Pat. Nos. 4,601,777, 4,251,824, 4,410,899, 4,412,224, and 4,532,530, the disclosures of each of which are totally incorporated herein by reference. Also known are acoustic ink jet printing systems, as disclosed in, for example, U.S. Pat. Nos. 4,308,547, 4,697,195, 5,028,937, 5,041,849, 4,751,529, 4,751,530, 4,751,534, 4,801,953, and 4,797,693, the disclosures of each of which are totally incorporated herein by reference. Other known droplet ejectors include those of the type disclosed in, for example, U.S. Pat. No. 6,127,198, the disclosure of which is totally incorporated herein by reference.
[0003] One difficulty faced by ink jet systems is wetting, drooling, or flooding of inks onto the printhead front face. Such contamination of the printhead front face can cause or contribute to blocking of the ink jet nozzles and channels, which alone or in combination with the wetted, contaminated front face, can cause or contribute to non-firing or missing drops, undersized or otherwise wrong-sized drops, satellites, or misdirected drops on the recording medium, and thus result in degraded print quality.
[0004] Current printhead front face coatings are often sputtered polytetrafluoroethylene coatings. When the printhead is tilted, some inks do not readily slide on the printhead front face surface. Rather, these inks flow along the printhead front face and leave an ink film or residue on the printhead which can interfere with jetting. For this reason, the front faces of UV and solid ink printheads are prone contamination by UV and solid inks.
[0005] In some cases, the contaminated printhead can be refreshed or cleaned with a maintenance unit. Such an approach, however, introduces system complexity, hardware cost, and sometimes reliability issues. Contamination of the printhead can also be somewhat minimized by adopting purging procedures. These procedures, however, can consume time and use excessive amounts of ink.
[0006] In the case of inks such as phase change and UV curable gel inks, contamination of a printhead front face can also be minimized by providing an oleophobic low adhesion front face coating that does not wet significantly with ink ejected from nozzle openings of the printhead. When heated to temperatures typically encountered during printhead fabrication processes, however, the surface property characteristics of many known oleophobic low adhesion coatings degrade to the point that they cannot be relied upon to minimize contamination of the printhead front face.
[0007] A need thus remains for an improved printhead front face design that reduces or eliminates wetting, drooling, flooding, or contamination of ink, including UV or solid ink, over the printhead front face. In addition, a need remains for an improved printhead front face design that is ink phobic and robust to withstand maintenance procedures such as wiping of the printhead front face. Further, a need remains for an improved printhead that is easily cleaned or in some cases that is self-cleaning, thereby reducing or eliminating hardware complexity, such as the need for a maintenance unit, reducing run cost and improving system reliability. Additionally, a need remains for materials for coating printhead front faces that, while enabling excellent cleaning and, in many cases, self-cleaning properties, also is sufficiently robust to survive both the temperature and pressure conditions encountered during printhead fabrication and the temperature conditions encountered during printer operation without degradation. There is also a need for printhead front face coatings that exhibit improved anti-scratch properties. In addition, there is a need for printhead front face coatings that exhibit improved chemical resistance to varied chemical environments.
SUMMARY
[0008] Disclosed herein is an ink jet printhead comprising a plurality of channels, wherein the channels are capable of being filled with ink from an ink supply and wherein the channels terminate in nozzles on one surface of the printhead, the surface being coated with a coating composition comprising a fluorinated poly(amide-imide) copolymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a sectional view of an ink jet printhead according to some embodiments disclosed herein.
[0010] FIGS. 2 to 4 illustrate a process of forming the ink jet printhead shown in FIG. 2 according to one embodiment.
DETAILED DESCRIPTION
[0011] Disclosed herein is a hydrophobic and oleophobic low adhesion surface coating for an ink jet printhead front face. When the coating is disposed on an ink jet printhead front face surface, jetted drops of inks, including ultra-violet (UV) gel ink (also referred to herein as “UV ink”) and solid ink, exhibit low adhesion towards the surface coating. The adhesion of an ink drop toward a surface can be determined by measuring the sliding angle of the ink drop (i.e., the angle at which a surface is inclined relative to a horizontal position when the ink drop begins to slide over the surface without leaving residue or stain behind). The lower the sliding angle, the lower the adhesion between the ink drop and the surface. As used herein, the term “low adhesion” means a low sliding angle of in one embodiment at least about 1°, and in one embodiment no more than about 30°, in another embodiment no more than about 25°, and in yet another embodiment no more than about 20°, although the sliding angles can be outside of these ranges.
[0012] The term “hydrophobic” as used herein means that water forms a contact angle with the surface of the coating of at least about 90°, and in many embodiments greater angles of 100° or more. The term “oleophobic” as used herein means that hexadecane forms a contact angle with the surface of the coating of at least about 60°, and in many embodiments greater angles of 80° or more.
[0013] The coatings disclosed herein comprise a fluorinated poly(amide-imide) copolymer. More specifically, the polymer is a copolymer of a poly(amide-imide) and a fluorinated ether. Examples of suitable poly(amide-imide)/fluorinated ether copolymers include block, alternating, and/or random copolymers such as those of the formulae
[0000]
[0000] and mixtures thereof, wherein: (i) R 1 is: (A) an arylene group, including substituted and unsubstituted arylene groups, wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the arylene group, in one embodiment with at least about 5 carbon atoms, and in another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like; (B) an arylalkylene group, including substituted and unsubstituted arylalkylene groups, wherein the alkyl portion of the arylalkylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like; or (C) an alkylarylene group, including substituted and unsubstituted alkylarylene groups, wherein the alkyl portion of the alkylarylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylarylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as tolyl or the like;
[0014] (ii) R 2 is: (A) an alkylene group, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkylene groups, wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkylene group, in one embodiment with at least about 2 carbon atoms, in another embodiment with at least about 4 carbon atoms, and in yet another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges; (B) an arylene group, including substituted and unsubstituted arylene groups, wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the arylene group, in one embodiment with at least about 5 carbon atoms, and in another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like; (C) an arylalkylene group, including substituted and unsubstituted arylalkylene groups, wherein the alkyl portion of the arylalkylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzylene or the like; or (D) an alkylarylene group, including substituted and unsubstituted alkylarylene groups, wherein the alkyl portion of the alkylarylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylarylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as tolylene or the like; and
[0015] (iii) R 3 is: (A) an arylene group, including substituted and unsubstituted arylene groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the arylene group, in one embodiment with at least about 5 carbon atoms, and in another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like; (B) an arylalkylene group, including substituted and unsubstituted arylalkylene groups, wherein the alkyl portion of the arylalkylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like; or (C) an alkylarylene group, including substituted and unsubstituted alkylarylene groups, wherein the alkyl portion of the alkylarylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylarylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as tolyl or the like;
[0016] (iv) “fluorinated ether” represents one or more partially fluorinated or fully fluorinated (perfluorinated) ether monomers, such as (but not limited to) block, random, and alternating copolymers having two, three, or more different fluorinated ether monomers, such as those of the formula
[0000]
[0017] wherein:
[0018] R 4 is: (A) a partially fluorinated or fully fluorinated (perfluorinated) alkylene group, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkylene groups, wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkylene group, in one embodiment with at least about 1 carbon atom, embodiment with no more than about 18 carbon atoms, in another embodiment with no more than about 12 carbon atoms, and in yet another embodiment with no more than about 6 carbon atoms, although the number of carbon atoms can be outside of these ranges, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; (B) a partially fluorinated or fully fluorinated (perfluorinated) arylene group, including substituted and unsubstituted arylene groups, wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the arylene group, in one embodiment with at least about 5 carbon atoms, and in another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; (C) a partially fluorinated or fully fluorinated (perfluorinated) arylalkylene group, including substituted and unsubstituted arylalkylene groups, wherein the alkyl portion of the arylalkylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; or (D) a partially fluorinated or fully fluorinated (perfluorinated) alkylarylene group, including substituted and unsubstituted alkylarylene groups, wherein the alkyl portion of the alkylarylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylarylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as tolyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%;
[0019] R 5 is: (A) a partially fluorinated or fully fluorinated (perfluorinated) alkylene group, including linear, branched, saturated, unsaturated, cyclic, substituted, and unsubstituted alkylene groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the alkylene group, in one embodiment with at least about 1 carbon atom, and in one embodiment with no more than about 18 carbon atoms, in another embodiment with no more than about 12 carbon atoms, and in yet another embodiment with no more than about 6 carbon atoms, although the number of carbon atoms can be outside of these ranges, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; (B) a partially fluorinated or fully fluorinated (perfluorinated) arylene group, including substituted and unsubstituted arylene groups, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in the arylene group, in one embodiment with at least about 5 carbon atoms, and in another embodiment with at least about 6 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as phenyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; (C) a partially fluorinated or fully fluorinated (perfluorinated) arylalkylene group, including substituted and unsubstituted arylalkylene groups, wherein the alkyl portion of the arylalkylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the arylalkylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as benzyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%; or (D) a partially fluorinated or fully fluorinated (perfluorinated) alkylarylene group, including substituted and unsubstituted alkylarylene groups, wherein the alkyl portion of the alkylarylene can be linear, branched, saturated, unsaturated, and/or cyclic, and wherein hetero atoms, such as oxygen, nitrogen, sulfur, silicon, phosphorus, boron, or the like either may or may not be present in either or both of the alkyl portion and the aryl portion of the alkylarylene group, in one embodiment with at least about 6 carbon atoms, and in another embodiment with at least about 7 carbon atoms, and in one embodiment with no more than about 36 carbon atoms, in another embodiment with no more than about 28 carbon atoms, and in yet another embodiment with no more than about 24 carbon atoms, although the number of carbon atoms can be outside of these ranges, such as tolyl or the like, and wherein the degree of fluorination is in one embodiment at least about 5%, in another embodiment at least about 10%, and in yet another embodiment at least about 20%, and is in one embodiment 100%;
[0020] m is an integer representing the number of repeat —OR 4 — groups, and can be in one embodiment at least 1, in another embodiment at least about 2, and in yet another embodiment at least about 5, and in one embodiment no more than about 10,000, in another embodiment no more than about 8,000, and in yet another embodiment no more than about 5,000, although the value can be outside of these ranges;
[0021] n is an integer representing the number of repeat —OR 5 — groups, and can be in one embodiment 0, in another embodiment at least 1, in yet another embodiment at least about 2, and in still another embodiment at least about 5, and in one embodiment no more than about 10,000, in another embodiment no more than about 8,000, and in yet another embodiment no more than about 5,000, although the value can be outside of these ranges;
[0022] (v) x is an integer representing the number of repeat polyimide units, and is in one embodiment at least about 5, in another embodiment at least about 10, and in yet another embodiment at least about 20, and in one embodiment no more than about 20,000, in another embodiment no more than about 10,000, and in yet another embodiment no more than about 5,000, although the value can be outside of these ranges; and
[0023] (vi) y is an integer representing the number of repeat fluorinated ether units, and is in one embodiment at least about 1, in another embodiment at least about 2, and in yet another embodiment at least about 5, and in one embodiment no more than about 10,000, in another embodiment no more than about 8,000, and in yet another embodiment no more than about 5,000, although the value can be outside of these ranges;
[0024] wherein examples of the substituents on the substituted alkylene, arylene, arylalkylene, and alkylarylene groups can be hydroxy groups, halogen atoms, amine groups, imine groups, ammonium groups, cyano groups, pyridine groups, pyridinium groups, ether groups, aldehyde groups, ketone groups, ester groups, amide groups, carbonyl groups, thiocarbonyl groups, sulfate groups, sulfonate groups, sulfonic acid groups, sulfide groups, sulfoxide groups, phosphine groups, phosphonium groups, phosphate groups, nitrile groups, mercapto groups, nitro groups, nitroso groups, sulfone groups, acyl groups, acid anhydride groups, azide groups, azo groups, cyanato groups, isocyanato groups, thiocyanato groups, isothiocyanato groups, carboxylate groups, carboxylic acid groups, urethane groups, urea groups, silyl groups, siloxyl groups, silane groups, mixtures thereof, or the like, wherein two or more substituents can be joined together to form a ring.
[0025] In one specific embodiment,
[0000]
[0000] is
[0000]
[0000] and
[0000]
[0000] is
[0000]
[0000] In another specific embodiment,
[0000]
[0000] is
[0000]
[0000] and
[0000]
[0000] is
[0000]
[0000] In another specific embodiment,
[0000]
[0000] is
[0000]
[0000] and
[0000]
[0000] is
[0000]
[0000] In another specific embodiment,
[0000]
[0000] is
[0000]
[0000] and
[0000]
[0000] is
[0000]
[0026] In one specific embodiment, the fluorinated poly(amide-imide) copolymer has at least one carboxylic acid functional group thereon. In another specific embodiment, the fluorinated poly(amide-imide) copolymer has at least one carboxylic acid functional group as a terminal end group.
[0027] In one specific embodiment, R 4 is CF 2 CF 2 and R 5 is CF 2 such that
[0000]
[0000] is —(CF 2 CF 2 O) r —(CF 2 O) q —, r is an integer representing the number of repeat (CF 2 CF 2 O) units, q is an integer representing the number of repeat (CF 2 O) units, r/q is in one embodiment at least about 0.9, and in another embodiment at least about 1.5, and in one embodiment no more than about 5, and in another embodiment no more than about 3, and Mn of
[0000]
[0000] is in one embodiment at least about 900, and in one embodiment no more than about 3,500. In another specific embodiment, r has an average value of about 4.4 and q has an average value of about 1.7, r/q is about 2.5, and Mn is about 2,000. In yet another embodiment, the fluorinated polyether portion is a poly(trifluoropropylene ether) (in a specific embodiment with an average Mw about 400).
[0028] Suitable fluorinated polyether precursors include FLUOROLINK® C, available from Solvay Solexis Inc., West Deptford, N.J., and like commercially available products. The synthesis of copolymers by amide-imide synthetic processes is known in the art and described in, for example, U.S. Patent Publication 2009/0234060, the disclosure of which is totally incorporated herein by reference. Methods of preparing fluorinated ethers are also known, and are described in, for example, U.S. Pat. Nos. 5,446,205 and 7,329,784 and U.S. Patent Publication 2004/0024153, the disclosures of each of which are totally incorporated herein by reference.
[0029] The copolymers have weight average molecular weights of in one embodiment at least about 2,000, in another embodiment at least about 4,000, and in yet another embodiment at least about 5,000, and in one embodiment no more than about 2,000,000, in another embodiment no more than about 1,000,000, and in yet another embodiment no more than about 500,000, although Mw can be outside of these ranges.
[0030] The copolymers have number average molecular weights of in one embodiment at least about 2,000, in another embodiment at least about 4,000, and in yet another embodiment at least about 5,000, and in one embodiment no more than about 1,000,000, in another embodiment no more than about 800,000, and in yet another embodiment no more than about 500,000, although Mn can be outside of these ranges.
[0031] The copolymers exhibit glass transition temperatures of in one embodiment at least about 80° C., in another embodiment at least about 100° C., and in yet another embodiment at least about 120° C., and in one embodiment no more than about 450° C., in another embodiment no more than about 400° C., and in yet another embodiment no more than about 350° C., although the temperature can be outside of these ranges.
[0032] The copolymer (or the precursor monomers) is present in the solids content of the wet coating composition in any desired or effective amount, in one embodiment at least about 80 percent by weight of the solids content of the wet coating composition, in another embodiment, at least about 90 percent by weight of the solids content of the wet coating composition, in yet another embodiment at least about 99 percent by weight of the solids content of the wet coating composition, and in still another embodiment 100 percent by weight of the solids content of the wet coating composition, although the amount can be outside of these ranges.
[0033] The copolymer is present in the dried coating (or the solids content of the wet coating composition) in any desired or effective amount, in one embodiment at least about 80 percent by weight of the dried composition, in another embodiment, at least about 90 percent by weight of the dried coating composition, in yet another embodiment at least about 99 percent by weight of the dried coating composition, and in still another embodiment 100 percent by weight of the dried coating composition, although the amount can be outside of these ranges.
[0034] The coatings disclosed herein can be employed as a printhead front face coating for an inkjet printhead configured to eject any suitable ink, including aqueous inks, solvent inks, UV-curable inks, dye sublimation inks, solid phase change inks, or the like. An exemplary ink jet printhead suitable for use with the oleophobic low adhesion coating disclosed herein is described in FIG. 1 .
[0035] Referring to FIG. 1 , an ink jet printhead 20 according to one embodiment includes a support brace 22 , a nozzle plate 24 bonded to the support brace 22 , and an oleophobic low adhesion coating, such as oleophobic low adhesion coating 26 .
[0036] The support brace 22 is formed of any suitable material, such as stainless steel or the like, and include apertures 22 a defined therein. The apertures 22 a communicate with an ink source (not shown). The nozzle plate 24 is formed of any suitable material, such as polyimide or the like, and includes nozzles 24 a defined therein. The nozzles 24 a communicate with the ink source via the apertures 22 a such that ink from the ink source is jettable from the printhead 20 onto a recording substrate through a nozzle 24 a.
[0037] In the illustrated embodiment, the nozzle plate 24 is bonded to the support brace by an intervening adhesive material 28 . The adhesive material 28 can be provided as a thermoplastic adhesive that can be melted during a bonding process to bond the nozzle plate 24 to the support brace 22 . The nozzle plate 24 and the oleophobic low adhesion coating 26 can also be heated during the bonding process. Depending on the material from which the thermoplastic adhesive is formed, the bonding temperature can be in a range of from about 180° C. to about 325° C., although the temperature can be outside of these ranges.
[0038] Conventional oleophobic low adhesion coatings tend to degrade when exposed to temperatures encountered during typical bonding processes or other high-temperature, high-pressure processes encountered during fabrication of ink jet printheads. The oleophobic low adhesion coating 26 disclosed herein, however, exhibits a sufficiently low adhesion (indicated by low sliding angles) and high contact angle with respect to an ink after it has been heated to the bonding temperature that it can provide a self-cleaning, contamination-free ink jet printhead 20 with high drool pressure. The ability of the oleophobic low adhesion coating 26 to resist substantial degradation in desirable surface properties, including low sliding angle and high contact angle, upon exposure to elevated temperatures, enables ink jet printheads having self-cleaning abilities while maintaining high drool pressure to be fabricated using high-temperature and high-pressure processes. An exemplary process of forming an ink jet printhead is described with respect to FIGS. 1 to 4 .
[0039] Referring to FIG. 2 , an ink jet printhead, such as printhead 20 , can be formed by forming an oleophobic low adhesion coating such coating 26 on a substrate 32 . The substrate 32 can be formed of any suitable material, such as polyimide or the like.
[0040] In one embodiment, the oleophobic low adhesion coating 26 may be formed on the substrate 32 by initially applying the reactant mixture that includes, for example, the mixture of monomers, including a fluorinated polyether such as FLUOROLINK® C, an anhydride, such as trimellitic anhydride, 4,4′-oxydiphthalic anhydride, 3,3′,4,4′-benzophenonetetracarboxylic dianhydride, or the like, as well as mixtures thereof, an isocyanate, such as methylene diisocyanate, toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, or the like, as well as mixtures thereof, and a suitable solvent, such as N-methyl pyrrolidinone, N,N-dimethylformamide, tetrahydrofuran, or the like, as well as mixtures thereof. After the reactant mixture is applied to the substrate 32 , the reactants are reacted together to form the oleophobic low adhesion coating 26 . The reactants can be reacted together by, for example, curing the reactant mixture. The reactant mixture is first cured at a temperature of in one embodiment at least about 25° C., in another embodiment at least about 35° C., and in yet another embodiment at least about 50° C., and in one embodiment no more than about 400° C., in another embodiment no more than about 350° C., and in yet another embodiment no more than about 300° C., although the temperature can be outside of these ranges, for a period of in one embodiment at least about 5 minutes, in another embodiment at least about 10 minutes, and yet another embodiment at least about 25 minutes, and in one embodiment no more than about 6 hours, in another embodiment no more than about 5 hours, and in yet another embodiment no more than about 4 hours, although the period of time can be outside of these ranges, followed by a high temperature post-cure at in one embodiment in one embodiment at least about 120° C., in another embodiment at least about 140° C., and in yet another embodiment at least about 160° C., and in one embodiment no more than about 450° C., in another embodiment no more than about 400° C., and in yet another embodiment no more than about 350° C., although the temperature can be outside of these ranges, for a period of in one embodiment at least about 5 minutes, in another embodiment at least about 10 minutes, and yet another embodiment at least about 15 minutes, and in one embodiment no more than about 6 hours, in another embodiment no more than about 5 hours, and in yet another embodiment no more than about 4 hours, although the period of time can be outside of these ranges.
[0041] The reactant mixture can be applied to the substrate 32 using any suitable method, such as die extrusion coating, dip coating, spray coating, spin coating, flow coating, stamp printing, blade techniques, or the like. An air atomization device such as an air brush or an automated air/liquid spray can be used to spray the reactant mixture. The air atomization device can be mounted on an automated reciprocator that moves in a uniform pattern to cover the surface of the substrate 32 with a uniform (or substantially uniform) amount of the reactant mixture. The use of a doctor blade is another technique that can be employed to apply the reactant mixture. In flow coating, a programmable dispenser is used to apply the reactant mixture.
[0042] In yet another embodiment, oleophobic low adhesion coating 26 can be first cured into a sheet and then applied and bonded to substrate 32 with any desirable or suitable adhesive material. Further details on this method are disclosed in, for example, U.S. Patent Publications 2011/0157278 and 2011/0228005, the disclosures of each of which are totally incorporated herein by reference.
[0043] Referring to FIG. 3 , the substrate 32 is bonded to the aperture brace 22 via adhesive material 28 , resulting in the structure shown in FIG. 5 . In one embodiment, the adhesive material 28 is bonded to the aperture brace 22 before being bonded to the substrate 32 . In another embodiment, the adhesive material 28 is bonded to the substrate 32 before being bonded to the aperture brace 22 . In yet another embodiment, the adhesive material 28 is bonded to the substrate 32 and the aperture brace 22 simultaneously.
[0044] In embodiments where the adhesive material 28 is provided as a thermoplastic adhesive, the adhesive material 28 is bonded to the substrate 32 and the aperture brace 22 by melting the thermoplastic adhesive at, and subjecting the oleophobic low adhesion coating 26 to, a bonding temperature and a bonding pressure. The bonding temperature is in one embodiment at least about 180° C., and in one embodiment no more than about 325° C., and in another embodiment no more than about 290° C., although the temperatures can be outside of these ranges. The bonding pressure is in one embodiment at least about 100 psi, and in one embodiment no more than about 400 psi, and in another embodiment no more than about 300 psi, although the pressures can be outside of these ranges.
[0045] After bonding the substrate 32 to the aperture brace 22 , the aperture brace 22 can be used as a mask during one or more patterning processes to extend the apertures 22 a into the adhesive material 28 , as shown in FIG. 1 . The aperture brace 22 can also be used as a mask during one or more patterning processes to form nozzles 24 a in the substrate 32 , thereby forming the nozzle plate 24 shown in FIG. 1 . The one or more patterning processes used to form nozzles 24 a can also be applied to form nozzle openings 26 a within the oleophobic low adhesion coating 26 , wherein the nozzle openings 26 a communicate with the nozzles 24 a . In one embodiment, the apertures 22 a can be extended into the adhesive material 28 by a laser ablation patterning process or the like. In one embodiment, the nozzles 24 a and nozzle openings 26 a can be formed in the substrate 32 and the oleophobic low adhesion coating 26 , respectively, by a laser ablation patterning process or the like.
[0046] The front face coatings disclosed herein are thermally stable under printhead fabrication conditions and printer operating conditions. The front face coatings exhibit oleophobic characteristics after being subjected to temperatures of in one embodiment at least about 180° C., and in one embodiment no more than about 325° C., and in another embodiment no more than about 290° C., although the temperatures can be outside of these ranges, and pressures of in one embodiment at least about 100 psi, and in one embodiment no more than about 400 psi, and in another embodiment no more than about 300 psi, although the pressures can be outside of these ranges, for periods of time of in one embodiment at least about 10 minutes, and in another embodiment at least about 30 minutes, and in one embodiment no longer than about 2 hours, although the period of time can be outside of these ranges. The surface coating can be bonded to a stainless steel aperture brace at high temperature and high pressure without any degradation, and the resulting printhead can prevent ink contamination because ink droplets can roll off the printhead front face, leaving behind no residue.
[0047] The oleophobic low adhesion surface coating includes an oleophobic low adhesion polymeric material configured such that jetted drops of ultra-violet gel ink or jetted drops of solid ink exhibit a contact angle of in one embodiment at least about 45°, in another embodiment at least about 55°, and in yet another embodiment at least about 65°, and in one embodiment no more than about 150°, although the contact angle can be outside of these ranges.
[0048] When ink is filled into the printhead, it is desired to maintain the ink within the nozzle until it is time to eject the ink. Generally, the greater the ink contact angle the better (higher) the drool pressure. Drool pressure relates to the ability of the aperture plate to avoid ink weeping out of the nozzle opening when the pressure of the ink tank (reservoir) increases. In some embodiments, the oleophobic low adhesion surface coatings described herein provide, in combination, low adhesion and high contact angle for ultra-violet curable gel ink and solid ink, which further provides the benefit of improved drool pressure or reduced or eliminated weeping of ink out of the nozzle.
[0049] The coatings disclosed herein have a surface energy of in one embodiment no more than about 80 dynes per centimeter, in another embodiment no more than about 75 dynes per centimeter, and in yet another embodiment no more than about 50 dynes per centimeter, although the surface energy can be outside of these ranges.
[0050] The coatings disclosed herein exhibit water contact angles of in one embodiment at least about 80°, in another embodiment at least about 90°, and in yet another embodiment at least 100°, although the value can be outside of these ranges.
[0051] Specific embodiments will now be described in detail. These examples are intended to be illustrative, and the claims are not limited to the materials, conditions, or process parameters set forth in these embodiments. All parts and percentages are by weight unless otherwise indicated.
Example I
[0052] Trimellitic anhydride (18.82 g) and FLUOROLINK® C (6.4 g; obtained from Solvay Solexis Inc.) were dissolved in 200 mL N-methylpyrrolidinone solvent. With mechanical stirring and under flowing nitrogen gas, hexamethylene diisocyanate (25.0 g) was added. The mixture was then slowly heated to 80° C. over 2 h, and was maintained at this temperature for 1.5 h. Thereafter, the reaction solution was heated to 145° C. for 2 h. After subsequent cooling to room temperature, a viscous brownish solution was obtained.
[0000]
[0053] r average value about 4.4, q average value about 1.7, r/q about 2.5
[0054] The solution thus obtained was applied on UPILEX polyimide film by a 0.25-mil Bird bar. The coating was dried first at 110° C. for 30 minutes, second at 160° C. for 45 minutes, and finally at 220° C. for 30 minutes. The cured film had a very smooth surface. The water contact angle of the cured film was 106.5°, the formamide contact angle was 93.4°, and the surface energy was 18.5 dyne/cm.
[0055] The obtained film had a glass transition temperature of about 155° C. as measured by DSC scanning, confirming the formation of a high performance polymer. Thermogravimetric analysis (TGA) to test the thermal stability of the polymer under air atmosphere showed less than 2.5% weight loss at 300° C., indicating high thermal stability, which was excellent for a printhead coating application.
[0056] It is believed that applying this film to a printhead nozzle plate as illustrated in FIGS. 1 to 4 as oleophobic low adhesion coating 26 will result in a printhead exhibiting, in some embodiments, advantages such as reduced or eliminates wetting, drooling, flooding, or contamination of ink over the printhead front face, ink phobicity and robustness to withstand maintenance procedures such as wiping of the printhead front face, ease of cleaning or, in some instances, self-cleaning properties, thereby reducing or eliminating hardware complexity, such as the need for a maintenance unit, reducing run cost and improving system reliability, sufficient robustness to survive both the temperature and pressure conditions encountered during printhead fabrication and the temperature conditions encountered during printer operation without degradation, improved anti-scratch properties, and improved chemical resistance to varied chemical environments.
Example II
[0057] The process of Example I is repeated except that the trimellitic anhydride is replaced with an equimolar amount of 3,3′,4,4′-biphenyltetracarboxylic acid dianhydride [BPDA]. It is believed that similar results will be obtained.
[0000]
Example III
[0058] The process of Example I is repeated except that the hexamethylene diisocyanate is replaced with an equimolar amount of toluene diisocyanate. It is believed that similar results will be obtained.
[0000]
Example IV
[0059] The process of Example I is repeated except that half of the hexamethylene diisocyanate is replaced with an equimolar amount of methylene bis-(4-cyclohexylisocyanate). It is believed that similar results will be obtained.
[0000]
Example V
[0060] The process of Example I is repeated except that the FLUOROLINK® C is replaced with an equimolar amount of poly(trifluoropropylene ether) dipropionic acid (average Mw 400). It is believed that similar results will be obtained.
[0000]
[0061] Other embodiments and modifications of the present invention may occur to those of ordinary skill in the art subsequent to a review of the information presented herein; these embodiments and modifications, as well as equivalents thereof, are also included within the scope of this invention.
[0062] The recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefor, is not intended to limit a claimed process to any order except as specified in the claim itself. | Disclosed is an ink jet printhead comprising a plurality of channels, wherein the channels are capable of being filled with ink from an ink supply and wherein the channels terminate in nozzles on one surface of the printhead, the surface being coated with a coating composition comprising a fluorinated poly(amide-imide) copolymer. | 1 |
FIELD OF THE INVENTION
The present invention relates to a spray means for a toilet pedestal particularly, although not exclusively, envisaged for use as an alternative to toilet paper used in water closets (generally referred to as "toilets").
More particularly, the present invention relates to a bidet attachment for a toilet to allow cleaning and drying of a person's genital area and anus.
DISCUSSION OF THE PRIOR ART
In-general, a person using a toilet employs toilet paper to clean his/her anus and/or genital area after using the toilet. The toilet paper must be periodically replenished and the toilet paper must be readily biodegradable in a sewerage system to which the toilet is connected.
It is known to provide a bidet for use in washing the person's anus and/or genital area after use of the toilet. Such bidets comprise, a pedestal, a cistern and a hot water system from which water fills the pedestal. The bidets operate by completely filling with water which uses about 10-15 liters of water which is inappropriate where water must be conserved. The bidet must be located adjacent a toilet and be readily accessible to a user of the toilet. Where the user has limited mobility, such as, in the case of physically handicapped people, it is generally not feasible to move the person from the toilet to the bidet to perform the washing function. Accordingly, such washing is generally performed by an aide to the handicapped person. Also, the bidet requires the use of a towel to dry the person's anus and/or genital area after use of the bidet. Further, the hot water system required by the bidet adds to the expense of the bidet installation. Still further, the conventional bidet takes up valuable space.
Various bidet attachments for toilets have been proposed in the past. The prior art bidet attachments fall generally into the broad categories of having spray nozzles that (a) pivot about vertical or
(b) horizontal axes and
(c) are disposed for movement fore and aft or
(d) transverse of a pedestal of the toilet. Spray nozzles which pivot about horizontal axes (category (b)) have a disadvantage in that a spray of water from the spray nozzle tends to be directed to a focal point irrespective of the angle of disposition of the spray nozzle. In order to enable cleaning of both anal and genital areas the spray nozzle must be at a relatively large distance from these areas. Hence, its effective operation is affected by variations in water pressure and difficulty in achieving accurate delivery of a spray of the water to said areas. See, for example, U.S. Pat. No. 4062072 by A. B. Roberts UK Patent Application No. 2142054 by Ina Seito Company Limited (Japan) and Australian Patent Application No. 80610/87 by J. Diaz and L. Diaz. These bidet attachments seem to be concerned with general washing of the entire anus and genital area and are not concerned with accuracy of confinement of spray. Therefore, they assume that drying will be with a towel and are not suited to drying by blowing with warm air because of the excessive amount of water used and the size of the wetted area. Whilst Roberts does disclose a hot air drying unit, separate to the bidet attachment, the unit directs air only generally at the area of the anus from a rear of the toilet pedestal and thus does not provide accurate drying to the anus, nor drying to the genital area. Also, the unit requires separate plumbing and mounting, which is inconvenient and more costly.
Bidet attachments of category (d) (transverse movement of the spray nozzle) have a disadvantage in that their movement is at right angles to the alignment of the anus and genital area. Hence, category (d) bidet attachments are only suited to application of broadly directed sprays of water for cleaning the anus and genital area simultaneously. Due to the amount of water used and the size of the wetted area such bidet attachments are not suited to drying by blowing with warm air. See for example, US Patent No. 4642820 by G. E. Boring and U.S. Pat. No. 4334329 by F. H. Miyanaga. Both of these patented inventions have a further disadvantage in that controls for the spray nozzle are located behind a user of the toilet and so are difficult to manipulate.
It is preferred to have a bidet attachment which falls into categories (a) and (c) since this provides the most accurate application of water to the anus and/or the genital area at the choice of the user and allows for use of relatively small amounts of water over relatively small areas. See, for example, U.S. Pat. No. 4406025 by L. F. Huck and U.S. Pat. No. 1,521,892 by H. S. Koppin. However, neither of these discloses passing air through the spray nozzle for drying the anus and genital area, nor valves necessary to enable use of the spray nozzle for carrying both water and air. Also, they are entirely silent as to the problems to be overcome in such application of air for drying the anus and genital area.
It is thus preferable to provide a bidet attachment, capable of use in cleaning a person's anus and/or genital area, which can be attached to a toilet pedestal and can be hand operated. The bidet attachment is thus available for self use and for use by aides to people unable to use the bidet attachment themselves. It is also preferred that the spray means be capable of drying the person's anus and/or genital area once cleaning is completed.
SUMMARY OF THE INVENTION
Therefore, the present invention provides a spray means for a toilet pedestal, the spray means being capable of fitting to a toilet pedestal and capable of hand operation to clean and dry a user's anus and/or genital area.
In the broadest form of the invention the spray means is used in association with a toilet pedestal but need not be attached to the toilet pedestal.
In accordance with one aspect of the present invention there is provided a spray means for use in cleaning and drying a person's anus and genital area, the spray means comprising:
a liquid supply means for supplying liquid under pressure;
a gas supply means for supplying gas under pressure;
a spray assembly for spraying the liquid and the gas as the anus and the genital area;
valve means connecting the liquid and gas supply means to the spray assembly; and,
control means operatively associated with the valve means for separately supplying liquid or gas to the spray assembly but not both simultaneously;
whereby, in use, the liquid can be directed to clean the anus and genital area and the gas can be directed to dry the anus and genital area via the spray assembly.
The spray assembly is in a form chosen from a set including a hand held wand having no attachment to the toilet pedestal; a wand guided to move fore and aft of the toilet pedestal; and a wand pivotably attached to a side of the toilet pedestal for pivoting fore and aft. The latter two forms are referred to as "bidet attachments for toilets".
The spray means also has heater means for heating liquid from the liquid supply means and gas from the gas supply means. The heater means heats the liquid to a temperature such that when the liquid contacts the person's skin the person is not scalded, typically less than about 38° C. Also, the heater means heats the gas to a temperature such that the gas is at about 90° C. when it exhausts from the spray assembly and thus about 45° C. when the gas contacts the person's wetted skin. The temperature loss is due to mixing of the exhausted air with ambient air between the spray assembly and the skin and air turbulence caused by the exhausting spray of air.
Preferably, where the wand is attached to the toilet pedestal, it is moveable between a storage position, whereby a spray nozzle of the wand is disposed for cleaning by water released from a cistern of the toilet, and an operational position, whereby, the spray nozzle is locatable underneath the user's anus and genital area.
Preferably, the control means includes interrupt means for preventing operation of the valve means when the spray assembly is between the storage and operational positions and to allow operation of the valve means when the spray means is in the storage and operational position.
Typically, the liquid supply means includes a pump connected to a tank of liquid; or a tank supplied by mains liquid via a float valve; or a mains isolator designed to prevent back flow of liquid into the mains from the liquid supply means.
Typically, the gas supply means includes a gas compressor which may conveniently be coupled to a gas reservoir.
In accordance with another aspect of the present invention there is provided a toilet pedestal having a spray means attached to it for cleaning and drying a person's arms and genital area, the spray means being as defined hereinabove.
BRIEF DESCRIPTION OF THE DRAWINGS
Five embodiments, being examples only, of the present invention will now be described, with reference to the accompanying drawings in which:
FIG. 1 is a perspective view, seen from above, of a bidet attachment having a base unit and a spray assembly according to one embodiment of the present invention, in the form of a wand, shown coupled to and guided along a toilet pedestal;
FIG. 2 is a schematic diagram of fluidic circuits of the bidet attachment of FIG. 1;
FIG. 3 is a perspective view, seen from above, of a spray assembly according to another embodiment of the present invention, in the form of a hand held wand, for use with the base unit shown in FIG. 1;
FIG. 4 is a perspective view, seen from above, of a spray assembly in accordance with yet another embodiment of the present invention, in the form of a wand pivotably mounted in a bracket;
FIG. 5 is a perspective view, seen from above, of the spray assembly of FIG. 4 shown adhered by a bracket to a toilet pedestal;
FIG. 6 is a part vertical cross sectional view of a spray assembly according to yet another embodiment of the present invention, in the form of a wand shown clamped by a bracket to a toilet pedestal; and,
FIGS. 7 and 8 are, respectively, plan and side views of a spray assembly according to yet another embodiment of the present invention, in the form of a wand pivotable in a vertically disposed hole formed in a lip of a toilet pedestal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown spray means 10 comprising a base unit 12 and a spray assembly 14 according to a first embodiment of the present invention. The spray assembly 14 is shown attached to a toilet pedestal 16 and the base unit 12 is contained in a housing 17.
As shown in FIG. 2 the base unit 12 comprises a liquid supply means in the form of a water supply unit 18, a gas supply means in the form of an air supply unit 20, valve means in the form of two solenoid valves 22 and 24 and a control means in the form of a control unit 26. The water supply unit 18 includes inlet 28 coupled to a supply of water. Where the supply of water is a low pressure a water pump 30 is provided to supply the water at pressure to a tank 32. Where the water at the inlet 28 is at mains pressure the inlet may be connected to a mains isolator for inhibiting flow of the water back into the mains or a holding tank whose water level is controlled by a float valve. The tank 32 is provided with a heating element 34 controlled by a thermostat 36 for heating the water in the tank 32 to a predetermined temperature, such as, for example, between 35 and 45° C., for instance about 38° C. An outlet 37 of the tank 32 is connected to the solenoid valve 22.
The air supply unit 20 includes an air inlet 38 to an air compressor 40. Typically, the air compressor 40 is a double acting compressor for providing compressed air at about 62 kpa (9 PSI). The air compressor 40 is connected to a heat exchanger 42 in the form of a mass of metal (such as aluminum) having a heating element 44 controlled by a thermostat 46. The thermostat 46 is set to heat the air to in excess of 90° C, for reasons explained hereinafter. An outlet 48 of the heat exchanger 42 is connected to the solenoid valve 24.
The two solenoid valves 22 and 24 are connected to a common line 50 connected to the spray assembly 14.
The control unit 26 includes a center-off toggle switch 52, located on the spray assembly 14, for hand manipulation. The switch 52 is electrically connected to relays 54 and 56 for switching the thermostats 36 and 46 for the heating elements 34 and 44, respectively, out of circuit, and switching a diac-triac controller 58 into circuit in their place. The diac-triac controller 58 is set to provide boosted heating to the tank 32 and the heat exchanger 42 when water and air, respectively, are flowing through them. The switch 52 is also electrically connected to the solenoid valves 22 and 24 so that movement of the switch 52 to a position marked "water" causes energization of the solenoid valve 22 and movement to a position marked "air" causes energization of the solenoid valve 24. Whilst the switch 52 is in an "off" position the heating elements 34 and 44 are controlled by the thermostats 36 and 46, respectively, to preheat the water in the tank 32 and the air in the heat exchanger 42. The control unit 26 also has a pressure switch (not shown) connected in series with switch 52 to inhibit operation of the solenoid valves 22 and 24 unless a person is sitting on toilet pedestal 16. The pressure switch is intended to avoid accidental operation of the base unit 12. Typically, the control unit 26 operates at 24 Volts AC and the heating elements 34 and 44 operate at mains voltage AC. Relatively low voltage operation of the control unit 26 is preferred so as to reduce the likelihood of electrocution in the event of short circuiting to ground via the body of a person using the spray means 10.
The spray assembly 14, as shown in FIG. 1, is in the form of a wand attached to and guided along a side 56 of a lip 58 of the toilet pedestal 16. The wand 62 comprises a hand grip 60, a spray conduit 62, a guide rod 64 and an umbilical cord 66. The hand grip 60 carries the switch 52 and receives one end of the umbilical cord 66. The other end of the umbilical cord 66 is connected via a quick release coupling 68 to the common line 50 and control unit 26 of the base unit 12 via a connector on an outside of the housing 17. The umbilical cord 66 has a fluid hose and control cables in it. The fluid hose is connected to a conduit in the hand grip 60 Eo the spray conduit 62. The control cables of the umbilical cord 66 are connected to the switch 52. The guide rod 64 depends from the spray conduit 62 and is disposed fore and aft of the toilet pedestal 16. The spray conduit 62 is shaped to conform to the shape of the interior of the toilet pedestal 16 underneath the lip 58. The spray conduit 62 extends substantially perpendicularly from a side of the hand grip 60.
The spray assembly 14 is guided along the toilet pedestal 16 by a guide base 70 attached between the toilet pedestal 16 and a toilet seat 72. The guide base 70 is typically made from plastics material and substantially conforms to the shape of the toilet pedestal 16 when viewed in plan. The guide base 70 is formed on its undersurface to co-operate with the upper edge of side 56 of the lip 58 of the pedestal 16 to form a slot which allows movement of the spray conduit along the fore and aft axis of the pedestal. A spray conduit 62 extends across the slot to extend to each side thereof. In addition the portion of the guide base rearward of the rebate is formed with a rearwardly extending axial passageway 76 which accommodates the guide rod 64 and permits axial movement of the guide rod 64 as the spray conduit 62 is caused to be moved between its end positions within the slot.
An interrupt means in the form of a cam 78 is disposed from the guide base 70 for actuating a microswitch 80 located on the hand grip 60. The cam 78 causes actuation of the microswitch 80 when the spray conduit 62 is moved from a storage position with its spray nozzle 82 disposed under the lip 58 of the toilet pedestal to an operational position whereby the spray nozzle 82 is disposable underneath the anus and genital area of the user. Actuation of the microswitch 80 enables electrical connection of the switch 52 to the remainder of the control unit 26. Hence the solenoid valves 22 and 24 can not be actuated unless the spray conduit 62 is in the operational position. When in the storage position water discharged from a cistern connected to the toilet pedestal 16, washes over the spray conduit 62 and the spray nozzle 82 to clean same.
In use, the spray means 10 according to the present embodiment is installed by mounting the guide base 70 upon the lip 58 of the toilet pedestal 16 under the toilet seat 72. The guide rod 64 of the spray assembly 14 is inserted into the hole 76 and the spray conduit 62 disposed over the lip 58 and into the interior of the toilet pedestal 16. A beam 75 is then fixed in place over the spray conduit 62 to form the slot 74. The quick release coupling 68 of the umbilical cord 66 is attached to the coupling of the housing 17. The housing 17 is connected to a supply of mains voltage electricity via a mains cord 84 and the Water inlet 28 is connected to a supply of water. Then the pressure switch, located in the guide base 70, is connected into the control unit 26.
A person wishing to use the toilet lowers the toilet seat 72 and sits on it to activate the pressure switch. The pressure switch activates the control unit 26 for preheating the water and heat exchanger 42. Once the person has finished using the toilet the person can clean his or herself by grasping the hand grip 60 and drawing it aftwardly whilst remaining seated on the toilet seat 72. Once the spray nozzle 82 is in the operational zone the microswitch 80 is actuated by the cam 78 to electrically connect the switch 52 to the remainder of the control unit 26. Toggling of the switch toward the "water" position then activates the solenoid valve 22 and the water pump 30 (if installed) to supply water from the water supply via the inlet 28 to the tank 32. The water in the tank 32 is heated and passes out via the outlet 37 to the solenoid valve 22 and to the common line 50. The heated water then flows out of the coupling and into the umbilical cord 66, through the hand grip 60, through the spray conduit 62 and out of the spray nozzle 82 for spraying the person's anus and genital area. With the switch 52 toggled to the "water" position the relay 54 disconnects the thermostat 36 and connects the diac-triac 58 to the heating element 34 to provide more accurate heating of water as it flows through the tank 32.
Once the person is satisfied that he or she is sufficiently clean the switch 52 is toggled to the "air" position to activate the solenoid valve 24 and the air compressor 40 to supply air to the heat exchanger 42 via the inlet 38. The air is heated in the heat exchanger 42 and passes out via the outlet 48 to the solenoid valve 24 and the common line 50. The heated air then flows along the same path as the water had previously and contacts the person's skin in the same areas to effect drying. In the "air" position the relay 56 disconnects the thermostat 46 and connects the diactriac 58 to the heating elements 44 to provide more accurate heating to the heat exchanger 42 as the air flows through it.
It has been discovered that the temperature of the air exhausting from the spray nozzle should be in excess of 90° C. so as to achieve air at about 45° C. at the surface of the person's skin. This is because the spray of exhausting air mixes with surrounding air. The temperature of the mixture is typically about half that of the exhausting air. Such a problem does not occur with the water since there is not similar mixing and the water has a much higher thermal inertia than the air since it is a liquid and not a gas.
When the person is satisfied that they are sufficiently dry the switch 52 is toggled to the "off" position to de-energize the solenoid valve 24 and the air compressor 40. The wand 54 is then pushed forward so that the microswitch 80 is deactivated and the spray nozzle 82 returned to the storage position. Flushing of the cistern then cleans the spray conduit 62 and the spray nozzle 82.
The base unit 12 may include adjusters for the thermostats 36 and 46 to take into account the ambient temperature. The adjusters could be manually operated or automatic.
The fluid lines of the spray means 10 from the outlets 37 and 48 to the spray nozzle 82 could be lined with heat insulative material to avoid temperature loss due to passage of fluid in the lines.
The heating elements could be stationed in the spray assembly 14 to assist in overcoming the problem of heat loss in the fluid lines. Typically, the heating elements in such a case would be operated at low voltage, say about 1.12 volts, and high current, say about 62 amps to lessen the risk of electrocution. The heating elements could take the form of a heavy gauge copper conductor, of about 5 mm diameter, running along the conduit 62 from its connection with the guide rod 64 to the spray nozzle 82, and electrically connected to the spray nozzle 82. The conduit 62 then forms the return path for the flow of electricity back to the guide rod 64. Two further conductors then connect, one to the first conductor and the other to the conduit 62 at the guide rod 64, and run along the guide rod 64 and into the base unit 12. Flow of electricity along the conduit 62 causes it to heat up and thus heat the water and air flowing through it. Preferably, a higher starting voltage may be used to overcome thermal inertia of the conduit 62 once the control unit 26 is activated by the pressure switch.
In FIG. 3 there is shown a spray assembly 100 according to another embodiment of the present invention. The spray assembly 100 is similar to the spray assembly 14 and like numerals denote like parts. The spray assembly 100 is in the form of hand held wand having no attachment to the toilet pedestal 16. The spray assembly 100 differs from the spray assembly 14 in that it has a spray conduit 102 which is substantially straight and depends in a lengthwise extending direction from the hand grip 60. Also, the spray conduit 102 has a crook, terminating at the spray nozzle 82, for avoiding touching the person's anus and genitals when in use.
Preferably, a cradle is fixed, such as by gluing, to the side of the toilet pedestal 16, or the housing 10, for carrying the spray assembly when not in use. Preferably, a pouch is provided for receiving and storing the spray assembly 100 when in transit.
In use, the umbilical cord 66 of the spray assembly 100 is connected to the housing in the same manner as the spray assembly 14. The switch 52 is operated in the same manner for spraying heated water and air out of the spray nozzle 82. The spray assembly 100 is used differently to the spray assembly 14 in that it can be freely hand manipulated to clean and dry the anus and genital area of the user.
In FIGS. 4 and 5 there is shown a spray assembly 200 according to yet another embodiment of the present invention. The spray assembly 200 is in the form of a wand pivotably attached to the side 56 of the toilet pedestal 16. The spray assembly 200 is similar to the spray assembly 14 and like numerals denote like parts. The spray assembly 200 comprises a bracket 210 and a spray conduit 212. The bracket 210 is typically curved for attaching, such as, by gluing, to the lip 58 of the toilet pedestal 16 as shown in FIG. 5. The bracket 210 includes a boss 218 disposed substantially at right angles to the curvature of the bracket 210.
As shown in FIGS. 4 and 5, the spray conduit 212 has a first portion 220 pivotably disposed within the boss 218. The spray conduit 212 has- a second portion 222 disposed substantially at right angles to the first portion 220, disposed upon the lip 58 and directed toward an interior of the toilet pedestal 16. The second portion 222 terminates at a third portion 224 which is disposed downwardly into the interior of the toilet pedestal 16 and substantially parallel to the first portion 220. The spray conduit 212 has a fourth portion 226 terminating the third portion 224. The fourth portion 226 is disposed underneath the lip 58. The spray conduit 212 also has a curved arm 228 extending from fourth portion 226. The arm 228 typically terminates at the spray nozzle 82 having a rose 232 designed to direct a spray of liquid, such as, for example, water upwardly from the spray nozzle 82.
Typically, the spray conduit 212 is made of a metal or plastics material and is relatively rigid. Preferably, the spray conduit 212 is a poor conductor of heat so as not to absorb heat from the heated water and air passing through it.
The spray conduit 212 is pivotable between the storage position and the operational position. During pivoting the spray nozzle 82 describes an arc 242 which represents an area proximate the person's anus and genital area at which area water and air can be sprayed upwardly.
The spray assembly 200 has a handle 243 for manipulation of the conduit 212 between the storage and operational positions. Typically, the handle 243 is substantially parallel to an axis drawn through the ends of the curved arm 228 of the spray conduit 212. The handle 243 includes the switch 52 for activating remainder of the control unit 26.
In use, the bracket 210 is typically glued to the lip 58 of the toilet pedestal 16. Fixing to the exterior of the toilet pedestal 16 is preferred since there is then less likelihood of the bracket 210 becoming soiled. Such fixing of the bracket 10 disposes the conduit 212 into the interior of the toilet pedestal 16. The spray assembly 200 is connected by the umbilical cord 66 to the base unit 12.
To operate the spray assembly 200 the handle 243 is grasped and the spray nozzle 82 of the spray conduit 212 pivoted from the storage position to the operational position whereat the handle 243 is pivoted back and forth to pivot the spray nozzle 82 back and forth beneath the users anus and genital area. Simultaneously, the switch 52 on the handle 243 is depressed to actuate the solenoid valves 22 and 24 as described hereinabove. The spray conduit 212 and the spray nozzle 82 are both cleaned when in the storage position when the toilet cistern is flushed.
It is envisaged that the conduit 212 could be made of stainless steel and/or could be chromium plated to resist corrosion and/or coated with cleanable insulative material.
In FIG. 6 there is shown a spray assembly 300 according to yet another embodiment of the present invention similar to the spray assembly 200 and like numerals denote like parts. The spray assembly 300 has a clump 302 for searing to the lip 58 of the toilet pedestal 16. The clamp 302 has a drive bolt 304 threadedly engaged with a bracket 306 shaped to fit over the lip 58. The drive bolt has a pad 308 for bearing against an outside of the lip 58. The bracket 302 has a cupped edge 310 for fitting underneath the lip 58 to resist the bracket 306 rising up off the lip 58.
In use, the spray assembly 300 is installed by fitting the cupped edge 310 under the lip 58 and threading the drive bolt 304 in the bracket 306 to force the pad against the lip 58. The handle 243 is then manipulated in the same manner as for that of the spray assembly 200.
In FIGS. 7 and 8 there is shown a spray assembly 400 according to yet another embodiment of the present invention similar to the spray assembly 200 and like numerals denote like parts. The spray assembly 400 has a pivot post 402 disposed vertically downwardly from the second portion 222 of the spray conduit 212 proximate its juncture with the handle 52. The pivot post 402 is received in a vertically disposed hole 404 located proximate an outer edge 406 of the lip 58 of the toilet pedestal 16. A depression 408 is provided about the hole 404 extending to the interior of the toilet pedestal 16. Typically, the depression 408 is triangular when viewed in plan and has one apex located at the hole 404 and the other apices located at the interior of toilet pedestal 16. The depression 408 has a depth typically slightly greater than the thickness of the second portion 222 so that the second portion can pivot in the depression 408 without contacting an underside of the toilet seat 72.
Preferably, a hole 404 and depression 408 is located on opposite sides of the lip 58 as shown in FIG. 7, to allow for left handed and right handed installations.
In use, the spray assembly 400 is operated in identical manner with spray assembly 200.
The spray means for a toilet pedestal has advantages over the prior art in that it allows for retrofitting to a toilet pedestal and is operable to clean, with water, and dry, with warm air, the anus and genital area of a user.
The spray assembly 14,100,200,300,400 is moveable fore and aft underneath the anus and genital area to enable accurate application of heated water for cleaning thereof without over wetting of the anus and genital area. Since the air is sprayed out of the same spray nozzle 82 as the water the air can be accurately applied to dry the wetted areas. The spray nozzle 82 and the spray conduit 62 and 212 are stored underneath the lip 58 of the toilet pedestal 16 and so are cleaned by water flushed into the toilet pedestal 16 from a cistern connected thereto.
The spray assembly 14 has the advantage of cooperation with the cam 78 for inhibiting activation of the solenoid valves 22 and 24 unless the spray nozzle 82 is in the operational position. The spray assembly 100 has the advantage that it can be readily transported and coupled to any base unit 12. Hence, the spray assembly 100 serves as a personal hygiene device useable with any toilet having one of the base units 12. The spray assemblies 200 and 300 have the advantage that they can be easily applied to the lip 58 and pivot about a vertical axis outside the lip 58 thus reducing the amount of the spray assembly 200 and 300 prone to becoming soiled. The spray assembly 400 has the advantage that no modification to the toilet seat 72 or the attachment of the toilet seat 72 to the toilet pedestal 16 is necessary in order to avoid the spray conduit 212 contacting the underside of the toilet seat 72 or becoming jammed between the lip 58 and the toilet seat 72.
Modifications and variations such as would be apparent to a skilled addressee are deemed within the scope of the present invention. For example, the water supply unit 18 and the gas supply unit 20 could include large stores of water and compressed gas, respectively, for supplying a plurality of spray assemblies 14. Such an arrangement could be used in situations where a plurality of toilets are provided in close proximity, such as, for example, in public toilet facilities, blocks of apartments in multistory arrangement and the like. | A bidet device useable with a toilet has a nozzle (82) which supplies water in an accurate confined spray to the anal or genital area followed by air blown through the same nozzle so as to dry the wetted areas. Both water and air are electrically heated in unit (12) under thermostatic control. A hand grip (60) is used to slide spray conduit (62) and nozzle (82) from a storage position under the lop of the toilet bowl to an appropriate longitudinal position. Switch (52) is then used to control a low voltage circuit which energizes solenoid valves for the alternate supply of water and air. The unit will not operate unless both microswitch (80) [activated by cam (78)] and a pressure switch responding to the user's weight, are closed. In alternative arrangements the spray assembly is carried on an arm turning on a vertical pivot attached to the toilet pedestal or it forms part of a hand-held wand having no attachment to the toilet pedestal. | 4 |
This application is a continuation of U.S. patent application Ser. No. 451,876 filed Dec. 18, 1989, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 226,271 filed Jul. 29, 1988, now U.S. Pat. No. 4,909,416.
FIELD OF THE INVENTION
This invention relates to dispensing devices and, more particularly, relates to dispensing devices for containing and dispensing flowable materials.
BACKGROUND OF THE INVENTION
Squeezable dispensing devices for dispensing flowable materials are well known and such devices have heretofore been developed and/or utilized wherein bladder containment and/or pressure dispensing are shown. Such arrangements, for example, are described in U.S. Pat. Nos. 3,223,289, 3,225,967, 3,270,920, 3,342,377 and 4,147,278 showing various arrangements wherein the contents of a bladder are urged therefrom by a gas introduced into a contained volume adjacent to the bladder.
Other arrangements making use of a bladder containing materials to be dispensed by pressure are shown in U.S. Pat. Nos. 4,469,250 issued Sep. 4, 1984 and 4,760,937, issued Aug. 2, 1988 to Evezich (the Applicant herein). In this arrangement a separate bladder is housed within an outer shell, the former showing a device having a removable cap and nozzle construction and utilizing a projection positioned at the base of the nozzle for piercing the bladder to allow dispensing of its contents, the various elements not being permanently affixed to one another.
Dispensing devices have also heretofore been known and/or utilized wherein an inflatable bladder is utilized to push contents out of a container (see for example U.S. Pat. Nos. 3,294,289, 4,213,545 and 3,592,365), as have devices utilizing volume reducing structures for selectively changing the volume of the dispensing device (see for example U.S. Pat. Nos. 2,715,981, 3,474,936, and 4,098,434).
While dispensing devices making use of bladders and/or pressure dispensing have heretofore been suggested and/or utilized, further improvements could nevertheless still be utilized.
SUMMARY OF THE INVENTION
This invention provides an improved dispensing device for containing and dispensing flowable materials. Dispensing of materials is achieved through use of a material handling unit containing the material to be dispensed at least partially housed within an outer container, the material handling unit including a relatively rigid portion communicating with the exterior of the device through a nozzle affixed to one end thereof and having a readily reshapable portion affixed to the other end thereof, both portions being configured for containment of a selected volume of material.
A one-way check valve is positioned at an outlet opening in the nozzle to permit flow of the contents of the unit therethrough but precluding passage of matter thereinto. A second one-way check valve is positioned to permit the flow of air from the exterior of the device to the volume defined between the inner container and the material handling unit. The outer container may be squeezable and may be adapted for use with pressure exerting structure such as a pump or bellows for selectively increasing pressure exerted on the readily reshapable portion of the material handling unit to thereby expel the contents therefrom without direct manual contact by a user of the device.
It is therefore an object of this invention to provide an improved containing and dispensing device for containing and dispensing flowable materials.
It is another object of this invention to provide an improved containing and dispensing device for dispensing flowable materials which has a material handling unit including a readily reshapable portion and in which the contents thereof are substantially protected from contaminants.
It is still another object of this invention to provide an improved containing and dispensing device for dispensing flowable materials including a material handling unit and an outer container, with the outer container having an inlet port allowing passage of matter therethrough into the volume between the outer container and a portion of the material handling unit.
It is yet another object of this invention to provide an improved containing and dispensing device for dispensing flowable materials having a disposable material handling unit and a reusable outer container.
It is still another object of this invention to provide an improved dispensing device for dispensing flowable materials having an outer container for containing a material handling unit including a first, relatively rigid, containment portion and a second, readily reshapable, containment portion, with materials being dispensed by both deformation of the second containment portion and by movement thereof into the first containment portion to thus expel the contents of the relatively rigid portion.
With these and other objects in view, which will become apparent to one skilled in the art as the description proceeds, this invention resides in the novel construction, combination, and arrangement of parts substantially as hereinafter described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiment of the herein disclosed invention are meant to be included as come within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a complete embodiment of the invention according to the best mode so far devised for the practical application of the principles thereof, and in which:
FIG. 1 is a perspective view of a first embodiment of a dispensing device;
FIG. 2 is a partially exploded perspective view of the dispensing device of FIG. 1;
FIG. 3 is a sectional view of the device of FIG. 1 taken along section line 3--3;
FIG. 4 is a partial sectional view of the device of FIG. 3 particularly illustrating the relationship of the two component external container;
FIG. 5 is a perspective view of the device of FIG. 1 showing material being dispensed;
FIG. 6 is a partial, exploded view of a second embodiment of a dispensing device;
FIG. 7 is a partial sectional view of the embodiment of the device shown in FIG. 6;
FIG. 8 is a partial sectional view of a third embodiment of a dispensing device and particularly illustrating one alternative nozzle and valving;
FIG. 9 is a partial perspective view of a fourth embodiment of a dispensing device;
FIG. 10 is a partial sectional view of the embodiment of the device of FIG. 9 taken along section line 10--10;
FIG. 11 is a sectional view of one available auxiliary attachment usable with the dispensing device of this invention;
FIG. 12 is a sectional view of a second auxiliary attachment usable with the dispensing device of this invention;
FIG. 13 is a perspective view of the dispensing device of this invention;
FIG. 14 is a cross sectional view of the device shown in FIG. 13;
FIG. 15 is a sectional view of an alternate arrangement of the dispensing device shown in FIG. 14;
FIG. 16 is an enlarged partial sectional view of the device shown in FIG. 15 particularly illustrating part of the structure of the inner containment portion of the device;
FIG. 17 is a perspective view of a second and, for purposes of this application, now preferred embodiment of the device of this invention;
FIG. 18 is a sectional view of the device shown in FIG. 17 taken along section line 18--18 illustrating the material handling unit in a substantially filled condition;
FIG. 19 is a sectional view of the device shown in FIG. 18 illustrating use of the readily deformable bladder of the material handling unit to aid expellation of the contents of the more rigid portion after material contained in the bladder has been expelled therefrom due to bladder deformation; and
FIG. 20 is an enlarged partial section view of the engaging and sealing structure of the device.
DESCRIPTION OF THE INVENTION
FIGS. 1 through 12 show devices shown, described and claimed in U.S. Pat. Nos. 4,469,250 and 4,760,937 issued to the applicant herein and are described herein as background and to illustrate certain basic structural elements of this invention.
Referring now to the drawings, a storage and dispensing device 15 for storing and dispensing materials is shown in FIG. 1. As shown, dispensing device 15 includes body 17 and dispensing conduit, or nozzle, 19 having an outlet terminus 21.
As best shown in FIG. 2, dispensing device 15 includes three components, a resilient outer container 23, a deformable, or readily reshapable, inner container 25, and a retainer ring 27 engagable with resilient outer container 23. Retainer ring 27 includes a threaded base 29 and a retainer lip 31. Deformable inner container 25 has thereon, at the joinder between deformable inner container 25 and nozzle 19, an annular ridge 33. Resilient outer container 23, in turn, includes inner container housing 35 having external threads 37 at the upper portion or body section thereof, external threads 37 being engagable with internal threads 39 of the retainer ring, thereby maintaining deformable inner container 25 within resilient outer container 23 by clamping of annular ridge 33 between retainer lip 31 and housing 35, and maintaining nozzle 19 through retainer ring 27.
As best shown in FIG. 3, dispensing device 15 includes curved nozzle base 41, which base is curved toward the inner portions of nozzle 19, and which, together with deformable inner container 25 provides a storage area for the materials to be dispensed. Deformable inner container 25 is permanently affixed, or joined, to nozzle 19, and, more particularly, is permanently connected with curved nozzle base 41 at joinder 43 which defines the outer circumference of curved nozzle base 41. Inlet terminus 45 defines an inner circumference of curved nozzle base 41, inlet terminus 45 opening to dispensing channel 47 and outlet terminus 21 through nozzle 19.
Nozzle 19 includes two sections, nozzle tip 49, and nozzle body 51. At inlet terminus 45, one-way valve 53 (which may be any of a variety of one-way valves known commercially) is disposed allowing passage of materials from deformable inner container 25 to dispensing channel 47, while substantially precluding movement of matter from dispensing channel 47 back into inner container 25.
At the bottom portions of inner container housing 35, a second one-way valve 55 (which may also be any of a variety of one-way valves known commercially) is located, which valve allows passage of air from the exterior of the dispensing device to volume 57 defined between inner container housing 35 and inner container 25. Valve 55 substantially precludes passage of air from volume 57 to the exterior of the dispensing device.
Turning now to FIG. 4, details of the two part outer container and one-way valving are shown. Valve 53 is shown, for example, to be a curved valve positioned at inlet terminus 45. While curved in its cross-section, valve 53 is more accurately viewed as a dome-shaped valve having its convex portion facing into dispensing channel 47 and its concave portion being presented to the interior of deformable inner container 25. Valve 53 is constructed, for example, of a resilient material having negligible resilience to stresses imposed against its convex surface but being resilient with regard to stresses imposed on its concave surface. Passageway 59 in valve 53 opens in response to stresses to the convex surface to allow passage of materials from inner container 25 to dispensing channel 47 and thereafter through outlet terminus 21, such stress being created by application of pressure to inner container 25, for example, by the squeezing of outer container 23.
As also shown in FIG. 4, retainer ring 27 is engagable at internal threads 39 by external threads 37 of resilient outer container 23. Retainer lip 31 brings annular clamping projection 61 to bear upon annular ridge 33 thereby clamping the annular ridge between clamping projection 61 and the upper surface of external threads 37 and sealing volume 57 at its upper extremity.
It may be seen, therefore, that when resilient outer container 23 is depressed, as shown in FIG. 5, material 63 is forced through outlet terminus 21 as air within volume 57 creates pressure on inner container 25. When inner container 25 is thus compressed, materials are forced through one-way valve 53 and into dispensing channel 47 and ultimately through outlet terminus 21. Upon release of resilient outer container 23, the outer container begins to return to its original shape thereby relieving the pressure on inner container 25 and allowing passageway 59 in valve 53 to close. However, deformable inner container 25 stays in its deformed shape as no air or other matter is allowed to pass back through valve 53 and occupy any volume thereof. As resilient outer container 23 regains its shape it draws air through one-way valve 55 from the exterior of the device through opening 65 into volume 57. When outer container 23 has fully regained its shape, the pressure between volume 57 and the exterior of the device will equalize thus allowing opening 65 in valve 55 to close, thereby disallowing passage of air back from volume 57 to the exterior of the device. When all of this has occurred, the process may be repeated, the volume of air within resilient outer container 23 thus being sufficiently replenished to continually apply pressure to inner container 25 until the inner container is substantially completely deformed and emptied of its contents.
Curved nozzle base 41 is configured so that a cone in deformable inner container 25 is not formed as would be the case if the nozzle base were flat, thereby allowing deformable inner container 25 to enter into the volume of the convex curvature of curved nozzle base 41 for a more complete evacuation of the contents within inner container 25.
Turning now to FIGS. 6 and 7, a second embodiment of a dispensing device is shown. Dispensing device 70 includes a resilient outer container 72 and a deformable inner container 74 which is preferably permanently joined with nozzle 76. Nozzle 76 may be identical in structure to that of nozzle 19 above-described, and includes outlet terminus 78 and base 80, base 80 having external threads 82 positioned below a sealing ridge 84. Outer container 72 includes inner container housing 86 having internal threads 88 at the upper portion thereof, internal threads 88 and external threads 82 of nozzle 76 being engagable.
Dispensing device 70 has many of the features of the dispensing device shown in FIG. 3. Curved nozzle base 90 is shown in FIG. 7 which, together with inner container 74 preferably permanently joined at joinder 92, forms the storage area for the materials. Base 90 has inlet terminus 94 at its inner circumference leading to dispensing channel 96 through one-way valve 98. At the bottom portion of resilient outer container 72, one-way valve 100 is disposed for the passage of air from the exterior of the device to volume 102 defined between outer container 72 and inner container 74. The dispensing device operates in the same manner as the previous embodiment, with the exception that nozzle 76 and inner container 74 form a unitary structure thereby providing a two-part construction for the dispensing device engagable at external threads 82 of nozzle base 80 and internal threads 88 at the upper portion of resilient outer container 72, the two portions when tightly engaged bringing annular sealing ridge 84 into a substantially sealing relationship with the upper portion of the internal threads 88 of outer container 72 thereby sealing volume 102 thereat.
In FIG. 8 a third embodiment of a dispensing device is shown, in many ways similar to the device shown in FIG. 7, but showing alternative one-way valving and selective dispensing channel closure. Turning first to the alternative one-way valving, one-way valve 105 is shown to include spring 107 and stopper 109, spring 107, at one end thereof, biasing stopper 109 toward inlet terminus 111 to dispensing channel 113, and spring 107 at its other end resting against support surface 115. When materials are being urged through inlet terminus 111, stopper 109 is forced away from inlet terminus 111 to dispensing channel 113 thereby allowing passage of materials, but when material flow ceases, spring 107 urges stopper 109 back into a sealing relationship with inlet terminus 111 thereby preventing the movement of air and matter from dispensing channel 113 through inlet terminus 111.
A second alternative one-way valve 117, is shown at the lower portion of the alternative embodiment shown in FIG. 8. Valve 117 is positioned in resilient outer container 119, at air inlet 121, through mounting hole 123 being held in place by retainer 125 at the exterior of the dispensing device. Retainer 125 is connected to valve flaps 129 by connector 127. As resilient outer container 119 begins to regain its shape after deformation, and air is drawn through air inlet 121 from the exterior of the device, valve flaps 129 are forced open thereby allowing the passage of air into the device until the pressure is equalized, whereupon the valve flaps 129 are closed.
Also shown in FIG. 8, threaded nozzle tip 131 is provided for receipt of threaded cap 133, threaded nozzle tip 131 and threaded cap 133 together providing outlet terminus 135. Outlet terminus 135 is normally closed where no stresses are imposed on inner walls 136 of threaded cap 133. However, when threaded cap 133 is tightened against threaded nozzle tip 131, normally closed outlet terminus 135 is forced into its open position thereby allowing materials to escape from the dispensing device.
Turning to FIG. 9, a fourth embodiment of a dispensing device 140 is shown, the device having a one-piece resilient body 142 having a nozzle 144 closed by removable sealing cap 146. Resilient body 142 includes one-way valve 148 at the upper portion thereof for selectively allowing passage of air from the exterior of dispensing device 140 to interior portions thereof.
As shown in FIG. 10, it may be appreciated that this one-piece construction of the dispensing device is similar in many regards to the prior embodiments shown herein. Body 142 is shown to include resilient outer container 150, as well as nozzle 144 and deformable inner container 152 having one-way valve 154 (similar to the valving shown in FIG. 8 for example) at the inlet terminus of dispensing channel 156. Dispensing channel inner walls 157 are joined with curved nozzle base 158 which in turn is joined with deformable inner container 152. Removable sealing cap 146 covers outlet terminus 159 of nozzle 144, being engagable at threaded nozzle tip 160. In this embodiment, volume 162 defined between resilient outer container 150 and deformable inner container 152 is shown to extend into portions of nozzle 144 through annular opening 164, thereby allowing placement of one-way valve 148 at the upper portion of the dispensing device, for passage of air from the exterior of the device into volume 162.
In FIG. 11 one of many auxiliary attachments usable with the dispensing device is shown. Nozzle extender 167 includes nozzle engaging base 169 having internal threads 171 therein for attachment of the nozzle extender to, for example, threaded nozzle tip 131 (shown in FIG. 8) or threaded nozzle tip 160 (shown in FIG. 10). Dispensing channel extension 173 resides through nozzle extender 167 and has multiple outlet termini 175.
In FIG. 12 a second nozzle extender 177 is shown. Herein a resilient nozzle 179 is shown with internal threads 181 at base 183 thereof and having dispenser channel extension 185 therethrough.
FIGS. 13 through 20 illustrate the containing and dispensing device of this invention. Dispensing device 195, as shown in FIG. 13, may be used in association with a dispensing apparatus 197 including a rack structure 199 for holding device 195 for activation thereof to cause dispensing of matter therefrom, as more fully set forth hereinbelow, by movable arm 201.
Dispensing apparatus 197 may be made mountable on bracket portion 203. Arm 201, which may be manually manipulable or be made mechanically responsive to a servomechanism or the like, is mounted on hinges 205 to framework member 207, and includes framework member 209 in contact with bottom portion 211 of device 195. The device is maintained in framework 199 through bracket mount 213 at the mid-portions of the device, and bracket mount 215 through which nozzle 217 is maintained. As will be more fully set forth hereinbelow, by depressing arm 201, contents of device 195 are expelled through outlet opening 219.
The embodiment of the device shown in FIGS. 13 and 14 is similar in many regards to the device shown in FIGS. 6 and 7 including, for example, utilization of one-way flow control valve 100, sealing ridge 84, and internal and external connecting threads 88 and 82, respectively.
As illustrated in FIG. 14, one-way flow control valve 223, for example a flapper valve, is integrally formed in the tip of nozzle 217 at outlet opening 219. Outer container 225 at least in part forms a chamber 226 at the interior thereof and includes a compressible pressure reducing structure 227, for example a bellows type structure, connected between bottom portion 211 and side wall 229 of outer container 225.
Material handling portion 231 of device 195, including nozzle 217, has a tubular portion 233 connected at base structure 235 of nozzle 217, within which a substantial amount of the contents of handling portion 231 are maintained.
Tubular portion 233 has open ends 237 and 239, with open end 239 having readily reshapable bladder 241 affixed to portion 233 adjacent thereto. Portion 233 is a relatively rigid structure relative to bladder 241 and bladder 241 has a volume and shape when fully inflated which preferably substantially corresponds to the volume and shape of relatively rigid portion 233 and nozzle 217.
Upon application of pressure to bottom portion 211 of outer container 225, volume reducing structure 227 is compressed by the movement of the bellows like wall segments 245 of the structure toward one another thereby effectively reducing volume 247 of outer container 225. Since valve 100 will be maintained in a closed position during pressurization of outer container 225, readily reshapable bladder 241 is partially inflated thus being forced a distance into relatively rigid member 233 and displacing an equal volume of the contents within member 233 and expelling contents through valve 223 and outlet opening 219.
When pressure on bottom portion 211 ceases, volume reducing structure 227 resiliently regains its original shape, thus creating a partial vacuum in volume 247 of outer container 225 and opening one-way valve 100 allowing fluid flow therethrough and thus maintaining the partial inflation of bladder 241 so that bladder 241 maintains its new position in relatively rigid tubular portion 243.
As may be appreciated, the portions of the device may be separately formed and assembled as heretofore set forth, or, may be formed as unitary structures, for example by blow molding or the like bladder 241, relatively rigid tubular member 233 and nozzle 217 in a single operation.
Turning now to FIGS. 15 and 16, an alternative arrangement of the containing and dispensing device shown in FIGS. 13 and 14 is shown which is similar in many regards to the device shown therein. Dispensing device 250 includes nozzle 144, one-way valve 148, one-way ball valve 154, dispensing channel 156, outlet opening 159, and annular opening 164 allowing communication between upper and lower portions of volume 162, all as also shown with respect to the embodiment of the device shown in FIG. 10.
However, the embodiment of the device shown in FIG. 15 includes an outer container 252 having a volume reducing structure 254 positioned at the upper portions thereof which operates in a fashion similar to that described with regard to volume reducing structure 227 heretofore described with the exception that pressure is applied by a user of the device to the upper portion of the container (as indicated by the arrow in FIG. 15).
In addition, dispensing device 250 includes nozzle base 256 connected to a wall of dispensing channel 156 at inlet terminus 260 to channel 156. Relatively rigid tubular portion 233 is attached at open end 237 thereof to nozzle base 256, for example at annular mounting ridge 264 (although it is to be realized that a unitary blow molded structure could also be provided).
As set forth in the description of FIG. 14, readily reshapable bladder 241 is affixed to open end 239 of relatively rigid tubular portion 233 for inflation thereof responsive to reduction of volume 162 by movement of volume reducing structure 254 as heretofore described.
As shown in FIG. 16, when the contents to be expelled from the device fully occupy available volume 266 of handling portion 231, bladder 241 is gathered at open end section 239 of relatively rigid tubular portion 233.
FIGS. 17 through 20 illustrate a second embodiment of the device of this invention. Device 270 may be mountable in wall mountable cabinet 272 utilizing mounting lips 274 on cabinet shelf 276 which engage mounting collar 278 formed in one portion of the device. Neck 280, having inlet opening 282 therethrough, has cap 284 positioned thereon for receipt through inlet terminus 286 thereof of fluid, for example air, to provide pressure at the internal portion of the device through conduit 288. Conduit 288 may be attached to any variety of pump or bellows, for example the foot operated bellows pump 290 including bellows structure 292 and one-way valve 294 (the valve allowing passage of air into the bellows and thus, as heretofore described, into the device but substantially precluding passage of air from the bellows and so the device).
Provision of the air pump serves substantially the same purpose as the bellows structure shown in FIGS. 14 and 15. Neck 280 is connected with, or formed as a part of, outer container 296. The materials to be dispensed are contained within material handling unit 298 including a relatively rigid portion 300 and a readily deformable bladder portion 302, both of which have a volume configured for containment of a selected quantity of materials to be dispensed.
Nozzle 304 is formed at, or connected to, one end of relatively rigid portion 300, and outlet opening 306 is described therethrough. One-way valve 308 is provided at the end of the nozzle to allow dispensing of matter therethrough while precluding passage of matter into the nozzle.
As shown in FIGS. 18 and 19, initially materials substantially fill both the relatively rigid and readily deformable portions of the material handling unit. As fluid is received into outer container 296 through inlet 282, readily deformable bladder 302 is deformed until the contents therein are substantially expelled, the readily deformable bladder being utilized thereafter to positively expel the contents of relatively rigid portion 300 as the fluid content within outer container 296 is increased. In this manner both the contents of the bladder and of the relatively rigid portion may be expelled utilizing the readily deformable nature of the material forming bladder 302.
As shown in FIG. 20, outer container 296 includes an inwardly facing engagable surface 310 (for example a female threaded surface). While shown as a two-part structure, it should be realized that outer container 296, nozzle 304, valve 308, neck 280 and threaded portion 310 may be of a unitary molded structure. Outwardly facing engagable surface 312 of relatively rigid portion 300 (for example a male threaded surface) are provided so that the outer container and the material handling unit may be engaged.
Annular face 314 of outer container 296 at one end of the engagable surface thereof, and annular lip 316 of relatively rigid portion 300 are provided to insure a reliable seal between the outer container and the relatively rigid portion of the material handling unit thereat, thus sealing volume 318 defined between the outer container and the material handling unit.
Unitary construction of the nozzle, neck, rigid and deformable portions of unit 298 is accomplished utilizing now known techniques (for example utilizing the Bottle Pack machine, a trademark product of the Rommelag Company of West Germany, such machinery being usable not only to form the material handling unit, but to substantially contemporaneously place contents within the unit, thereby providing an inexpensive, disposable material handling unit).
A variety of materials may be used in constructing the dispensing device of this invention. The construction of the device may include one, two, three or more components thereby allowing for selective disposability and/or reuse of all or portions of the dispensing device.
Use of an inner dispensing and containment portion having a relatively rigid tubular structure, nozzle, and readily reshapable bladder allows for greater safety and integrity of the contents of the inner portion against leakage and the like during shipment and/or use of the device, and is particularly useful where the outer container is reusable and the inner dispensing and containment portion is disposable and would thus be typically supplied separately from the outer containment portion.
Additionally, a more complete evacuation of the contents of the inner containment portions may be achieved through use of the curved nozzle base. Nozzle extenders of many and varied uses may be constructed for attachment to the dispensing device and the nozzle may be constructed to receive caps for sealing the dispensing channel, thus further preventing contaminants from reaching either the dispensing channel or material to be dispensed from the dispensing device.
In summary, an improved dispensing device for containing and dispensing predetermined, usually non-compressible, materials is shown herein including a material handling unit having a readily reshapable containment portion, a relatively rigid containment portion and a nozzle and which is at least partially housed in an outer container, the device making use of one-way valving positioned to permit ejection of the contents of the inner container through the nozzle but precluding passage of contaminants into the unit. | A device is disclosed for containing and dispensing flowable materials contained in a material handling unit which is located at least in part within an outer container. The material handling unit includes a first, relatively rigid portion having a nozzle affixed to one end thereof and a readily reshapable bladder affixed to the other end thereof, with the nozzle having a one-way check valve permitting ejection of the contents therefrom. The outer container admits air into the space between the containers to thereby cause selective expellation of the contents of the material handling unit without direct manual contact by a user with the device. | 1 |
The Goverment has rights in this invention pursuant to Contract No. F08635-82-C-0001 awarded by the Department of the Air Force.
TECHNICAL FIELD
This invention is directed to a system which is active on a missile before the firing of its rocket motor and which senses heat around the missile which might ignite the rocket motor. When such heat is sensed, the sides of the rocket motor are opened to prevent pressure buildup in the rocket motor due to fuel combustion and, thus, prevent the rocket from generating thrust.
BACKGROUND OF THE INVENTION
The usual missile has a rocket motor and armament and guidance control systems. The armament has a safety thereon which prevents arming of the warhead until after it is launched. The warhead can be designed to be safe in a fire. However, when a missile motor or a rocket motor is subjected to temperatures which would be reached in a fortuitous fuel fire, the solid fuel of the rocket motor will ignite. Unless steps are taken, ignition will cause thrust and the missile will be propelled. Should this occur in an enclosed space such as a hangar or on an airport or a flight deck, the resultant missile flight is quite dangerous and destructive. Thus, there is need for a missile motor and rocket motor safety system which senses the ambient temperature and prevents the motor from developing thrust.
In addition, the same safety problem exists with any pressure vessel or pressurized gas generator, which may develop thrust when a valve or fitting or adjacent line is burned off by an adjacent fire.
SUMMARY OF THE INVENTION
In order to aid in the understanding of this invention, it can be summarized that it is directed to a thermally actuated safety system wherein a thermal sensor detects temperature around the missile motor, rocket motor, gas generator or pressure vessel above a predetermined value and the system partially or completely cuts the motor case or other pressure vessel when the sensed temperature is reached in order to prevent fuel combustion or other violent pressure release from producing thrust or other damage.
It is a purpose and advantage of this invention to provide a thermally actuated safety system wherein the rocket motor or pressure vessel is rendered ineffective to produce thrust when, while on the ground, it is subjected to temperatures over a sufficient time which will ignite the rocket motor fuel or violently burst the pressure vessel. It is a further purpose and advantage of this invention to provide a safety system which detects and responds to the ambient temperature condition surrounding a rocket motor or other pressure vessel such that when, on the ground, should these temperatures reach dangerous levels over a sufficient length of time, the rocket motor or pressure vessel casing is cut to laterally vent the products of rocket fuel combustion, thus significantly eleminating or releasing the contained pressure without generating significant thrust.
Other purposes and advantages of this invention will become apparent from a study of the following portion of the specification, the claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, with parts broken away, of a missile carrying the thermally actuated safety system of this invention.
FIG. 2 is an enlarged section taken generally along the line 2--2 of FIG. 1.
FIG. 3 is a further enlarged view of the control portion of the safety system, with parts broken away and parts taken in section, as seen when the cover is removed, generally along the line 3--3 of FIG. 1.
FIG. 4 is a longitudinal section through the control portion, as seen generally along the line 4--4 of FIG. 3.
FIG. 5 is an enlarged view of the safety latch shown in FIG. 3, with the latch in the safe position.
FIG. 6 is a section through the control portion at the position of the safety latch, taken generally along line 6--6 of FIG. 4.
FIG. 7 is an enlarged view, with parts broken away and parts taken in section, showing the sealing cap over the stem of the safety latch.
FIG. 8 is an enlarged section through the cutting explosive cord which in the preferred embodiment is a linear shaped charge lying against the motor case, as seen generally along the line 8--8 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Missile 10 is broken away at the left or forward end thereof in FIG. 1. The forward end carries the guidance electronics and warhead of the missile. Most of the portion of the missile 10 shown in FIG. 1 is the rocket motor portion. The rocket motor has a case 12 which throughout most of its length is in the form of a cylindrical tube. The rocket motor case is normally closed, except for nozzle 14 at its rear end. Rocket motor case 12 normally carries a grain of solid rocket fuel therein. Upon combustion, this grain produces hot gas which raises the pressure within the rocket motor case. The hot gas is expelled from nozzle 14 producing thrust. Rocket motor case 12 is normally sufficiently strong to withstand the pressure of hot gas generation therein. The safety system of this invention is directed to opening the side of the rocket motor case 12 or weakening it sufficiently so that internal hot gas pressure causes opening of the side as the pressure rises.
Missile 10 is carried on a rail on the aircraft by means of hook 16. There is a similar hook farther forward on the missile. Opposite the hook, harness cover 18 is secured to the outside of the motor case 12 and extends forward along the outside of the missile from the motor case. Harness cover 18 carries various usual electrical connections across the rocket motor between the guidance and control sections.
The invention is illustrated in connection with a missile wherein the rocket motor case 12 is the outer wall of the aft part of the missile. This necessitates a harness cover which then also serves as a cover for the safety system of this invention. The harness cover also acts to provide an appropriate standoff distance for the thermal cord. In those missiles with a slip-in motor case, the system of this invention can be housed within the airframe with the thermal cord recessed into the skin.
When the safety system is used with other gas generators or pressure vessels, the thermal cord can be positioned with hardware that provides the proper standoff.
On its exterior surface, harness cover 18 has recesses 20 and 22 therein, see FIG. 2. Two lengths of thermal cord 24 and 26 lie in these recesses, substantially flush with the exterior of the harness cover 18. Thermal cords 24 and 26 are pyrotechnic devices which are specifically sensitive to temperature and are formulated to ignite (and provide a signal indicative thereof) when a preselected temperature and temperature duration have been reached. In the present case, thermal cords 24 and 26 self-ignite in a maximum time of 30 seconds when exposed to temperatures above 550° F. to 600° F. The signal must be provided by ignition of the thermal cords in a time less than the fast cookoff time of the rocket motor grain or other device being protected. The fast cook-off time is the time that the motor is exposed to a given temperature with a requirement for survival (i.e. no explosion or ignition of the motor fuel grain). Two cords are provided for redundancy. They are protected by a thin coat of black epoxy sealant. The inner ends of the cords 24 and 26 extend through an opening in harness cover 18, into an opening in the control module 28 to terminate in propellant 30 within bore 32 within control module 28. The outer end of bore 32 is closed by plug 34, see FIG. 4, which is held in place by pin 36. An O-ring around plug 34 aids in sealing, and in addition, packing is provided at the inner end of the plug and adhesive sealant is provided at the outer end of the plug. Propellant 30 generates hot gas when it is ignited by one of the thermal cords 24 or 26. With the right hand end of the bore 32 closed, as seen in FIG. 4, the gas expands to the left through the bore. Piston 38 is slidablly mounted in the bore and carries an O-ring therearound to protect propellant 30 before it is ignited and obturates the gas chamber. When the propellant is ignited, piston 38 is thrust to the left.
Piston 38 carries firing pin 40 thereon. Firing pin 40 extends toward transfer assembly 42 which contains percussion primer 44 and booster charge 46. Booster charge 46 has an explosive output. The transfer assembly 42 carrying primer 44 and booster charge 46 is a separate unit inserted into bore 48 in the body of control module 28. Bore 48 is in line with bore 32. Firing pin 40 is of such length that when fired, the firing pin 40 strikes primer 44 so that flame is generated to the left through bore 48. Shear pin 41 holds piston 38 in its unactuated position until propellant 30 generates sufficient gas so that pressure shears the pin 41. Thereupon, the gas under pressure thrusts firing pin 40 to the left.
Block ring 50 is of arcuate shape. It is in the form of a segment of a circular, tubular cylinder. Block ring 50 is positioned in its pocket 52, which is also of arcuate shape. Pocket 52 is sufficiently long to permit rotation of ring 50 within the pocket from the safe position illustrated in FIG. 3 to a firing position. In the safe position shown, block ring 50 completely closes off bore 48 so that the portion in which transfer assembly 42 is located is physically separated from the left end of the bore and prevents explosive transfer from the booster to the cutting charge. This is a physical barrier safety mechanism. This mechanism prevents ignition of primer 44 (without striking by the firing pin 40) from initiating flame propagation. Shear pin 58 prevents inadvertent rotation of the block ring. However, block ring 50 can be rotated so that window 54 in the block ring is in alignment with bore 48 to permit explosive propagation leftward through bore 48 when the unit is in firing condition.
Actuator 56 is positioned in the way of firing pin 40 when block ring 50 is in the blocking position. When the firing pin 40 moves to the left, it engages on actuator 56 which moves to the left. As the actuator moves to the left, it engages ring 50, shears pin 58 and moves the ring to its non-blocking position. As actuator 56 moves to the left, it drops off of shoulder 60 to move out of the way of firing pin 40. Thereupon, firing pin 40 can strike and fire the primer 44 to cause explosive propagation leftward down bore 48.
The left end of bore 48 has therein the end of an explosive charge such as linear shaped charge 62. As is seen in FIG. 8, the linear shaped charge 62 has a V-shaped linear explosive charge 64 and is captivated within charge holder 66 which, in turn, is surrounded by protective tubing 68. The charge holder is preferably of rubberlike material which maintains proper standoff. The protective tubing is of a suitable material for preventing moisture from collecting near the explosive. The protective tubing is preferably a heat-shrinking synthetic polymer composition material. Charge holder 66 carrying linear shaped charge 62 is secured by adhesive 69 within harness cover 18, as shown in FIG. 8. This maintains the charge at the proper standoff distance. When the explosive charge is ignited, it preferably cuts one or more stress raising notches in the outer portion of the case, or may cut directly through the case to the grain. The stress raising notches may be cut in selected locations along the length of the case. These notches or cuts are sufficient so that when the grain ignites, the rocket motor case splits and pressure is vented out of the split side rather than developing pressure which causes significant thrust by exhausting from the nozzle. In this way, the missile is prevented from uncontrolled flight due to fire while the missile is in storage, transport, or on the airplane prior to flight. Selectivity of notching or cutting along the length of the linear shaped charge can be controlled by insertion of an energy-absorbing structure such as lead wire within the V-groove along the charge in the lengths where no cutting is desired.
The use of a shaped charge for case cutting is preferred. However, linear non-shaped explosives such as Primacord or non-linear explosives can be used for case cutting.
When the case is subjected to fire, the exterior surface of the grain (next to the case) will burn so that pressure will build up between the grain and the case to split open the case at the stressraising notches. No nozzle thrust is produced because the interior of the grain is not ignited.
The use of a stress-raising notch rather than a cut protects the grain from an exterior fire that might ignite the grain early if the case were split open. In addition, the explosion should not cause substantial distribution of debris, which could endanger nearby fire fighters.
In some missiles, the aerodynamic heating of the missile 10 during normal flight is sufficiently high to cause ignition of the thermal cords 24 and 26. Of course, destruction of the missile in flight toward its target is undesired and, for this reason, in such missiles an inertial mechanism is provided in control module 28. Inertia mass 70 is positioned within pocket 72. Pocket 72 is sufficiently long to permit longitudinal sliding of the mass within the pocket. The side walls of the pocket guide the mass to limit it to longitudinal motion. Cover 74 encloses the mass within its pocket and also serves to cover block ring 50 within its pocket 52 and retain actuator 56 in its place. Compression spring 76 engages around firing pin 40 and between piston 38 and inertia mass 70. When the missile is accelerated upon launch, the acceleration forces inertia mass 70 to the right end of its pocket, compressing spring 76. With the inertia mass 70 in this position, piston 38 cannot move to the left because piston 38 is larger than the pocket in mass 70 in which lies spring 76. With mass 70 in the right position, the firing pin 40 cannot reach the primer in transfer assembly 42. Latch assembly 78 has shaft 80 which carries latch 82. When in the unactuated position shown in FIG. 3, latch 82 lies in longitudinal slot 84 in mass 70. Leaf spring 86 lies just outside of the slot 84 and is positioned and oriented to turn latch 82. It is seen that as the inertia mass 70 moves to the right with respect to the missile, from the position of FIG. 3 to the position of FIG. 5, the spring turns the latch. When the compression spring 76 attempts to return inertia mass 70 to the left, the latch engages against the end 88 of mass 70 because the latch is out-of-line with its slot. This retains inertia mass 70 in the rightmost position and prevents the firing pin 40 from moving to the left and precludes opening of the block ring and firing of the primer.
The missile may be dropped, or otherwise subjected to accelerations during shipping and handling, which would cause the inertia mass to move to the safe position shown in FIG. 5 where the thermally actuated safety system is ineffective. In order to provide visual inspection of the position of the latch, boss 90 which carries the shaft 80 therein, extends outward into an opening in harness cover 18 as shown in FIG. 6 and FIG. 7. The outer end of shaft 80 of the latch assembly has slot 92 therein which is in line with latch 82. Thus, the slot 92 is visible from the exterior of the missile so that the state of the safety system can be readily inspected and observed. In order to prevent contamination from entering into control module 28 through the opening between shaft 80 and boss 90, transparent sealing cover 94 is snapped into place, see FIG. 7. The outer end of the shaft is undercut and cover 94 snaps into that undercut and firmly engages in the shaft hole within the boss. Since the cover 94 is transparent, the orientation of slot 94 can be inspected. Should the latch assembly be in the system inactive position of FIG. 5, it can be returned to the active position by removal of cover 94 and engagement of a screwdriver in slot 92. The screwdriver will rotate the latch into alignment with longitudinal slot 84, whereupon the spring will return the inertia mass 70 to the left, active position.
As can be seen from this description of the structure, the entire thermally actuated rocket motor safety system is incorporated within the already existing harness cover 18. Therefore, there is no adverse influence upon the missile drag. Furthermore, the system is thermally activated, in direct response to high ambient temperature and sufficient time.
The system is arranged so that the temperature sensing portion is remote from the rocket motor case cutter. Since it is remote, the control module 28 can be placed therebetween. The control module maintains the system in the armed state and is placed in a safe condition by acceleration of the missile after the missile launch to prevent inadvertent firing of the rocket motor case cutter due to aerodynamic heating. The armed and safe positions are visible by inspection from the exterior of the missile. In this way, a thermally actuated rocket motor safety system provides safety against missile thrust due to fire near the missile while the missile is on the ground, during storage, transport or positioning on the aircraft ready for use.
This invention has been described in its presently contemplated best mode, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims. | A thermally actuated rocket motor safety system has a fire temperature pyrotechnic sensor which ignites a gas generator (30) which drives piston (38) to the left. Firing pin (40) strikes the primer in transfer booster assembly (42). The transfer booster assembly transmits explosive energy through window (54) in now open block ring (50) to initiate charge (62) which lies adjacent the rocket motor case. This stresses the rocket motor case by producing a stress raising notch in the case wall. Subsequent grain burning opens the case to vent the rocket motor pressure. Inertia mass (70) slides to the right upon acceleration due to normal rocket motor firing and locks in the rightmost position by means of latch (82). In the locked position, inertia mass (70) prevents leftward motion of the firing pin (40). | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to semiconductor memory and, more particularly, to test and repair of semiconductor memory.
[0003] 2. Description of Related Art
[0004] Semiconductor memory is a crucial resource in modem computers, being used for data storage and program execution. With the exception of the central processor itself, no other component within the computer experiences as high a level of activity. Traditional trends in memory technology are toward greater density (more memory locations, or “cells,” per part), higher speed and improved reliability. To some extent, these goals are inconsistent. For example, as memory density increases, the incidence of defects also rises. As a result, production yields of high-density memory devices with zero defects would be so low as to render them prohibitively costly. However, an alternative to building perfect devices is to include spare memory cells along with the primary memory of the device. Additional internal circuitry detects faulty cells, and swaps good cells for known-bad ones. Therefore, as long as there are sufficiently many working cells to replace the defective ones, a fully functional memory device can be made. The primary memory is sometimes referred to as “accessible memory,” and the spare memory as “redundant memory.” The techniques for internally detecting faulty memory cells and for replacing them with working cells are commonly referred to as “built-in self-test” (hereinafter “BIST”) and “built-in self-repair” (hereinafter “BISR”), respectively. BIST and BISR are instrumental in obtaining acceptable yields in the manufacture of high-performance semiconductor memory.
[0005] Conventional memory devices are typically organized as a matrix of rows and columns, in which each individual cell has a unique row/column address. A popular memory architecture incorporating the above-described BIST and BISR techniques configures spare memory locations as redundant rows. Thus, a nominal m×n memory device is actually configured as m rows and n columns of accessible memory, with p rows (and n columns) of redundant memory. Redundant memory rows are not part of the nominal m×n address space of the device, except when used to replace defective accessible memory rows. Circuitry within the memory device itself performs both the test (BIST) and repair functions. During BIST, this circuitry generates test patterns to identify faulty memory locations. Then, during BISR, it reroutes internal connections, circumventing these locations and effectively replacing defective rows of accessible memory with working redundant rows.
[0006] Most currently used BIST/BISR methods test not only the accessible memory, but the redundant rows that are swapped in to replace accessible memory locations that have failed. The memory is certified as repairable only if there are enough functional redundant rows to replace every faulty row in the accessible memory; otherwise, it is considered non-repairable. A memory test generally involves writing a specific bit pattern to a range of memory cells, then reading back the values actually stored and comparing them to the desired pattern. In practice, this task is not easily accomplished. There are a variety of failure mechanisms that the BIST algorithm must be able to recognize. The simplest of these, in which memory cells are “stuck” in a particular logic state, are readily detected. Others, such as interaction between adjacent rows or columns of the memory, are less obvious. A memory cell that is susceptible to adjacent row interaction, for example, tends to follow the logic transitions of neighboring cells; this condition would not be apparent, however, if the cell were tested alone. In order to reveal interaction-related failures, memory tests are often conducted using alternating bit patterns in adjacent rows or columns of the memory matrix (commonly referred to as a “checkerboard” pattern).
[0007] It is often desirable to incorporate improvements in the BIST to achieve better fault coverage. However, in conventional BIST/BISR methods, the test and repair functions are highly interdependent. Consequently, modification of the BIST algorithm may entail corresponding changes to the BISR mechanism. Therefore, even minor changes to the test algorithm may necessitate difficult or extensive modification of the repair circuitry. In some cases, the modified BIST may be inconsistent with the existing BISR circuitry. The conventional BIST/BISR methodology is too complicated to permit upgrading BISR circuitry to support BIST enhancements.
[0008] A typical BIST/BISR method employs two BIST passes (also referred to herein as BIST “stages,” or “runs”). In the first pass, the accessible memory is tested row-by-row until a defect is encountered. The row containing the defect is then replaced by the first available redundant row and retested. This process continues until all of the accessible memory has been tested, or until there are no more redundant rows to use as replacements. In the first case, a second BIST run is performed, verifying all of the accessible memory. In the second case, the device is flagged as non-repairable. This method suffers from several drawbacks, among them the fact that the total test time is not predictable. The duration of the test is dependent on the number of bad accessible memory rows, each of which has to be replaced and retested. Since there is no way to know the test time in advance, precise test scheduling during production is impossible.
[0009] The data retention test is another critical evaluation of the memory that may be performed by the BIST. This involves writing a test pattern to the memory, waiting for some prescribed interval, and then reading the memory to determine whether the test pattern was retained. The conventional BIST/BISR method is so complicated that it can significantly prolong data retention tests and make the results difficult to evaluate.
[0010] In view of the above-mentioned problems, it would be desirable to have a method for built-in self-repair of semiconductor memory devices in which the BISR mechanism is substantially independent of the BIST mechanism, such that changes to the BIST could be accommodated with little or no modification to the BISR. Ideally, the BISR could be integrated with any BIST engine without modification. Under the method, the BISR should be consistent with upgrading fault coverage capability in the BIST, e.g., readily supporting improved versions of tests for adjacent row interaction, data retention, etc. In addition, a system embodying the method should be efficient and permit estimation of total test time.
SUMMARY OF THE INVENTION
[0011] The problems outlined above are addressed by a system and method for a self-repairing memory that can be integrated with any BIST mechanism, without extensive modification to either the BIST or BISR mechanisms. A BISR “Wrapper” system interfaces the BIST engine to the BISR repair circuitry. The BISR Wrapper makes use of standard status signals present in any BIST engine, and directs the operation of the BISR circuitry. With the Wrapper, BISR operation need no longer be closely coupled to the operation or internal structure of the BIST. Consequently, modification of the BIST mechanism, e.g., to improve fault coverage, can be implemented without influencing the BISR. This is believed to be an important advantage of the new method, since a major impediment to BIST enhancement is often the collateral effort involved in redesigning the BISR. The new method also has the advantage that test time is consistent and predictable.
[0012] The system disclosed herein may be used for self-test and self-repair of a memory comprising first and second arrays. In an embodiment, the system consists of a first m×n memory array, a second p×n memory array, a single built-in self-test (BIST) engine adapted to test the first and second arrays as a single joint array and detect rows failing the test, and repair circuitry. The BIST is configured to generate row addresses that span the entire memory array (i.e., m+n rows). According to this embodiment, the entirety of the memory is tested as a single addressable array, and rows in the first and second arrays that fail the test are detected. The repair circuitry enters the addresses of failing rows into a repair table. The repair table is an internal register, each entry of which is associated with a non-failing row from the second array. Thus, the repair table maps failing rows in the first array to replacement rows in the second array. Once the repair table has been created, the repair circuitry uses it to replace failing rows in the first array with non-failing rows from the second array. Replacement is accomplished by redirecting the input/output (I/O) lines from a failing row to the corresponding replacement row, based on the mapping in the repair table. The repaired memory is retested as a single addressable array. During the retest, failing rows in the second array are ignored. If failing rows are detected in the repaired first array during the retest, a “fail” result is returned; otherwise, a “pass” result is returned. The first array may represent the accessible portion of the memory and the second array the redundant portion. In an embodiment of the system disclosed herein, testing of the memory is done during the first stage of a two-pass procedure, and retesting during the second stage. The operation of the self-test and self-repair systems is directed by some hardware embodiment of a finite state machine (FSM), e.g., a programmable logic array. Memory tests performed by the BIST may consist of writing a bit pattern to a portion of the memory, then reading back the contents and comparing them to the original bit pattern. A commonly used bit pattern, called a checkerboard, consists of alternating 1's and 0's.
[0013] In addition to faulty row replacement, the repair table is used to assign addresses generated by the BIST that exceed the dimensions of the first array (i.e.,>m) to rows in the second array. When the BIST asserts these “out-of-range” addresses, the repair circuitry redirects the I/O lines to the associated redundant rows; this enables the BIST to test the redundant portion of memory, which it cannot directly access.
[0014] A BISR Wrapper method for combining self-test and self-repair of a semiconductor memory is also contemplated herein. According to this method, a memory consisting of first and second arrays is tested as a single contiguous array, and the addresses of failing rows recorded. Using the results of this test, a repair table is then created. Each entry of the repair table is associated with a non-failing row from the second array and contains the address of one of the failing rows. Upon completion of the repair table, the entire memory is retested, this time ignoring failing rows in the second array. During retesting and in actual use, each failing row from the first array whose address is contained in one of the table entries is replaced by the non-failing row from the second array associated with that entry. Replacement of a first row by a second row consists of redirecting the I/O lines to the second row. At the conclusion of the retest, the Wrapper method returns a final result of “fail” if a row from the first array fails, and a final result of “pass” otherwise. The method also discloses using the repair table to map row addresses extending beyond the address range of the first array to rows in the second array, and using the repair circuitry to automatically redirect I/O lines to those rows upon detection of the out-of-range addresses. This allows the second array to appear as a contiguous extension of the first array during testing.
[0015] In addition to the above-mentioned BISR Wrapper system and method, a computer-usable carrier medium having program instructions executable to implement the above-described BISR Wrapper method is also contemplated herein. The carrier medium may be a storage medium, such as a magnetic or optical disk, a magnetic tape, or a memory. In addition, the carrier medium may be a wire, cable, or wireless medium along which the program instructions are transmitted, or a signal carrying the program instructions along such a wire, cable or wireless medium. In an embodiment, the carrier medium may contain program instructions in a hardware description language, such as Verilog, to configure circuitry within the memory device capable of implementing the FSM, and self-test/self-repair logic.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
[0017] [0017]Figs. 1 a and 1 b illustrate the organization of an exemplary memory device capable of self-repair, and the control signals used to access the memory;
[0018] [0018]FIG. 2 depicts testing of a memory device, using a three-stage BIST;
[0019] [0019]FIG. 3 shows self-test and self-repair circuitry corresponding to a three-stage BIST;
[0020] [0020]FIG. 4 shows the activity of status signals between a generic BIST engine and the BISR Wrapper throughout the self-test/self-repair sequence;
[0021] [0021]FIG. 5 shows the circuitry associated with an embodiment of the method and system disclosed herein;
[0022] [0022]FIG. 6 is a top-level flowchart, illustrating the sequence of operations in an embodiment of the BISR Wrapper method disclosed herein;
[0023] [0023]FIG. 7 shows an embodiment of circuitry used for redundant row replacement, according to the system and method disclosed herein;
[0024] [0024]FIG. 8 shows a detailed flowchart of the Fault Locations Analysis and Repair Execution (FLARE) diagnostic procedure used in an embodiment of the BISR Wrapper method disclosed herein; and
[0025] [0025]FIG. 9 shows a detailed flowchart of redundant row allocation (repair) procedure used in an embodiment of the BISR Wrapper disclosed herein.
[0026] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] A typical memory device, as considered herein and shown in Figs. 1 a and 1 b , may be organized as m×n cells of accessible (i.e., addressable) memory 10 and p×n cells of redundant memory 11 . The use of redundant memory locations, together with on-chip circuitry for testing memory cells and remapping memory addresses, permits built-in self-test (BIST) and built-in self-repair (BISR) of memory devices. In the accessible memory 10 , addresses are decoded and activate specific rows. The system may access only those addresses for writing and reading the data from memory. In the Built-in Self Repair (BISR) memory shown in FIG. 1, which not only has system accessible address rows arrays, but also redundant row arrays, the redundant row arrays share the data bit-line with accessible memory arrays. The memory USEROW input 14 is used to share the data bitline between accessible memory arrays and redundant row arrays; USEROW=1 selects the redundant rows, and USEROW=0 selects the accessible rows. Each redundant row has individual RROW inputs to activate specific redundant rows. The redundant rows, RRow 0-RRow p−1, are depicted in Fig. 1 a as being contiguous with the accessible rows, Row 0-Row m−1, with RRow p−1 adjacent to Row 0. However, it should be understood that the configuration shown is merely exemplary, and other arrangements are consistent with the method contemplated herein. Fig. 1 b shows the various control signals used to address the memory array. The Address control signals 12 for the accessible rows are attached to pins on the device package, as are the Data I/O signals 17 . Address control signals 12 interface to the memory array through Address Decoder 13 . The internally accessible bus 15 accesses the redundant rows. Hence, rows Row 0-Row m−1 are externally accessible (along with data input/output bus 18 ), while rows RRow 0-RRow p−1 are not. Internally accessible control circuitry 16 connects the I/O lines 17 to either the accessible 10 or the redundant 11 rows. The control circuitry 16 receives control signals 19 , which include write enable (WE), clock (CLK), device enable (EN) signals. USE_ROW line 14 selects either the externally accessible Address control lines 12 or the internal RRow lines 15 as the source of the current memory address. The ability to switch address and control lines between the accessible and redundant portions of the memory device is required for self-test and self-repair.
[0028] A common memory test consists of writing a “checkerboard” pattern to all the memory locations and then reading it back. This test consists of placing alternating1's and 0's in all the locations, and then verifying that the written values were actually stored in those locations. If a particular cell is defective it will appear as a discrepancy in the checkerboard pattern when it is read back. A cell that cannot be written to will in effect be “stuck” at either a 1 or 0. An attempt to write the opposite value to that cell will fail, and will show up as an anomaly in the checkerboard upon reading back the memory. As an example, assume that the memory location in column 3 of row 1 is defective (indicated by crosshatched pattern) and is stuck at logic level 0. The checkerboard bit pattern shown in FIG. 1 a attempts to write a logic level 1 to the faulty cell, but when the memory is read back the resulting pattern is as shown in FIG. 1 b . The anomalous occurrence of a 0 in column 3 of row 1 indicates that the written value was not stored, betraying the bad memory cell. Note that two complementary checkerboard patterns are required for a complete test, since this ensures that each cell is tested with both a 1 and a 0.
[0029] The checkerboard pattern can also be used to detect interaction between adjacent rows. In such cases, certain cells tend to follow the logic transitions of neighboring cells. As an example, assume the memory cell in column 3 of row 1 is initially at logic state 0, but that it interacts with an adjacent cell (e.g., column 3 of row 2 ). When the neighboring cell in row 2 is set to logic state 1, the interacting cell changes along with it. As noted in the previous example, the checkerboard pattern writes alternating logic states to adjacent cells. When the memory is read back, the error induced by interaction with the adjacent row is revealed as an anomalous bit pattern in the checkerboard pattern.
[0030] Some currently existing BIST/BISR routines consist of a two-stage procedure in which self-test and self-repair functions are performed concurrently. In the first of two BIST runs, the addressable memory is tested row-by-row and defective accessible memory rows are replaced with redundant memory rows on an as-needed basis. A comprehensive test of the addressable memory is then performed in the second BIST run. As described earlier, such methods may be prone to overlook certain types of memory errors, with the possible result that defective devices are certified as good, or good devices flagged as bad.
[0031] To obtain more rigorous and complete test coverage of the memory device, a three-stage BIST/BISR method may be used to test the entire redundant and accessible portions of the memory device before implementing self-repair. In the first BIST run, a checkerboard pattern is used to test the redundant memory, along with the adjacent row of accessible memory. A similar test is performed on the accessible memory in a second BIST run. Self-repair is then attempted, using known-good redundant rows to replace faulty accessible rows. A third BIST run performs a verification test on the repaired accessible memory. If any errors are detected during the third BIST run, the memory is failed; otherwise, it is certified as good.
[0032] BIST routines are typically embodied as a state machine, often referred to as a BIST engine. The state machine may be created using some form of silicon compiler and implemented using circuitry internal to the memory device. However, the majority of the available silicon in the memory device is allocated to the memory array itself, limiting the complexity of the BIST. Consequently, a BIST engine is generally designed to operate with a fixed array size. Thus, a separate BIST is needed for each array size that is encountered in the complete BIST/BISR sequence.
[0033] For example, the three-stage BIST/BISR method discussed above requires three different array sizes to be handled by the BIST and BISR circuitry. As shown in FIG. 2, the complete memory array 20 is comprised of redundant rows RRow 0-RRow p−1, and accessible rows Row 0-Row m−1. The first BIST stage 22 tests the (m+1)×n array consisting of the m accessible rows, together with the adjacent redundant row RRow p−1. Similarly, the second stage 24 tests the (p+1)×n array consisting of the p redundant rows, together with the adjacent accessible row Row 0. Finally, the third stage tests the m×n array consisting of the m rows of the (repaired) accessible memory. As discussed in detail below, not only does each array size require a dedicated BIST, but the associated BISR circuitry must often be modified whenever the respective BIST changes. BIST methods employing more than two stages would therefore require additional dedicated BIST circuitry.
[0034] [0034]FIG. 3 is a block diagram illustrating a typical interface between a three-stage BIST/BISR system and a memory device such as the one shown in FIG. 1. The figure represents circuitry within the memory device, with externally accessible signals shown entering and exiting the device at the far left. In this figure, the memory matrix 30 is comprised of both accessible 32 and redundant 34 rows. BIST engines 36 , 38 , and 40 , shown in FIG. 3 are each configured to access a different-sized portion of the entire memory matrix 30 . In this case, BIST 1 36 may make a first-stage test of the accessible memory 32 together with an adjacent redundant row (m+1 rows), while BIST 2 38 performs a second-stage test of the redundant memory 34 together with an adjacent accessible row (p+1 rows). BIST 3 40 verifies the repaired accessible memory 32 (m rows). Various memory control signals, such as memory address, write enable, etc., are shared between the BISTs and the outside world via multiplexer 46 . During normal operation, these control signals are furnished by external circuitry, but during self-test the signals are generated by the BISTs. BISR 42 switches multiplexer 46 , and also mediates access to the redundant memory. Each BIST receives an ENABLE signal from the BIST/BISR Control Unit 48 , and generates an error flag when a defect is detected (ERRN) and a flag indicating that the test stage is complete (BIST_DONE). Since BISTs 36 , 38 and 40 each test different portions of the memory, their flags are combined by the BISR 42 . The BISR uses the flags, together with the current memory address, to perform self-repair of the accessible memory. Overall status and results are presented by the BISR 42 as externally accessible signals ERRN, FAIL and DONE flags 44 . Operation of the three BISTs and the BISR is coordinated by the BIST/BISR Control Unit 48 .
[0035] The data input (system_in bus 50 ) and output (mem_data_out bus 52 ) normally constitute an “I/O path” for the accessible memory array. That is, data are written to a row of accessible memory via system_in 50 and read from the accessible row via mem_data_out 52 . However, the BISR is able to reroute the I/O path to a redundant row, using RR_controls bus 54 . When a defect in the accessible memory is discovered during self-test, the BISR places the defective row address in a lookup table (referred to herein as a “repair table”). Associated with each defective row address in the repair table is a redundant row. To repair the memory, the BISR reassigns the address of each defective row to one of the available redundant rows using the repair table. In effect, the BISR substitutes a good row for a bad one. When the repaired memory device is in use, the BISR performs this substitution dynamically. Each time the memory is accessed, the BISR compares the current address with the defective row addresses in its repair table; in the event of a match, the BISR automatically substitutes the corresponding redundant row into the I/O path. Clearly, there is some overhead associated with these additional operations. However, the BISR circuitry is typically fast enough not to significantly degrade the operating speed of the memory device. At the end of the third BIST stage, when the test is concluded, BISR 42 sets the DONE and (depending on the test outcome) FAIL indicators 44 .
[0036] A checkerboard pattern may be used to test for adjacent row interaction in the first BIST run. This pattern must comprise all the accessible rows, together with the redundant row adjacent to the accessible memory. BISTs 36 , 38 and 40 , typically cannot directly access the redundant rows 34 . Therefore, BISR 42 must address the adjacent redundant row (using redundant row control signals 54 ), while the BIST generates the bit pattern for the row. Along with the memory address, the BISR monitors the error indicator ERRN for each of the BISTs. Depending on which BIST is active, the BISR may or may not substitute redundant rows for the memory address at the time of the error. Such coordinated interaction between the BIST and BISR requires logic circuitry common to both. Therefore, if the BIST is modified, corresponding changes must often be made to the BISR. This is a drawback, since the test algorithms that are the basis for the BIST state machines are frequently subject to change. Therefore, while it is desirable to incorporate improved test procedures in the BIST, the associated (possibly extensive) changes to the BISR present an obstacle.
[0037] The method disclosed herein removes any dependence of the BISR on the specific implementation of the BIST by employing a “Wrapper” system, which integrates the BIST and BISR functions so that the BISR uses only the BIST_DONE and BIST_ERRN status flags of the BIST. Conceptually, the BISR wrapper is a combination of built-in self test and repair logic that should be compatible with any memory BIST engine. Changes in the BIST mechanism or algorithm do not affect the BISR algorithm. Thus, the BISR wrapper logic is substantially independent of the BIST. To be compatible with the BISR wrapper design, the BIST unit needs only BIST_DONE and BIST_ERRN outputs and a BIST_ENABLE input. This generic interface renders the BISR a virtual “black box”. Operational details, such as the number and type of tests carried out by the BIST, therefore become irrelevant to the BISR. Consequently, modifications to the BIST (e.g., improvements to the test algorithm) can be introduced without affecting the BISR circuitry. Furthermore, according to the method disclosed herein, a single fixed-size BIST is used for the entire BIST/BISR procedure. The single BIST is designed to address an array that is larger than the accessible memory. For example, if the memory device is organized as an m×n accessible memory array, together with a p×n redundant memory array, the BIST will be configured to address a single (m+p)×n array. Row addresses beyond the accessible memory (>m) are herein referred to as “out-of-range” addresses. Self-test and self-repair may be accomplished in a two-pass procedure, in which the same array size is used in both passes. This is preferable to a multi-BIST system, since it requires less complex circuitry and uses less of the available die area in the memory device.
[0038] [0038]FIG. 4 shows how the BIST status flags change throughout the self-test/self-repair process. The process begins with a reset 120 of the self-test/self-repair logic. During the first BIST run 122 , BIST_EN=1, indicating that the built-in self-test logic is active during the comprehensive test of the memory. Upon completion of the first BIST run, the BIST_DONE flag goes high. While the redundant row allocation process takes place 124 , BIST_EN=0 and the BIST_DONE flag is reset. When the redundant row allocation process finishes, the FLARE_DONE flag is raised, triggering the start of the second BIST run 126 . While the BIST tests the repaired memory, the BIST_EN signal is high again, until the test is completed 128 .
[0039] [0039]FIG. 5 is a block diagram of an embodiment of a system based on the BISR Wrapper method disclosed herein. This BISR wrapper design includes three units: the BIST unit (engine) 62 , the BISR FSM control logic unit (BISR finite state machine 68 , together with BISR control logic unit 64) and the FLARE (Fault Location Address, Repair Allocation) unit 66 . The BISR FSM control logic unit handles the input and output signals of the BIST, such as BIST_ENABLE 94 , BIST_ERRN 86 , BIST_DONE 90 and BIST_FAIL 91 , and generates three output signals: ERRN, DONE and FAIL 92 . This system tests an (m+p)×n memory array 60 , comprised of m accessible and p redundant rows.
[0040] As mentioned above, the BIST is configured to test the entire memory array—both the accessible and the redundant portions. Therefore, the BIST generates row addresses from 0 to m+p−1. Addresses from 0 to m−1 correspond to the accessible rows, which are directly accessible by the BIST, while addresses from m to m+p−1 correspond to the redundant rows, which are not normally accessible to the BIST.
[0041] [0041]FIG. 6 contains a flowchart of the operation of the FSM control logic unit, which is a combination of the BISR finite state machine and BISR control logic (items 68 and 64 in FIG. 5). At the start of its operation 150 , a reset signal 152 is required for initializing the BISR wrapper system. After being reset 156 , the BISR FSM control logic unit functions as the central control unit of the BISR wrapper system. When the BISR FSM logic unit is reset, then activated, it disables ( 154 and 158 ), then enables ( 160 and 164 ) the BIST and FLARE units for the first BIST-run to test the memory. Once the first BIST-run begins 166 , BISR_FSM logic unit waits for the BIST_DONE signal generated from the BIST unit. When BIST_DONE toggles, the BISR_FSM logic unit disables the BIST 170 and FLARE units 174 , and enables the redundant row allocation (i.e., repair) process 176 . While redundant row allocation is performed 178 , the FSM waits for the FLARE_DONE signal generated from the FLARE unit. The FLARE_DONE signal toggles when the Repair Allocation Process is finished in the FLARE unit, and the substitution of good redundant rows for faulty accessible rows is complete 180 . FLARE_DONE triggers the BISR_FSM control logic unit to start the second BIST-test 182 (of the repaired memory) by enabling the BIST unit 184 . During the second BIST-run 186 , the FSM waits for the BIST_DONE signal, while the BIST unit tests the entire memory. The BISR Control Logic (part of the BISR FSM control logic unit) monitors 188 the BIST_ERRN signal from the BIST. The objective of the 2 nd BIST stage is to confirm the absence of defects in the accessible memory. Consequently, faults occurring at out-of-range addresses (i.e., BIST_ADDR>m) are of no interest, so the BISR FSM control logic unit ignores the BIST_ERRN signal and disables the memory for addresses in this range. On the other hand, if the BIST_ERRN signal toggles while BIST_ADDR is within the accessible memory range, the BISR FSM control logic unit raises the FAIL signal, signifying that the memory is not repairable. Note that this will happen only if there are not enough good redundant rows in the memory array to replace all of the defective accessible rows. During the redundant row allocation process 178 , a repair table was created that associates faulty accessible rows with usable redundant rows. During the second BIST run, this table is used by the FLARE unit logic 190 to substitute the usable redundant rows for the faulty accessible rows. (The logic for making this substitution is discussed in greater detail below.) When the second BIST run finishes, the BIST unit toggles BIST_DONE, which triggers the BISR FSM control logic to disable the BIST unit 194 and raise the DONE signal, completing the self-test/self-repair process. If the FAIL flag is active at the end of the process 192 , the memory is defective; otherwise, the memory is deemed good.
[0042] The following registers and counters are used in an embodiment of the BISR Wrapper method described herein:
[0043] FRAC (Faulty Row Address Counter) is a counter used to record the number of faulty rows detected in the first of two BIST passes through the memory array.
[0044] FRAR (Faulty Row Address Reference) is a p-element array used by the FLARE unit to associate each redundant row with a specific row address R addr . Initially, the row addresses are simply the out-of-range addresses (i.e., m≦R addr ≦m+p−1). As explained in detail below, this permits the BIST unit to test the redundant rows in the first BIST run. Following the redundant row allocation operation, the FRAR contains the addresses of faulty accessible rows detected during the first BIST run, so that usable redundant rows may be substituted for them in the second BIST run.
[0045] FRAS (Faulty Row Address Storage) is a p-element array, each element of which is the address of a faulty accessible row. The Faulty Row Address Counter (FRAC) serves as an index into this array. For example, if Row 31 is the 5 th of 5 faulty accessible rows, then
FRAC=5,
[0046] and
FRAS[FRAC−1]=31
[0047] RR_info (Redundant Row Information) is a flag register p bits long (one bit for each redundant row). Each bit indicates whether the corresponding redundant row is usable or not. For example, if RR_info[3]=1, then RRow 3 is usable; otherwise, RRow 3 is faulty.
[0048] RR_enable (Redundant Row Enable) is a flag register p bits long. Each bit is used to enable (or disable) a corresponding redundant row, so it can be substituted for a faulty accessible row. As described in more detail below, the redundant rows are enabled/disabled using combinatorial logic in the FLARE unit.
[0049] [0049]FIG. 7 illustrates an embodiment of circuitry used by the FLARE unit to allow the BIST to access the redundant rows portion of the memory array. This circuitry switches in redundant rows when the BIST generates out-of-range addresses (m, . . . , m+p−1) during the first BIST run. It is also used to substitute good redundant rows for faulty accessible rows during the second BIST run. Recall that FRAR is an array containing p row addresses. This array associates each of the redundant rows with a row in the memory array. For example, the assignment FRAR[p−6]=m−3 associates RRow p−6 with Row m−3. Exclusive NOR gates 100 compare the row addresses 104 contained in the FRAR array with the current row addresses 106 generated by the BIST. A match results in the corresponding XNOR gate raising one input of the associated AND gate 102 to a HIGH logic level. The XNOR gate outputs are gated by AND gates 102 , dependent on redundant row enable signals 110 . (The redundant row enable signals are controlled by the corresponding bits in the RR_enable register, described above.) If the FLARE unit has enabled the particular redundant row 110 , the AND gate 102 activates the corresponding memory address line 108 . The USE_ROW line 114 driven by OR gate 112 routes the Data I/O bus to either the accessible (USE_ROW=0) or redundant (USE_ROW=1) portion of the memory array. Whenever any of the redundant row address lines is taken HIGH, OR gate 112 raises the USE_ROW line 114 , placing the corresponding redundant row into the I/O path.
[0050] During the first of the two BIST runs, Faulty Row Address Reference array FRAR[0:p−1] is initialized with the p out-of-range addresses:
FRAR[i]=m+i
(0≦ i<p )
[0051] Thus, when the BIST generates an out-of-range address m+i, it is automatically mapped to the i th redundant row. During the first BIST run, as the memory is tested, the addresses of faulty accessible rows are recorded. At the end of the first BIST run, these faulty row addresses are loaded into FRAR[0:p−1] by the redundant row allocation process (discussed in more detail below), thus associating each faulty accessible row with one of the redundant rows. When the accessible memory is retested in the second BIST run, each time the BIST asserts the address of a previously detected faulty row, the circuitry of FIG. 7 substitutes the associated redundant row. This substitution of usable redundant rows for faulty accessible rows, using the FRAR array and the circuitry of FIG. 7, achieves repair of the memory array.
[0052] A flowchart of FLARE unit diagnostics during the 1 st BIST stage appears in the FIG. 8; this sequence of operations corresponds to item 166 of FIG. 7. The FLARE unit's registers are initialized with specific logic values 202 and 204 . The BISR_FSM control logic asserts the BIST_ENABLE and FLARE_ENABLE signals to enable both BIST and FLARE units. The FRAR array is initialized 202 with the out-of-range addresses corresponding to the redundant rows:
FRAR[i]=m+i
[0053] for
0 ≦i<p
[0054] As explained earlier, this initial assignment maps each out-of-range address m≦i<m+p generated by the BIST to the contents of some FRAR[i], and enables the BIST to access the associated redundant row RRow i. All p bits in the RR_info registers are set to 1 204 :
RR_info=111, . . . ,11
[0055] As discussed above, each bit in the RR_info register corresponds to a redundant row; if a given bit is set to 1, the associated redundant row is usable (i.e., has no defects). The FRAS array (which stores the addresses of faulty accessible rows) is initialized 206 :
FRAS[i]= 0
[0056] for
0 ≦i<p
[0057] The RR_enable register is initialized 208 :
RR_enable=111, . . . ,11
[0058] Each bit in RR_enable corresponds to a redundant row; if a given bit is 1, the associated redundant row is enabled (i.e., may be swapped into the I/O path). At the start of the 1 st BIST stage, the assumption is that all the redundant rows are usable. Finally, the FRAC counter (which counts faulty accessible rows) is set to zero 210 :
FRAC=0
[0059] The BIST unit starts generating memory control signals and data patterns to test memory by writing and reading back the same data. Not only the accessible memory arrays, but also redundant rows, are tested, since the BIST unit generates out-of-range values for BIST_ADDR (i.e., BIST_ADDR≧m). When the FLARE unit receives the out-of-range BIST_ADDR, it activates the corresponding redundant row (using the circuitry of FIG. 7). When the BIST unit finds defects in memory, it toggles the BIST_ERRN signal. The BIST_ERRN signal appears at the ERRN output through the BISR FSM control logic unit. The FLARE unit detects BIST_ERRN signal and BIST_ADDR, and recognizes whether the defects detected are from accessible memory arrays or redundant row arrays 214 . If a defect is found within the accessible memory range (i.e., BIST_ADDR<m), the current error count is checked to make sure it does not exceed the number of redundant rows (i.e., FRAC≧p) 216 . Since the redundant rows are used for repair, if the number of defective accessible rows is greater than the number of redundant rows the memory cannot be repaired. If FRAC does not exceed the number of redundant rows, the current faulty row address is compared against the addresses contained in the faulty row address storage register 218 (FRAS), to determine if the current row has already been detected. If the current faulty row has already been flagged for repair, we check to see if any more rows remain to be tested 230 . Otherwise, the faulty row address is entered into the FRAS register 226 , at the location determined by the Faulty Row Address Counter (FRAC):
FRAS[FRAC]=BIST_ADDR
[0060] BIST_ADDR is then incremented 228 , in preparation for testing the next row, and we check to see if the last row has been tested 230 .
[0061] If BIST_ERRN toggles when the row address is out-of-range (i.e., BIST_ADDR≧m) 220 , then a faulty redundant row has been encountered. A faulty redundant row cannot be used to replace a defective accessible row, and must be disabled. A redundant row is flagged as unusable by setting the corresponding flag in the RR_info register to 0 224 . In the subsequent repair process, unusable redundant rows are physically disabled. If there are no more rows to be tested 230 the first BIST run is complete. Upon completion of the first BIST run, the FLARE unit is disabled 232 by the BISR FSM control logic, and the redundant row allocation process begins 236 .
[0062] The redundant row allocation process associates the faulty row addresses stored in the FRAS registers to the specific FRAR locations corresponding to usable redundant rows found during the first BIST run. In other words, this process creates a repair table based on FRAS, FRAC, and the RR_info results. There are 4 possible results from the first BIST run:
[0063] (1) No defects were found in the accessible memory arrays.
[0064] (2) The number of defective accessible rows is less than number of non-defective redundant rows.
[0065] (3) The number of defective accessible rows is equal to number of non-defective redundant rows.
[0066] (4) The number of defective accessible rows is greater than the number of non-defective redundant rows.
[0067] Each of these cases will be examined in detail below:
[0068] In Case ( 1 ), all the accessible memory arrays are non-defective, so no Repair Allocation Process will take place during this stage. The FLARE unit generates a FLARE_DONE signal at the end of this stage.
[0069] In Case ( 2 ), the memory has ample non-defective redundant rows to replace the defective accessible rows. In this case, the FLARE needs to assign one of the addresses in the FRAR array to each individual FRAS register value (individual defective row address). As discussed above in connection with FIG. 7, this allows the FLARE unit to replace the defective row with a corresponding non-defective redundant row. Before doing this, the FLARE unit determines the location of non-defective redundant rows using the RR_info registers. Individual RR_info register logic values represent the status of corresponding the redundant row—i.e., if the RR_info register value is at logic 1, the corresponding redundant row is non-defective; otherwise, the corresponding redundant row is defective. This procedure is explained in the following example.
[0070] Assume, for example, the array of RR_info registers RR_info[0:3] represents four redundant rows. Further assume that RR_info[0]=1, RR_info[1]=0, RR_info[2]=1, and RR_info[3]=1 at the end of the first BIST run. Note that RR_info[1]=0 implies that redundant row 1 is faulty. Each location in array FRAS can store a faulty row address, and there were two different faulty addresses stored in the first two FRAS locations. Therefore, the FRAC value should be 2 at the end of the first BIST run. Initially, the FLARE unit checks whether the RR_info[0] flag is at logic 1 (indicating that this redundant row is not faulty, and can be used for replacement of a faulty accessible row), and if so, it sets flag bit RR_enable[0] to logic 1. Since, RR_info[0]=1, FRAR[0] is set to the faulty accessible row address contained in FRAS[0]. Next, the FLARE unit checks RR_info[1] (the second redundant row) which is set to logic value 0 (indicating that the redundant row is bad, and not available for use as a replacement). In this case, flag bit RR_enable[1] is set to logic 0 (disabling the redundant row), and FRAR[1] is also set to 0. Then FLARE unit checks the RR_info[2] flag bit. Since RR_info[2] is set to logic 1, the FLARE unit recognizes that redundant row 2 is non-defective, so it sets RR_enable[2] to logic 1 and FRAR[2] is set to the faulty accessible row address contained in FRAS[1]. At this point, since FRAC indicates that there are no more faulty addresses stored in FRAS locations, the FLARE unit sets FRAR[3] to 0 and RR_enable[3] to logic 0, to disable redundant row [ 3 ] from being activated accidentally, and then raises the FLARE_DONE signal. For this example, at the end of the repair process:
FRAR[0] = FRAS[0] RR_info[0] = 1 RR_enable[0] = 1 FRAR[1] = 0 RR_info[1] = 0 RR_enable[1] = 0 FRAR[2] = FRAS[1] RR_info[2] = 1 RR_enable[2] = 1 FRAR[3] = 0 RR_info[3] = 1 RR_enable[3] = 0
[0071] Actually, the allocation process is finished when the RR_info[x] reaches 2 (i.e. x=2), which is same as the FRAC value (i.e., FRAC=x). This occurs when every faulty accessible row has been paired with a usable redundant row, at which point, the remaining redundant rows are not needed. The FLARE unit sets the unneeded FRAR and RR_enable registers to a default value of logic 0. The RR_enable signals are used in conjunction with the circuitry of FIG. 7; wherever FRAR[x] is valid, the corresponding RR_enable[x] register value has to be logic 1, so the faulty accessible row whose address is contained in FRAR[x] can be replaced by specific redundant row RRow x.
[0072] In Case ( 3 ), we assume there is a third defective accessible row. The address of the third faulty accessible row would then be contained in FRAS[2]. Following the procedure used for case ( 2 ) above, we arrive at the same result, except that his time FRAR[3] contains the third faulty row address (from FRAS[2]).
FRAR[0] = FRAS[0] RR_info[0] = 1 RR_enable[0] = 1 FRAR[1] = 0 RR_info[1] = 0 RR_enable[1] = 0 FRAR[2] = FRAS[1] RR_info[2] = 1 RR_enable[2] = 1 FRAR[3] = FRAS[2] RR_info[3] = 1 RR_enable[3] = 1
[0073] Note that all three non-defective redundant rows have been used to repair the three faulty accessible rows.
[0074] For Case ( 4 ), we assume the RR_info values remain as above. This time however, we assume that four faulty accessible rows have been detected. Although all four FRAS registers now store different defective addresses, the FRAR values can only be set to contain the first three of the FRAS addresses, since there aren't four usable redundant rows to perform the repair. This situation is as follows:
FRAR[0] = FRAS[0] RR_info[0] = 1 RR_enable[0] = 1 FRAR[1] = 0 RR_info[1] = 0 R_enable[1] = 0 FRAR[2] = FRAS[1] RR_info[2] = 1 RR_enable[2] = 1 FRAR[3] = FRAS[2] RR_info[3] = 1 RR_enable[3] = 1 FRAS[3] ! (unrepairable faulty address)
[0075] This time, the last defective address in FRAS[3] did not get repaired, since the memory has run out of non-defective redundant rows. Unrepaired faulty addresses will be detected during the second BIST run (which tests the repaired memory); at that time, the unrepaired faulty accessible row address will force the BISR FSM control logic to raise the FAIL signal.
[0076] A flowchart of the sequence of operations comprising the redundant row allocation process appears in FIG. 8. When the first BIST run is finished 250 , the FLARE unit is disabled 252 . Results from the first BIST run are retrieved and counters i and j, which index through the redundant rows and the faulty accessible rows, respectively, are initialized 254 . As the allocation of redundant rows proceeds, the counters are checked 258 to determine if the process is complete. If not, RR_info[i] is checked 262 , to see if the next redundant row is usable. If so, the i th redundant row is enabled 268 by setting RR_enable[i]=1, and then allocated as a replacement for the j th faulty accessible row 274 , by setting FRAR[i]=FRAS[j]. As discussed above, this allows the circuitry of FIG. 7 to substitute the i th redundant row when the j th address is asserted. If RR_info[i]=0, the i th redundant row is not usable (having been found faulty in the first BIST run); in this case, the i th redundant row is disabled 264 by setting RR_enable[i]=0. Counter i is incremented 256 , to get the next redundant row, where as counter j is not incremented; counter j is only incremented when RR_info[i]=1. When the counter check 258 determines that the process is complete 260 , the FLARE_DONE signal is raised 266 , to indicate that the FLARE unit is ready to swap redundant rows for faulty accessible rows. This triggers the start of the second BIST run 270 and 272 .
[0077] When the BISR FSM control unit detects the FLARE_DONE signal, it enables the BIST unit again to test repaired memory. Throughout the second BIST run (and during normal operation), the FLARE unit remains disabled and never gets reset, so the repair information is retained in the FRAR and RR_enable locations, and redundant rows will be used to replace the defective accessible memory rows.
[0078] A number of advantages are believed to result from the method and system described herein. Since a single BIST is used, as opposed to multiple BISTs configured for different array sizes, the size and complexity of the on-chip BIST/BISR circuitry is reduced. Moreover, the BISR Wrapper permits a generic BIST to be used; therefore, the BISR is unaffected by changes in the BIST algorithm. Consequently, designers may more easily incorporate improved BISTs in their memory devices. Furthermore, since the BIST addresses the entire memory array, adjacent row interaction tests can be performed using a checkerboard pattern that spans both the accessible and redundant portions of the memory, greatly improving fault coverage. Resources required for implementation of the BISR Wrapper system disclosed herein are no more extensive than would be needed for implementation of existing BIST/BISR approaches, so its incorporation into memory devices is believed to be straightforward.
[0079] It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention is believed to present a system and method for built-in self-test and self-repair of a semiconductor memory. Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Details described herein, such as the number and order of BIST runs, are exemplary of a particular embodiment. It is intended that the following claims be interpreted to embrace all such modifications and changes and, accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A “Wrapper” system and method are presented for integrating built-in self-test (BIST) and built-in self-repair (BISR) functions in a semiconductor memory device. The wrapper reduces the usual dependency of BISR circuitry on the BIST design, so that modifications and enhancements to the BIST may be made without requiring significant changes to the BISR. A generic BIST engine with an extended address range (spanning both the accessible and the redundant rows) is used to test the entirety of memory as a single array, preferably using a checkerboard bit pattern. The memory is tested in two stages, using the same BIST algorithm. In the first stage, faulty rows in each memory portion are identified and their addresses recorded. At the end of the first stage a repair process allocates good redundant rows to replace faulty accessible rows. During the second stage, repair of the accessible memory portion is verified, while defects among the redundant portion are ignored. Compared to existing methods, the new method is believed to greatly simplify the interface between the BIST and the BISR circuitry, reduce the overall size of test and repair circuitry, and provide improved test coverage. | 6 |
SUMMARY OF THE INVENTION
The present invention relates to a method of obtaining sufficient supporting force for a concrete pile sunk into a hole.
A concrete pile is gradually sunk into a leading hole substantially concurrently with the progress of the excavation thereof. This method does not cause any noise or any vibration. Therefore, it is effective to reduce city noises. However, the supporting force of a concrete pile sunk into a hole is inferior to that of a driven pile. One method of obtaining sufficient supporting force for a pile sunk into a leading hole has been recently developed. In that method, a supporting hole is excavated below a pile after the pile has been sunk through a desired distance and cement milk is poured into the supporting hole so as to stabilize the bottom of the pile. However, the supporting force obtained by the method is not enough. Because, since the circumferential wall of the supporting hole is loosened by the excavation of the hole, cement milk is not sufficiently fixed.
The object of the present invention is to provide a method of obtaining enough supporting force for a pile sunk into a hole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevation view showing a process a process of excavating a leading hole for a pile;
FIG. 2 is a sectional elevation view showing a process of excavating a supporting hole below the pile;
FIG. 3 is a sectional elevation view showing a process of obtaining sufficient supporting force in accordance with the first embodiment;
FIG. 4 is a sectional elevation view of a main part for explaining the first embodiment;
FIG. 5 is a sectional elevation view showing a process of obtaining sufficient supporting force in accordance with the second embodiment; and
FIG. 6 is a sectional elevation view showing one example of a means to counteract the expansion-pressure.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a screw auger 11 with a bit 12 at the forward end thereof is inserted through a hollow part 14 of a concrete pile 13. A leading hole 15 is bored with the said bit 12, excavated soil is carried above the ground by the screw auger 11, and the concrete pile 13 is gradually sunk into the leading hole 15 substantially concurrently with the progress of the excavation thereof. After the concrete pile 13 has been sunk through a desired distance, vanes 16 of the bit 12 are unfolded to excavate a supporting hole 17 the outer diameter of which is larger than that of the concrete pile 13. In that case, the circumferential wall of the hole 17 is loosened by the excavation in a range 18 shown with a dotted line in FIG. 2.
In FIG. 3, a solidifying material 19 is poured into the hole 17 from the forward end of the bit 12, and the material 19 and gravel within the hole 17 are stirred with the bit 12 so as to be mixed together. The solidifying material 19 is expanded as the time passes. After the solidifying material 19 has been poured up to a determined height of the hollow part 14 of the pile 13, the screw auger 11 is withdrawn above the ground together with the bit 12. In FIG. 4, the pile 13 is pressed further downward a little so that the forward end of the pile 13 can be sunk into the solidifying material 19 within the hole 17.
In the first embodiment, the solidifying material 19 consists of cement milk or mortar as a main component and cement expansion agent of calcium sulfoaluminate system or lime system. The said solidifying material gradually expands with the hole 17 substantially concurrently with the hardening of cement. Therefore, the circumferential wall of the hole 17 is subjected to expanding pressure as shown in FIG. 4. Loose part 18 of the hole 17 is pushed outward by the expanding pressure so that its durability can be restored. As the result, the pile 13 is securely supported.
The second embodiment of the present invention will be described hereinafter. An expanding solidifying material 19 consists of cement milk or mortar as a main component, and a little aluminum powder. The said solidifying material 19 generates gas before cement is hardened, so that it rapidly expands within the hole 17. Because of rapid expansion of gas, the expanding pressure escapes from the hollow part of the pile 13 to the upper part. Therefore, the expanding pressure is not so effective as to retighten the loose part 18 of the hole 17. In the present embodiment, as shown in FIG. 5, a rapidly hardening material 20 to be fixed to the circumferential wall of the hollow part 14 is poured above the solidifying material 19. The hollow part 14 is sealed by the rapidly hardening material 20 so that the expanding pressure is prevented from escaping upward. Since the rapidly hardening material 20 is placed above the solidifying material 19, its specific gravity should be smaller than that of the solidifying material 19. For example, cement suspension containing water glass No. 1, No. 2 or No. 3 or rapidly hardening cement milk may be used.
Cement milk or mortar, which is the main component of the solidifying material 19, permeates into the loose part 18 by the pressure of the gas generated from the solidifying material. The expanding pressure effectively acts in order to retighten the circumferential wall 18 of the supporting hole 17 so that the durability of the supporting hole 17 can be restored. When the solidifying material 19 is completely hardend, the pile 13 is securely supported similarly to the first embodiment.
In the first embodiment, the solidifying material 19 gradually expands concurrently with the hardening of cement, and a frictional force causes at the circumferential wall of the hollow part 14 by the expanding pressure. Accordingly, the expanding pressure never escapes to the upper hollow part, and thereby a rapid hardening material 20 is not required.
In the abovementioned two embodiments, the main component of the solidifying material 19 is cement milk or mortar. Therefore, gravel remained within the hole 17 is utilized so as to be mixed into the cement milk or mortar. If it is estimated that only very little gravel is remained, or if neither stirring nor mixing is executed with the bit, it is preferable to use cement concrete as the main component of the solidifying material 19. In the abovementioned embodiments, expanding agent is previously mixed with the main component of the solidifying material 19. It is also possible to execute the mixing when the solidifying material 19 is poured into the supporting hole and stirred therein. The expansion ratio of the solidifying material can be selected by the mixture ratio of the expanding agent to cement, and further the expanding pressure can be selected by the expansion ratio. If the expanding pressure is selected so as to be large, a steel tube or a steel band may be provided at the forward end of the pile 13, for example inserted into the hollow part 14 or attached to the outer periphery, or other various reinforcing means (For example, as shown in FIG. 6, a steel tube 21 is fixed to the bottom of the pile 13 in order to counteract the expansion-pressure.) may be provided in order to reinforce the pile.
Table 1 shows concrete examples of the first and second embodiments.
Table 1______________________________________ Second Embodiment First First Second Embodiment Ex. Ex.______________________________________ main component cement cement mortar milk milk more more ratio of water more than than thanSolidi- to cement 45% 45% 55%fying expanding agent Lime system alu- alu- minum minumMaterial powder pow- der ratio of the 0.07- 0.09- expanding 5 - 30 % 0.09 0.11 agent to % % cement cement sus- pensionRapidly Hardening Material containing water glassNecessary Length of theRapidly Hardening more than 1 × DiMaterialExpansion Ratio 110 - 130 200 - 220(Volume Ratio) % % more than less than 10 -Expanding Pressure 10 Kg./cm.sup.2 Kg./cm.sup.2 (Reinforcement (Reinforcement of a pile is of a pile is not required.) required.)______________________________________
In the abovementioned description, a leading hole is excavated, a pile is sunk into the leading hole concurrently with the progress of its excavation, and after the pile has been sunk through a desired distance, another hole the diameter of which is larger than that of the pile is excavated below the pile. The present invention is not limited to the excavation of a large diameter hole below a pile. Similar effect can be displayed in other general processes. For example, similarly to the case shown in FIG. 1, a bit the outer diameter of which is approximately the same as the inner diameter of a hollow part 14 of a pile 13 is attached at the forward end of a screw auger 11, the auger 11 is inserted through the hollow part 14 of the pile 13, a leading hole 15 the diameter of which is approximately the same as the inner diameter of the pile is excavated below the pile 13, and the pile 13 is gradually sunk into the leading hole 15 as the excavated soil is carried above the ground with the screw auger 11, and consequently after the pile 13 has been sunk through a desired distance, the excessive leading hole 15 (corresponding to the hole 17 described in the above embodiments) is filled with a solidifying material 19. Therefore, the loose circumferential wall of the excessive leading hole 15 is retightened. As the result, the diameter of the excessive hole 15 is made a little larger than that of the pile, and thereby the pile is securely supported in a larger area.
The effects of the present invention are as follows.
(1) The circumferential wall of a supporting hole which has been loosened by the excavation is retightened by the effect of an expanding solidifying material, so that the supporting force is increased and the stability of the pile is improved.
(2) The diameter of the supporting hole is made larger by the expansion and permeation of the solidifying material.
(3) The forward end of the hollow part of the pile is plugged by the solidifying material or the rapidly hardening material.
Moreover, since the ascent of the underground water into the hollow part of the pile can be prevented, the supporting force is increased. | The present invention relates to a process of setting a concrete pile without noise or vibration which is thereby effective to decrease city noises. A concrete pile is sunk into a leading hole substantially concurrently with the progress of the excavation thereof. After the pile has been sunk through a desired distance, another supporting hole is excavated below the pile. A solidifying material, such as cement milk, mortar, or cement concrete including a cement expansion agent of calcium sulfoaluminate system or lime system, is poured into the supporting hole. The solidifying material is expanded within the supporting hole and permeates into the circumferential wall thereof, which is loosened by the excavation, so as to retighten the wall. Therefore, sufficient supporting force can be obtained. | 4 |
RELATED APPLICATIONS
Applicant claims the benefit of provisional application Ser. No. 60/416,449, filed Oct. 7, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The instant invention relates to a memorial for deceased humans or animals, the method of forming the memorial fixes the cremation remains in a permanent medium.
2. Description of the Prior Art
Cremation has been used world wide for many centuries by many societies. The method has been chosen over burial either because of religious reasons or convenience. The body is reduced in mass to what is commonly referred to as ashes, which can last indefinitely as it is primarily inorganic matter. The “ashes” are composed of primarily bone ash.
Traditionally ashes from cremation have been stored in closed containers or urns. In some instances it is the desire of the deceased to have his ashes spread upon a particular location. When an urn is utilized to store cremation remains, the urn is normally kept in a safe, secure location to avoid its overturning and spillage. Many individuals with human cremated remains, and pet owners who have become particularly attached to their pet, would prefer to have the cremation remains memorialized in a more permanent medium so that it could be displayed without fear of breakage or spillage. These containers do not allow the cremated remains to be viewed without being taken from the container or the container opened. Applicant's memorial would allow for display.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide for a novel method to convert the ashes or other cremation remains of a human or animal into a solid and durable fixed medium.
It is another object of the present invention to provide for a novel formulation for a fixed medium, including and incorporating cremation residue.
SUMMARY OF THE INVENTION
A memorial for deceased humans or animals in which the cremated residue or ash is blended or mixed with particulate glass, the mixture being heated to form a liquid pool of glass with the cremation residue or ash dispersed, infused and/or absorbed therein, the molten glass and ash being removed from the heat source after a suitable time period and transferred to a mold in the shape of the memorial, the mold allowed to cool until the memorial sets, the memorial then removed from the mold and reheated in an annealing oven at a suitable temperature for a suitable time so as to eliminate possible cracking and scoring, the memorial once removed from the annealing oven can be further cut, polished, faceted, engraved or the like. The initial mixture of particulate glass and cremation residue and ash can be further combined with a coloring agent if so desired before heating or before transfer to the memorial mold.
DETAILED DESCRIPTION OF THE INVENTION
The cremated remains or residue are gathered together and examined for particle size. If large pieces of residue such as bone are present, the cremated remains or residue is either ground to a particle size consistency equivalent to that of coffee grindings, or the larger particles are mechanically extracted from the residue, mechanically crushed and then ground to the desired consistency. Preferably usable ash must pass through a screen mesh of no larger than 0.020 mesh. In certain instances, the cremated remains or residue will be examined by passing a magnet over the residue to extract any foreign metals. Once the cremated remains or residue exists in a homogeneous particle size, that portion or amount to be used for the memorial is positioned in a sealed container with ground glass and shaken until a homogeneous mixing of the glass particulate and cremated remains or residue is achieved.
Applicant's process does not treat the cremation remains or residue to remove any impurities from within the bone or ash as taught by the prior art. Further, the Applicant's process does not reheat the cremation remains or residue. Applicant's process maintains the impurities that accumulated during the life of the animal and human and that were left after the cremation process. The amount of cremation remains or residue utilized in making the memorial depends upon the size of the memorial and the size of the animal. The amount of cremated remains used is a function of the size of the product, not the size of the animal. In the case of small animals, all of the cremated remains may be used in the creation process and in the case of larger animals, only a portion of the amount of cremated remains will be utilized. Still further, depending upon the desires of the client, the process can control the visibility of the cremated remains within the memorial by varying the size and/or volume of the cremation remains or residue.
The process uses an over the counter, commonly sold glass commonly referred to as “art glass”, available in either clear transparent or a wide range of colors. The preferred mesh size would be 0.062 mils. However, Applicant has performed the process using sheet glass, which is ground up, or preground sheet glass available in four consistencies, fine, course, medium, and powder or cullet. Chunks or sheets of glass may be used without grinding to achieve desired affects.
The percentage of cremated remains to ground glass can vary from between 1% to 40% of the total mix by weight. If color is desired, colored glass can be substituted for a portion of the clear glass, keeping the percentage of cremation remains to ground glass the same. This colored glass can be added and mixed homogeneously with the clear glass and the cremated remains or residue, or this colored glass can be positioned at a particular location in the crucible to impart a color at a particular location in the finished product. As an alternative to colored glass, coloring agents may also be substituted, as may any decorative glass additive.
The homogeneous mixture is then placed into a crucible of the appropriate size for the volume of the finished form which is desired. The crucibles can vary in size and can be formed of any material that will not leach into the glass when the crucible and glass are subjected to heat. Once the glass and cremation remains or residue are positioned in the crucible, the crucible is placed in a cool oven and ramped up to 2,200° F. or placed in an oven preheated to 2,200° F. and maintained at 2,200° F. for a minimum period of two hours. This two hour period is often referred to in the trade as “soak time”. The two hour soak time will yield a suitable molten or liquid mix of glass and cremated remains. If one desires a finished product with less visible cremated remains, then the soak time may be increased to as high as twelve hours. The minimum, however, is a two hour soak time at a constant temperature of 2,200° F. This minimum soak time is suitable for crucibles and contents up to 30 grams. Crucibles and contents over 30 grams require longer soak times as the volume increases. Once the required soak time has been achieved, the crucible would be removed from the oven and its liquid contents poured into a mold. However, it should be pointed out that it is possible to substitute the mold for the crucible and have the glass and cremated remains and residue melted in the oven as described heretofore with the mold being removed and allowed to cool. Alternatively, the crucibles may be placed in a preheated oven and the oven left to recover from loss of heat and returned to 2,200° F.
After a minimum two hour soak time at 2,200° F., the contents of the crucibles will become viscus and pourable. In the preferred embodiment, the crucible is then removed from the oven and poured into a mold of the desired design of the memorial product. The molds are constructed of various grades of steel, other suitable metals, graphite, clay or ceramic. In order to achieve a smooth exterior surface, the molds can be preheated. If a textured finish is desired, the mold is left at room temperature. Still further, after the contents are poured into the mold, a torch may be used to apply heat to the upper surface to polish that surface as it cools. Another alternative is, after the memorial is released from the mold, it could be placed back in the oven and the temperature brought to just the slumping point, approximate 1,500° F. for a few minutes then placed in the annealing oven. This procedure is called “fire polishing”.
Alternatively, the crucible could be removed from the oven and as it cooled, the contents could be slumped mechanically using a stainless steel rod or other suitable device and dropped or pressed into the mold, as opposed to pouring.
As the mold cools, and the contents have cooled sufficiently to maintain a shape outside of the mold, the contents are removed from the mold and quickly placed in an annealing oven on ceramic shelves set at 1,000° F. The annealing process is carried out in order to let the surface of the product or design flow and smooth out, and it is necessary to eliminate possible cracking and scoring after cooling. The exact temperature of the annealing technique is dependent upon the type of glass which is used. The annealing temperature is no greater than 1,000° F. When the annealing oven is ready to be cooled, it initially ramps down from its highest temperature to 850° F. At 850° F. it then ramps down to 750° F. at the rate of approximately 18°-20° F. per hour. When the 750° F. temperature has been reached, the oven shuts off and gradually cools at a faster rate than 18° F. per hour until the product is tolerable to touching with bare skin. Designs of up to 50 grams can be annealed in as little as 12 hours, and larger designs will take longer and possibly significantly longer, depending upon the thickness. Once the design has been removed from the annealing oven, it can be further cut, polished, faceted, laser engraved, sand blasted, mechanically engraved, left to stand alone, mounted on a plaque, displayed in a box, interred in a columbarium, buried, or formed into a piece of jewelry.
The item can be carbide or diamond drilled to create a pocket to add additional cold remains, such as a locket of hair or other desirable items into the finished product and then resealed.
Applicant's process controls the appearance of the finished product which is cast, cut, molded or worked by hand into any desired shape. Depending upon the glass used, the particle size of the cremation remains or residue and the ratio of cremation remains or residue to glass, the finished product may be clear in color with specks of particulate matter appearing in random patterns free floating within the crystal, black specks may appear, and the cremated remains or residue can appear in any color from white to black at the conclusion of the process with white to gray being the most common. If clear, uncolored glass is used, it can take on color as a result of being mixed with cremated remains, the color ranging from very light aqua/green to dark amber to dark green and be either opaque or translucent.
The shape of the finished product may be utilitarian in nature in the form of a piece of jewelry, a vase, bowl, vessel, table top displays, wall hangings, or a sculpture, or other art form, such as a touch stone or a paper weight. The shape may be created by melting glass crystal and infusing the cremated remains and then pouring into molds or melting and slumping into molds, mechanical pressure being applied to the product in the mold in either process. Alternatively, the shape may be created by casting a piece larger than the finished product and cutting or faceting it after cooling. Still further, the shape may be created by “gathering” or inserting a metal rod into the molten batch of glass crystal, extracting or gathering glass onto the rod from the batch, and rolling the glass onto cremated remains. In this method the glass and the cremated remains are worked by hand until the cremated remains are disbursed in a desired pattern. Additional glass is added by reinserting the metal rod with the glass and cremated remains into the batch. Coloring can be achieved by the process heretofore described, or can be introduced by working colored glass into the glass gathered on the rod, or can be mixed with the cremated remains prior to rolling the glass on the rod into the cremated remains. The glass gathered on the rod can then be worked by hand or slumped into a mold in order to achieve the desired shape. Additionally, cremated remains may be placed between layers of slumping glass. In this application, the glass does not take on color as it does not mix with the cremated remains.
While the present invention has been described with respect to the exemplary embodiments thereof, it will be recognized by those of ordinary skill in the art that many modifications or changes can be achieved without departing from the spirit and scope of the invention. Therefore it is manifestly intended that the invention be limited only by the scope of the claims and the equivalence thereof. | A memorial for deceased humans or animals in which the cremated residue or ash is blended or mixed with particulate glass, the mixture being heated to form a liquid pool of glass with the cremation residue or ash dispersed, infused and/or absorbed therein, the molten glass and ash being removed from the heat source after a suitable time period and transferred to a mold in the shape of the memorial, the mold allowed to cool until the memorial sets, the memorial then removed from the mold and reheated in an annealing oven at a suitable temperature for a suitable time so as to eliminate possible cracking and scoring, the memorial once removed from the annealing oven can be further cut, polished, faceted, engraved or the like. The initial mixture of particulate glass and cremation residue and ash can be further combined with a coloring agent if so desired before heating or before transfer to the memorial mold. | 8 |
BACKGROUND
[0001] Transistors are foundational devices of the semiconductor industry. One type of transistor, the field effect transistor (FET), has among its components gate, source, and drain terminals. A voltage applied between the gate and the source terminals generates an electric field that creates an “inversion channel” through which current can flow. Such current flow may be controlled by varying the magnitude of the applied voltage.
[0002] Many configurations and fabrication methods have been devised for transistor gate terminals (as well as for other transistor components). One such configuration is what is called a double gate transistor, in which a transistor has two gates instead of a single gate. Forming such a transistor can raise certain difficulties such as tip implants into a non-gated or channel region of the transistor, which can cause undesired off-state leakage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a plan view of a double gate transistor in accordance with an embodiment of the present invention.
[0004] FIGS. 2A and 2B are cross-section and top views of the embodiment of FIG. 1 .
[0005] FIG. 3 is a flow diagram of a method for forming self-aligned tip spacers in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0006] In various embodiments, self-aligned tip spacers may be provided in a multi-gate transistor structure to mask a portion of a silicon-on-insulator (SOI) structure. By masking off a part of the SOI structure, these spacers may act as masks to prevent implantation into the area under them, while the side surfaces of the SOI structure are implanted as needed. This is so, as diffusions that are performed to implant tip material can occur at an angle such as a 45° angle.
[0007] Referring now to FIG. 1 , shown is a plan view of a double gate transistor 10 in accordance with an embodiment of the present invention. As shown in FIG. 1 , transistor 10 includes a buried oxide layer (BOX) 20 . While not shown in FIG. 1 , it is to be understood that BOX 20 may be formed on a suitable substrate such as a silicon substrate. A silicon structure 30 , which may be a SOI layer that is patterned into a fin-type structure formed on BOX 20 . In turn, a front gate 40 a and a back gate 40 b , which may be formed of polysilicon may be deposited and patterned to form the front and back gates respectively. Front and back gates 40 a and 40 b may be separated by an insulator 50 which may be a nitride layer, for example. A high dielectric constant (high-K) material may be present at the interfaces between the sidewalls of SOI 30 and gates 40 a and 40 b , as the high-K insulator may be formed prior to gate polysilicon deposition. To mask off a portion of the top surface of SOI 30 , a localized spacer 55 may be formed, also of nitride, for example. While only shown on one side of transistor 10 , it is to be understood that a corresponding spacer may be formed on the other side of transistor 10 .
[0008] FIG. 2A shows a cross-section view along the line B-B′ of FIG. 1 and a top down view of the transistor structure, respectively. Specifically, as shown in FIG. 2A by presence of tip spacers 55 a and 55 b , after diffusion of implants zero or reduced diffusions are present in locations 35 immediately underneath spacers 55 a and 55 b . Instead, the implants are primarily provided in portions 30 a and 30 b , while pure silicon remains in SOI portion 30 . Similarly, from a top down view as shown in FIG. 2B spacers 55 a and 55 b abut insulator 50 to provide a mask over the underlying portions 35 of SOI 30 .
[0009] Referring now to FIG. 3 , shown is a flow diagram of a method in accordance with one embodiment of the present invention. As shown in FIG. 3 , method 100 may be used to form a double gate transistor in accordance with one embodiment. Method 100 may begin by patterning a stack structure that is formed of multiple layers including a SOI layer, an oxide layer, and a nitride layer (block 110 ). Specifically, trenches may be formed on either side of a stack by performing nitride and SOI dry etching. Thus a silicon fin may be formed over an underlying oxide layer, e.g., a BOX layer that is exposed on either side of the fin, with dielectric and insulation layers formed over the fin.
[0010] Referring still to FIG. 3 , then at block 120 a polysilicon layer may be deposited and then polished down to the level of the nitride layer. Note that polysilicon does not exist along the stack profile after the polishing step. The polysilicon may be used to form the double gates, i.e., on either side of the stack. Then at block 130 a hard mask layer may be deposited, which may be a nitride-based hard mask, in some embodiments.
[0011] Referring still to FIG. 4 at block 140 , the hard mask and underlying nitride layer may be selectively removed, e.g., via an etch process that will lead to localized tip spacers that extend from both sides of the insulation layers longitudinally. After the hard mask etch, the hard mask is completely etched away with most of the nitride layer underneath. At the same time, polysilicon, when exposed, is also eroded. Laterally, however, the hard mask etch can be designed to give a slight flare, and at the bottom of the hard mask flare the nitride layer is also tapered during the same etch process. Consequently, this flare is transferred to the underlying nitride layer. Note that the dual stack hard mask/nitride may be patterned with photoresist. Therefore, spacers will be formed at the nitride sidewalls due to this tapering. This taper is the main reason for the spacer to be created on top of the SOI during the subsequent processing steps.
[0012] The amount of nitride recessed laterally may be controlled during the final part of the etch sequence so as to not eliminate this spacer. In various embodiments, a predetermined control of radio frequency (RF) power and etch chemistry may be implemented. For example, in some embodiments a derivative of a conventional plasma etch may be used. Further, RF power may be modified. Specifically a power in the 500-1500 watts (W) range may change the extent of the spacer footing. Still further, pressures may be changed from approximately 100 to 200 milliTorrs (mT) to enable this flared shape rather than a vertical etch. Typical etch chemistries include methyl fluoride, carbon monoxide and oxygen (CH 3 F, CO and O 2 ). This subsequent nitride etch can also be carried out immediately post polysilicon etch, without inserting a break in the etch step (between poly and nitride etch). Various tool configurations such as electron cyclotron resonance (ECR) or inductively coupled plasma (ICP) sources can also be employed to etch the nitride on the SOI to create the final desired structure.
[0013] Referring still to FIG. 4 , another patterning process may be performed to remove polysilicon from the non-gate, i.e., the implantation regions, to thus expose the SOI fin (block 150 ). Specifically, a polysilicon etch may be followed by a slight nitride-clean dry etch step, such that the SOI is exposed, with no spacer along its sidewalls, while the self-aligned nitride spacer remains along the insulation layers' sidewalls. This patterning thus preserves the localized tip spacers. The top hard mask can then be stripped off to give the final structure.
[0014] This etching will enable diffusion of source and drain materials into the SOI fin. Furthermore, due to the self-aligned tip spacers, these tip implantations will not impinge into the channel region present under the stack. These self-aligned tip spacers may thus act as a mask on the top surface of the SOI fin extending from the insulation layer to protect a channel region present under the remaining insulation layer. Thus, diffusions may be performed to implant tips into the SOI fin (block 160 ). Further processing may be performed to form the source and drains, metallization contacts and so forth.
[0015] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | In one embodiment, the present invention includes a double gate transistor having a silicon fin formed on a buried oxide layer and first and second insulation layers formed on a portion of the silicon fin, where at least the second insulation layer has a pair of portions extending onto respective first and second portions of the silicon fin to each act as a self-aligned spacer structure. Other embodiments are described and claimed. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a base for supporting an upright post of a garden umbrella or the like.
Various types of bases for this purpose have been manufactured, for example simple concrete forms and various metal frame structures, all of which serve to support the vertical post for the umbrella with the intention of preventing it tipping when knocked or due to wind forces. These arrangements have the disadvantage that either they are insufficiently stable or they are so heavy that they are difficult to transport.
An alternative arrangement which has been manufactured previously is that of a rotationally molded or blow molded hollow body formed from suitable plastics material which can then be filled with a suitable fluid ballast, for example water through a filler cap. Blow molding requires relatively larger amounts of material to make a particular product and is therefore more expensive than other processes. In addition, even though when the ballast has been removed the support is very light it is also very bulky and therefore remains difficult to transport.
SUMMARY OF THE INVENTION
It is one object of the present invention, therefore, to provide an improved base for supporting an upright post for example for a garden umbrella, which can be filled with a suitable fluid ballast material and therefore when empty is very light and yet can be transported very simply and manufactured economically.
According to the invention, therefore, there is provided a base for supporting an upright post comprising a receptacle portion having an underside for standing on a support surface and a post supporting plinthe for receiving a lower end of said post, and a lid portion for covering said receptacle portion so as to define therewith a hollow container having a surrounding wall for receiving and containing a fluid ballast material, said lid portion having a first aperture through which said post can pass for engaging said plinthe and said receptacle and lid portions being formed from plastics material and having cooperating peripheral connecting means by which they can be interconnected.
Preferably the device includes a third portion in the form of a tube which can be supported around the plinthe of the receptacle portion with an upper end located around a collar so the post can be guided by the tube from the collar onto the plinthe. The tube also can prevent the ballast material entering the interior of the tube so that the post cant be removed and reinserted without difficulty.
In addition, the plinthe can provide a first annular outer supporting ledge for receiving a first larger diameter of post and a second inner supporting annulus for receiving a second smaller diameter of post. The collar in the lid portion can include an inner frangible ring which can be broken away when it is required to insert the larger diameter of post.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the best mode known to the applicant and of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view through a base according to the invention.
FIG. 2 is a top plan view of the base of FIG. 1.
FIG. 3 is a top plan view of the receptacle portion of the base of FIG. 1 with the lid portion removed.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
The base as illustrated in the drawings comprises a receptable portion 10 and a lid portion 11 together with a tube portion 12.
The receptacle portion 10 comprises a substantially circular lower wall 13 and an upstanding peripheral sidewall 14 to define a receptacle for a fluid ballast material which may be water or other suitable material. The lower wall 13 includes a central pedestal or plinthe 15. The plinthe 15 comprises an outer collar 16 surrounding a first annular surface 17. A second annular surface 18 inward of the surface 17 and spaced further downwardly toward the lower wall 13 is provided in the plinthe. A central depression 19 is arranged inwardly of the annular wall 18 with the sides of the depression 19 and the interconnecting portion 20 between the annular surfaces arranged on the same line and defining the upper edge of four fins 21 which act to support the annular surfaces relative to a base surface on which the receptacle portion sits. It will be noted therefore that the underside of the fins 21 extends inwardly from the collar 16 to a point 22 from which the lower edge inclines upwardly to terminate at the bottom of the depression 19.
The bottom surface 13 includes a main planar surface portion 23 and three annular or substantially annular depressions 24 arranged co-axially around the plinthe and extending downwardly from the main surface 23 to contact the support surface on which the portion sits. The outer and central depressions 24 are broken at 90 degree spacings around the lower wall. The depressions therefore act to provide strength and stiffening for the lower surface 23.
The outer wall 14 interconnects with the outer depression 24 at a rim 25 and from that position extends upwardly and slightly outwardly to a bead 26 at an upper edge of the wall. The bead is arranged peripherally with a curved upper edge 27 and a sharpened outer edge 28 defined by an upwardly inclined lower surface 29.
The lid portion 11 comprises a generally conical upper wall 30 extending downwardly from a central collar 31 to a snap ring connector 32 at the lower edge of the wall 30 for connection to the bead 26. The snap ring connector is in the shape of an inverted U with a central area shaped to receive the bead 26 and a latch projection 33 extending inwardly from the outer leg of the U so as to snap under the edge 28 when the bead is pressed into position with the U. An inwardly turned edge 34 of the inner leg of the U acts to guide the bead 26 into the correct position within the snap connector. The upper conical surface 30 includes four depressed ribs 35 again arranged at 90 degree spacing around the conical wall to provide strengthening and an attractive appearance. A filler opening 36 is provided in the upper wall 30 between two of the ribs 35 and is frusto-conically shaped so as to define a substantially flat upper surface 37 for receiving a cap (not shown).
The central collar 31 extends upwardly and slightly downwardly from a central annular flat portion 38 of the upper wall. The slightly downward extension provides a flange 39 which cooperates with the outer collar 16 of the plinthe 15 to locate the tubular portion 12. The upper portion of the collar 31 includes an inwardly extending frangible portion 40 which has slots 41 around a weakening line to allow the frangible portion to be broken away.
A pair of upstanding stiffening ribs 42 extend outwardly from the side of the collar so as to support a screw receiving flange 43 which is a screw threaded at an opening 44.
The lid portion 11 and the receptacle portion 10 can be manufactured simply by blow molding from polyethylene plastics material. This is because they are a simple open part as opposed to the conventional hollow part. Furthermore, the lid portion when inverted can be stacked inside the receptacle portion to substantially reduce the dimensions of the product for transportation. Alternatively, a number of receptacle portions can be stacked and the corresponding lid portions separately stacked to yet further reduce the bulk of transportation. The tube portion 12 is a simple extruded part.
When assembling the base for use, the tubular portion 12 is inserted on the outer surface of the plinthe which is slightly tapered so as to receive the tubular portion in a press fit. Subsequently the lid portion is arranged over the tubular portion and pressed downwardly so that the peripheral seal is completed interconnecting the U-shaped snap 32 and the bead 26. At this stage the upper end of the tubular portion 12 is located by the flange 39. The base can then be filled with the fluid ballast material through the filler cap which is then replaced. Due to the press fit between the tubular portion 12 and the collar 16, little if any ballast material enters the area inside the tubular portion 12. A post can therefore be inserted through the collar 31 into the tubular portion and guided thereby to the plinthe 15.
Depending upon the diameter of the post concerned, the frangible portion 40 can remain in position in which case the post passes inside the portion 40 and sits on the lower most annular support ring 18 of the plinthe. A larger diameter of post can be accommodated by breaking away the frangible portion 40 whereupon the post then sits upon the annular ring 17 of the plinthe.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A base for a garden umbrella is formed from a lower receptacle portion and an upper lid portion which interconnect with a snap ring around the periphery of an upper wall of the receptacle portion. A plinthe centrally of the lower portion cooperates with a collar centrally of the lid portion to locate a tube which guides the post of the garden umbrella to sit on the plinthe. The assembled base can then be filled with a suitable fluid ballast material. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to German Patent Application Serial No. 102007051945.3 filed Oct. 31, 2007, the entirety of which is incorporated herein by reference thereto.
BACKGROUND
The invention relates to a method for controlling the feed of sheets to a sheet-fed printing press having a sheet feeder comprising multiple components, each component being assigned an individual drive and these components being provided for supplying the sheets in a sheet stack, for separating the sheets from a sheet stack and for feeding the sheets to the sheet-fed printing press.
DE 195 05 560 A1 discloses a method for controlling the sheet feed in a sheet processing printing press. In this printing press, the sheets to be printed are taken from the top of a feeder unit stack and conveyed to the installation of the printing press over a predefined conveyor path. At the beginning of the conveyor path, a sheet inspection is performed with regard to double sheets and defective sheets and the sheet conveyance is stopped, depending on the result of the sheet inspection. On detection of a double sheet or defective sheet, withdrawal of additional sheets from the feeder unit stack is stopped immediately and the number of sheets that can still be conveyed into the printing press and printed there before the double sheet or defective sheet in the direction of sheet on the conveyor path reaches the front mark of the installation conveyance is determined. The ink feed is stopped even before the last sheet situated upstream from the double sheet or defective sheet in the direction in conveyance of the sheet enters the printing press. After withdrawal of a sheet from the feeder unit stack has been stopped, sheet conveyance is stopped exactly when the double sheet or defective sheet has reached the installation. Then the number of sheets yet to be fed into the printing press is determined from the distance between the installation and the sheet inspection in combination with the degree of underfeeding in the case of underfed sheet feeding and the format length of the sheets.
One disadvantage of this approach is that in shutdown of the sheet conveyor belt, the underfed sheets may be displaced with respect to one another and cannot approach the printing press again in this state without problems.
EP 1 281 647 B1 therefore presents a method for conveying sheets in a sheet feeder unit of a sheet processing machine by means of which this disadvantage is to be avoided. With this printing press, the rate of travel of the conveyor belt for conveying the fed sheets is variable, independent of the operating speed of the machine in accordance with the predefined speed profiles, so that when starting or stopping of the feeder unit, the conveyor belt can be stopped and/or started in accordance with a predetermined acceleration profile.
DE 102 16 135 A1 discloses a method for controlling the sheet feed to a sheet processing machine having a sheet feeder unit which comprises, among other things, a sheet separator for separating the sheets from a stack and a table with belts or a suction table with belts. The sheets are conveyed to the machine and inspected with regard to double sheets, defective sheets or skewed sheets. If there is such a sheet or if there is a disturbance in the downstream machine, the sheet feed is stopped, in which a sampling device that detects the height level of the stack is provided and the drive of the sheet feeder unit is provided by individual drives, which are controlled by means of an electronic processing unit that is connected to a control unit of the downstream machine. After breaking the connection between the electronic processing unit and the machine control unit, the synchronization of the individual drives is eliminated, so that the individual drives can be operated at will. The individual drives may also be operated optionally in different directions of rotation or brought to a standstill.
This process takes places directly on stoppage of the feeder unit. The disadvantage here is that other driven components of the feeder unit are stopped in an undefined position which makes renewed startup difficult.
Therefore, the object of the present invention is to develop a method by means of which at least two drives of components of the feeder unit are brought to a standstill in a defined position in a targeted manner when the feeder unit is shut down.
SUMMARY
According to the invention, this object is achieved by a method for controlling the feed of sheets to a sheet-fed printing press with a sheet feeder unit comprising multiple components such that these components are provided for supplying the sheets in a stack for separating the sheets from the stack and for conveying the sheets to the feeder printing mechanism of the sheet-fed printing press. An individual drive is assignable to each of these components. These individual drives are operable in synchronization with one another during the printing by the sheet-fed printing press. The synchronization between at least two individual drives is eliminated when the sheet feeder is shut down, wherein these individual drives are shut down individually and synchronized in relation to one another again in resuming operation of the sheet feeder unit such that they assume a predefinable position for each individual drive when the individual drives are shut down.
The invention has the advantage that an optimal stop point is achieved for the components of the sheet feeder so that operation can be resumed without problems.
The invention will now be explained in greater detail below on the basis of an exemplary embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a sheet-fed printing press formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The respective drawing shows a sheet feeder unit 1 with a table with belts 2 . The table with belts 2 is designed as a suction table with belts 2 . 1 . The inventive approach is explained on the example of a sheet feeder unit 1 with a suction table with belts 2 . 1 , in which sheets 8 are held by vacuum on suction belts 26 . 1 , such that the inventive approach may also be implemented on a sheet feeder unit 1 with a table with belts 2 in which the sheets 8 are guided in a known way through pressure rollers arranged on a rod grating against conveyor belts 26 of the table with belts. A feeder table 3 with front marks 4 , a vibrating system 5 and a feed cylinder 6 of a feed printing mechanism 7 of a sheet-fed printing press are arranged downstream from the suction table with belts 2 . 1 .
The sheet feeder unit 1 consists of multiple components, each component being assigned an individual drive 19 , 28 , 31 .
A stack 9 consisting of the sheets 8 is positioned on a stack plate 10 in the sheet feeder unit 1 . The stack plate 10 is attached to conveyor means 11 , which are connected to a lift (not shown). A sheet separator 12 is assigned as an additional component to the top of the stack 9 . The sheet separator 12 has separation suction cups 13 and conveyor suction cups 14 as well as undercut edge stops 15 . The sheet separator 12 is provided so that it is adjustable in height by means of an actuator drive 16 in the sheet feeder unit 1 . In addition, the sheet separator 12 may be displaced in or against a direction of conveyance 17 for adaptation of the format. In the exemplary embodiment, a sampling device 18 is assigned to the sheet separator 12 to detect the height level of the stack 9 . The sampling device 18 may also be provided at any other location on the sheet feeder unit 1 . The sheet separator 12 is driven by means of a first individual drive 19 , which may be designed as an electric motor, for example. Blowers 36 are also provided on the rear side and optionally on the sides of the stack 9 for predrying the sheets 8 on the stack 9 and for blowing under the sheets 8 during conveyance. To be able to form an air cushion that will support the sheets 8 , side plates 20 are arranged on the sides of the stack 9 . However, it is also possible to assign laterally bordering guide elements 20 . 1 to the stack 9 .
On the front side of the stack 9 , a shaft 21 extends over the width of the stack 9 as an additional component of the sheet feeder unit 1 , its drive being provided by a third individual drive 31 . Downstream from this a blow pipe 22 whose direction of blowing runs approximately opposite a direction of conveyance 17 .
The suction table with belts 2 . 1 as an additional component of the sheet feeder unit 1 comprises a drive roller 23 and a reversing roller 24 , between which a suction box 25 is provided, at least one suction belt 26 . 1 being wrapped around the rollers 23 , 24 . The suction belt 26 . 1 is put under tension by tension rollers 27 . The suction belt 26 . 1 is provided with suction openings in a known way, coming into operative connection with suction bores provided in the suction box 25 in their movement in the direction of conveyance 17 , driven by the drive roller 23 . The drive roller 23 is driven by a second individual drive 28 , e.g., an electric motor. Stepping wheels 29 correspond to the drive roller 23 and are controlled periodically against the drive roller 23 within an operating cycle.
The front marks 4 are controlled into an operating position against the feeder table 3 downstream from the suction table with belts 2 . 1 from a catch position beneath the feeder table 3 . An inspection device 32 is provided for the feeder table 3 . The vibrating system 5 arranged downstream from the feeder table 3 has a sheet holding system 30 and executes a pivoting movement between the feeder table 3 and the feeder cylinder 6 of the feeder printing mechanism 7 .
The individual drives 19 , 28 , 31 that drive the sheet separator as well as the sheet conveyor means, the actuator drive 16 and the inspection device 32 are connected to an electronic processing unit 33 of the sheet feeder unit 1 which is in turn connected to a control unit 34 of the downstream sheet-fed printing press. The sheet feeder unit 1 is readjusted in synchronization with the sheet-fed printing press via the machine control unit 34 and the electronic process unit 33 .
To do so, a rotary angle sensor 35 may be assigned, for example, to the feed cylinder 6 , which is connected to the machine control unit 34 . The individual drives 19 , 28 , 31 run in synchronization with one another over 360° of a single-turn shaft as well as within a unit of time.
In synchronized readjustment of the sheet feeder unit 1 , the top sheet 8 is separated from the stack 9 by the separating suction cups 13 driven by the first individual drive 19 assigned to the sheet separator 12 and is transferred to the conveyor suction cups 14 which convey the separated sheets 8 in the direction of conveyance 17 . The separation of the sheets 8 is supported by the fact that the stack 9 is loosened by blowers 36 and air is blown by the additional blowers 36 under the respective sheets 8 conveyed by the conveyor suction cups 14 . The sheets 8 conveyed by the conveyor suction cups 14 are guided by the stepping wheels 29 that make contact in cycles against the drive roller 23 and are then released by the conveyor suction cups 14 . The shaft 21 driven by the third individual drive 31 is pivoted out of the path of the sheets 8 and the blowing air feed to the blow pipe 22 is interrupted. The sheets 8 guided by the stepping wheels 29 against the drive roller 23 are picked up by the suction belts 26 . 1 , which are constantly being acted upon by a vacuum via the suction box 26 , and then are conveyed as a stack of sheets onto the feeder table 3 and with the front edge toward the front marks 4 in the working position. In the exemplary embodiment, an inspection device 32 which detects the sheets 8 is provided for the feeder table 3 . It is also possible to provide multiple measurement devices that inspect the sheets 8 and distribute them over the path of the sheets 8 as they travel from the sheet feeder unit 1 to the front marks 4 .
If no sheets 8 that are subject to defects are detected by the inspection device 32 , then the sheet 8 in contact with the front marks is transferred by the sheet holding system 30 of the vibrating system 5 and conveyed to the feed cylinder 6 whereby the front marks 4 are pivoted into their position beneath the feeder table 3 . If a sheet 8 subject to defects is detected by the inspection device 32 , a signal is supplied from the inspection device 32 to the electronic processing unit 33 and the synchronization between at least two individual drives 19 , 28 , 31 is canceled thereby. In the exemplary embodiment, these include the first individual drive 19 and the second individual drive 28 . It is also possible to eliminate the synchronization of all individual drives 19 , 28 , 31 .
The individual drives 19 , 28 are shut down individually. The conveyor belt 26 is stopped within the shortest possible amount of time in a process that is optimized for acceleration. This takes place in such a way that the conveyor belt 26 experiences a negative acceleration when stopped such that it comes to standstill in a technologically minimal time while maintaining the distance between the sheet 8 of the stack of sheets.
In shutdown of the individual drives 19 , 28 , they assume a position predefined for each individual drive 19 , 28 . Thus, for example, the sheet separator 12 moves into a position which allows it to start up again with no problem. The goal here is for the sheet separator 12 to reach this predefinable position within a technologically minimal amount of time. The sheet separator 12 may move in the direction of conveyance 17 or opposite the direction of conveyance 17 .
After removing the defective sheet 8 from the feeder table 3 , removal of the sheets 8 on the suction table with belts 2 . 1 is initiated by a startup signal supplied manually to the electronic processing unit 33 . In doing so the blowing air and suction air supply to the sheet separator 12 as well as the blowing air supplied to the blowers 36 are interrupted and the blow pipe 22 is acted upon by blowing air.
When the sheet feeder unit 1 is started up again, the first individual drive 19 and the second individual drives 28 are synchronized with one another again. The actuator drive 16 of the sheet separator 12 is lowered into its working position, the suction air and blowing air supplied to the sheet separator 12 and the blowing air supplied to the blowers 36 are activated and the blowing air supplied to the blow pipe 22 is interrupted. At the same time, the individual drives 19 , 28 are activated such that the original direction of rotation of the second individual drive 28 is restored, so that the sheets 8 are removed from the stack 9 in the direction of conveyance 17 and can be sent to the front marks 4 . After aligning the first sheet 8 with the front marks 4 , the connection between the electronic processing unit 33 and the machine control unit 34 is restored and the sheet feeder unit 1 is connected to the suction table with belts 2 within one working cycle.
The present invention is not limited just to the exemplary embodiment described above. Other components of the sheet feeder unit 1 , not specified in the exemplary embodiment but provided with individual drives, may be operated in the manner described here. | A method for controlling the feed of sheets to a sheet-fed printing press is provided for a sheet feeder unit comprising an individual drive assigned to each of a plurality of components provided for supplying the sheets in a stack, separating the sheets from a stack and supplying the sheets to the press. The method includes stopping at least two of the individual drives in a predefined position in a targeted manner when shutting down the feeder unit. The individual drives are operated in synchronization with one another during printing operation. The synchronization between the at least two individual drives is canceled when the sheet feeder unit is shut down. These drives are shut down individually and synchronized with one another when the sheet feeder unit is started up again such that in shutdown, each individual drive assumes a predefinable position. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a floating-type head slider which is, for example, provided in a magnetic recording/reproducing apparatus and configured to have a magnetic head float over a surface of a recording medium at the time of driving, and a recording/reproducing apparatus having such a head slider.
[0003] 2. Description of the Related Art
[0004] Generally, in a recording/reproducing apparatus such as a hard disk device, it is necessary to avoid wear/damage due to contact of a surface of a magnetic disk with a magnetic head. Accordingly, a floating-type slider having an air bearing surface (air lubricating surface) is provided for a magnetic head so as to ensure a predetermined gap between the magnetic head and a magnetic disk by means of an air pressure at the time of disk rotation, which results in information recording in a non-contact manner.
[0005] [0005]FIG. 13 is a perspective view showing a general slider 100 viewed from underneath. As shown in FIG. 13, the slider 100 is arranged to have rails 101 a, 101 b each having an air bearing surface (air lubricating surface), and a magnetic head 102 is fixed at an end surface of the rail 101 b. And, as shown in FIG. 14, an airflow generated when a magnetic disk 103 is rotated produces a floating power (pressure) onto the rails 101 a and 101 b. The floating power makes the slider 100 and the magnetic head 102 float above a surface of the magnetic disk 103 with a slight gap (flying height) therebetween. There have been realized a flying height of about 0.04 μm in a currently commercially available hard disk drive, and that of about 0.02 μm in a study level.
[0006] According to a hard disk device of a floating head type, as described above, even in a case of a disk having unevenness on a surface thereof, it is possible to reduce a spacing loss by making the magnetic head follow the unevenness on the surface. In addition, it is possible to prevent a magnetic head from contacting with a surface a magnetic disk so as to prevent the magnetic disk from wear and damage.
[0007] By the way, as described above, the flying height of the slider is significantly minute. Accordingly, even in a case where a quite small amount of dust comes into the hard disk device, there may be caused a serious damage to the hard disk device. Therefore, it is a usual manner that a hard disk device is assembled in a highly controlled clean room.
[0008] However, in a removable-type hard disk device in which a disk can be attached/detached, there is always a large slot provided to the hard disk device for inserting and pulling out a recording medium, and, inevitably, dusts of an amount existing in a usual life environment always come into the device. Once a dust comes into the air bearing surface of the floating-type head slider, the amount of the flying height changes and data cannot be recorded and read correctly, or further, the data may be damaged due to the contact of the slider with the disk. Accordingly, in a removable-type hard disk device employing a floating-type head system, dust control becomes the most important problem to be solved.
[0009] In addition, in late years, there are many cases using a personal computer in the open air along with the significant popularization of notebook type personal computers. In a case of taking out and using a personal computer in the open air, possibility of various kinds of vibration and shock to be given to a built-in hard disk device increases, which brings a problem of damages to the hard disk due to vibration caused by a slider. Because a spring hardness itself of an air film generated by air pressure caused between a slider and a magnetic disk at the time of disk rotation has a hardness of about 50 times of that of a suspension which supports a car, the slider hardly vibrates widely due to some vibration or shock externally given. However, in a case where a housing of the personal computer hits some corner or a case where the personal computer itself hits the ground, the slider may vibrate widely and contact with the hard disk. Accordingly, it is quite dangerous to mount a hard disk device in a personal computer for outdoor use, in view of data protection.
[0010] However, in consideration of an advantage of the hard disk device being high-speed processing, large capacity and low in price, even in a case of a notebook type personal computer premised to be used outdoors, there is no other choice than employment of a hard disk device. Accordingly, a hard disk device is required to secure reliability in a case of receiving external vibration and shock, in other words, it is quite important to prevent a slider from contacting with the hard disk.
SUMMARY OF THE INVENTION
[0011] The present invention is made in consideration of the above-described problem to be solved and there are provided a floating head slider having high reliability even in an environment to which dust may come into and a recording/reproducing apparatus in which such a floating head slider is employed.
[0012] In order to solve the above problem, according to a first essential view point, there is provided a floating-type head slider having at least a rail plane which functions as an air bearing in accordance with a kinetic pressure of an air flow caused by rotation of a recording medium, which supports a recording/reproducing device for recording and reproducing information keeping a predetermined gap between the device and a surface of the recording medium, wherein all of or almost all of edges (i.e., rails) of the rail plane comprises only a plurality of straight lines and arcs each being a part of one of an ellipse and a circle, for smoothly connecting ends of two of the straight lines. Herein, it is preferable that an edge of the rail plane which is positioned at a same height level is configured to be continuously endless.
[0013] According to such configuration, in a case of sudden contact of a slider with a magnetic disk due to vibration and shock given to the slider, it becomes less possible to damage a surface of a disk by configuring the edge (rail) of the rail plane with only a plurality of straight lines and arcs each being a part of an ellipse or a circle for smoothly connecting ends of two of the straight lines. Incidentally, it is preferable that the head slider comprises a plurality of rail planes with a plurality of height levels.
[0014] Furthermore, it is desirable that an area of a rail plane which comes closest to the magnetic disk is 30% or more, more preferably, 40% or more of the entire area, which functions as the air bearing, of the slider.
[0015] According to such a configuration, in a slider having multi-level edges (rails), when an area of a first rail plane which comes closest to the magnetic disk is set to be as large as possible against to an entire area of an air bearing surface of the slider, it is possible to reduce variation in floating height even in a case where a dust sticks onto the rail plane. In addition, even in a case where the slider comes into contact with the disk, because the contact pressure between the slider and the disk is kept low, it becomes less possible that the disk is damaged.
[0016] In addition, it is desirable that the rail plane comprises at least leg portions provided at a center portion and both end portions opposing to a moving direction and a connecting portion provided ahead in the moving direction for connecting among the leg portions. According to such construction, the rail plane has a comb-like shape.
[0017] In addition, according to a second essential view point of the present invention, there is provided a recording/reproducing device having a floating-type head slider having at least a rail plane which functions as an air bearing in accordance with a kinetic pressure of an air flow caused by rotation of a recording medium, which supports a recording/reproducing device for recording and reproducing information keeping a predetermined gap between the device and a surface of the recording medium, wherein an edge of the rail plane comprises only a plurality of straight lines and arcs being a part of an ellipse or a circle, for smoothly connecting ends of two of the straight lines.
[0018] According to such constitution, a recording/reproducing device having the floating-type head slider according to the first point of view can be provided.
[0019] As described above, according to the present invention, a floating-type head slider having high reliability even in an environment into which a dust may come and a recording/reproducing apparatus in which such a floating-type head slider is employed can be provided.
[0020] Incidentally, the other characteristic features of the present invention and significant effect introduced by the present invention can be understood by the following description of embodiments of the present invention and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a perspective view showing a magnetic disk device according to an embodiment of the present invention.
[0022] [0022]FIG. 2 is a schematic structural view enlargedly showing a tip portion of an arm of the apparatus shown in FIG. 1.
[0023] [0023]FIG. 3A is a perspective view of the slider shown in FIG. 2, viewed from underneath; FIG. 3B is a plan view of the slider shown in FIG. 2; and FIG. 3C is a longitudinal cross-sectional view of the slider shown in FIG. 3A, cut along the line III-III.
[0024] [0024]FIG. 4 shows another form of the slider shown in FIG. 2.
[0025] [0025]FIG. 5 similarly shows still another form of the slider shown in FIG. 2.
[0026] [0026]FIG. 6 similarly shows still another form of the slider shown in FIG. 2.
[0027] [0027]FIG. 7 similarly shows still another form of the slider shown in FIG. 2.
[0028] [0028]FIG. 8 similarly shows still another form of the slider shown in FIG. 2.
[0029] [0029]FIG. 9 similarly shows still another form of the slider shown in FIG. 2.
[0030] [0030]FIG. 10 is a schematic view for explaining a defect of a conventional slider.
[0031] [0031]FIG. 11A is a perspective view of a conventional pad-type slider, viewed from underneath, and FIG. 11B is a plan view thereof.
[0032] [0032]FIG. 12 is a graph showing a result of a comparative test according to the present invention.
[0033] [0033]FIG. 13 is a perspective view of a general slider, viewed from underneath.
[0034] [0034]FIG. 14 is a schematic view for explaining an operation of the general slider.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] Now, an embodiment of the present invention will be described with reference to the drawings.
[0036] [0036]FIG. 1 is a perspective view showing an example of a configuration of a hard disk device 1 (hard disk drive) built in or externally connected to a computer or the like.
[0037] In FIG. 1, reference numeral 2 shows a housing of the hard disk device 1 . A spindle motor which is not shown in the figure is installed on a bottom portion of the housing 2 . A magnetic disk 3 is rotatively driven at a fixed angular velocity by the spindle motor.
[0038] In addition, a base end portion 4 a of an arm 4 is swingably held at a corner of the housing 2 . A voice coil motor which is not shown in the figure is connected to a base end portion 4 a of the arm 4 , and swingably drives a tip portion 4 b of the arm 4 along a top surface of the magnetic disk 3 .
[0039] As shown in FIG. 2, the slider 6 of the present embodiment is held at the tip portion 4 b of the arm 4 via a suspension 5 . The suspension 5 comprises a spring portion 7 fixed on the side of the base end portion 4 a of the arm 4 , and a gimbal 8 and a pivot 9 for connecting the slider 6 to the spring portion 7 . In addition, the slider 6 has a function of ensuring a predetermined gap (flying height) between the slider 6 and the magnetic disk 3 by keeping a balance between a downward load applied by the suspension 5 and an upward floating power generated by the air pressure due to the rotation of the magnetic disk 3 .
[0040] A magnetic head 10 is fixed at a rear end plane of the slider 6 . The arm 4 is swingably driven when a predetermined voltage is applied to the voice coil motor. According thereto, the magnetic head 10 fixed to the slider 6 moves along a substantially radial direction of the magnetic disk 3 , in other word, the slider 6 carries out a seeking operation, so as to record or reproduce information on or from a predetermined track of the magnetic disk 3 .
[0041] Next, the structure of the slider 6 of the present embodiment will be explained in detail.
[0042] [0042]FIG. 3A is a perspective view of the slider 6 viewed from underneath; FIG. 3B is a plan view of the slider 6 ; and FIG. 3C is a longitudinal cross-sectional view of the slider 6 cut along the line III-III.
[0043] As shown in FIGS. 3A to 3 C, the slider 6 has a first rail 12 and a second rail 13 . In this description, a rail means an edge of a rail plane. With these rails 12 and 13 , a first rail plane 15 , a second rail plane 16 and a third rail plane 17 each having different height level are constituted. All of the first and second rails 12 and 13 comprises of straight lines and arcs each being a part of ellipses or circles to connect these straight lines smoothly, having an endless shape which are not segmented along the way. Furthermore, an air introducing end 11 of the first and second rails 12 and 13 has a single-peaked shape. The slider 6 is configured so that an area of the first rail plane 15 occupies more than 40% of the total area of the first, second and third rail planes 15 - 17 .
[0044] In addition, the first rail plane 15 is formed to be a ctenoid, i.e., comb-like shape having three leg portions 15 a - 15 c, and these three leg portions are mutually connected at a front side of the moving direction to be unified. According to such construction, there are formed negative pressure pockets 18 and 19 between the leg portions 15 a and 15 b and between the leg portions 15 b and 15 c, respectively. The magnetic head 10 is fixed to a rear end portion along a moving direction of the leg portion 15 b which is positioned at the center of the slider 6 .
[0045] Next, operation of the slider 6 having such construction will be explained.
[0046] The slider 6 is designed to utilize a positive pressure in a direction away from the magnetic disk 3 and a negative pressure in a direction toward the magnetic disk 3 so as to have a predetermined gap (flying height) between the magnetic disk 3 and the slider 6 keeping the difference between the positive pressure and the negative pressure and the load applied by the suspension in balance.
[0047] In this case, the area of the first rail plane 15 is relatively large in comparison with the other rail planes 16 and 17 , the first rail plane 15 receives most of the above-mentioned positive pressure. Accordingly, in comparison with a conventional slider, it is possible with the slider 6 of the present invention to reduce the load per unit area on the rail plane closest to the magnetic disk 3 .
[0048] According to the constitution described above, the following operation and effect can be attained.
[0049] First, even in a case where a dust is generated on the first rail plane 15 , it becomes possible to maintain the flying height of the slider 6 .
[0050] In other words, according to the construction described above, it is possible to have a large area for the first rail plane 15 , it becomes possible to reduce charge of load per a unit area of the rail plane. Furthermore, power of resistance against a negative pressure increases by existence of a negative pressure pocket. Accordingly, even in a case where a dust exists on the first rail plane 15 , influence for generation of a positive pressure can be kept small. This enables generation of a positive pressure enough for floating of the slider 6 .
[0051] In the second place, even in a case where floatability falls down significantly due to the existence of a large amount of the dust and the slider 6 comes into contact with the magnetic disk 3 , the contact pressure thereof can be kept small.
[0052] In other words, according to the above construction, the first rail plane 15 which is positioned at the highest level comes into contact with the magnetic disk 3 in such a case. In this case, because the charge of load per a unit area of a rail plane is small, as having mentioned above, the contact pressure with the magnetic disk 3 becomes small, as a result. This brings an effect that the magnetic disk 3 receives less damage.
[0053] In the third place, according to the above construction, since the rail plane is also formed in the leg portion 15 b positioned at the center of the first rail plane 15 and all rails are formed endlessly with a plurality of straight lines and arcs each being a part of an ellipse and a circle for connecting end portions of one of the straight lines and another straight line smoothly, the magnetic disk 3 is less damaged.
[0054] In other words, in order to take a lot of air flow to stabilize the floatation, the air bearing surface of the slider 6 is generally processed so that the center portion thereof has a convex shape, that is, so-called “crown”, toward the magnetic disk in comparison with the both edge portions. When a pad-type rail plane having processed to have a “crown” approaches the magnetic disk, as shown in FIG. 10, an edge portion 20 of a divided rail plane first comes into contact with the magnetic disk 3 geometrically, which results in a strong possibility of damage of the magnetic disk by a sharp edge of the rail plane.
[0055] On the other hand, the slider 6 of the present embodiment has the leg portion 15 b at a center portion thereof and all rails are formed continuously. Furthermore, since there are formed the negative pressure pockets 18 and 19 between the leg portions 15 a and 15 b and leg portions 15 b and 15 c, respectively, a resistance force against the negative pressure improves. Accordingly, the problem mentioned above hardly occurs, and possibility to damage the disk with an edge of the rail becomes low.
[0056] In addition, in recent years, in order to stabilize the floatation of the slider, such a slider 26 having a plurality of pad-shaped rails 21 to 25 , as shown in FIG. 11, prevails among the sliders. It is known that such a slider 26 having the pad-shaped rails 21 - 25 is superior in dynamic floating stability, brings less lowering in floating height in rare air, however, on the other hand, in a case where the slider 26 comes into contact with the magnetic disk due to vibration or shock, the magnetic disk may be damaged with the sharp corner of the rails 21 to 25 .
[0057] On the other hand, since all the rails are formed to be endless with straight lines and arcs for connecting end portions of the straight lines, the slider 6 of the present embodiment is effective in preventing the magnetic disk from being damages. The present embodiment has been described with reference to FIGS. 3A to 3 C, however, it is also possible to utilize a slider having a shape as shown in FIGS. 4 to 9 , for example. In FIG. 4, a tip portion (to which the magnetic head is attached) of the leg portion 15 b has a larger area. In addition, each of the leg portions 15 a and 15 c has a narrower tip portion. In FIG. 5, all the rails of the leg portions 15 a to 15 c are arranged to be parallel, and areas of the leg portions 15 a and 15 c are made to be smaller while the negative pockets 18 and 19 are arranged to be larger. FIGS. 6 to 9 show modified examples in which the area of the bottom 115 of the leg portion 15 b are varied, respectively. As described above, although the shape of the leg portion and the negative pressure pocket can be diversely arranged, the rails are formed with straight lines and arcs for connecting ends of the straight lines in every embodiment. In addition, the rail is constituted to be endless with continuity, and the rail plane has a single peak toward an air introducing end.
Example
[0058] Now, a result of a test comparing durabilities of the conventional pad-type slider 26 and the slider 6 of the present embodiment will be described.
[0059] Three kinds of sliders were used for the comparing test: the first slider is a slider having pad-type rail planes (as shown in FIG. 11), the second and the third sliders are those according to the present invention (as shown in FIGS. 3A to 3 C). A ratio of the first rail for the total area of the air bearing surface of the slider in each of the first to third sliders is 15.2%, 34.4% and 41.9%, respectively. All sliders are in size of 1.25×1.0×0.3 mm, and application load thereto by a suspension is 3.0 gf.
[0060] The comparing test is conducted such that the three kinds of sliders are floated for a long time in a controlled dust existing atmosphere so as to measure a contact force between the slider and the disk, at regular intervals. Results of the comparing test are shown in FIG. 12.
[0061] According to FIG. 12, the contact force rises first in the conventional pad-type slider (that is shown in FIG. 11), and next, one of the sliders of the present invention, whose area ratio of the first rail plane is 34.4%, and subsequently, the other one whose area ratio being 41.9%. In other words, it is found that the smaller the area ratio of the first rail plane against the total area of the slider, the earlier the contact force rises. Thus, it is found that a slider of the present invention is more superior to a conventional slider.
[0062] In addition, although it is not described precisely, an acceleration coefficient of this experimental test is about 1000 times in view of another experimental test, and thus, the durability of 40 hours or more in this experimental test is required to guarantee a durability of five years or more of the slider being used in a device. On the other hand, the contact force rises sharply in the conventional slider, and the rails and the disk were damaged in a short time during the experimental test, quality of product level cannot be guaranteed.
[0063] On the other hand, in view of the result of the experimental test, it becomes possible to guarantee reliability of product level by setting an area ratio of the first rail plane toward the air bearing surface of the slider to be 30% or more, more preferably, an area ratio of 40% or more further improves the durability.
[0064] It is noted that the present invention is not limited to the embodiment described above, and of course, various modification can be made within a scope of the invention.
[0065] For example, in the embodiment described above, the recording/reproducing apparatus is a hard disk device, however, the recording/reproducing apparatus is not limited to this case. The present invention may be applied even to a floppy disk recording/reproducing apparatus or the like only if the apparatus employs a floating type head slider.
[0066] In addition, the floating type slider described above may be a near-contact type. | A floating-type head slider having a rail plane which functions as an air bearing in accordance with a kinetic pressure of an air flow caused by rotation of a recording medium, which supports a recording/reproducing device for recording and reproducing information keeping a predetermined gap between the device and a surface of the recording medium, wherein an edge (a rail) of said rail plane comprises only either of ellipses and circles, and tangent lines thereof, preferably the edge of the rail plane is constituted to be continuously endless, and by utilizing such floating-type head slider, there is provided a floating head slider having high reliability even in an environment to which dust may come into and a recording/reproducing apparatus in which such a floating head slider is employed. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/760,362, filed Feb. 4, 2013, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a travel pillow for comfortably supporting a vehicle passenger's head.
BACKGROUND OF THE INVENTION
[0003] Sleeping in the seat of a vehicle can often be uncomfortable and challenging. Many vehicles, including aircraft, are equipped with small travel pillows that are usually positioned between the passenger's head and the seat's headrest. However, the pillow intermittently shifts, waking the passenger and often disturbing an adjacent passenger. Furthermore, the head is usually supported in an awkward position that can cause neck cramps and other spinal ailments. Prolonged tilting of the head can cause neck strains, cramps and perhaps more severe medical problems.
[0004] Various travel pillows exist in the prior art that are purported to overcome many of the above-described problems. The most common travel pillow consists of a U-shaped or C-shaped cushion that encircles the neck to prevent the head from swaying or tilting. However, because a portion of the cushion rests between the nape of the neck and a seat backrest, the chin is forced downwardly, against the chest, which can be uncomfortable and disruptive.
[0005] Accordingly, there is currently a need for a travel pillow that overcomes the above-described disadvantages associated with conventional travel pillows.
SUMMARY OF THE INVENTION
[0006] The present invention is a unique form and design of travel pillow that allows two people who are traveling and sitting next to each other to rest in an upright position using a pillow like object to rest or sleep comfortably. It has unique design, shape, size, function and material construction. It can also be used by a single person against another solid/secure object, i.e. the seat and/or tray in front of where you are sitting, or the edge/wall of a vehicle such as a train, car, bus or airplane (in the window seat).
[0007] The invention includes three basic components—the Central Support Triangle (CST) that sits in the middle of, i.e between two people, or sits between one person and another secure object. The second component is a Comfort Pillow (CP) which slips into the third component the Comfort Pillow Slip (CPS) which is attached with VELCRO® on two opposite sides of the CST.
[0008] The first component, the “Central Support Triangle” (CST) serves as the center and the principal support of the object. It is a triangle shaped object of unique size, dimension and material construction. When the CST sits between two people there is a portion of the bottom of the CST that sits/rests on each person's shoulder of the two people sitting side by side.
[0009] The dimensions of the Central Support Triangle (CST) are roughly 8″ tall×8″ long×5″ wide at the bottom and 3″ wide at the top. The CST is constructed of a Ethylene-Vinyl Acetate copolymer (EVA) or similar and can have a range of degree specific to the hardness. The preferred degree of hardness/density is 38 degrees.
[0010] The location of the centerline of VELCRO® “hooks” piece, which is embedded/attached on the CST, is 2″ down from the top of the CST. There are two ⅞″ VELCRO® square pieces embedded/attached to the CST. They are embedded/attached on two opposite (left & right) sides of the CST. These two pieces of VELCRO® on the CST is what each CPS piece of VELCRO® will attach to. This VELCRO® attachment is what helps hold the CP in place. Although reference is made here to the VELCRO® trademark, it is contemplated herein that the any similar securing functionality may be utilized, including, for exemplary purposes only and without limitation, tiny hooks and loops such as those generally associated with the VELCRO® trademark and/or general usage of the word “velcro” (whether or not such usage is in reference to the trademark and/or the trademark's owner).
[0011] A Comfort Pillow (CP) sits on two opposite sides of the CST. The preferred dimensions of the CP are either 8″ or 10″ diameter circle or square. The CP is constructed of any type of pillow material. The CP will be inserted into the third component, the CPS.
[0012] The Comfort Pillow Slip (CPS) is a basic pillow cover which will have a piece of VELCRO® (loop side) sewn on one side of the CPS. The top of the VELCRO® “loops” square will be sewn 3″ down from the top of the pillow and will be on the side opposite of an image, if present, on the CPS. The CPS is capable of having a 8″ or 10″ pillow fit within it. The CP will fit into the CPS through a small opening in the bottom of the CPS, which will have a basic zipper or button securement method. The VELCRO® “loops” side of the CPS will attach to one side of the CST which has VELCRO® “hooks” attached to it. The CPS can be removed and washed easily. Further, it is contemplated herein that the VELCRO® “loops” may be disposed on the CST and the “hooks” side may be disposed on the CPS.
[0013] Using the aforementioned three components, a person can slip two CPs into their own individual CPSs. Upon securing the CP within the CPS, each CPS/CP can be secured to the CST by attaching the VELCRO® loops on the CPS to the VELCRO® hooks on the CST. Once both CPS/CPs are attached to the CST the “Travel Triangle” can be used as intended.
[0014] The Travel Triangle is designed for two people sitting side by side. It works such that the CST rests in part on each person's shoulder allowing each person to lean on the CP which is on their respective side of the CST. With the CST resting on their shoulders, neither the CP's or CST will move. Thus the three pieces (CP-CST-CP) will act as a support between the people's heads so they can relax and rest while traveling in a sitting position. This same concept of using the Travel Triangle as a resting support works with a single person against another solid object/force as well.
[0015] The CST and CP's act as a support structure between the two opposing forces of the traveler's heads (or one person's head and another solid/secure object) so that each can rest their head comfortably without the Travel Triangle shifting greatly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order for the advantages of the invention to be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0017] FIG. 1 illustrates an axonometric view of a travel pillow according to one embodiment of the invention;
[0018] FIG. 2 illustrates a dimensional axonometric view of a travel pillow according to one embodiment of the invention;
[0019] FIG. 3 illustrates a front view of a travel pillow according to one embodiment of the invention;
[0020] FIG. 4 illustrates a side view of a travel pillow according to one embodiment of the invention;
[0021] FIG. 5 illustrates a bottom view of a travel pillow according to one embodiment of the invention;
[0022] FIG. 6 illustrates an axonometric view of a travel pillow with VELCRO® square dimensioning according to an alternative embodiment of the invention;
[0023] FIG. 7 illustrates a dimensional axonometric view of a travel pillow with VELCRO® square dimensioning according to an alternative embodiment of the invention;
[0024] FIG. 8 illustrates a front view of a travel pillow with VELCRO® square dimensioning according to an alternative embodiment of the invention;
[0025] FIG. 9 illustrates a side view of a travel pillow with VELCRO® square dimensioning according to an alternative embodiment of the invention;
[0026] FIG. 10 illustrates an enlarged view of the VELCRO® hooks according to one embodiment of the invention;
[0027] FIG. 11 illustrates a front view of a travel pillow with comfort pillows and comfort pillow slips disposed about the sides;
[0028] FIG. 12 illustrates a side view of a travel pillow with a comfort pillow and comfort pillow slip disposed about one of the sides;
[0029] FIG. 13 illustrates an enlarged view of the VELCRO® loops;
[0030] FIG. 14 illustrates a bottom view of a comfort pillow slip; and
[0031] FIG. 15 illustrates a front view of a travel pillow according to an embodiment of the invention with comfort pillows and comfort pillow slips disposed about the sides, with users positioned about the sides of the travel pillow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] With reference to FIGS. 1-15 , details of the Central Support Triangle (CST) 10 will now be discussed. The (CST) 10 serves as the center and the principal support of the invention. CST 10 is a triangle shaped object of unique size, dimension and material construction. When the CST is located between two people, as shown in FIG. 15 , there is a portion of the bottom 12 of the CST 10 that sits/rests on each person's shoulder 100 , 102 of the two people sitting side by side. In this position, passengers sitting next to one another can rest their heads 104 , 106 on sides 16 and 14 respectively.
[0033] The dimensions of the Central Support Triangle (CST) 10 are roughly 8″ tall×8″ long×5″ wide at the bottom and 3″ wide at the top. CST 10 is constructed of a Ethylene-Vinyl Acetate copolymer (EVA), or similar, and can have a range of degree specific to the hardness. The preferred degree of hardness/density is 38 degrees.
[0034] FIGS. 6-10 show a means for attaching CP or CPS to the CST 10 . In a preferred embodiment, CST 10 is attached to CPS with a hooks piece 18 . CP or CPS are preferably positioned along a centerline of VELCRO® hooks piece 18 , which may be embedded or attached on the CST 10 . In a preferred embodiment, hooks piece 18 is 2″ below the top of the CST 10 , as shown in FIGS. 6-9 . There are two ⅞″ VELCRO® square pieces embedded/attached to the CST 10 . They are embedded/attached on two opposite (left 14 & right 16 ) sides of the CST. These two pieces of VELCRO® on the CST 10 is what each CPS piece of VELCRO® will attach to. This VELCRO® attachment is what helps hold the CP in place.
[0035] A Comfort Pillow (CP) 108 , 110 sits on two opposite sides of the CST 10 . The preferred dimensions of the CP 108 , 110 are either 8″ or 10″ diameter circle or square. The CP 108 , 110 is constructed of any type of pillow material. The CP 108 , 110 will be inserted into the third component, the CPS 112 .
[0036] The Comfort Pillow Slip (CPS) 112 is a basic pillow cover which will have a piece of VELCRO® (loop side) sewn on one side of the CPS 112 . The top of the VELCRO® “loops” square will be sewn 3″ down from the top of the pillow and will be on the side opposite of an image if present on the CPS 112 . The CPS 112 is capable of having a 8″ or 10″ pillow fit within it. The CP 108 , 110 will fit into the CPS through a small opening 114 in the bottom of the CPS 112 , which may have a basic zipper or button securement method. The VELCRO® “loop” side of the CPS 112 will attach to one side of the CST 10 which has VELCRO® “hooks” attached to it. The CPS 112 can be removed and washed easily.
[0037] Using the aforementioned three components, a person can slip two CPs 108 into their own individual CPS 112 . Upon securing the CP 108 within the CPS 112 , each CPS/CP can be secured to the CST 10 by attaching the VELCRO® loops on the CPS 112 to the VELCRO® hooks on the CST 10 . Once both CPS/CPs are attached to the CST 10 the “Travel Triangle” can be used as intended.
[0038] The Travel Triangle is preferably used by two people sitting side by side. It works such that the bottom 12 of CST 10 rests in part on each person's shoulder allowing each person to lean their head on the CP which is on their respective side of the CST 10 . With the CST 10 resting on their shoulders, neither the CP's or CST 10 will move. Thus the three pieces (CP-CST 10 -CP) will act as a support between the people's heads so they can relax and rest while traveling in a sitting position. This same concept of using the Travel Triangle as a resting support works with a single person against another solid object/force as well.
[0039] The CST 10 and CP's act as a support structure between the two opposing forces of the traveler's heads 104 , 106 (or one person's head and another solid/secure object) so that each can rest their head comfortably without the Travel Triangle shifting greatly, as shown in FIG. 15 .
[0040] The CP's will be attached on each side of the CST 10 with hooks piece 18 . In one embodiment, the attachment material will have a dummy cover to them so the VELCRO® doesn't wear away.
[0041] In an alternative embodiment, the Travel Triangle can be packaged for easy transport while traveling. It will be packaged such that the CST 10 , CPSs, and CPs can fit in a small plastic travel bag that can be clipped to a suitcase or packed away.
[0042] A detailed description of how the 3 “Travel Triangle” components work together is described above. In operation, a user can attach the CPS/CPs to the CST 10 via the VELCRO® attachments. The “Travel Triangle” can then be set between two forces, either on two peoples shoulders in between their heads or on one persons shoulder and against a wall, or on a table/pull out tray so a person's head can lean forward and the back of the chair acts as the other force. Once the “Travel Triangle” is at a spot that is somewhat stable, a person can rest their head(s) on their pillow and enjoy their sleep.
[0043] While the present invention has been fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment of the invention, 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 of the invention as set forth in the claims. | The invention includes a travel pillow comprising a Central Support Triangle (CST) configured to rest on the shoulders of two people sitting next to one another or on the shoulder of one person who is positioned adjacent to another secure object, two Comfort Pillows (CP) that provide a soft surface for a user's head, and two Comfort Pillow Slips (CPS) that serve as a cover for the CP, wherein the CPSs are attached on two opposite sides of the CST. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to heating systems including an automatically controlled stack damper apparatus, and, more particularly, to a control circuit which provides fail-safe operation of the stack damper apparatus and the fuel ignition and supply apparatus for such systems.
2. Description of the Prior Art
Heating systems employing furnaces having fuel-fired burners require a vent stack to conduct combustion products away from the burner. Many such systems, include an automatically controlled stack damper which permits the vent stack to be closed to minimize heat losses when the furnace is not operating, and to open the vent at the start of each heating cycle. To insure that the stack damper is open in advance of each operation of the burner, systems in which automatic dampers are used generally include an interlock arrangement between the damper control mechanism and fuel supply and ignition apparatus of the system which requires that the damper be fully open before the burner operates.
In one known arrangement in which a primary burner control is conditional on and subsequent to the opening of a stack damper, a drive motor is energized in response to a request for heat and drives the damper to an open position. Limit switches complete the burner circuit and deenergize the drive motor. The motor is energized at the end of the heat run to move the damper to the closed position, and a further limit switch deenergizes the motor when the damper reaches the closed position. Movement of the damper away from its fully open position permits a limit switch to operate and interrupt the burner circuit.
Although such systems prevent operation of the fuel supply apparatus unless the vent stack is open, and maintain the system locked out under certain failure conditions, due to the interlock arrangement, the system may also be locked out following a flame out or a momentary power interruption, an undesirable condition.
A further consideration is that in systems which employ proven pilot type fuel supply apparatus, it is desirable that the pilot valve be deenergized if the pilot fuel fails to be ignited within a predetermined time, commonly referred to as a trial for ignition interval. In one known arrangement, the trial for ignition interval is defined by an electronic timer circuit which controls a solid state switch to effect the deenergization of the pilot valve if a pilot flame fails to be sensed before the end of the trial for ignition interval. However, should the solid state switch fail, the pilot valve will remain operated after the trial for ignition interval, defeating the function of the trial for ignition timer.
SUMMARY OF THE INVENTION
The present invention provides a control circuit for a fuel supply and ignition control system of the intermittant pilot type. The control circuit controls the operation of the pilot and main fuel supply valves of the system and positioning of a vent stack damper plate which normally positioned to close the vent stack, but is repositioned to open the stack to vent combustion products away from the burner apparatus during operation of the system.
At the start of each operating cycle, the stack damper drive motor is energized and drives the damper plate from the closed position to the open position. The pilot valve and a spark generating circuit are also energized at start-up for a trial for ignition interval defined by the excursion time of the damper plate as it is driven from the closed position to the open position. If ignition fails to occur during the trial for ignition period, then a limit switch, which is operated as the damper plate approaches the fully open position, interrupts the pilot valve energizing path so that the pilot valve closes. This results in total shut-off of fuel to the burner apparatus.
In normal operation, the pilot fuel is ignited before the damper plate reaches the fully open position, and a flame sensing circuit senses the pilot flame and operates a flame relay which completes a holding path for the pilot valve to maintain it operated. When the damper plate reaches the fully open position, a limit switch operates to connect the main valve to the holding path for energization and a further limit switch operates to deenergize the drive motor to maintain the damper plate open. The stack damper drive motor is also energized over a path including further normally closed contacts of the flame relay.
In accordance with a feature of the invention, the flame sensing circuit is energized continuously and independently of control contacts which close to activate the control circuit at the start of an ignition cycle. Accordingly, any fault of the flame sensing circuit, or a welded contact failure of the flame relay will manifest itself by causing the system to go to a lockout state at the start of the next ignition cycle.
A flameout during a heat run will result in the fuel valves being shut off and the damper plate being driven to the closed position. When the damper plate reaches the closed position, a new trial for ignition cycle is initiated. Similarly, for a momentary power interruption during a heating cycle, then when power is restored, the damper plate is cycled closed, with the fuel valves deenergized, and a retry for ignition is initiated. In either case, the system is limited to one re-try for ignition, and if the pilot fuel is not ignited during such interval, the system is locked out.
The lockout function is provided by a start relay which is energized at the start of each ignition cycle and operates to complete the energizing path for the pilot valve and to interrupt the return drive path for the drive motor. Under normal conditions, the start relay is deenergized when the damper plate reaches the fully open position, if the flame relay was previously operated. However, should the flame relay fail to operate before the end of the trial for ignition period, then the start relay is maintained operated preventing reenergization of the drive motor as long as the control circuit is activated.
In summary, during each ignition cycle, the trial for ignition interval is defined by the excursion time of the damper plate as it is driven from the closed position to the open position. If a pilot flame fails to be sensed before the end of the trial for ignition interval, the pilot valve is deenergized, providing total shut-off of fuel supply to the burner apparatus, and the start relay will maintain the system in a lock out state as long as the control circuit is activated.
The control circuit provides fail-safe operation for virtually any fault condition, including welded contact failure for the control relays and limit switches of the circuit. A relay checking arrangement prevents start-up for a fault condition in the flame sensing circuit or the flame relay. Also, a fault in the flame sensing circuit which allows the flame relay to operate while the system is locked out, does not affect system safety. That is, for such fault condition, the damper plate will be driven closed, and subsequent start-up will be prevented since the flame relay will be operated. However, the system will recycle following a flameout or a momentary power interruption, with the start relay or a momentary power interruption, with the start relay limiting the system to only one re-try for ignition before causing the system to be locked out.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic circuit diagram of a control circuit for a fuel supply and ignition control system provided by the present invention; and,
FIG. 2 is also a schematic circuit diagram of the control circuit shown in FIG. 1, but with the contact layout rearranged to more clearly illustrate the control paths provided by the various contacts.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, the heating system is of the pilot ignition type and includes a fuel-fired heating apparatus having a pilot valve 11 which supplies fuel to a pilot outlet 13 and a main valve 12 which supplies fuel to a main burner 14. The pilot valve 11 and main valve 12 are connected in a redundant configuration by which fuel is supplied to the inlet of the main valve through the pilot valve 11, so that the supply of fuel to the main valve 12 is interrupted whenever the pilot valve 11 is closed. The fuel supplied to the pilot outlet 13, when the pilot valve 11 is open, is ignited by sparks provided by a spark generating circuit 16 to provide a pilot flame. The fuel supplied to the main burner 14, when the main valve 12 is operated, is ignited by the pilot flame to establish a flame at the main burner 14 providing heat for the system.
A vent stack 21 is provided to vent combustion products away from the main burner. A motor driven damper plate 22, which is mounted within the vent stack 21, is normally maintained in a position to close the vent stack preventing heat loss via the vent stack 21 when the heating system is shut down. In response to a request for heat, the damper drive motor 23 is energized and drives the damper plate 22 to the open position, represented by the dashed lines in FIG. 1, and when the heating demand has been met, the damper drive motor 23 returns the damper plate 22 to the closed position to reclose the vent stack.
The operation of the pilot valve 11, the main valve 12, the stack damper drive motor 23 and the spark generating circuit 16 are controlled by a control circuit 18 which includes a start relay R1, a flame relay R2, which is controlled by a flame sensing circuit 20, and a checking relay R3. The control circuit 18 also includes a pair of limit switches 36 and 38 which are mechanically linked to the shaft 24 of the motor 23 and are operated as the motor drives the damper plate between its open and closed positions.
The start relay R1 controls the operation of the pilot valve and the spark generating circuit at the start of each ignition cycle, and disables the spark generating circuit if a pilot flame is established before the damper plate is driven fully open. In accordance with one aspect of the invention, the excursion time of the stack damper plate, as it is driven from the closed to open position, defines the trial for ignition time for the system. The excursion time is in the order of thirty seconds. If for any reason a pilot flame fails to be sensed before the damper plate reaches the fully open position, the pilot valve is deenergized and the system is locked out when the limit switches 36 and 38 are operated.
Should a pilot flame fail to be established before the damper plate reaches the fully open position, then the flame relay R2 is unoperated, and relay R1 remains energized via its contacts R1A and contacts R2B. Thus, contacts R1B are kept open, preventing reenergization of the drive motor so that the damper plate remains in the open position, and the fuel valves are kept deenergized because contacts R2C are open.
In accordance with another aspect of the invention the flame relay R2 has respective normally closed contacts R2A and R2B connected in the energizing paths for the damper drive motor 23 and the pilot valve solenoid 11A. If for any reason contacts R2A and R2B are open at start-up, the system will go to a lock out condition. The relay R2 also provides a holding path for the pilot valve solenoid via normally open contacts R2C if a pilot flame is established before the damper plate is driven fully open. The checking relay R3 is operated at the start of each ignition cycle and via its contacts R3B prepares a holding path for the pilot valve solenoid 11A. The contacts R3B are connected in parallel with flame relay contacts R2A and provide a checking function in that if contacts R2A are open at start-up the system is locked out because, the energizing paths for the drive motor 23 and the start relay are interrupted. Also, continuation of an ignition cycle is predicated on the operation of the checking relay R3 before the flame relay R2 operates because relay R1 will drop out, and relay R3 cannot energize unless relay R1 is operated.
The cam operated switch 36 controls the energization and deenergization of the damper drive motor 23. The limit switch 36 via its contacts CA1-CA2 provide an energizing path for the damper drive motor 23 which path is interrupted when the damper plate has been driven to its fully open position. Contacts CA1-CA3 provide a return drive path for the motor to return the damper plate to its closed position following the termination of a heating cycle. Contacts CC1-CC2 of limit switch 36 effect disabling of the start relay R1 following a successful ignition cycle. The limit switch 38 controls the operation of the fuel valves and has its contacts CB1-CB2 connected in the energizing path for the pilot valve solenoid 11A and its contacts CB1-CB3 operated, when the damper reaches the fully open position, to connect the main valve solenoid 12A to the pilot valve solenoid holding path.
Briefly, in operation when thermostatically controlled contacts THS close at the start of an ignition cycle, the start relay R1 is operated and effects energization of the spark generating circuit 16, the checking relay R3, and the pilot valve solenoid 11A. When the pilot valve operates, fuel is supplied to the pilot outlet 13 for the ignition by the sparks provided by the spark generating circuit 16. The damper drive motor 23 is also energized over a path including normally closed contacts R2A of the flame relay and contacts CA1-CA2 of limit switch 36 which are closed when the damper plate is in the closed position. When the damper motor 23 is energized, the motor shaft 24 drives the damper plate 22 from the closed position towards the open position.
Normally, the pilot fuel is ignited, before the damper plate reaches the fully open position, and the flame sensing circuit 20 senses the pilot flame and operates the flame relay R2 which opens its contacts R2B interrupting the pilot valve solenoid energizing path. However, contacts R2C close to maintain the pilot valve solenoid energized over a path including contacts R3B of the checking relay R3.
When the damper plate 22 reaches the fully open position, limit switch 36 operates and contacts CA1-CA2 open deenergizing the damper drive motor 23 and contacts CC1-CC2 open deenergizing the start relay R1. When the start relay drops out, its contacts R1C open deenergizing the spark generator 16. Contacts CB1-CB3 of limit switch 38 close to connect the main valve solenoid 12A to the pilot valve holding path for operating the main valve. If a pilot flame fails to be sensed before contacts CB1-CB2 open, then the energizing path for the pilot valve solenoid is interrupted causing the pilot valve to close and shut off the supply fuel to the pilot outlet.
When contacts THS open at the end of a successful ignition cycle, the fuel valves are deenergized and relay R3 drops out completing a return drive path for the damper motor 23 when then returns the damper plate to the close position. When the damper plate reaches the close position, contacts CA1-CA3 of limit switch 36 open, deenergizing the drive motor.
DETAILED DESCRIPTION
Considering the control circuit in more detail, power is supplied to the control circuit over input terminals 51 and 52 thereof which are connectable to a 24 VAC source. Terminal 51 is connected over normally open thermostatically controlled contacts THS to a conductor L1, and terminal 52 is connected directly to a further conductor L2.
The limit switches 36 and 38 each comprise cam actuated switches, the operation of which is controlled by way of cams CA and CB. The cams CA and CB are mechanically linked to the shaft 24 of the motor 23. The limit switch 36 includes a resilient switch arm CA1, which is movable by way of cam CA, and a pair of fixed contacts CA2 and CA3. Cam actuator portions 41 and 42 are disposed at opposed positions along the periphery of the cam CA. As shown in FIG. 1, for switch 36 which controls the energization of the drive motor 23, actuator portion 41 maintains switch arm CA1, which is biased to normally engage contact CA3, in engagement with contact CA2 completing a portion of the energizing path for drive motor 23 when the damper plate 22 is in the closed position. When the motor is energized at the start of a heating cycle, the cam CA is rotated counterclockwise and when the cam CA is rotated approximately 90°, the actuator portion 41 disengages the switch arm CA1 which then moves out of engagement with contact CA2 and into engagement with contact CA3 deenergizing the motor and completing a portion of the return drive path for the motor 23. When the motor is reenergized at the end of the heating cycle, the cam CA is again driven counterclockwise and when cam CA has been rotated through another 90°, actuator portion 42 engages the switch arm CA1, moving the switch arm CA1 out of engagement with contact CA3 and into engagement with contact CA2, interrupting the motor return drive path.
Cam switch 36 also includes resilent switch arm CC1 which engages contact CC2, completing a portion of the energizing path for the operate winding 53 of the start relay R1 when the damper place 22 is in the closed position. Contacts CC1 and CC2 are opened, interrupting the energizing path for winding 53 when the damper plate 22 is in the open position.
Similarly, limit switch 38, which controls the valve operation, includes a resilient switch arm CB1, which is movable by cam CB, and fixed contacts CB2 and CB3. Cam CB has cam actuator portions 43 and 44, which are normally disengaged from the switch arm C1B permitting the switch arm CB1 to engage contact CB2 when the damper plate 22 is in the closed position. The cam actuator portion 43, for example, causes the switch arm CB1 to be moved out of engagement with contact CB2 and into engagement with contact CB3 with a few angular degrees less than 90° of rotation of the cam CB to a position corresponding to the fully open position for the damper plate 22.
Contacts CB1 and CB2 of limit switch 38 complete a portion of the energizing path for the checking relay R3 and the pilot valve solenoid 11A when the damper plate 22 is in the closed position and are operated to interrupt the pilot valve energizing path when the damper plate 22 is driven to the fully open position. Contacts CB1 and CB3 of limit switch 38 complete a portion of the energizing path for the main valve solenoid 12A when the damper plate is in the open position.
The operate winding 53 of the start relay R1 is connected in circuit with normally closed contacts CC1-CC2 of limit switch 36 and normally closed contacts R2A of the flame relay R2 between conductors L1 and L2, permitting energization of the winding 53 when contacts THS close at the start of the heating cycle. When operated, relay R1 closes its contacts R1A providing a holding path for the winding 53 over its contacts R1A and normally closed contacts R2B of the flame relay. Also, contacts R1C close connecting the pilot valve solenoid 11A and the operate winding 54 of the checking relay R3 to conductor L1 through contacts CB1-CB2 of limit switch 38 and contacts R2B.
Flame sensing circuit 20 is connected by way of conductors L1' and L2 directly to terminals 51 and 52 and is thus energized continuously and independently of the thermostatically controlled contacts THS. The flame sensing circuit 20 may, for example be similar to the one disclosed in my U.S. Patent Application Ser. No. 790,408 entitled FUEL IGNITION CONTROL SYSTEM, and which is assigned to the assignee of this application. The structure and operation of the flame sensing circuit 20 is set forth in the referenced application. For purposes of this description it is sufficient to state that in the absence of a flame, flame sensing circuit 20 maintains the flame relay R2 deenergized. When a flame impinges on the flame sensing electrode 58, the flame sensing circuit 20 effects energization of the operate winding 55 of the flame relay R2 causing the relay to operate. Flame relay R2 has normally closed contacts R2A connected in the energizing path for the damper motor 23 and the start relay R1. Further contacts R2B are connected in the energizing path for the pilot valve solenoid 11A and the operate winding 54 of the checking relay R3. In addition, normally open contacts R2C of the flame relay R2 complete the holding path prepared by contacts R3B of the checking relay between conductors L1 and L2 for the pilot valve solenoid 11A and the checking relay operate winding 54, for maintaining the pilot valve and the checking relay operated when flame relay contacts R2B open following operation of the flame relay.
The checking relay R3 has its operate winding 54 connected in circuit with cam switch contacts CB1-CB2, normally open contacts R1C of the start relay R1 and normally closed contacts R2B of the flame relay between conductors L1 and L2, permitting energization of the winding 54 when the start relay R1 operates. When operated, relay R3 closes its contacts R3C connecting the spark generating circuit 16 between conductors L1 and L2 over a path including contacts R1C and R2B. Also, contacts R3A are open, interrupting the return drive path for the damper motor 23.
The spark generating circuit 16 my be similar to one shown and described in my U.S. Pat. No. 3,902,839, which is assigned to the assignee of this application. When energized, the spark generating circuit generates high voltage pulses which are applied via ignition transformer (not shown) to the spark electrodes 17 causing sparks to be generated in the proximity of the pilot outlet 13 for igniting the pilot fuel. The spark generating circuit 16 is deenergized when contacts R3C are open.
OPERATION
The operation of the circuit 18 will be described with reference to FIG. 2 which is the same circuit as that shown in FIG. 1, but with the contact layout rearranged to more clearly illustrate the control paths provided by the various contacts. Also, in FIG. 2, contacts C3A, C2A, C2C, C2B and C3B correspond to limit switch contact pairs CA1-CA3, CA1-CA2, CC1-CC2, CB1-CB2 and CB1-CB3, respectively, shown in FIG. 1.
Referring to FIG. 2, when power is applied to the input terminals 51 and 52, the flame sensing circuit 20 is energized. Under normal conditions, the flame sensing circuit 20 maintains relay R2 deenergized so that contacts R2A and R2B are closed and contacts R2C are open. Also, initially the stack damper plate 22 is positioned to close the vent stack, and, cams CA and CB are in the positions illustrated in FIG. 1 so that contacts C3A and C2B are open and contacts C2A, C2C and C3B are closed.
When contacts THS close in response to a request for heat, current flows from conductor L1 through contacts R2A and C2A and through the winding of the drive motor 23 to conductor L2. The drive motor is thus energized and operates to drive the damper plate 22 towards the open position and to rotate cams CA and CB counterclockwise in the direction of arrows in FIG. 1. Current also flows from conductor L1 through contacts R2A, C2C and the operate winding of relay R1 to the conductor L2. Accordingly, the start relay R1 operates to close contacts R1A to latch the relay on through normally closed flame relay contacts R2B. Also, contacts R1C also close to complete an energizing path for the pilot valve solenoid 11A and the operate winding 54 of checking relay R3 through limit switch contacts C2B and contacts RB2. In addition, contacts R1B open, interrupting the return drive path for the drive motor 23.
When energized, relay R3 operates to close contacts R3B to latch the relay on over a path including contacts R3B, C2C, R1A, R1C and C2B; to close contacts R3C to energize the spark generating circuit 16; and to open contacts R3A, which are connected in the return drive path for the drive motor. When closed, contacts R3B shunt flame relay contacts R2A completing a portion of the holding path for the pilot valve permitting it to remain energized when contacts R2A and R2B of the flame relay open following operation of the flame relay R2 when a pilot flame is sensed.
When the pilot valve solenoid 11A is energized, the pilot valve 11 operates and supplies fuel to the pilot outlet for ignition by sparks provided by the spark generating circuit 16 which is also energized at this time. The trial for pilot ignition time is defined by the excursion time of the damper plate as it is driven from the closed position to the open position. The timing function is provided by the cam operated limit switch 38 which operates to interrupt the energizing path for the pilot valve solenoid just before the damper plate reaches the fully open position. If a pilot flame fails to be sensed before cam switch 38 operates, then the energizing paths for the pilot valve solenoid 11A and the checking relay R3 are interrupted. The pilot valve closes, interrupting the supply of fuel to the pilot outlet, and also preventing fuel from being supplied to the main valve 12, thereby providing 100% shut off of fuel supply to the burner apparatus. Also, relay R3 drops out, deenergizing the spark generating circuit 16 by opening contacts R3C, and opening contacts R3B to prevent inadvertent energization of the pilot valve should a fault occur in the flame sensing circuit, permitting relay R2 to operate. When limit switch 36 operates as the damper plate reaches the fully open position, contacts CA2 open, deenergizing the drive motor. Although contacts R3A reclosed when relay R3 dropped out, the return drive path for the motor is kept interrupted by contacts R1B which are kept open because relay R1 remains operated. The system is thus locked out with the drive motor and both fuel valves deenergized. The system remains locked out until thermostat contacts THS are opened, disconnecting power from conductors L1 and L2, which permits relay R1 to drop out and reclose contacts R1B. This causes reenergization of the drive motor which responsively drives the damper plate to the closed position.
Normally, a pilot flame is provided within the thirty second time interval as the damper is driven from the closed position to the open position. When the pilot fuel ignites, the flame sensing circuit 20 responds to the flame to energize the operate winding 55 of the flame relay R2. When relay R2 operates, contacts R2A and R2B open and contacts R2C close, connecting the pilot valve solenoid to the holding path provided over contacts R3B. The damper drive motor is maintained energized over contacts R3B and C2A when contacts R2A open, and the motor continues to drive the damper plate towards the fully open position.
A few angular degrees before the damper plate reaches its fully open position, limit switch 38 opens contacts C2B and closes contacts C3B. The pilot valve solenoid is maintained energized over a holding path provided by contacts R2C and R3B, and the main valve solenoid 12B is connected to the holding path by contacts C3B, and the main valve is operated to supply fuel to the main burner for ignition by the pilot flame.
When the damper plate reaches the fully open position, contacts C2C open to interrupt the energizing path for relay R1. This causes relay R1 to drop out and contacts R1A and R1C open deenergizing the spark generating circuit 16. Also, contacts R1B, which are connected in the return drive path for the damper motor, close. However contacts R3A are open, preventing reenergization of the drive motor at this time.
In addition, contacts C2A open, interrupting the energizing path for the damper drive motor 22 to stop the damper plate 22 at the fully open position. Also, contacts C2C close to connect the drive motor to its return drive path which is maintained interrupted at this time by contacts R3A.
Should a flameout occur following a successful ignition cycle, the flame relay R2 will drop out, opening contacts R2C deenergizing the fuel valves and relay R3. When relay R3 drops out, the damper motor is energized over contacts R3A, R1B and C3A to drive the damper plate back to the closed position. When the damper plate reaches the closed position contacts C2C, C2A and CB3 are reclosed allowing a further trial for ignition to be initiated. Thus, the system provides recycling under flameout conditions.
In the event of a momentary loss of power to the system during an operating cycle, the flame sensing circuit 20 and relay R2 are deenergized as are relay R3 and the fuel valves. Accordingly, when power is restored, a return drive path is provided for the damper motor over contacts R3A, R1B and C3A, permitting the damper plate to be cycled to the closed position to initiate a further trial for ignition cycle. It is pointed out, for a flameout or power loss condition, the start relay R1, permits only one re-try for ignition and should a pilot flame fuel to be established during such further trial for ignition, the system goes to lockout. This is because with relay R1 maintained operated, its contacts R1B interrupt the return drive path for the motor 23.
When contacts THS open after the heating demand has been met, the fuel valves are deenergized to extinguish the flame. Relay R3 is also deenergized and causes contacts R3A to close and complete the return drive path for the damper motor. The damper motor responsively drives the damper plate from the open position towards the closed position, rotating cams CA and CB further in the counterclockwise direction.
When the damper plate reaches its fully closed position, cam CA causes contacts C3A to open to deenergize the drive motor. Also contacts C2A and C3A close, and cam switch contacts C3B open and contacts C2C close to prepare the system for the next heating cycle.
Having thus disclosed in detail preferred embodiments of my invention, persons skilled in the art will be able to modify certain of the structure which has been disclosed and to substitute equivalent elements for those which have been illustrated; and it is, therefore, intended that all such modifications and substitutions be covered as they are embraced within the spirit and scope of the appended claims. | A control circuit for a fuel supply and ignition control system controls the operation of pilot and main valves of the system and of a motor which controls the positioning of a vent stack damper plate to normally close the vent stack and to open the vent stack at the start of each ignition cycle. At the start of each ignition cycle, a start relay is operated to energize the pilot valve and a spark generator for a trial for ignition interval defined by the excursion time of the damper plate as it is driven to the open position. When the pilot fuel is ignited, a flame sensing circuit operates a flame relay which completes a holding path for the pilot valve and when the damper plate reaches the fully open position, limit switches connect the main valve to the holding path and deenergize the drive motor and the start relay. If a pilot flame is not sensed before the end of the trial for ignition period, one of the limit switches deenergizes the pilot valve, and the start relay prevents reenergization of the drive motor, locking out the system. The control circuit includes a relay checking arrangement whereby start-up is prevented if for any reason the flame relay is operated at the start of an ignition cycle. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to compositions and methods for preventing or treating Plasmodium falciparum malaria. In particular, this invention relates to surfactant compositions and methods for reversing malarial resistance to quinoline antimalarials.
2. Description of the Prior Art
Plasmodium falciparum malaria is the world's most important parasitic infection accounting for an estimated 300 to 500 million cases and 1.5 to 2.7 million deaths annually [reviewed in Kain, 1998a]. P. falciparum infection accounts for over 90% of the morbidity and mortality associated with malaria. Young children living in malaria-endemic areas and other non-immune individuals are at the greatest risk of developing severe complications such as cerebral malaria leading to death. Despite intensive research, no specific treatments have been identified to prevent or improve the outcome of patients with severe malaria [White, 1998]. Severe and cerebral malaria carries a high fatality rate (>15%) even for young, previously healthy individuals [White 1998]. With escalating drug resistance and the lack of an effective vaccine, there is an urgent need for alternative therapeutic strategies.
Malaria associated morbidity and mortality is increasing because of widespread resistance to chloroquine, which is one of the safest and least expensive antimalarials. Chloroquine-resistant P. falciparum malaria was first recognized over 40 years ago and has since spread to almost all malaria-endemic areas [Su, 1997]. Chloroquine-resistant malaria has extended into the high transmission areas of Africa resulting in a public health crisis since switching to alternative antimalarials, such as mefloquine, artemisinin derivatives, halofantrine or quinine, is economically untenable for many countries in sub-Saharan Africa. Recent reports indicate that escalating mortality due to widespread malaria resistance is now taking place [Marsh, 1998].
The mechanism of chloroquine-resistance in P. falciparum remains controversial. However, it is frequently compared to multidrug resistance in mammalian cells that is often mediated by P-glycoproteins [Bray, 1998]. Mammalian P-glycoproteins are intrinsic membrane protein drug transporters that actively pump a wide variety of drugs and other xenobiotic compounds out of cells. Although P-glycoproteins can pump many types of chemotherapeutic agents like vinblastine and adriamycin out of cancer cells, the multidrug resistance phenotype of such cells can be modified by a variety of compounds including the immunosuppressant, cyclosporin A and calcium channel blockers such as verapamil. These chemosensitizers, competitively interact with drug-binding sites on P-glycoprotein, thereby interfering with the transport of chemotherapeutic agents out of cells.
It is known that drug resistance in P. falciparum can be reversed by calcium channel blockers such as verapamil [Martin. 1987]. The antipsychotics (e.g. chlorpromazine [Basco. 1992]), and histamine (H-1) receptor antagonists (e.g. promethazine [Oduola. 1998], chlorpheniramine [Basco, 1994]) also reverse chloroquine-resistance in P. falciparum in vitro and in malaria animal models [Bray. 1998]. However, these agents are pharmacologically active compounds with multisystem effects that result in a variety of undesirable side effects. Furthermore, these compounds are often more expensive than chloroquine itself and the concentrations required to reverse clinical drug-resistance for some of these agents can be toxic.
Accordingly, there is a need for safe, stable and inexpensive compositions and methods which reverse resistance to malarial quinoline.
SUMMARY OF THE INVENTION
This invention provides safe, stable and inexpensive compositions and methods which reverse resistance to malarial quinoline. The combination of a quinoline and a surfactant offers a treatment for malaria that:
1. is inexpensive for use in developing countries, 2. is comprised of two stable compounds that do not require expensive or unusual storage conditions, 3. provides increased absorption and decreased excretion of the anti-malarial component, and 4. does not require the introduction of other pharmacological agents with undesirable side effects.
It is an object of the invention to provide an agent that reverses quinoline resistance in P. falciparum malaria. Quinoline antimalarials include, but are not limited to, the 4 amino-quinolines (chloroquine, mefloquine, quinine, and quinidine) and the 8 amino-quinolines (primaquine and etaquine [WR238605])
According to a first aspect of the invention, a composition for reversing malarial resistance to quinoline antimalarials is provided. The composition comprises a synthetic, a natural or a hybrid surfactant in an admixture with a pharmaceutically acceptable carrier, excipient, or diluent. Preferably, the surfactant is the synthetic compound nonylphenolethoxylate (“NPE”) having between 10 and 70 ethoxylate units.
According to a second aspect of the invention, a composition for the treatment or prevention of malaria is provided. The composition comprises a pharmaceutically effective amount of a quinoline in combination with a surfactant, the surfactant being adapted to reverse malarial resistance to the quinoline. Preferably, the surfactant is NPE having between 10 and 70 ethoxylate units.
According to a third aspect of the invention, a method of treating or preventing malaria is provided. The method comprises administering to a patient in need thereof one or both of the compositions described above.
According to a fourth aspect of the invention, a method of treating or preventing malaria is provided. The method comprises the steps of:
(a) forming a composition by combining a pharmaceutically effective amount of quinoline with a pharmaceutically effective amount of a surfactant; and
(b) administering an effective dose of the composition to a patient infected with or at risk of contracting malaria.
Preferably, the surfactant is NPE having between 10 and 70 ethoxylate units.
Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating preferred embodiments of the invention are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiments thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows the general chemical structure of nonylphenolethoxylates (NPEs).
FIG. 2 shows anti- P. falciparum activity and sensitizing potential of NPEs. NPE solutions with increasing average EO content were tested for anti- P. falciparum activity and the IC 50 S of these materials were determined using a non-linear regression analysis. IC 50 results are expressed on both a per weight basis (A, top panel) and on a molar concentration basis (B, middle panel). The ability of a 5 μM concentration of NPEs to sensitize P. falciparum in vitro to chloroquine was determined (C, bottom panel). The degree of chloroquine resistance is calculated as the IC 50 value observed in the presence of various NPEs divided by the control (no NPE added) chloroquine IC 50 (240±60 nM). Values greater than 1 indicate that the particular NPE is rendering the P. falciparum parasites less sensitive to chloroquine, while values less that 1 indicate that the particular NPE is sensitizing the P. falciparum to chloroquine. Anti- P. falciparum activity and sensitization are representative results obtained from multiple determinations. Results are plotted as mean with the standard error (as calculated by Sigma Plot) indicated with bars. IC 50 values represent the concentration at which 50% of the parasites present are killed or have their growth inhibited.
FIG. 3 shows the effect of adding increasing amounts of NP30 on the degree of chloroquine resistance of P. falciparum . The degree of chloroquine resistance is calculated as the IC 50 value observed in the presence of various concentrations of NP30 divided by the control (no NPE added) chloroquine IC 50 (274±56 nM). Values greater than 1 indicate that the particular NPE is rendering the P. falciparum parasites less sensitive to chloroquine, while values less that 1 indicate that the particular NPE is sensitizing the P. falciparum to chloroquine. Non-linear analysis of the data points indicates that a NP30 concentration of approximately 1 μM (0.0002% on a weight/volume basis) results in a 50% decrease in the degree of chloroquine resistance of the parasites.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the description refers to nonylphenolethoxylate or NPE, as a preferred surfactant, such references are not intended to be limiting. It will be understood to those skilled in the art that natural surfactants, such as fatty acids, oils, bile acids, cholates, cholesterol esters, phospholipids, and chemically modified forms of these materials, as well as synthetic surfactants such as the Brij™ series, the Tween™ series, the octylphenol ethoxylate (OPE) Series, the NPE series and any of the synthetic surfactants such as those listed in “Industrial Surfactants” by Ernest W. Flick, Noyes Publications, Park Ridge, N.J. USA (1988) ISBN 0-8155-1173-6 may be used and are within the scope of this invention.
As shown in FIG. 1 , nonylphenolethoxylates (NPEs) consist of a hydrophobic tail group with a polymeric hydrophilic head portion consisting of repeating units of ethoxylate. NPEs are synthesized by co-polymerization of ethylene oxide with nonylphenol thereby producing a polydisperse mixture of head group lengths (X values) as described by Robert M. Weinheimer and Pierre T. Varineau in their 1998 book “Nonionic surfactants” Volume 72 of the Surfactant Science Series, edited by Nico M. van Os, published by Marcel Dekker, Inc. (New York) (ISBN 0-8247-9997-6).
Nonylphenolethoxylates [Charuk. 1998] (NPEs, FIG. 1 ) are synthetic surfactants that are inexpensive enough to used in a variety of household products. They can be used as wetting agents and have been tested as intestinal permeability enhancers to improve oral drug delivery [Swenson, 1994]. Their toxicology has been investigated [Larson, 1963; Finnegan, 1953] as has their absorption, distribution and excretion in humans and rodents [Swenson, 1994; Knaak, 1966]. NPEs are rapidly absorbed orally and topically and are actively excreted into the urine of healthy control subjects by kidney P-glycoprotein [Charuk, 1998]. We have determined that the nonylphenol (NP) series of ethoxylate (EO) containing surfactants reversed chloroquine resistance in both established laboratory lines of P. falciparum and patient isolates. Optimal chloroquine resistance reversal for P. falciparum in vitro was seen for NPEs with approximately 30 ethoxylate units, whereas maximal activity for reversing mammalian P-glycoprotein multidrug resistance occurs with NPEs of 9 ethoxylate units [Loe, 1993]. This finding indicates that NPEs can be directed to interact preferentially with the parasite simply by altering the number of ethoxylate units in the surfactant's structure.
Methods
P. falciparum cultures were grown in A+ blood obtained by venipuncture of volunteers. Cultures of the laboratory lines ItG and 3D7 [Dolan, 1993] and the patient isolates were maintained by the method of Trager and Jensen [Trager, 1976] using RPMI 1640 supplemented with 10% human serum and 50 μM hypoxanthine. Patient isolates were obtained from pre-treatment blood samples from patients enrolled in ongoing and ethically approved studies at the Tropical Disease Unit (TDU), University of Toronto [Kain, 1998b; Zhong, 1999]. In vitro drug susceptibility testing was performed using the WHO In Vitro Micro Test (Mark III) [1997]. The IC 50 values were determined using a non-linear regression analysis of the dose-response curve.
NPEs were obtained from Union Carbide and were extensively dried by lyophilizing before being made up as 1% (w/v) stock solutions in water.
Results
Initial experiments were undertaken to confirm that the parasite lines (e.g. 3D7) used for experimentation were chloroquine sensitive, or to examine the degree of chloroquine resistance present by determining the IC 50 for the ItG line, Isolate 1 and Isolate 2 (Table 1). We then proceeded to determine what effect increasing concentrations of surfactant alone had on each P. falciparum isolate in vitro. NPE preparations with a common hydrophobic tail group but with hydrophilic head groups of varying EO chain length were assayed for their direct activity against P. falciparum . On a per weight basis. NPEs with an average EO head length of >10 but <40 had the greatest anti- P. falciparum activity. When the results were corrected for the average molecular weights of the preparations it was observed that all NPEs with average EOs of >10 had low IC 50 values ( FIG. 2B ). The IC 50 values of these surfactants were significantly lower than the concentrations at which micelles form (>100 μM). The mechanism of action of NPEs is therefore unlikely to be simple disruption of membrane integrity. We then determined if NPEs were capable of reversing chloroquine resistance. Initial experiments indicated that 8 μM NP15 was able to reverse chloroquine resistance as effectively as 1 μM verapamil in the chloroquine resistant ItG line and two drug resistant patient isolates, one from India and one from Africa (Table 1). To determine if chloroquine sensitization was also dependent on the number of EO units in the head group of the surfactant, the reversal potential of the NPE series was determined using 5 μM concentrations of each surfactant. We determined that an NPE preparation with an average EO head length of 30 was the most effective chloroquine resistance reversal agent ( FIG. 2C ). To determine if both the tail and head groups were required for activity, the effect of the ethoxylate polymer polyethylene glycol (PEG, n˜75), which has no tail group, was assayed. PEG was completely ineffective as a chloroquine sensitizing agent (Table 1) indicating that both the head and tail portions of NPE are required for reversal activity.
To determine what concentration of NP30 that was necessary to reverse chloroquine resistance to clinically achievable levels (−100 nM) the degree of chloroquine resistance was determined for several concentrations of NP30 ( FIG. 3 ). The degree of chloroquine resistance is calculated as the IC 50 value observed in the presence of various concentrations of NP30 divided by the control (no NPE added) chloroquine IC 50 (274±56 nM). Values greater than 1 indicate that the particular NPE is rendering the P. falciparum parasites less sensitive to chloroquine, while values less that 1 indicate that the particular NPE is sensitizing the P. falciparum to chloroquine. Non-linear analysis of the data points indicates that a NP30 concentration approximately 1 μM (0.0002% on a weight/volume basis) results in a 50% decrease in the degree of chloroquine resistance of the parasites.
Discussion
The future use of NPEs as a malarial chloroquine resistance agents can be rationalized since unlike other reversal agents, they have weak, or no, pharmacological properties. Studies of NPE pharmacokinetics in mammals [Knaak, 1966] demonstrate that they are rapidly excreted. NPEs, particularly those with EO>10, are less toxic than shorter EO chain length surfactants (EO<10) [Finnegan, 1953]. Furthermore, NPEs represent a new class of P. falciparum sensitizing agents since they are uncharged molecules that do not have the requisite nitrogen atom in their structure [Bray, 1998]. Finally, NPEs are as stable and inexpensive as chloroquine itself, and therefore, their use in combination with chloroquine represents an inexpensive treatment or prevention option.
Treatment or prevention of malaria with a chloroquine/NPE combination provides at least three benefits:
1) NPEs enhance the gastrointestinal uptake of chloroquine [Swenson, 1994]. Varying the length of the head group of NPEs alters the hydrophobe/hydrophile balance of the surfactant, and while longer EO polymers may be less well absorbed they still facilitate intestinal absorption. 2) NPEs in the absence of a quinoline have antimalarial activity. Our results indicate that NPEs with longer head groups (those found in preparations with an average ethoxylate unit content of 30 units per nonylphenol group) inhibit the development of P. falciparum in red cells and therefore NPEs on their own function as anti-malarials. 3) While NPEs and chloroquine are antimalarial agents when used separately, in combination they have additive or synergistic effects that make them a potent anti-malarial combination. Further, since P. falciparum is sensitive to NPEs with head group lengths ≧15 EOs it is possible to treat or prevent P. falciparum infection with little, or no, effect on mammalian P-glycoprotein function. [Charuk, 1998].
The NPEs used in this study are a subset of the available head/tail group combinations that comprise commercially-available surfactants. Further separation of poly-disperse NPE preparations into compounds with uniform head group lengths may allow us to further define the optimal head length (EO number) that sensitizes chloroquine-resistant P. falciparum . An examination of other types of ethoxylate-containing surfactants will also allow us to determine which tail groups are most active. We believe that fatty acids, oils, bile acids, cholates, cholesterol esters, phospholipids, and chemically modified forms of these materials (such as Cremophor [Woodcock et al.], and Solutol H515 [Coon et al., Buckingham et al.]) as well as synthetic surfactants such as the Brij™ series, the Tween™ series, the OPE Series, the NPE series and any of the synthetic surfactants such as those listed in “Industrial Surfactants” [Ernest W. Flick, Noyes Publications, Park Ridge, N.J. USA (1988) ISBN 0-8155-1173-6] are promising malarial drug resistance reversal agents.
To design and obtain products that reverse malarial resistance to chloroquine we will systematically test a variety of commercially available surfactants. To assay for reversal activity, human red blood cells parasitized with P. falciparum will be placed in 96 well cell culture plates. The plate will contain a series of chloroquine concentrations (typically from 5,000 to 5 nM) and after 24 hrs the viability of the malaria will be determined using an assay that measures the levels of Plasmodium lactate dehydrogenase present [Mackler, 1993]. The data obtained from the enzyme assay will be analyzed using a non-linear curve fitting program (Sigma Plot—Jandel) and an IC 50 value will be derived. This process is repeated in the presence of putative surfactant sensitizing agents. The ability of a surfactant to sensitize Plasmodium to chloroquine or other quinolines is then expressed as the degree of resistance (IC 50 with agent/IC 50 without agent, where reversal of resistance gives values <1, increased resistance values >1, no effect values=1) [Oduola. 1998]. Using this assay we will evaluate surfactants with common tail groups, and then determine the effect of varying the head group (poly EO) on the compound's ability to sensitize P. falciparum to chloroquine and other quinolines. A wide variety of surfactants are commercially available, however they are usually polydisperse mixtures of single tail groups with a range of head group lengths that average to a stated value. These mixtures will be separated into their individual monodisperse constituents to allow us to determine the sensitization potential of individual surfactant species. The in vivo effect of surfactant sensitizing agents will be determined by infecting a cohort of Aotus monkeys with P. falciparum isolates with known quinoline resistance properties. One group of animals will be treated with a quinoline alone, a second will be treated with a surfactant preparation alone, and a third group will be treated with a quinoline in combination with a surfactant. The course of the infections will be followed and the efficacy of the quinoline/surfactant combination will be determined.
In view of the results described above, products containing natural, synthetic or hybrid surfactants in combination with quinolines, can be selected and designed in the manufacture of pharmaceutical compositions for the treatment or prevention of malaria. The pharmaceutical compositions can be administered to patients by methods known to those skilled in the art, such as oral capsule, aerosol administration, direct lavage and intravenous injection. Dosages to be administered depend on patient needs, on the desired effect and on the chosen route of administration.
The pharmaceutical compositions can be prepared by known methods for the preparation of pharmaceutically acceptable compositions which can be administered to patients, and such that an effective quantity of the products are combined in a mixture with a pharmaceutically acceptable vehicle. Suitable vehicles are described, for example in Remington's Pharmaceutical Sciences (Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa., USA 1990).
On this basis, the pharmaceutical compositions could include one or more active ingredients, in association with one or more pharmaceutically acceptable vehicles, such as carriers, excipients or diluents, and contained in buffered solutions with a suitable pH and isoosmotic with the physiological fluids. The methods of combining suitable products with the vehicles is well known to those skilled in the art.
When used for parenteral administration, the pharmaceutical compositions of the present invention may be formulated in a variety of ways. Aqueous solutions having the composition of the present invention may be encapsulated in polymeric beads, liposomes, nanoparticles or other injectable depot formulations known to those of skill in the art. (Examples thereof may be found, for example, in Remington's Pharmaceutical Sciences, 18th Edition, 1990.)
Compositions including a liquid pharmaceutically inert carrier such as water may also be considered for both parenteral and oral administration. Other pharmaceutically compatible liquids may also be used. The use of such liquids is well known to those of skill in the art. (Examples thereof may be found, for example, in Remington's Pharmaceutical Sciences, 18th Edition, 1990.)
The dose level and schedule of administration may vary depending on the particular product used, the method of administration, and such factors as the age and condition of the patient.
Oral formulations of products may optionally and conveniently be used in compositions containing a pharmaceutically inert carrier, including conventional solid carriers, which are conveniently presented in tablet or capsule form. Formulations for rectal or transdermal use may contain a liquid carrier that may be oily, aqueous, emulsified or contain certain solvents suitable to the mode of administration. Suitable formulations are known to those of skill in the art. (Examples thereof may be found, for example, in Remington's Pharmaceutical Sciences, 18th Edition. 1990.)
Having illustrated and described the principles of the invention in a preferred embodiment, it should be appreciated to those skilled in the art that the invention can be modified in arrangement and detail without departure from such principles. All modifications coming within the scope of the following claims are claimed.
All publications, patents and patent applications referred to in this application are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.
REFERENCES
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17. Oduola A M, Sowunmi A, Milhous W K, et al. In vitro and in vivo reversal of chloroquine resistance in Plasmodium falciparum with promethazine. Am J Trop Med Hyg 1998:58(5):625–9.
18. Su X, Kirkman L A, Fujioka H, Wellems T E. Complex polymorphisms in an approximately kDa protein are linked to chloroquine-resistant P. falciparum in Southeast Asia and Africa. Cell 1997;91(5):593–603.
19. Swenson E S, Milisen W B, Curatolo W. Intestinal permeability enhancement: structure-activity and structure-toxicity relationships for nonylphenoxypolyoxyethylene surfactant permeability enhancers. Pharm Res 1994:11(10):1501–4.
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23. Zhong K J Y, Kain K C. Evaluation of a colorimetric PCR-based assay to diagnose plasmodium falciparum malaria in travelers. J Clin Microbiol 1999;37(2):339–41. | According to the first aspect of the invention, a composition for reversing malarial resistance to quinolines is disclosed. The composition includes a surfactant, such as nonylphenolethoxylate (NPE) in an admixture with a pharmaceutically acceptable carrier, excipient, or diluent. According to a second aspect of the invention, a composition for the prevention or treatment of malaria is provided. The composition comprises a pharmaceutically effective amount of a quinoline in combination with a surfactant, such as NPE, for reversing malarial resistance to quinolines. According to a third aspect of the invention, a method of preventing or treating malaria in a person is provided. The method comprises administering to a patient in need thereof one or both of the compositions described above. | 0 |
The present invention claims foreign priority to Japanese patent application No. P.2005-098165, filed on Mar. 30, 2005, the contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control system for a adjustable damping force, which controls variably an adjustable damping force of a damper provided to a suspension apparatus of a vehicle in response to a moving condition of the vehicle.
2. Description of the Background Art
In Japanese Patent Unexamined Publication No. JP-A-60-113711, the adjustable damping force in which MRF (Magneto-Rheological Fluids), whose viscosity is changed by applying a magnetic field, is employed as a viscous fluid of the adjustable damping force for the suspension apparatus and also a coil used to apply the magnetic field to the magneto-rheological fluids in the fluid passage is provided to a piston, which is slidably fitted into a cylinder, is known. According to this adjustable damping force, an damping force of this damper can be controlled arbitrarily by changing a viscosity of the magneto-rheological fluids in the fluid passage by applying the magnetic field generated by supplying an electric current to the coil.
An damping force generated by a adjustable damping force set forth in Japanese Patent Unexamined Publication No. JP-A-60-113711 is changed by a current supplied to a coil of the damper. When the driving stability control to suppress a rolling and a pitching of the vehicle by changing an damping force of the damper is to be carried out, a target damping force that is proportional to a rate of change in a lateral acceleration and a rate of change in a longitudinal acceleration of the vehicle sensed by a sensor with respect to time is calculated. Then, a current value to be supplied to the coil of the damper is searched from a map using this target damping force and a damper speed as parameters.
Meanwhile, it is inevitable that the noise is superposed on outputs of the sensors that sense the lateral acceleration and the longitudinal acceleration of the vehicle to calculate the target damping force of the damper. When the output of the sensor is large, an occupied rate of noise is small and the influence of noise is negligible. But an output itself of the sensor is small when the vehicle goes straight on at a constant speed, a occupied rate of noise in the sensor output is increased. In this manner, when a sensing precision of the lateral acceleration and the longitudinal acceleration sensed by the sensors is lowered by the noise, it is possible that a precision of the target damping force of the damper is lowered and then the driving stability control cannot be exactly executed.
SUMMARY OF THE INVENTION
The present invention has been made in light of the above circumstances, and it is an object of the present invention to suppress an influence of noises on outputs of sensors, which sense a moving condition of a vehicle, to the lowest minimum to control an damping force of a damper in a suspension system.
In order to achieve the above object, according to a first aspect of the present invention, there is provided a control system for a adjustable damping force, comprising:
a damper provided on a suspension apparatus of a vehicle;
a damper speed sensor detecting speed of the damper;
a moving condition sensor detecting moving condition of the vehicle; and
a control unit determining target damping force in accordance with the moving condition, determining control parameter based the damper speed and the target damping force by using a map, and outputting the control parameter so as to adjust damping force of the damper,
wherein the map is set so as to satisfy following conditions to thereby perform stable control of the damping force when the damper speed is not more than a predetermined value:
when the damper speed is constant value and is not more than the predetermined value, the control parameter is increased with gradient A as the target damping force is increased;
when the damper speed is constant value and is more than the predetermined value, the control parameter is increased with gradient B as the target damping force is increased, wherein the gradient A is larger than the gradient B; and
when the target damping force is constant, the control parameter is decreased as the damper speed is increased.
According to a second aspect of the present invention, as set forth in the first aspect of the present invention, it is preferable that the map is set in such a manner that when the damper speed is not more than the predetermined value, the control parameter depends on the target damping force and the control parameter does not depend on the damper speed.
According to a third aspect of the present invention, as set forth in the first aspect of the present invention, it is preferable that the gradient A and B are positive values.
According to a fourth aspect of the present invention, as set forth in the first aspect of the present invention, it is preferable that the gradient A and B are variable relative to the damper speed and/or the target damping force.
According to a fifth aspect of the present invention, there is provided a control method for controlling damping force of a damper provided on a suspension apparatus of a vehicle, comprising the steps of:
determining target damping force based on a moving condition of a vehicle;
detecting damper speed;
determining control parameter of the damper based on the damper speed and the target damping force by using a map so as to adjust the damping force of the damper; and
outputting the damping force to the damper,
wherein the map is set so as to satisfy following conditions to thereby perform stable control of the damping force when the damper speed is not more than a predetermined value:
when the damper speed is constant value and is not more than the predetermined value, the control parameter is increased with gradient A as the target damping force is increased;
when the damper speed is constant value and is more than the predetermined value, the control parameter is increased with gradient B as the target damping force is increased, wherein the gradient A is larger than the gradient B; and
when the target damping force is constant, the control parameter is decreased as the damper speed is increased.
According to a sixth aspect of the present invention, as set forth in the fifth aspect of the present invention, it is preferable that the map is set in such a manner that when the damper speed is not more than the predetermined value, the control parameter depends on the target damping force and the control parameter does not depend on the damper speed.
According to a seventh aspect of the present invention, as set forth in the fifth aspect of the present invention, it is preferable that the gradient A and B are positive values.
According to an eighth aspect of the present invention, as set forth in the fifth aspect of the present invention, it is preferable that the gradient A and B are variable relative to the damper speed and/or the target damping force.
In this case, the lateral acceleration sensor Sc and the vehicular speed sensor Sd in the embodiment correspond to the sensors that sense the moving condition of the vehicle of the present invention.
According to a configuration of the present invention, in searching the control parameter used to adjust the damping force of the damper provided to the suspension system of the vehicle from the map by using the damper speed and the target damping force decided based on respective outputs of the sensors that sense the moving condition of the vehicle, the map sets the values, which are relatively higher than the actual damping force characteristics, as map data in the area where the damper speed is less than a predetermined value, i.e., the area where the noise has the great influence on the sensor outputs. Therefore, the control parameter obtained by the map search can be set relatively low, it can be prevented that the control parameter of the damping force of the damper is varied largely or varied in a short period by the influence of noise, and the driving stability control of the vehicle can be executed exactly and the noise cause by switching the damping force of the damper can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a suspension system of a vehicle;
FIG. 2 is an enlarged sectional view of a adjustable damping force;
FIG. 3 is a flowchart of damping force control of the damper;
FIG. 4 is a map used to search target current based on damper speed and target damping force; and
FIG. 5 is a graph showing output containing a noise of a lateral acceleration sensor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An implementation mode of the present invention will be explained based on an embodiment of the present invention shown in the accompanying drawings hereinafter.
FIG. 1 to FIG. 5 show an embodiment of the present invention. FIG. 1 is a front view of a suspension system of a vehicle, FIG. 2 is an enlarged sectional view of a adjustable damping force, FIG. 3 is a flowchart of an damping force control of the damper, FIG. 4 is a map used to search a target current based on a damper speed and a target damping force, and FIG. 5 is a graph showing an output containing a noise of a lateral acceleration sensor.
As shown in FIG. 1 , a suspension system S that suspends a wheel W of a four-wheel vehicle includes a suspension arm 13 for supporting a knuckle 12 vertically movably onto a vehicle body 11 , a adjustable damping force 14 for connecting the suspension arm 13 and the vehicle body 11 , and a coil spring 15 for connecting the suspension arm 13 and the vehicle body 11 . A signal from a sprung acceleration sensor Sa for sensing sprung acceleration, a signal from a damper displacement sensor Sb for sensing displacement (stroke) of the damper 14 , a signal from a lateral acceleration sensor Sc for sensing the lateral acceleration of the vehicle, and a signal from a vehicle vehicular speed sensor Sd for sensing vehicle speed are input into an electronic control unit U that controls damping force of the damper 14 .
As shown in FIG. 2 , the damper 14 has a cylinder 21 whose lower end is connected to the suspension arm 13 , a piston 22 fitted slidably into the cylinder 21 , a piston rod 23 extended upward from the piston 22 to pass through an upper wall of the cylinder 21 and connect its upper end to the vehicle body, and a free piston 24 fitted slidably into a bottom portion of the cylinder. An upper-side first fluid chamber 25 and a lower-side second fluid chamber 26 are partitioned by the piston 22 in the cylinder 21 , and also a gas chamber 27 into which a compressed gas is sealed is partitioned under the free piston 24 .
A plurality of fluid passages 22 a . . . are formed in the piston 22 to cause an upper surface and a lower surface to communicate with each other, and the first and second fluid chambers 25 , 26 are communicated mutually via these the fluid passages 22 a . . . . The magneto-rheological fluids sealed in the first and second fluid chambers 25 , 26 and the fluid passages 22 a . . . is constituted by dispersing fine grains of the magnetic material such as iron powders into the viscous fluid such as oil. The magneto-rheological fluids has such a property that, when a magnetic field is applied, the fine grains of the magnetic material are aligned along lines of magnetic force and thus the viscous fluid is hard to flow to yield an increase in an apparent viscosity. A coil 28 is provided to an inside of the piston, and a current supply to the coil 28 is controlled by the electronic control unit U. When current is supplied to the coil 28 , magnetic fluxes are generated as indicated with an arrow shown in FIG. 2 and then the viscosity of the magneto-rheological fluids is changed by the magnetic fluxes passing through the fluid passages 22 a . . . .
When the damper 14 is contracted and then the piston 22 moves downward in the cylinder 21 , a volume of the first fluid chamber 25 is increased but a volume of the second fluid chamber 26 is decreased. Therefore, the magneto-rheological fluids in the second fluid chamber 26 flows into the first fluid chamber 25 to pass through the fluid passages 22 a . . . in the piston 22 . On the contrary, when the damper 14 is expanded and then the piston 22 moves upward in the cylinder 21 , a volume of the second fluid chamber 26 is increased but a volume of the first fluid chamber 25 is decreased. Therefore, the magneto-rheological fluids in the first fluid chamber 25 flows into the second fluid chamber 26 to pass through the fluid passages 22 a . . . in the piston 22 . At that time, the damper 14 generates an damping force by a viscous resistance of the magneto-rheological fluids passing through the fluid passages 22 a . . . .
At this time, when a magnetic field is generated by supplying a current to the coil 28 , an apparent viscosity of the magneto-rheological fluids that pass through the fluid passages 22 a . . . in the piston 22 is increased, and thus the fluids are hard to pass through the fluid passage 22 a . . . . Therefore, an damping force of the damper 14 is increased. An amount of increase in this damping force can be controlled freely by amplitude of a current that is supplied to the coil 28 .
In this case, when a volume of the second fluid chamber 26 is decreased because an impulsive compressive load is applied to the damper 14 , the free piston 24 is moved downward while causing the gas chamber 27 to contract, so that an impact can be absorbed. Conversely, when a volume of the second fluid chamber 26 is increased because an impulsive tensile load is applied to the damper 14 , the free piston 24 is moved upward while causing the gas chamber 27 to expand, so that an impact can be absorbed. In addition, when a volume of the piston rod 23 fitted in the cylinder 21 is increased because the piston 22 is moved downward, the free piston 24 is moved downward to absorb an amount of increase in the volume.
Then, the electronic control unit U controls individually an damping force of four dampers 14 . . . of respective wheels W . . . in total based on a sprung acceleration sensed by the sprung acceleration sensor Sa, a damper displacement sensed by the damper displacement sensor Sb, and a lateral acceleration sensed by a lateral acceleration sensor Sc (or a speed sensed by a vehicular speed sensor Sd) Accordingly, the electronic control unit U executes selectively the ride control such as the skyhook control, which enhances a riding feeling by suppressing the motion of the vehicle when such vehicle gets over unevenness on a road surface, or the like and the driving stability control, which suppresses a rolling caused at a time of the vehicle turning and a pitching caused at a time of rapid acceleration or rapid deceleration, in response to the driving condition of the vehicle.
In FIG. 3 , a flowchart explaining an action of the driving stability control to suppress the rolling by enhancing damping force of the dampers 14 . . . when the vehicle turns is shown.
First, in step S 1 , a lateral acceleration derivative dYG/dt is calculated by differentiating a lateral acceleration YG sensed by the lateral acceleration sensor Sc with respect to time. Then, target damping force Ft to be generated in the damper 14 is calculated by multiplying the lateral acceleration derivative dYG/dt by gain Gain. Then, in step S 2 , a damper speed Vp is calculated by differentiating damper displacement sensed by the damper displacement sensor Sb with respect to time. Then, in step S 3 , target current is searched by applying the target damping force Ft and the damper speed Vp to a map in FIG. 4 . Then, in step S 4 , the target current is supplied to the coil of the damper 14 to generate the target damping force Ft. Thus, the driving stability performance can be improved by suppressing the rolling of the vehicle.
FIG. 4 is a map used to search the target current based on the target damping force Ft and the damper speed VP. When the damper speed Vp is constant, the target current is increased as the target damping force Ft is increased. In contrast, when the target damping force Ft is constant, the target current is decreased as the damper speed Vp is increased.
FIG. 5 shows a waveform of the lateral acceleration YG that the lateral acceleration sensor Sc outputs when the vehicle makes a lane change from one lane of two adjacent lanes to the other lane and then makes a lane change from the other lane to one lane once again. Here, two sinusoidal curve-like waves each having one period can be observed. Theses waves correspond to one lane change respectively, and an area in which the lateral acceleration YG is almost 0 corresponds to a situation that the vehicle is going straight on. A high-frequency noise is superposed on the waveform of the lateral acceleration YG that the lateral acceleration sensor Sc outputs. Theoretically a value of the lateral acceleration YG could have a constant value 0 when the vehicle runs straight, and the lateral acceleration derivative dYG/dt obtained by differentiating the lateral acceleration YG with respect to time could also have a constant value 0. However, actually the lateral acceleration derivative dYG/dt does not become 0 due to the influence of noise, and the target damping force Ft obtained by multiplying the lateral acceleration derivative dYG/dt by the gain Gain also does not become 0. Thus, predetermined value corresponding to the noise is output.
In a case where the target current is searched based on the target damping force Ft and the damper speed Vp by using a map in FIG. 4 , only when the target damping force Ft is slightly changed if the conventional characteristics indicated by a broken line, value of the target current is largely changed in an area where the damper speed Vp is small. For example, in case the damper speed Vp is 0 m/s, the target current is changed from 1 A to 6 A when the target damping force Ft is changed simply from 100 N to 500 N. In contrast, in case the damper speed Vp is 0.04 m/s, the target current is changed simply from 1 A to 2 A even when the target damping force Ft is changed from 130 N to 1000 N.
Therefore, in the area where the damper speed Vp is small, the target current is changed largely only when the target damping force Ft is changed slightly because of the influence of noise. It is possible that an damping force of the damper 14 cannot be exactly controlled. In addition, when the target damping force Ft is changed in a short period because of the influence of noise, an damping force generated by the damper 14 is also changed in a short period. Therefore, there is the problem that the noise generated in switching the damping force of the damper 14 is increased.
Therefore, in the present embodiment, the target damping force Ft corresponding to the target current is set to predetermined value that is higher than the proper value indicated by a broken line (see a solid line) in the area where the damper speed Vp is lower than a minimum speed (in the embodiment, 0.014 m/s) in FIG. 4 . According to this setting, it can be prevented that the target current is largely changed correspondingly even when the target damping force Ft is changed due to the influence of noise, and it can be prevented that the driving stability control cannot be exactly executed because the damping force of the damper 14 is unnecessarily varied during the straight running of the vehicle, and also generation of the noise to switch the damping force of the damper 14 can be suppressed to the lowest minimum.
In this case, the ride control applied when the above driving stability control is not executed is the well-known skyhook control. The dampers 14 . . . are controlled to increase the damping force when the sprung speed (the upward direction is positive) and the damper speed (the expanding direction is positive) are in the same direction, while the dampers 14 . . . are controlled to decrease the damping force when the sprung speed and the damper speed are in the opposite direction. The sprung speed can be obtained by integrating the sprung acceleration sensed by the sprung acceleration sensor Sa, and the damper speed can be obtained by differentiating a damper displacement sensed by the damper displacement sensor Sb.
With the above, the embodiment of the present invention is explained. But various changes of design can be applied to the present invention within a scope that does not depart from a gist of the invention.
For example, in the embodiment, the minimum speed of the damper speed Vp used to change the characteristics of the map, which is used to search the target current based on the damper speed Vp and the target damping force Ft, is set to 0.014 m/s. But the value of the minimum speed may be varied appropriately.
Also, in the embodiment, the driving stability control that suppresses the rolling of the vehicle based on the lateral acceleration derivative dYG/dt obtained by differentiating the lateral acceleration YG that is sensed by the lateral acceleration sensor Sc with respect to time is explained. But the present invention can also be applied to the driving stability control that suppresses the pitching of the vehicle based on the longitudinal acceleration derivative dXG/dt that is obtained by second differentiating the speed sensed by the vehicular speed sensor Sd with respect to time.
For example, in the embodiment, an damping force of the damper 14 . . . is adjustably controlled by using the magneto-rheological fluids. But an approach of variably controlling an damping force can be chosen freely.
While there has been described in connection with the preferred embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modification may be made therein without departing from the present invention, and it is aimed, therefore, to cover in the appended claim all such changes and modifications as fall within the true spirit and scope of the present invention. | Upon searching control parameter used to adjust damping force of a damper from a map in accordance with damper speed and target damping force decided based on moving condition of the vehicle, the map sets the control parameter, which are relatively higher than the actual damping force characteristics, as map data in the area where the damper speed is less than a predetermined value, the area where the noise has the great influence on the sensor outputs. Therefore, it can be prevented that the control parameter of the damping force is varied largely or varied in a short period by the influence of noise, and the driving stability control of the vehicle can be executed exactly and the noise caused by switching the damping force of the damper can be reduced. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Gimballed-mirror target sighting devices.
2. Description of the Prior Art
Prior art target sighting devices of the type employing a C-shaped-gimbal-supported mirror that directs optical information from a line of target sight to a reflected optical path aimed toward a fixed optical pickup assembly, insofar as applicant is aware, have employed either a cantilevered rotary shaft support at the closed end only of the C-shaped gimbal, or an arrangement including a shaft at such closed end together with a yoke appended to the otherwise open end of the gimbal and a shaft affiliated with the fixed optics assembly. Either of these arrangements can be made to perform well, but each tends to lack either symmetry or rigidity that must be accounted for in the design of the device in order to avoid undesirable aim-influencing mirror movement under influence of a vibratory environment, such as may exist on an aircraft.
SUMMARY OF THE INVENTION
The present invention, in providing ring-bearing rotary support for the open optical-output-path end of the C-shaped elevation gimbal, introduces a rigidity to such gimbal and mirror thereon in a highly-efficient structural manner, while preserving a symmetry about the central axis of the gimbal that discourages inertial creation of torsional moments by rectilinear vibratory movement of the device. At the same time, transmission of rotary vibration of the device about the elevation axis through friction of the relatively large ring bearing is significantly limited by the annular flex pivot assembly that is so constructed as to maintain rigidity with respect to rectilinear or straightline motion.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a three-dimensional partially-exploded view of pertinent portions of a gimballed-mirror target sighting device embodying the invention;
FIG. 2 is a front elevation outline view showing details of an illustrative construction of the ring bearing and annular flex pivot assembly of the present invention in affiliation with a mounting member and in support of the open-ended elevation gimbal;
FIG. 3 is a fragmented view, partly in outline and partly in section, of a portion of the flex pivot assembly showing details with respect to its construction;
FIG. 4 is a fragmental view of a schematic representation of a small-diameter shaft support for the rear or closed end of the elevation gimbal; and,
FIGS. 5A and 5B are fragmental views of schematic representations of typical support and actuating means for aiming the mirror in the target device embodying the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a target sighting device embodying the improvement of the present invention comprises a vertically-disposed C-shaped elevation gimbal EG having a vertical member 10 joining top and bottom horizontal members 11 and 12, respectively. Gimbal EG supports a vertically extending flat aimable mirror AM mounted on vertical stepped aligned stub shafts 14 (FIG. 5) at top and bottom of the mirror. The axis of rotation of the stub shafts 14 coincides with a vertically extending azimuth axis AA that lies in the same vertical plane as the reflective surface of the mirror AM, such as its front face. Although not directly involved with the present invention, the target sighting device in which the invention is embodied also includes a stabilized body SB having vertically separated horizontal members 16 and 18 joined at one end by a vertical end piece 19 carrying horizontal and vertical stabilization gyros 20 and joined at the other and forward end by ring member 21. The stabilized body SB is also carried on the elevation gimbal EG by the stub shafts 14.
During the usual operation of a target sighting device of this type, the stabilized body SB and elevation gimbal EG will be caused to assume positions substantially as shown in FIG. 1 in which they extend at right angles with respect to one another, with the forward ring end of the stabilized body SB pointed along a line of sight LOS along which it is desired to search for a target (not shown), and with the mirror AM positioned to reflect images arriving from along such line of sight at right angles along a reflected optical path ROP to a fixed optical pickup assembly FOPA. At this time, i.e. during target search, the gyros 20 on stabilized body SB will be inactive to facilitate its angular movement in unison with gimbal EG and mirror AM which are maintained effectively locked together by a control system (not shown), torque motor means 22 for turning the stabilized body SB about the azimuth axis AA relative to the elevation gimbal EG, and a torque motor means 24 (FIG. 4) for turning the elevation gimbal EG about the elevation axis EA relative to a fixed mount FM via a small diameter shaft 25 and bearing means (not shown) affiliated with rear vertical member 10 of elevation gimbal EG. The target sighting device and its parts as thus "locked" together move in unison with the vehicle, airplane for example, on which the device is mounted until a target is picked up along the line of sight LOS. At this time, the gyros 20 and control of the torque motor means 22 and 24 will be effectuated to enable the stabilized body SB to hold an inertial position pointed toward the target while the vehicle, aircraft for example, changes its attitude to a limited extent relative to the line of sight LOS maintained by the stabilized body SB. At this time, any change in attitude of the vehicle relative to the elevation axis EA will not affect aiming of the mirror AM, since it and the elevation gimbal EG will be held against turning about such axis by the stabilized body SB through the medium of the shaft means 14 (FIG. 5). At the same time, a change in angular position of the vehicle relative to the azimuth axis AA results in turning of the elevation gimbal about such axis in correspondence with such vehicle turning, through the medium of the fixed mount FM support for such gimbal. Such elevation gimbal turning occurs relative to the stabilized body SB about the azimuth axis AA and automatically effectuates angular movement of the mirror AM about the same axis to one half the extent that such gimbal turned. This is realized by operation of a half-angle drive means 26 at the bottom of the gimbal EG (FIG. 5) that responds to relative turning movement between the elevation gimbal EG and the stabilized body SB about the azimuth axis AA and is operatively connected to the mirror AM through a system of various sized pulleys and belts, for example, (not shown). Thus, during such limited vehicle maneuvering the mirror AM is automatically adjusted to be maintained aimed toward the target to maintain a target image or optical target information directed toward the fixed optical pickup assembly FOPA.
Referring to FIG. 1, it will be apparent that slight vibratory movement of mirror AM in rectilinear or straightline fashion, perpendicularly of the line of sight LOS or of the azimuth axis AA or of the elevation axis EA, for example, does not tend to smear an image reaching the optical pickup assembly FOPA, it will not tend to cause the mirror to lose sight of the target, since its aim does not tend to be disturbed. On the other hand, angular vibratory disturbance of the mirror about these axes, even slightly, tends to cause jittering degradation of image information.
Accordingly, since symmetry of the elevation gimbal EG as well as its rigidity can affect the nature and extent of undesirable motion of the mirror AM in the presence of vehicle vibration that can be transmitted to the target sighting device via its mount FM, the present invention supports the rear of the elevation gimbal EG via the relatively small diameter shaft 25 (FIG. 4) which can be made to have very little rotary friction by use of small-diameter ball bearing assemblies 30, and supports the front of such gimbal via a rigidizing ring 32 joining the projecting ends of gimbal members 11 and 12, an annular flex pivot assembly 33, a ball-bearing ring bearing 34, and a bracket member 35 for attachment to the fixed mount FM.
Support of the forward end of the elevation gimbal EG by the ring bearing 34 provides for support of such gimbal both fore and aft to afford a high degree of rigidity that tends to be lacking when cantilevered rear support only is employed. Such ring bearing and associated components, in being located at one side of the azimuth axis AA opposite to that of the rear member 10 of gimbal EG, tends to provide inertial balance to the assembly with respect to such axis, while its symmetry with respect to the elevation axis affords a similar balance with respect to the latter axis also. The ring bearing 34 et al is located between the mirror AM and the optical pickup FOPA and located concentrically around the elevation axis and reflected optical path to provide a compact arrangement. The annular flex pivot assembly can be press fit into the inner circumferential edge of the mounting ring 32, the ring bearing 34 can be press fit into the center of such assembly 33, and a boss 36 on bracket member 35 can be press fit into the center of the ring bearing.
The ring bearing 34, while intended to provide low-friction rotary support for the front end of the elevation gimbal EG does include a number of ball bearings 37 interposed radially between the usual annular raceways 38 and 39 which must be proportioned to preload such ball bearings 37 to assure adequate rigidity for the requirements of the device. Since the preloaded bearings 37 are located some considerable radial distance from the axis EA, they tend to create a circumferential friction force relative to any turning effort that may be imposed on the inner bearing raceway 38 by angular vibration introduced via the mount FM and bracket 35. As will be described, the annular flex pivot assembly prevents any such circumferential vibration that may become transmitted through the preloaded ring bearing assembly 34 from undue influence on the elevation gimbal EG and mirror AM, while preserving linear rigidity.
Referring particularly to FIG. 2, the annular flex pivot assembly 33 comprises a plurality of tensioned metal tape elements 40 extending radially between inner and outer ring members 41 and 42 at circumferentially spaced apart intervals. Opposite ends of the tape elements are bent and held in clamped contact with the inner surface of the ring members 41 and 42 by rounded-edge clamp members 43 retained by machine screws 44. By use of a slotted-end tool 45 (FIG. 3), the free end of each tape element 40 can be gripped and drawn tight by a twisting motion in cooperation with a reaction with a respective clamp member 43 in a partially relaxed state of the respective machine screw 44, such gripping of the free end of the tape member being in the nature of twist-opening of a coffee can by use of a key supplied with the can to remove the annular tab near the upper end of the can. After suitable tensioning, the screw 44 is tightened to secure the clamp 43 for gripping the metal tape element end. A slot in the bent end of the tape element 40, through which the screw can extend, enables such end to be pulled under the clamp member 43 to accommodate such tightening. Each tape element 40 is oriented such that its wider faces extend axially with respect to the assembly to provide rigidity in such direction. As is desired, low amplitude circumferential vibration at the inner ring 41 meets negligible resistance from the tape members 40 which flex at their anchor points at the clamp members 43. Linearly, the array of tensioned tape members 40 are rigid.
In one test configuration, an annular flex pivot assembly constructed to include sixteen steel tape elements 40 each two thousandths of an inch thick and one quarter of an inch long each tensioned at four pounds succeeded in maintaining a stabilization error of the device of less than 10 to 25 microradian deviation in mirror pointing accuracy during subjection of the device to vibrations typical of those currently experienced on fighter aircraft. | An improved target sighting device of the type particularly suited for use on moving vehicles, such as military aircraft, and in which a vertically-disposed C-shaped elevation gimbal is supported for rotary movement about an elevation axis at the center of the gimbal to enable a vertically extending mirror on the gimbal to be aimed toward a target along a line of sight at one side of the gimbal, for reflection of target information along such axis and through the open end of the gimbal to a fixed optical pickup assembly. Improvement resides in the support of the open end of the gimbal by a ring bearing encircled by an annular flex pivot assembly that limits the extent of rotary aim-influencing vibration that can be transmitted from the exterior of the device to the gimbal and mirror circumferentially through the ring bearing by friction. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a sensor and more specifically to a sensor for measuring the length of filament, thread or the like drawn from a storage device.
2. Description of the Prior Art
A previously proposed sensor arrangement for a weaving loom is shown in FIG. 1 of the drawings. In this arrangement weft yarn y is wound onto a drum 2 by a winding arrangement 3 and retained thereon by a retaining device 4. During picking the retaining device 4 is actuated to retract a blocking member 5 from a recess 6 formed in the drum 2 and permit a number of loops of weft yarn y to be drawn axially off the drum.
The amount of yarn y stored on the drum is controlled by a first sensor 7 which directs a beam of light against the drum and which, in response to the amount of light reflected therefrom, induces suitable energization of the winding arrangement 3 in a manner to maintain a predetermined length of yarn on the drum. The amount of yarn permitted to be released from the drum 2 during each picking operation is controlled by a second sensor 8, which, like the first, directs a beam of light against the drum 2 in a manner that the passage of weft yarn y across the point where the beam impinges on the drum 2, induces a change in the amount of light reflected and thus the output of the light receiving section of the second sensor 8. A control unit 9 is responsive to the output of the second sensor 8 and controls the operation of the retaining device 4.
However, the latter mentioned sensor arrangement has suffered from the drawback that when applied to high speed weaving machines wherein weft yarns having a diameter ranging from tens of microns to hundreds of microns, are exposed to the beam of light for only a few micro seconds, accurate detection of each loop being drawn off the drum becomes extremely difficult. Non-detection of one of more loops of weft yarn y being drawn off the storage drum 4 of course invites an inevitable malfuction of the loom.
A full description of the above mentioned arrangement may be found in Japanese Patent Application first publication No. Sho 57-29640 or corresponding U.S. Pat. No. 4,407,336 issued in the name of Steiner on Oct. 4, 1983.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a sensor arrangement via which the amount of thread such as weft yarn extracted from a storage device may be accurately detected and which advantageously but not necessarily, finds utility in high speed weaving looms.
In brief, the present invention features a sensor wherein the spiralling motion induced in a thread as it is drawn axially off a temporary storage drum is utilized to cause the thread to move around a relatively small guide aperture on or in close proximity of the periphery thereof, once per loop of thread drawn off the drum, whereby a beam of light produced at or near the periphery of the aperture is, without fail, cut or reflected by the relatively slow moving thread.
More specifically, a first aspect of the present invention comes in the form of a sensor arrangement for sensing the amount of thread being supplied from a source thereof to an apparatus which uses same, comprising, a guide in which an aperture is formed and through which the thread passes from the source to the apparatus, means for inducing a spiralling motion in the thread prior entering the aperture in a manner that the thread moves around the aperture, and a sensor responsive to the movement of the thread in the aperture and which produces a signal indicative thereof.
A further aspect of the present invention comes in the form of a device which includes a source of thread, a storage member onto which thread from the source is wound for temporary storage prior use, an apparatus which uses the thread, a guide interposed between storage member and the apparatus, the guide having an aperture through which the thread passes from the member to the apparatus, and a sensor associated with the guide for sensing the amount of thread which passes through the aperture.
Yet another aspect of the invention comes in a weaving loom which includes therein a source of weft yarn, a temporary storage drum having an axis and onto which a length of the weft yarn may be wound to form a plurality of loops, a device for picking at least a portion of the length of weft yarn stored on the drum into a shed of warp yarn, a guide disposed between the picking device and the drum for guiding the weft yarn as it is drawn axially off the drum, the guide having an aperture the center of which is essentially coaxial with the drum, and a sensor mounted on the guide, the sensor being responsive to the movement of the weft yarn as it moves around the aperture under the influence of the spiralling motion induced therein due to the loops of weft yarn being drawn off the drum.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the arrangement of the present invention will become more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 shows the prior art arrangement discussed briefly in the opening paragraphs of the present invention;
FIG. 2 is an elevational view of a weaving loom including therein a first embodiment of the present invention;
FIG. 3 is a front elevation of a proximity switch arrangement froming part of the loom shown in FIG. 2;
FIG. 4 is a circuit shown in block diagram form suitable for use with the first embodiment of the present invention;
FIG. 5 is a timning chart showing the signals inputted to and outputted by the various elements shown in the circuit arrangement of FIG. 4; and
FIG. 6 is an elevation similar to that of FIG. 2 but which shows a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 2 a first embodiment of the present invention is shown. In this arrangment a mounting bracket 10 forming part of a weaving loom frame 12 rotatably supports a hollow shaft 14 through which a weft yarn y is fed. One end of the shaft 14 is provided with a pulley 16 which is operatively connected with an electric motor 18 by a V-belt (or the like) 20. The other end of the shaft 14 is provided with an arm 22. This arm, as shown, is provided with an aperture 24 near the free end thereof through which the weft yarn y is threaded. It will be noted that the shaft 14 is provided with suitable apertures or through holes (not shown for simplicity of illustration) through which the weft yarn may be fed to the arm.
A temporary storage drum 26 is rotatably mounted on the end of the shaft 14 through suitable roller bearings or the like. This drum is held stationary by weights or magnets (not shown) and further constructed of three of more segments which permit the diameter thereof to be varied. The reason for this will become apparent hereinlater. The drum is also formed with a tapered or frusto-conical section 28 which is arranged with respect to the arm so that upon energization of the motor 18 the arm 22 rotates about the drum 26 to wind loops of weft yarn thereonto. The frusto-conical section 28 serves to induce the newly wound on weft yarn loops to slide along the drum toward a uniform diameter section 30 thereof during operation of the loom.
Located adjacent the periphery of the drum is a retaining device generally denoted by the numeral 32. As shown, this device includes an actuator 34 and a plunger 36 which is normally projects into a recess 38 formed in the uniform diameter section 30 of the drum, and thus prevents any of the loops of yarn y wound of the drum 26 from being removed therefrom. The plunger 36 is arranged to project through an aperture 40 formed in a cover 42 on which a weft yarn sensor 44 is mounted. Upon energization of the actuator 34 the plunger 36 is retracted into the aperture formed in the cover 42.
In this embodiment the weft yarn sensor 44 is arranged to emit a beam of light which impinges on the uniform diameter section 30 of drum and which senses the presence of a predetermined amount of the weft yarn y stored thereon via either one of (a) using a drum having a highly reflective surface and detecting the reduction in reflection caused by the loops of weft yarn, or (b) using a non-reflective drum and sensing the increase in reflection induced by the weft yarns intercepting and reflecting the beam. The selection of the above mentioned alternatives, of course, is made in view of the colour and texture of the yarn being used in the loom.
A picking device generally denoted by the numeral 46 is mounted on the frame 12 in a manner essentially coaxial with the shaft 14 and drum 26. Interposed between the picking device 46 and the drum 26 is a guide 48. This guide is formed with an aperture 50 the center of which is essentially coaxial with the drum.
A proximity switch arrangement 52 is mounted on the loom frame. This switch (shown in greater detail in FIG. 3) comprises a stationary member 54 which includes a "Hall effect" switch or the like, and a movable element 56 fixed on a main shaft 58 of the loom. The movable member 56 is arranged to pass by the stationary member 54 either at, or in a timed relation with, the picking operation of the loom. The output of this switch is fed to a control circuit 60 which also receives the output of the sensor 44.
In this embodiment a sensor 62 is mounted on the picking device side of the guide 48. This sensor includes a light emitting section and light receiving section. The construction of this sensor 62 is such that the beam produced by the light emitting portion is reflected by the weft yarn each time it moves around the aperture and passes thereover under the influence of the spiralling motion produced therein as it is drawn off the drum 26 and travels toward the guide 48. The diameter of the aperture 50 is of course notably smaller than the diameter of the drum 26 whereby the speed with which the weft yarn y interrupts the light beam produced by the light emitting portion of the sensor 62 is relatively low compared with that over the surface of the drum. Accordingly, the time for which the light beam is reflected by the yarn and received by the light receiving section of the sensor, is vastly increased over that which occurs in the prior art arrangement discussed hereinbefore and accordingly enables accurate detection of each loop of yarn drawn off the drum. The output of the sensor 62 is applied to the control circuit 60.
By varying the diameter of the drum 26, the length of weft yarn y contained in a given number of loops may be readily calculated and thus adjustment made for a given width of cloth being woven in the loom.
The operation of the first embodiment is such that during each picking operation the control circuit 60 in response to the output of the proximity switch 52 energizes the actuator 34 to withdraw the plunger 36 and permit a number of weft yarn loops to be drawn off. Upon the sensor 62 indicating a preselected number of loops having been drawn off and fed to the picking device 46 through the guide 48, the control circuit 60 de-energizes the actuator and terminates the picking operation. Simultanously, upon the sensor 44 detecting the number of loops wound on the drum 26 ready for picking having fallen blow a preselected number, the control circuit 60 energizes the motor 18 to wind on some more yarn. As will be appreciated, the loops wound on the frusto-conical portion 28 will slide therealong and onto the uniform diameter portion 30 until the light beam produced by the light emitting section of the sensor 44 intercepts same.
FIG. 4 shows an example of circuitry which may be used in the control circuit 60. As illustrated this circuit includes a NOT circuit 64 which receives the output of the proximity switch 52 and which is connected to a S (set) terminal of a flip flop circuit 66 including two NAND circuits 68, 70 and a counter 72 which also receives the output of the proximity switch 52 at a SC (start count) terminal thereof. The output of the sensor 62 is fed to an amplifier 74 which outputs a signal to the input terminal of the counter 72. The output of the counter 72 is fed to a NOT circuit 76 connected to the R (reset) terminal of the flip flop 66. A "Q" terminal of the flip flop 66 is connected via an amplifier 78 to the actuator 34 of the retaining device 32. A "Q'" terminal of the flip flop 66 is connected through a monostable multivibrator or "ONE SHOT" circuit 80 to a delay circuit 82 connected to the RC (reset count) terminal of the counter 72. With this arrangement, upon a signal being applied to the SC terminal of the counter 72, the counter begins counting. Upon a predetermined number being reached the counter outputs a signal which resets the flip flop 66 and the counter 72 (with a give delay).
FIG. 5 shows in time chart form the operation of the above described circuit. As shown, upon the proximity switch outputting a pulse (see chart 5(a)) indicative of the initiation of a picking operation the flip flop 66 is set to produce a high level signal on its Q output as shown in chart 5(d). Accordingly, the actuator 34 is energized and extracts the plunger 36 as shown in chart 5(e). Upon the plunger 36 having been drawn out of the recess 38, the weft yarn y is drawn off the drum 26 by the picking device 46 the operation of which is initiated at the same time as the proximity switch 52 produces the aforementioned pulse. Upon the counter 72 having counted up to the predetermined number (for example 3) the flip flop 66 is reset by the output of counter 72 shown in chart 5(c) and the signal appearing on the "Q" output thereof assumes a low level (see chart 5d). The plunger 36 is accordingly permitted to move toward and re-enter the recess 38 (as shown) whereupon the picking operation is terminated. Upon the Q output falling to a low level, a high level signal appears on the Q' output of the flip flop 66 which triggers the monostable multivibrator 80 to output a high level signal for a predetermined duration which is transmitted (with a predetermined delay) via the delay circuit 82 to the RC terminal of the counter 72. The counter is therefore reset ready for the next picking operation.
FIG. 6 shows a second embodiment of the present invention. This arangement is essentially identical with the first except for the provision of a probelike projection 90 mounted on shaft 91 extending from the drum 26. The projection 90 is arranged to extend into the aperture 50 and deflect the weft yarn toward the periphery of the aperture 50 as it passes through the guide 48 toward the picking device 46. This maintains the yarn within a predetermined distance of the periphery and hence the sensor 62', which in this embodiment is disposed in the guide per se. This arrangement unfailingly maintains the weft yarn y within a predetermined distance of the light emitting and receiving portions of the sensor 62' and therefore eliminates any possibility of the weft yarn y passing by the sensor undetected. The projection 90 is arranged to be non-reflective (viz., have a dark colour and mat finish) to avoid any undesired reflections occuring.
A device suitable for use as the sensors 62, 62' and 44 utilized in the above described embodiments is commercially available from the SKAN-A-MATIC corporation under the trade name of SKAN-COAX FIBER OPTIC SKANNER S322-3 SERIES. | A sensor which measures the amount of thread (weft yarn) drawn off a temporary storage drum and fed to a device which picks same into a shed of warp yarns, utilizes the spiralling motion of the thread as it is drawn axially off the drum, to induce the thread to move around in close proximity of the periphery of a guide aperture once for each loop of thread drawn off the drum and cut or reflect a light beam produced at or near the periphery of the aperture. | 3 |
FIELD OF THE INVENTION
This invention relates to a table positioner for use with radiographic equipment, and, more particularly, relates to a table positioner for effecting smooth translating and continuous lengthwise angular movement of such a table.
BACKGROUND OF THE INVENTION
The use of a table for positioning a patient in order to effect treatment and/or a diagnostic examination is well known, and such tables have heretofore been controlled utilizing various devices for effecting needed movement, including the use of electric motors and the like.
Improvements in positioners for such tables are, however, deemed to be still useful and/or needed for at least some applications. In particular, now known positioners for some such tables have not been able to impart lengthwise angular movement in a full 90° from horizontal, have lacked the ability to impart a smooth translating and/or continuous motion, have required that the table have an undue height above floor level for effective use, when horizontally positioned, have required a plurality of pivot points and/or extension devices, and/or have failed to provide adequate imaging coverage of a patient on the table.
SUMMARY OF THE INVENTION
This invention provides an improved table positioning system for use with radiographic equipment and which allows the table to be lengthwise angularly displaced up to 90° in either direction from a horizontal position, with such movement being effected by a smooth translating and continuous motion that allows the table to be positioned low, relative to floor level, when in a horizontal position, and yet be lengthwise angularly moved from the horizontal position with the then lower end of the table being maintained near floor level but without making floor contact during such movement of the table.
It is therefore an object of this invention to provide an improved table positioning system.
It is another object of this invention to provide an improved table positioning system useful in conjunction with radiographic equipment.
It is still another object of this invention to provide an improved table positioning system having smooth translating and continuous motion.
It is still another object of this invention to provide an improved table positioning system for maintaining the table low, with respect to floor level, when in a horizontal position and yet enables the table to be lengthwise angularly moved in reciprocal directions up to a full vertical position with the then lower end of the table being maintained close to but avoiding floor contact during said movement of the table.
It is yet another obejct of this invention to provide an improved table positioning system which provides adequate imaging coverage of a patient on the table.
With these and other objects in view, which will become apparent to one skilled in the art as the description proceeds, this invention resides in the novel construction, combination, and arrangement of parts substantially as hereinafter described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiment of the herein disclosed invention are meant to be included as come within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a complete embodiment of the invention according to the best mode so far devised for the practical application of the principles thereof, and in which:
FIG. 1 is an isomeric view of an imaging apparatus having the table positioning system of this invention incorporated therein;
FIG. 2 is an end view of the imaging apparatus shown in FIG. 1;
FIG. 3 is a rear section view taken through lines 3--3 of FIG. 2 and illustrating the frame in a horizontal position relative to floor level;
FIG. 4 is a view similar to that of FIG. 3, but showing the frame lengthwise angularly oriented at an angle of approximately 35° from horizontal;
FIG. 5 is a view similar to that of FIGS. 3 and 4, but showing the frame lengthwise angularly oriented at a full 90° from horizontal;
FIG. 6 is a side section view taken through lines 6--6 of FIG. 3;
FIG. 7 is a section view taken through lines 7--7 of FIG. 6;
FIG. 8 is a section view taken through lines 8--8 of FIG. 6;
FIG. 9 is a section view taken through lines 9--9 of FIG. 6;
FIG. 10 is a section view taken through lines 10--10 of FIG. 6;
FIG. 11 is a section view taken through lines 11--11 of FIG. 3;
FIG. 12 is a partial perspective and schematic view illustrating a pulley and cable system utilized in conjunction with raising and lowering the radiographic apparatus; and
FIG. 13 is a block diagram of an electrical unit which can be utilized for effecting lengthwise angular frame movement.
DESCRIPTION OF THE INVENTION
Imaging device 15 having the table positioning system of this invention incorporated therein is best shown by the isomeric drawing of FIG. 1, augmented by the end view of FIG. 2. As shown, imaging device 15 includes a base unit 17 having mounted thereon a lengthwise angularly moveable frame 18, which frame has a table 20 and a C-arm 21 moveably mounted thereon.
Base 17 includes a horizontally extending floor engaging section 23 (which can include a plurality of stacked plates, if desired, as indicated in FIGS. 3 through 5) and a vertically extending support section 24, which section extends upwardly from section 23. Support section 24, as shown best in FIGS. 3 through 5, includes a mounting plate 25 having support plates 26 and 27 connected at the outer edge portions thereof and extending rearwardly therefrom. Support section 24 also includes triangularly shaped support plates 28 and 29 connected with and extending outwardly from support plates 26 and 27, respectively.
Electric motor 31 is mounted on support plate 26 and has a dual belt motor shaft pulley 32 thereon that is rotated by the motor. Reduction box 33 is mounted at the top of floor engaging section 23 and has a dual belt pulley 34 thereon with pulleys 32 and 34 having dual belts 35 extending therearound. In addition, reduction box 33 has an output drive shaft 37 which is connected to lower chain sprocket 38 (see FIGS. 6 and 10) and to flexible coupling 39 (see FIG. 6) connected to shaft 40, which shaft has mounted thereon lower frame drive gear 41, which gear has gear teeth 42 thereon.
Upper chain sprocket 43 is mounted on shaft 44, which shaft is freely rotatable within bearing 45 which extends through mounting plate 25 and is mounted on yoke 46. The opposite end of shaft 44 has mounted thereon an upper frame drive gear 47, which gear has teeth 48 thereon. Chain 49 extends around lower and upper sprockets 38 and 43, and is tensioned by gears 50 and 51, which gears are mounted on plate 25 by straps 52 and 53, respectively, as shown in FIG. 9.
Frame 18 has a half-moon shaped radial gear rack, or cog, 54 formed therein at a semi-cylindrical wall portion of rear wall 55. Gear rack 54 has inwardly facing gear teeth 56 engageable with the teeth 48 of upper frame drive gear 47 (as shown best in FIG. 7) so that driving rotation of gear drive 47 causes movement of the frame. As shown best in FIGS. 3 through 5, gear rack 54 extends from near the bottom of frame 18 arcuately upwardly and inwardly to the central top portion of the frame and then arcuately downwardly and outwardly to near the bottom of the frame.
Plate-like yoke 46 has a lower portion 57 which widthwise spreads outwardly at an upper portion 58. Bearing 45 is centrally mounted at the upper portion 58 of yoke 46 (as brought out hereinabove, shaft 44 is received through bearing 45). Guide members 59 are provided at each of the upper outer edges of the upper portion 58 of yoke 46. As shown best in FIG. 11, each guide member 59 includes a pair of rollers 60 and 61 positioned at the opposite sides of gear rack 54 by means of mounts 62 and 63, respectively, which mounts have pins 64 and 65 upon which rollers 60 and 61 are mounted for free rotation.
The lower center portion 57 of yoke 46 is pivotally mounted to L-shaped wall section 67 of frame 18 by means of pivot pin 68 which extends rearwardly from depending wall 69 of wall section 67.
Wall section 67 is mounted on the inner side wall 71 of wall 55 of frame 18, and inner wall 71 has an inwardly extending wall section 72 below wall section 67. Wall section 72 has gear rack, or cog, 74 mounted thereon with the teeth 75 of gear rack 74 facing outwardly from the bottom wall. As shown best in FIGS. 3 through 5, gear rack 74 follows the outline of the lower portion of frame 18 and has a slight curvature at the center portion that rapidly increases in curvature at the outer edges. This curvature is selected as needed to achieve the desired ends as brought out more fully herein- after.
As best shown in FIG. 8, the teeth 42 of lower gear rack drive 41 engage the teeth 75 of gear rack 74 to impart driving motion to frame 18. As best shown in FIG. 6, a support 77 is utilized to support bearing 79 (which receives shaft 40). Bearing 79 has an upwardly extending arm 81 with a pin 82 mounted thereon. Pin 82 has a roller 83 mounted thereon, and roller 83 rolls along the upper portion of wall section 72. A lower frame support 85 is also provided and has an upstanding roller 86 mounted thereon to engage the lower edge of wall 55.
The curvature of gear racks 54 and 74 on frame 18, in conjunction with yoke 46 which is pivotally mounted on frame 18, allows table 20 to be maintained at a low table height, relative to floor level, and yet allows the table to be lengthwise angularly displaced, or tilted, up to 90° in either direction from horizontal.
While not a part of the positioning system to lengthwise angularly displace the frame (and hence the table), the imaging apparatus also includes structure for raising the table (and lowering the same from a raised position) while maintaining the table widthwise horizontal (i.e., not rotated about a lengthwise axis), as well as structure to move the C-arm lengthwise and widthwise with respect to the table and angularly around the table.
As shown in FIG. 1, arms 88 and 89 extend from the opposite outer sides near the top of frame 18 to table 20. As shown, each of these arms has inner and outer portions 91 and 92 with arm portion 92 being pivotally mounted with respect to arm portion 91 just rearwardly of table 20 by means of a pivot pin 94. Table 20 is, in turn pivotally mounted at the other end of arm portion 92 by means of pivot pin 95. Pivoting of the outer arm portions, as well as pivoting of the table itself, is effected by use of pivoting arrangement 97, as shown in FIG. 6. As shown, support 98, mounted on wall 99 extending outwardly from wall 55, has gear 101 mounted thereon, which gear engages straight rack 102. Rack 102 is connected with arm 103 having a cable pulley (not shown) mounted thereon, which cable pulley is part of a pulley and cable arrangement to cause pivotal movement of the outer arm portion 92 with the table being pivoted as needed to maintain the table in a horizontal position as the table is raised or lowered, as needed or desired, by movement of the outer arm portions.
C-arm 21 is mounted on frame 18 for longitudinal movement along the top of the frame (and hence along the length of table 20) in reciprocal directions, as needed or desired, by means of trolley 105. As shown in FIG. 1, trolley 105 is mounted at the top 106 of frame 18 with trolley 105 having rollers 108 and 109 at the rear wall 110 of the trolley riding on opposite sides of inwardly directed horizontal plate 111, rollers 112 and 113 at the front wall 114 of the trolley riding on opposite sides of inwardly directed horizontal plate 115, and rollers 116 and 117 extending downwardly from trolley bottom plate 118 with the rollers contacting the opposite sides of wall 55 at the top thereof. Movement of trolley 105 is effected by pulley and cable arrangement 120, as indicated in FIG. 6. As shown, pulley 121 is mounted on plate 122 (connected to plate 114 of trolley 105) with plate 122 (and trolley 105) being driven by cables 123 extending around pulleys 121 (and other pulleys (not shown) extending along the unit). Rollers 124 and 125 are mounted on plate 122 and roll along walls 55 and 115, respectively.
A counterweight 126 is provided at the forward side of wall 55 (behind front wall 128 as shown in FIG. 1) and is mounted thereat on plate 130 (connected with plate 122). Plate 130 has rollers 132 and 133 thereon, which rollers roll along rail 134 mounted on wall 55. Counterweight 126 is driven in reciprocal directions lengthwise along frame 18 to balance trolley displacement from the center of frame 18 by means of pulley and cable arrangement 120.
As also shown in FIGS. 1 and 2, boom 136 extends forwardly from trolley 105 to C-arm 21 and rearwardly to control unit 138. Boom 136 is moveable forwardly and rearwardly with respect to trolley 105 by means of a rack and gear arrangement (not shown) similar to that shown in connection with pivotal movement of the outer arm portions and table 20 as brought out hereinabove. This movement effects widthwise movement with respect to table 20.
C-arm 21 is also moveable in both clockwise and counter-clockwise directions with respect to the curvature of the C-arm (and hence around table 20), as well as movement in reciprocal twisting directions with respect to the C-arm, as indicated in FIG. 1. Such movements are effected by pulley and cable arrangements and gear and rack arrangements similar to those described hereinabove.
A radiographic instrument, as indicated in FIG. 1, has one portion 139 moveably positioned with respect to plate 140 at the top end of C-arm 21 and another portion 141 in fixed position at the bottom end of C-arm 21. The radiographic instrument can be, for example, X-ray equipment, and movement of portion 139 toward and away from table 20 is accomplished by means of a pulley and cable arrangement 142, as shown in FIG. 12. As shown, cable 143 is connected with various pulleys 144 (one of which is mounted on portion 139 of the radiographic instrument) and with counterweight 145 to counter balance the weight of portion 139 of the diagnostic equipment.
While the lengthwise angular movement of frame 18 (and hence table 20) may be effected by manually controlling energization of electric motor 31, such movement may also be effected by an electronic control unit 146, as shown in FIG. 13. As shown, movement of joystick 147 is translated into an electrical signal by potentiometer 149, and this analog signal is converted into a digital signal by A/D converter 150 and then coupled to imager system controller 151. The output from controller 151 is converted to an analog output at D/A converter 152 and the resulting analog signal is coupled to a variable speed DC drive 153, the output of which drives motor 31 to cause the desired lengthwise angular movement of frame 18 and, therefore, table 20.
A position potentiometer 154 senses the actual table position and produces an analog output signal indicative thereof, which analog signal is coupled to A/D converter 155 where the signal is converted to a digital signal, which digital signal is then coupled to imager system controller 151. Limit switches 157 and 158 are also provided as safety limits to limit angular movement of the table to a 90° displacement in either direction.
Frame 18 is shown in horizontal position in FIG. 3. In this position, table 20 is also in a horizontal position with no angular displacement about a widthwise central axis. When lengthwise angular displacement is desired (i.e., movement parallel with the lengthwise, or longitudinal, axis), motor 31 is energized (either manually, as by closing a switch connecting the motor to a power source, or by utilizing the system as shown in FIG. 13), and energization of the motor causes gears 41 and 47 to impart driving motion to gear racks 74 and 54, respectively, to cause angular movement of frame 18. As can be appreciated from the foregoing, smooth translating and continuous motion is imparted to frame 18 since a single continuous drive motor is utilized to drive continuous curved gear racks in conjunction with a yoke that is pivoted on frame 18 and has one gear drive mounted thereon. As indicated in FIG. 4, when frame 18 (and hence table 20) is horizontally positioned, yoke 46 is vertically positioned and gears 41 and 47 are at the center of gear racks 74 and 54, respectively. When frame 18 is angularly displaced, yoke 46 pivots about pivot 68 as the frame moves due to movement of gear racks 74 and 54 under the drive force of driving gears 41 and 47 to thereby impart translating movement to frame 18 to move the frame outwardly and upwardly, as shown in FIG. 4, where the frame is shown to be angularly displaced at an angle of about 35° from horizontal. When frame 18 is angularly displaced to a 90° position from horizontal (i.e., to a vertical position as shown in FIG. 5), yoke 46 has pivoted so that the normally lower base portion is now above frame 18 and gears 41 and 47 are near one end of gear racks 74 and 54, respectively.
This lengthwise angular movement of frame 18 allows table 20 to be positioned at a low table height above floor level when horizontally positioned and yet allows the table to be lengthwise angularly displaced to the full vertical position in either direction from horizontal without the then lower end of the table (or frame) contacting the floor (or base) though being constantly adjacent thereto. This enables a focal spot coverage of up to about 70 inches lengthwise of a patient which has not been heretofore possible.
The imaging device is useful for various diagnostic and treatment procedures including, for example, those possible with conventional X-ray equipment, and the positioning system of this invention has been found useful in positioning a patient on the table to aid in successful completion of such procedures.
As can be appreciated from the foregoing, this invention provides an improved positioning system for effecting lengthwise angular displacement of a frame and table that is particularly useful in positioning a patient for imaging by radiographic equipment. | A table positioner is disclosed for use with radiographic equipment to cause smooth translating and continuous angular movement of the table in reciprocal directions from a lengthwise horizontal position to lengthwise vertical positions. When in a lengthwise horizontal position, the positioner causes the top of the table to have a sufficiently low vertical height above floor level to enhance utilization of the radiographic equipment for imaging of a patient on the table, and yet still allows lengthwise angular movement of the table from this low horizontal positioning to full vertical positioning with the then lower end of the table being maintained in a position close to floor level but precluding floor contact during any portion of table movement. Lengthwise angular movement of the table is effected through use of a pair of gear racks mounted on a moveable frame with the gear racks being curved in opposite directions with respect to one another and engageable with drive gears one of which is mounted on a pivotable yoke mounted on the frame and operating in conjunction with the gear racks and drive gears to effect the smooth translating and continuous motion of the frame. | 0 |
FIELD OF THE INVENTION
The present invention generally relates to data storage devices such as disk drives, and it particularly relates to a read/write head for use in such data storage devices. More specifically, the present invention provides a method of incorporating a layer of expansive material in the read/write head to counteract the forces that cause undesirable pole tip protrusion of the read/write head during operation.
BACKGROUND OF THE INVENTION
An exemplary conventional read/write head comprises a thin film write element with a bottom pole P 1 and a top pole P 2 . The pole P 1 has a pole tip height dimension commonly referenced as “throat height”. In a finished write element, the throat height is measured between the ABS and a zero throat level where the pole tip of the write element transitions to a back region. The ABS is formed by lapping and polishing the pole tip. A pole tip region is defined as the region between the ABS and the zero throat level. Similarly, the pole P 2 has a pole tip height dimension commonly referred to as “nose length”. In a finished read/write head, the nose is defined as the region of the pole P 2 between the ABS and the “flare position” where the pole tip transitions to a back region.
Pole P 1 and pole P 2 each have a pole tip located in the pole tip region. The tip regions of pole P 1 and pole P 2 are separated by a recording gap that is a thin layer of non-magnetic material. During a write operation, the magnetic field generated by pole P 1 channels the magnetic flux from pole P 1 to pole P 2 through an intermediary magnetic disk, thereby causing the digital data to be recorded onto the magnetic disk.
During operation of the magnetic read/write head, the magnetic read/write head portion is typically subjected to various thermal sources that adversely cause ambient and localized heating effects of the read/write head. One such thermal source is attributed to a heat transfer process to the magnetic read/write head from the effect of the spinning magnetic disk.
During a typical operation, the magnetic disk spins at a rapid rate of rotation, typically on the order of several thousands of revolutions per minute (RPM). This rapid rotation generates a source of friction in the ambient air between the ABS and the spinning magnetic disk, thus causing an elevation in the air temperature.
Furthermore, the heating of the motor that drives the magnetic disk causes an additional elevation of the air temperature. In totality, the ambient air temperature may rise from a room temperature of about 25° C. to as high as 85° C. Typically, the read/write head is initially at a room temperature. Consequently, there exists a tendency for a heat transfer process to take place between the ambient air at a higher temperature and the read/write head at lower temperature. The heat transfer causes a rise in the temperature of the read/write head to promote a thermal equalization with the ambient air temperature.
Additionally, the read/write head is also subjected to various sources of power dissipation resulting from the current supplied to the write coils, eddy current in the core, and the current in the read sensor. The power dissipation manifests itself as a localized heating of the read/write head, resulting in a temperature rise similar to the foregoing ambient temperature effect.
The temperature increase of the read/write head further causes a variant temperature distribution as a result of the thermal conduction of diverse materials that compose the read/write head. Typically, most wafer-deposited materials such as those composing the poles P 1 and P 2 have greater coefficients of thermal expansion (CTE) than that of the substrate. Consequently, the temperature increase effects a general positive displacement of the read/write head as well as a local pole tip protrusion beyond the substrate.
In a static test environment without the effect of the spinning magnetic disk, the localized heating may cause a temperature elevation of as high as 70° C. However, in an operating environment of a magnetic disk drive, the temperature rise resulting from the localized heating may be limited to about 40° C., primarily due to the alleviating effect of a convective heat transfer process induced by the rotating air between the pole tip region and the spinning magnetic disk. The temperature increase associated with the localized heating further promotes an additional protrusion of the pole tip relative to the substrate.
A typical pole tip protrusion in a static environment may be approximately 30 to 35 nm. In an operating environment of a magnetic disk drive, the pole tip protrusion is reduced to a typical value of 7.5 nm to 12 nm. Since a typical flying height is approximately 12.5 nm, the pole tip protrusion associated with thermal heating of the read/write head can cause the read/write head to come into contact with the spinning magnetic disk. While a typical flying height may be about 12.5 nm, there are currently a significant number of low flying heads with flying heights less than 12.5 nm. A steady evolution to lower flying heights exacerbates the problem of physical interference between the pole tip protrusion and the spinning magnetic disk.
This physical interference with the spinning magnetic disk causes both accelerated wear and performance degradation. The wear effect is due to abrasive contact between the slider and the disk. Pulling the softly sprung slider slightly off track impacts the track following capability of the recording device.
In an attempt to resolve the foregoing problem, a number of conventional designs of read/write heads incorporate the use of a material with a coefficient of thermal expansion (CTE) that is lower than that of the substrate. Functionally, the low CTE material is generally used as an insulator between various metals in a conventional magnetic read/write head. An exemplary material used in a conventional magnetic read/write head is silicon oxide, SiO 2 , which typically has a CTE of 2 parts per million.
In the presence of a temperature rise resulting from a thermal heating of the read/write head, such a material tends to expand at a lower rate than the substrate. This lower expansion rate develops a thermally induced axial restraining force between the material and the substrate. This restraining force effectively reduces the expansion of the substrate, thus mitigating the natural protrusion of the pole tip.
Although this technology has proven to be useful, it would be desirable to present additional improvements. SiO 2 has poor thermal conductivity that generally impedes the heat extraction process from the surrounding material to the SiO 2 material. Consequently, in spite of the low CTE associated with SiO 2 , the low thermal conductivity of SiO 2 does not sufficiently reduce the temperature rise of the pole tip region and the pole tip protrusion is not adequately reduced with the use of SiO 2 .
Furthermore, SiO 2 lacks elasticity due to its ceramic characteristics. In the presence of the thermally induced axial restraining force, a shear stress is developed at the interface of SiO 2 and the surrounding material. This shear stress tends to promote a delamination of the SiO 2 material, posing a reliability problem for the read/write head of a conventional design.
In recognition of the issues associated with the use of SiO 2 in a conventional read/write head, some alternative materials have been proposed but have not been entirely successfully applied to a read/write head. As an example, while these materials such as Cr, W, possess higher thermal conductivities than SiO 2 , they are not readily available for deposition and patterning in a read/write head at a wafer-level process.
Thus, there is a need for a read/write head that provides a reduced pole tip protrusion resulting from a thermal heating of the magnetic read/write head during operation. The need for such a design has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
The present invention can be regarded as a read/write head for use in a data storage device to reduce pole tip protrusion. The read/write head includes an air bearing surface; a pole tip region; an insulation layer formed adjacent to the pole tip region; a coil embedded in the insulation layer contributing to a protrusion force that generates a pole tip protrusion; and a layer of thermally expansive material formed over the insulation layer, and recessed from the air bearing surface, that expands in response to heat absorption, causing a rotational moment of force that counteracts the protrusion force thus reducing the pole tip protrusion.
The present invention can also be regarded as a write element for use in a read/write head having an air bearing surface, so as to reduce pole tip protrusion. The write element includes a pole tip region; an insulation layer formed adjacent to the pole tip region; a coil embedded in the insulation layer which contributes to a protrusion force that generates a pole tip protrusion; and a layer of thermally expansive material formed over the insulation layer, and recessed from the air bearing surface, that expands in response to heat absorption, causing a rotational moment of force that counteracts the protrusion force thus reducing the pole tip protrusion.
The present invention can also be regarded as a disk drive that includes a base; a spindle motor attached to the base; a disk positioned on the spindle motor; and a head stack assembly that is coupled to the base. The head stack assembly includes an actuator body; an actuator arm cantilevered from the actuator body; and a read/write head that is coupled to the actuator arm. The read/write head includes an air bearing surface; a pole tip region; an insulation layer formed adjacent to the pole tip region; a coil embedded in the insulation layer which contributes to a protrusion force that generates a pole tip protrusion; and a layer of thermally expansive material formed over the insulation layer, and recessed from the air bearing surface, that expands in response to heat absorption, causing a rotational moment of force that counteracts the protrusion force thus reducing the pole tip protrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a data storage device utilizing a read/write head of the present invention;
FIG. 2 is a perspective view of a head gimbal assembly comprised of a suspension, and a slider to which the read/write head of FIG. 1 is secured, for use in a head stack assembly;
FIG. 3 is a cross-sectional view of the read/write head of FIGS. 1 and 2 , illustrating the placement of a thermally expansive layer;
FIG. 4 is a top view of the read/write head of FIGS. 1 , 2 , and 3 , further illustrating the placement of the thermally expansive layer;
FIG. 5 is another view of the read/write head of FIG. 3 illustrating a rotational moment of force created by the thermally expansive layer to reduce pole tip protrusion;
FIG. 6 is a cross-sectional view of a conventional read/write head;
FIG. 7 is a force diagram of the conventional read/write head of FIG. 6 illustrating the forces that cause pole tip protrusion;
FIG. 8 is a force diagram of the read/write head of FIG. 5 illustrating the reduction in pole tip protrusion induced by a rotational moment of force resulting from the expansion of the thermally expansive layer of FIG. 4 ;
FIG. 9 is a graph comparing the pole tip protrusion of the conventional read/write head of FIG. 6 with that of the read/write head of FIG. 3 , in response to ambient heating;
FIG. 10 is a graph comparing the pole tip protrusion of the conventional read/write head of FIG. 6 with that of the read/write head of FIG. 3 in response to current heating; and
FIG. 11 is a cross-sectional of a read/write head that does not utilize a diffuser, illustrating the placement of a thermally expansive layer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a hard disk drive 100 in which an embodiment of the present invention may be used. An enclosure of the hard disk drive 100 comprises a cover 102 and a base 104 . The enclosure is suitably sealed to provide a relatively contaminant-free interior for a head disk assembly (HDA) portion of the hard disk drive 100 . The hard disk drive 100 also comprises a printed circuit board assembly (not shown) that is attached to base 104 and further comprises the circuitry for processing signals and controlling operations of the hard disk drive 100 .
Within its interior, the hard disk drive 100 comprises a magnetic disk 126 having a recording surface typically on each side of the disk, and comprises a magnetic head or slider that may suitably be a magneto-resistive (“MR”) head such as a GMR head. The GMR head has an MR element for reading stored data on a recording surface and an inductive element for writing data on the recording surface. The exemplary embodiment of the hard disk drive 100 illustrated in FIG. 1 comprises three magnetic disks 126 , 128 , and 130 providing six recording surfaces, and further comprises six magnetic heads.
Disk spacers such as spacers 134 and 136 are positioned between magnetic disks 126 , 128 , 130 . A disk clamp 132 is used to clamp disks 126 , 128 , 130 on a spindle motor 124 . In alternative embodiments, the hard disk drive 100 may comprise a different number of disks, such as one disk, two disks, and four disks and a corresponding number of magnetic heads for each embodiment. The hard disk drive 100 further comprises a magnetic latch 110 and a rotary actuator arrangement. The rotary actuator arrangement generally comprises a head stack assembly 112 and voice coil magnet (“VCM”) assemblies 106 and 108 . The spindle motor 124 causes each magnetic disk 126 , 128 , 130 positioned on the spindle motor 124 to spin, preferably at a constant angular velocity.
A rotary actuator arrangement provides for positioning a magnetic head over a selected area of a recording surface of a disk. Such a rotary actuator arrangement comprises a permanent-magnet arrangement generally including VCM assemblies 106 , 108 , and head stack assembly 112 coupled to base 104 . A pivot bearing cartridge is installed in a bore of the head stack assembly 112 and comprises a stationary shaft secured to the enclosure to define an axis of rotation for the rotary actuator arrangement.
The head stack assembly 112 comprises a flex circuit assembly and a flex bracket 122 . The head stack assembly 112 further comprises an actuator body 114 , a plurality of actuator arms 116 cantilevered from the actuator body 114 , a plurality of head gimbal assemblies 118 each respectively attached to an actuator arm 116 , and a coil portion 120 . The number of actuator arms 116 and head gimbal assemblies 118 is generally a function of the number of magnetic disks in a given hard disk drive 100 .
Each of the head gimbal assemblies (HGA) 118 is secured to one of the actuator arms 116 . As illustrated in FIG. 2 , HGA 118 is comprised of a suspension 205 and a read/write head 210 . The suspension 205 comprises a resilient load beam 215 and a flexure 220 to which the read/write head 210 is secured.
The read/write head 210 comprises a slider 225 secured to the free end of the resilient load beam 215 by means of flexure 220 and a read/write element 230 supported by slider 225 . In the example illustrated in FIG. 2 , the read/write element 230 is secured to the trailing edge 235 of slider 225 . Slider 225 can be any conventional or available slider. In another embodiment, more than one read/write element 230 can be secured to the trailing edge 235 or other side(s) of slider 225 .
FIG. 3 is a cross-sectional view of the read/write element 230 incorporating a thermally expansive layer 305 that is comprised of thermally expansive material, according to the present invention. The read/write element 230 integrates a write element 310 and a read element 315 . An undercoat 320 is formed over a substrate layer 325 . The read element 315 is formed of a first shield layer (shield 1 ) 330 that is formed on the undercoat 320 . The undercoat 320 is preferably made of alumina (Al 2 O 3 ).
The first shield layer 330 is made of a material that is both magnetically and electrically conductive. As an example, the first shield layer 330 can have a nickel iron (NiFe) composition, such as Permalloy, or a ferromagnetic composition with high permeability. The thickness of the first shield layer 330 can be in the range of approximately 0.5 micron to approximately 20 microns.
An insulation layer (not shown) is formed over substantially the entire surface of the first shield layer 330 to define a non-magnetic, transducing read gap. The insulation layer can be made of any suitable material, for example alumina (Al 2 O 3 ), aluminum oxide, or silicon nitride.
The read element 315 further comprises a second shield layer (shield 2 ) 335 that is made of an electrically and magnetically conductive material that may be similar or equivalent to that of the first shield layer 330 . The second shield layer 335 is formed over substantially the entire surface of the insulating layer (not shown) and has a thickness that can be substantially similar or equivalent to that of the first shield layer 330 . A piggyback gap (not shown) is formed on the second shield layer 335 .
The write element 310 is comprised of a first pole or pole layer (P 1 ) 340 that extends, for example, integrally from the piggyback gap. P 1 340 is made of a magnetically conductive material. A first coil layer 345 comprises conductive coil elements. The first coil layer 345 also forms part of the write element 310 , and is formed within an insulating layer ( 12 ) 350 . The first coil layer 345 may comprise a single layer of, for example, 1 to 30 turns, though a different number of turns can alternatively be selected depending on the application or design.
A second pole or pole layer (P 2 ) 355 is made of a magnetically conductive material, and may be, for example, similar to that of the first shield layer 330 and P 1 340 . The thickness of P 2 355 can be substantially the same as, or similar to, that of the first shield layer 330 .
A third pole or pole layer (P 3 ) 360 is made of a hard magnetic material with a high saturation magnetic moment Bs. In one embodiment, the saturation magnetic moment Bs is equal to or greater than approximately 2.0 teslas. P 3 360 can be made, for example, of CoFeN, CoFeNi, and CoFe.
A pole tip region 365 comprises P 3 360 , P 2 355 , and the portion of P 1 340 near the air bearing surface of the read/write element 230 . The writing element 310 further comprises a third shield layer (shield 3 ) 370 .
A second coil layer 375 comprises conductive coil elements. The second coil layer 375 forms part of the write element 310 , and is formed within an insulating layer (I 3 ) 380 . The second coil layer 375 may comprise a single layer of, for example, 1 to 30 turns, though a different number of turns can alternatively be selected depending on the application or design.
A fourth shield layer (shield 4 ) 385 (also referred to as the upper shield 385 ) covers a portion of I 3 380 . A diffuser 390 covers a portion of the fourth shield layer 385 and a portion of I 3 380 .
In one embodiment, the thermally expansive layer 305 covers a portion of diffuser 390 and I 3 380 . An overcoat 395 covers the thermally expansive layer 305 and the remaining exposed portion of the read/write element 230 .
The thermally expansive layer 305 is preferably comprised of a material having a coefficient of thermal expansion that ranges between approximately 5 ppm/K and 100 ppm/K. For example, the thermally expansive layer 305 can be made of photoresist material.
The thermally expansive layer can be, for example, approximately 10 microns thick, 70 microns long, and 340 microns wide as illustrated by the top view of the read/write element 230 , shown in FIG. 4 relative to pads 401 , 402 , 403 , 404 , and 405 .
FIG. 5 illustrates the forces generated by the expansion of the thermally expansive layer 305 . During operation, the temperature of the read/write element 230 increases, resulting from ambient heating and current heating.
Current heating comprises resistive heating in the first coil layer 345 and in the second coil layer 375 , and eddy currents in the magnetic materials of P 1 340 , P 2 355 , and P 3 360 . Ambient heating comprises friction heating of the air between the read/write head and the spinning magnetic disk, and heating from the drive motor of the data storage device.
The thermally expansive layer 305 absorbs a portion of the thermal energy in the read/write element 230 , and consequently expands. The expansion of the thermally expansive layer 305 exerts forces that are illustrated by forces F 1 505 , F 2 510 , and F 3 515 .
Force F 2 510 applies pressure to the overcoat 395 , causing a clock-wise rotational moment of force 420 around a central region of rotation 421 , near the pole tip region 365 . The rotational moment of force 420 counteracts a protrusion force in the pole tip region 365 , reducing the pole tip protrusion. The size, shape, and placement of the thermally expansive layer 305 are designed to optimally place the rotational moment of force 420 so as to reduce pole tip protrusion. In addition, force F 3 515 applies pressure to a portion of I 3 380 , limiting the expansion of I 3 380 .
For comparison purposes, a conventional read/write element 600 is illustrated by the diagram of FIG. 6 . The conventional read/write element 600 is constructed generally similarly to the read/write element 230 , but without the thermally expansive layer 305 .
The force diagram of FIG. 7 illustrates the expansion forces induced in the conventional read/write element 600 . The material used in I 3 380 and I 2 350 is typically thermally expansive. During operation, the temperature of I 3 380 and I 2 350 increases as a result of thermal transfer from the heat sources in the read/write element 230 : the current heating and the ambient heating.
The resultant force created by the expansion of I 3 380 and I 2 350 can be characterized as forces F 4 710 , F 5 715 , F 6 720 , F 7 725 , F 8 730 , F 9 735 , and F 10 740 . Protrusion forces F 6 720 , F 7 725 , F 8 730 , F 9 735 , and F 10 740 cause pole tip protrusion into the ABS.
The force diagram of FIG. 8 illustrates the effect of adding the thermally expansive layer 305 to the read/write element 230 . The resultant forces created by the expansion of the thermally expansive layer 305 , I 3 380 , and I 2 350 can be characterized as forces F 11 805 , F 12 810 , F 13 815 , F 14 820 , and F 15 825 . The forces F 1 505 , F 2 510 , and F 3 515 (of FIG. 5 ) exerted by the thermally expansive layer 305 counteract and redirect the forces exerted by I 3 380 and I 2 350 .
The rotational moment of force 420 created by the forces F 1 505 , F 2 510 , and F 3 515 , which are exerted by the thermally expansive layer 305 , redirect the protrusion forces, as illustrated by reduced protrusion forces F 11 805 , F 12 , 810 , and F 13 , 815 . Rather than pushing the pole tip region 365 into the ABS, the direction of the forces F 11 805 and F 13 815 is generally along (or parallel to) the ABS, reducing the protrusion forces F 11 805 , F 12 , 810 , and F 13 , 815 . The rotational moment of force 420 also changes the direction of force F 5 715 to that of force F 14 820 . Force F 4 710 is counteracted by force F 15 825 that is created by the thermally expansive layer 305 , thus reducing the expansion of I 3 380 .
The effect of the thermally expansive layer 305 on pole tip protrusion is further illustrated by the graphs of pole tip protrusion shown in FIGS. 9 and 10 . The x-axis corresponds to the ABS surface. The zero point on the x-axis corresponds to a write gap of the read/write element 230 or the conventional read/write element 600 . The write gap is located between P 1 and P 2 . The heat source for the graph of FIG. 9 is ambient heating. The heat source for the graph of FIG. 10 is current heating.
As shown in FIG. 9 , the pole tip protrusion of the conventional read/write element 600 at the write gap is approximately 8.5 nm due to ambient heating. In contrast, the pole tip protrusion of the read/write element 230 of the present design, incorporating the thermally expansive layer 305 , is less than approximately 6 nm, that is a reduction in pole tip protrusion of approximately 45%.
As further illustrated in FIG. 10 , the pole tip protrusion of the conventional read/write element 600 at the write gap is approximately 10 nm due to current heating. In contrast, the pole tip protrusion of the read/write element 230 having a thermally expansive layer 305 is less than approximately 8 nm, that is a reduction in pole tip protrusion of approximately 20%.
In a further embodiment illustrated by the diagram of FIG. 11 , the thermally expansive layer 305 may be used in a read/write element 1105 that does not comprise a diffuser. In this embodiment, the thermally expansive layer 305 is placed in the range of approximately 0 um to approximately 1.0 um above poles P 1 340 , P 2 355 , and P 3 360 , primarily over layer I 3 355 . An overcoat 395 covers the thermally expansive layer 305 and the remaining exposed portion of the read/write element 1105 . | A write element for use in a read/write head having an air bearing surface, so as to reduce pole tip protrusion. The write element includes a pole tip region; an insulation layer formed adjacent to the pole tip region; a coil embedded in the insulation layer which contributes to a protrusion force that generates a pole tip protrusion; and a layer of thermally expansive material formed over the insulation layer, and recessed from the air bearing surface, that expands in response to heat absorption, causing a rotational moment of force that counteracts the protrusion force thus reducing the pole tip protrusion. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a black pigment, a process for making such a pigment and paints and/or plastics containing this pigment.
Heat stable black pigments which contain no carbon have generally been made from materials containing heavy metals and/or other highly toxic materials. Such materials are described, for example, in the Colour Index published in Great Britain and the brochure entitled "Classification and Chemical Descriptions of Mixed Metal Oxide Inorganic Colored Pigments" published by the Dry Color Manufacturers' Association, 1117 North 19th Street, Suite 100, Arlington, Va., 22209. These heavy metal-containing and/or highly toxic materials are, however, undesirable in many applications.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an inorganic black pigment in which no heavy metal-containing or highly toxic material is present.
It is also an object of the present invention to provide an inorganic black pigment useful in making paints, organic coatings and plastics which is capable of withstanding a curing cycle at temperatures of 500° to 1000° F.
It is another object of the present invention to provide an inorganic black pigment having very low oil absorption and high tinting strength.
These and other objects which will become apparent to those skilled in the art are achieved by calcining a mixture which includes a source of an oxide of manganese and a source of strontium oxide and/or calcium oxide. This calcination produces one of two distorted perovskite phases, both of which are black.
DETAILED DESCRIPTION OF THE INVENTION
The inorganic pigment of the present invention may be made from raw materials such as manganese dioxide, manganese carbonate, strontium carbonate, calcium carbonate, and the like. The amount of raw material employed is naturally dependent upon the composition of the specific raw material. However, the quantity of material must be such that upon calcination, the product composition is within the ranges given in detail below. Upon being calcined at high temperature, these raw materials are converted into a distorted perovskite structure in which (a) manganese oxide or manganese dioxide and (b) strontium oxide and/or calcium oxide are present in the proper proportions. Appropriate calcination temperatures are generally between 1200° and 1900° F., preferably about 1300° to 1700° F. In actual production, saggers are typically used for the calcination but any device or apparatus capable of withstanding the calcination temperature may be employed.
The products of this calcination are useful as pigments which impart an intense black coloration to paints and other organic coatings. The pigment is also useful for coloring plastics. It is particularly useful in the formulation of materials which must withstand a curing cycle at temperatures of 500° to 1000° F.
The perovskite pigment of the present invention exhibits black coloration and has the following broad oxide composition:
25 to 84 mol % of an oxide of manganese and
75 to 16 mol % of strontium oxide and/or calcium oxide.
In addition to these oxides, small amounts of conventional mineralizers such as alkali halides, alkaline earth halides, boric acid, etc., may be included in the raw materials to facilitate the calcination reaction.
When strontium oxide is used as the alkaline earth oxide, the preferred oxidic composition is:
60 to 78 mol % of a manganese oxide
22 to 40 mol % strontium oxide
together with any conventional mineralizers such as those described above.
When calcium oxide is the alkaline earth oxide used, the preferred composition is:
38 to 52 mol % of an oxide of manganese
48 to 62 mol % calcium oxide
in addition to any conventional mineralizers such as those described above.
Up to 10 mol % of iron oxide, cobalt oxide, or vanadium oxide may be substituted for manganese in these compositions. However, unless done carefully, green or brown colors will result. For similar reasons, incidental impurities of about 3 to 5 mol % are usually considered the limits of toleration in these black pigments.
When the concentration of manganese oxide or manganese dioxide deviates from the required limits on either the high or low side, brown pigments result. For similar reasons, excessive concentrations of impurities yield colors other than black and are undesirable.
With respect to other black pigments currently available, the pigment of the present invention has a number of unique properties. First, the oil absorption is very low, thereby enabling very efficient usage of pigment. Additionally, the product of the present invention has a high tinting strength and yields a very neutral gray when combined with titanium dioxide.
Having thus described my invention, the following examples are given by way of illustration. The percentages given are mol percents unless otherwise indicated.
EXAMPLES
EXAMPLE 1
A batch was compounded from 450.5 grams of strontium carbonate, 249.5 grams of manganese carbonate, 9.9 grams of potassium fluoride, 9.9 grams of sodium chloride, and 9.9 grams of ammonium bifluoride. This batch was weighed out, blended, and calcined in a sagger in a gas-fired kiln at 1350° F. for 3 hours. After calcining and cooling to room temperature, the calcined pigment was removed from the sagger, broken up, pulverized, and then fluid energy milled. The pigment had the following molar formulation: 60% strontium oxide, 40% manganese dioxide, and residual amounts of carbonate and mineralizers.
X-ray diffraction analysis of this material showed it to be a distorted perovskite. The oil absorption of the pigment was measured in accordance with ASTM Procedure D-281 and found to be 11.9 grams. The pH was measured in accordance with ASTM Procedure D-1208 and found to be 9.0.
To evaluate the color of this pigment in a paint, 10.0 grams of the pigment were added to 14.0 grams of soya oil alkyd resin, 16.5 grams of mineral spirits, 2.4 grams of naphtha, and 0.13 grams of driers. This mixture was placed on a paint shaker and shaken for 30 minutes with 30 grams of beads. The paint was then strained and 0.3 cc of additional driers were added. The paint was drawn down on a 0.006-inch Bird applicator and was allowed to air dry for at least 24 hours. The color was then measured on a Diano-Hardy Visible Spectrophotometer and the results were as follows: R d =5.0, a=0.2, b=0.6. In this system of color measurement, a black is indicated by an R d value of less than about 6.0 and "a" and "b" values less than about 1.5 in absolute value.
To further evaluate the color of the pigment, 5.0 grams of the pigment and 5.0 grams of pigment-grade titanium dioxide were prepared in a paint formulation otherwise similar to the one given above. The color of this 1:1 formulation was measured as follows: R d =27.6, a=31 0.4, b=1.2. In this system the neutrality of the formulation is indicated by the extent to which the "a" and "b" values do not increase in absolute value. The R d value increases as the color goes from a black to a gray.
EXAMPLE 2
A batch was compounded from 1304.0 grams of strontium carbonate, 2526.0 grams of manganese carbonate, 57.6 grams of ammonium bifluoride, 56.2 grams of potassium fluoride, and 56.0 grams of sodium chloride. This batch was weighed out, blended, and calcined in a sagger in a gas-fired kiln at a temperature of 1570° F. for 3 hours. After calcining and cooling to room temperature, the calcined pigment was removed from its sagger, broken up, pulverized, and then fluid energy milled. The product pigment had the following molar formulation:
30% strontium oxide,
70% manganese oxide,
plus residual amounts of carbonate and mineralizers. The crystal phases, as measured by X-ray diffraction, were a mixture of two distorted perovskites. The oil absorption of this pigment was then measured in accordance with ASTM Procedure D-281 and found to be 23.8 grams.
To evaluate the color of this pigment in a paint formulation, 10.0 grams of the pigment were mixed with 14.0 grams of soya oil alkyd resin, 16.5 grams of mineral spirits, 2.4 grams of naphtha, and 0.13 grams of driers. This mixture was placed in a paint shaker and shaken for 30 minutes with 30 grams of beads. The paint was then strained and 0.3 cc of additional driers were added. The paint was then drawn down on a 0.006-inch Bird applicator and allowed to air dry for at least 24 hours. The color was measured on a Diano-Hardy Visible Spectrophotometer and found to be: R d =4.7, a=0.2, b=0.5.
To further evaluate the color of the pigment, 5.0 grams of the pigment were mixed with 5.0 grams of pigment-grade titanium dioxide to produce a paint formulation otherwise identical to that described above. The paint prepared therefrom had the following color values: R d =17.7, a=-0.5, b=-3.7.
EXAMPLES 3-15
Batches having the compositions given in Table 1 were each weighed out, blended and calcined in a sagger in a gas-fired kiln. The batches used in Examples 3-12 and 14-15 were calcined at 1700° F. for 3 hours. The batch used in Example 13 was calcined at 1300° F. for 3 hours. After calcining and cooling to room temperature, each of the calcined pigments was removed from the sagger, broken up, pulverized, and then fluid energy milled. Aside from residual amounts of volatile carbonate and mineralizers, the calcined pigments had the molar compositions given in Table II. The phases present were determined by X-ray diffraction to be one or more distorted perovskites. The oil absorptions as measured by ASTM Procedure D-281 were those given in Table III.
In order to evaluate the color of each of these pigments in a paint formulation, 10.0 grams of each pigment were mixed with 14.0 grams of soya oil alkyd resin, 16.5 grams of mineral spirits, 2.4 grams of naphtha, and 0.13 grams of driers. Each of these paints was then placed on a paint shaker and shaken for 30 minutes with 30 grams of beads. The paints were then strained and 0.3 cc of additional driers were added to each formulation. The paints were then drawn down on a 0.006-inch Bird applicator and allowed to air dry for at least 24 hours. The color properties were measured on a Diano-Hardy Visible Spectrophotometer and the results are given in Table III.
TABLE 1__________________________________________________________________________RAW BATCHES PREPAREDRaw Material EXAMPLES(gms) 3 4 5 6 7 8 9 10 11 12 13 14 15__________________________________________________________________________StrontiumCarbonate 160.9 153.5 263.3 126.0 216.5 153.5 -- 77.8 55.3 -- -- 84.5 69.2CalciumCarbonate -- -- -- -- -- 53.8 185.6 -- -- 170.1 52.3 -- 9.7ManganeseCarbonate 89.1 83.2 72.9 209.2 107.9 127.7 147.1 161.5 183.8 67.3 186.0 116.9 158.7PotassiumFluoride -- -- 4.5 4.9 4.7 5.0 5.7 3.5 3.6 4.2 3.9 3.6 3.6SodiumChloride -- -- 4.6 4.9 4.7 5.0 5.7 3.5 3.6 4.2 3.9 3.7 3.6AmmoniumBifluoride -- -- 4.6 5.0 4.8 5.1 5.9 3.6 3.7 4.3 4.0 3.7 3.7Boric Acid -- 8.8 -- -- -- -- -- -- -- -- -- -- --AmmoniumMetavanadate -- -- -- -- 11.5 -- -- -- -- -- -- 22.4 --Ferric Oxide -- -- -- -- -- -- -- -- -- -- -- 15.2 --Cobalt Oxide -- -- -- -- -- -- -- -- -- -- -- -- 1.6__________________________________________________________________________
TABLE II__________________________________________________________________________MOLAR FORMULAS OF PIGMENTS (IN MOL PERCENT)EXAMPLESOxide 3 4 5 6 7 8 9 10 11 12 13 14 15__________________________________________________________________________SrO 60.0 60.0 75.0 33.3 60.0 40.0 -- 28.6 20.0 -- -- 33.3 25.0CaO -- -- -- -- -- 20.0 60.0 -- -- 75.0 25.0 -- 5.0MnO.sub.2 40.0 40.0 25.0 66.7 36.0 40.0 40.0 71.4 80.0 25.0 75.0 55.5 69.0VO.sub.2 -- -- -- -- 4.0 -- -- -- -- -- -- 5.6 --Fe.sub.2 O.sub.3 -- -- -- -- -- -- -- -- -- -- -- 5.6 --CoO -- -- -- -- -- -- -- -- -- -- -- -- 1.0plus residual amounts of carbonate and mineralizers__________________________________________________________________________
TABLE III__________________________________________________________________________PROPERTIES OF PIGMENTS EXAMPLES 3 4 5 6 7 8 9 10 11 12 13 14 15__________________________________________________________________________ Oil Absorption -- -- 15.6 20.2 17.4 19.3 19.3 23.8 21.1 37.6 28.4 18.3 22.9Color InMasstoneR.sub.d 4.6 5.3 5.3 4.6 5.4 5.2 5.0 4.5 4.7 4.9 4.6 4.6 4.4a 0.3 1.3 0.3 0.2 0.7 0.9 0.0 0.1 0.4 0.5 0.4 0.1 0.2b 0.4 1.7 1.6 0.1 1.4 1.4 0.4 0.0 0.5 1.1 0.6 -0.1 0.0__________________________________________________________________________ | An inorganic black pigment is made by calcining raw materials such as manganese dioxide, manganese carbonate, strontium carbonate or calcium carbonate. The product is a perovskite structure made up of (a) 25-84 mol % of a manganese oxide and (b) 75-16 mol % SrO and/or CaO plus residual carbonates and mineralizers. The thus-produced black pigment is particularly advantageous in that it contains no heavy metals or highly toxic material and that it has very low oil absorption and high tinting strength. | 2 |
FIELD OF THE INVENTION
This invention relates to scroll wheels on mice, trackballs and other user input devices.
BACKGROUND OF THE INVENTION
In many computers, user input (e.g., cursor control, screen scrolling, etc.) is often achieved by way of a pointing device such as a mouse or a trackball. A typical computer mouse 1 is shown in FIG. 1 . Mouse 1 has a case 16 having a bottom case 20 and an upper case 18 . As a user slides mouse 1 across a planar (or substantially planar) surface, motion detectors and encoders within case 16 may convert the two-dimensional movement of the mouse across the surface into horizontal and vertical motion of a cursor, pointer, or other object on a computer screen. Mouse 1 has two buttons 8 and 12 which a user can “click” or “double click” to select something on a computer screen. Other mice may have fewer or additional buttons, or other features. Mouse 1 may be connected to a computer or other device by a cord 5 through which mouse 1 may receive power and communicate with a computer (or other device). Alternatively, mouse 1 could be battery powered and communicate via a wireless connection.
Mouse 1 also has a scroll wheel 14 . Scroll wheel 14 is located such that the mouse user can comfortably turn the scroll wheel with a finger. The mouse and/or computer may be configured such that turning the wheel causes the screen image to scroll upwards or downwards. The scroll wheel may be configured to perform other functions, such as moving a screen object in a z direction; changing the zoom or other attributes of a screen image; scrolling horizontally; and innumerable other functions. A scroll wheel may also be configured to act as an additional button when pressed by the user.
To prevent the scroll wheel from rotating undesirably (e.g., when the user is moving the mouse but not turning the wheel), to provide a desired tactile sensation for the user, and to provide a means of indexing wheel rotation into discrete increments, some type of restraint is typically imposed on scroll wheel rotation. A common restraint consists of a series of regularly-spaced ridges, detents or other structures on a surface of the wheel or its axis, and a follower biased into contact with the detents. As the wheel rotates, the follower is biased to resist movement out of a detent, and the torque necessary to continue rotating the wheel increases slightly. As the user increases the applied torque (i.e., continues to turn the wheel), the follower rides over a ridge (or other structure separating two detents), whereupon the needed torque decreases until the follower is biased into the next detent. In this way, the user can easily gauge (and make) relatively uniform scrolling movements.
Existing mice scroll wheels restrain wheel rotation through a variety of configurations. U.S. Pat. No. 5,912,661, titled “Z-Encoder Mechanism” and owned by assignee of this invention, describes a configuration in which the detents are located on the axle of the scroll wheel. A metal spring attached to a printed circuit board within the mouse biases a follower into contact with the detents. An improvement upon this configuration is described in U.S. Pat. No. 6,353,429, titled “Detented Optical Encoder” and also owned by the assignee of this invention. Specifically, instead of a metal spring biased into contact with the axle detents, a plastic bracket contacts the axle near one of its rotational hubs and biases the axle upward so as to provide z-switch functionality. A follower, located within the portion of the bracket cradling the axle, is thereby simultaneously biased into contact with the detents. Further improvements are possible, however. For example, the configuration described in the '429 patent requires assembly of at least 4 parts to provide indexed rotation. Because each of these parts (like all mechanical components) will have dimensional tolerances, a “tolerance stack-up” of the assembly results. This tolerance stack-up can potentially result in a rotational torque that may vary from mouse to mouse unless relatively small tolerances are maintained. This can increase manufacturing expense.
In another configuration, regularly-spaced radially-extending indentations are molded into (or otherwise formed in) a side of a scroll wheel in a spoke-like arrangement A follower piece is biased into contact with the spoke-like indentations on the side of the wheel. The follower piece may be a molded extension of a carriage or other structure supporting a wheel axle, or it may be a separate member that is attached to the carriage. A potential disadvantage of this configuration, however, is the variability in torque required to rotate the wheel in one direction versus the other. In the case of a separate member attached to the carriage, an additional part is required, resulting in additional assembly steps, cost and potential tolerance stacking problems. In yet another configuration, the indentations are not formed in the side of the wheel in a spoke-like arrangement. Instead, a series of ridges and/or depressions are formed on an inner circumference of the wheel. A follower is biased radially outward into contact with the ridges and/or depressions. However, known scroll wheels implementing this configuration utilize a separate biasing member that is not an integral part of the carriage supporting the wheel axle.
A scroll wheel having circumferential detents that are acted upon by a biased follower integrally formed as part of the carriage would result in advantageous savings in assembly steps and expense. Such a design would also facilitate greater control over the fit of the components and allow greater performance consistency among the scroll wheels in different nice. For these and other reasons, advantages can be obtained from further refinements in scroll wheel design.
SUMMARY OF THE INVENTION
The present invention improves upon existing scroll wheel designs by providing a single component that rotatably supports the scroll wheel, and which has an integral follower arm extending into a well within which the scroll wheel rotates. Formed on a circumferential surface of the scroll wheel are regularly spaced detents or other structures forming regularly spaced regions of alternating height. Located on an end of the follower arm is a follower which rests within the detents. As the scroll wheel rotates and the follower is pushed out of a detent, the follower arm biases the follower radially into the surface on which the detents are located. By integrally forming the follower and follower arm as part of the same component that houses and rotatably supports the scroll wheel, the number of components is reduced, reducing tolerance stack-up and providing other advantages. The carriage may further be pivotably attached to a mouse or other structure, and a tab formed on the carriage. In this manner, the scroll wheel can also function as an externally depressible button.
In one embodiment, a modular scroll wheel assembly includes a scroll wheel sized for movement by a finger of a human user. The scroll wheel has a circumferential surface with regularly spaced regions of alternating height located on that surface. The modular scroll wheel assembly further includes a single-piece carriage that supports and rotatably holds the scroll wheel. The carriage has first and second sides that define a wheel well within which the scroll wheel rotates. An integral follower arm is disposed on the first side of the carriage; the follower arm has a follower in contact with the circumferential surface and is biased to resist deflection as the scroll wheel rotates.
An embodiment of a computer mouse according to the invention includes a housing sized and configured for manual movement by a user across a surface so as to permit a corresponding movement of a screen object on a computer display. The housing has a bottom case and an upper case coupled to the bottom case, and at least two depressible buttons movably attached to the upper case. The mouse further includes a scroll wheel having a circumferential surface with regularly spaced regions of alternating height located around that circumferential surface. A single-piece carriage rotatably supports the scroll wheel such that a portion of the scroll wheel extends outside of the housing. The carriage includes first and second sides forming a wheel well within which the scroll wheel rotates, and an integral follower arm on the first side of the carriage. A follower on an end of the arm is in contact with the circumferential surface and is biased to resist deflection as the scroll wheel rotates.
Other features and advantages of the invention are set forth below in the detailed description or will be apparent to persons skilled in the art in light of that description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective outer view of a computer mouse having a scroll wheel.
FIG. 2 is a front perspective view, with the upper case removed, of the mouse of FIG. 1 .
FIG. 3 is an exploded front perspective view of a scroll wheel, carriage and other internal components of the mouse of FIG. 1 .
FIG. 4 is an assembled front perspective view of a scroll wheel, carriage and other internal components of the mouse of FIG. 1 .
FIG. 5 is another assembled front perspective view of a scroll wheel, carriage and other internal components of the mouse of FIG. 1 , but from a different angle than that of FIG. 4 .
FIG. 6 is another exploded front perspective view of a scroll wheel, carriage and other internal components of the mouse of FIG. 1 , but from a different angle than that of FIG. 3 .
FIG. 7 is a top view of a scroll wheel, carriage and other internal components of the mouse of FIG. 1 .
FIG. 8 is a cut-away view taken along lines 8 — 8 of FIG. 7 .
FIG. 8A is an enlarged view of a region of FIG. 8 that has been rotated 90° counterclockwise.
FIG. 9 is a perspective view of a scroll wheel carriage according to the invention.
FIG. 10 is an enlarged perspective view of a region of FIG. 9 .
FIG. 11 is an enlarged top view of the follower arm and a portion of the carriage.
DETAILED DESCRIPTION OF THE INVENTION
An improved scroll wheel assembly according to the present invention is shown in FIGS. 1-11 . With reference to FIG. 2 , the upper case, as well as buttons 8 and 12 , have been removed for purposes of illustration. Located within mouse 1 and attached to lower case 20 is a printed circuit board 44 . Printed circuit board 44 electrically interconnects various mouse components, and also provides an internal structure to which other components may be attached. Scroll wheel 14 has an attached axle 22 . Axle 22 rotates within axle guides 58 (see FIG. 3 ) defined within carriage 56 . The mouse of FIGS. 1-11 is used only by way of example. Persons skilled in the art will appreciate that the invention is likewise applicable to other mouse designs. Such persons will also appreciate that the invention is likewise applicable to trackballs, keyboards and other input devices having (or capable of having) a scroll wheel.
FIG. 3 is an “exploded” front perspective view of an embodiment of the improved scroll wheel assembly according to the present invention. The upper case of the mouse has been removed for clarity, and various circuit components also omitted for purposes of clarity. Most of the lower case of the mouse has also been removed, with portion 20 ′ representing a small part of the lower case 20 . FIG. 4 is similar to FIG. 3 , but in an assembled condition. Scroll wheel 14 may (but need not) include an outer surface 15 that is textured to allow for easier movement by the user. In the depicted embodiment, scroll wheel 14 includes a hub 49 that is substantially open on at least one face, and has an exposed inner circumferential surface 50 exposed by the opening in that face. Evenly spaced along inner circumferential surface 50 are a series of peaks and troughs forming detents 52 . The series of peaks and troughs may include a sinusoidally-shaped series of peaks and troughs. Axle 22 is attached to wheel 14 , which attachment may be strengthened by spokes 54 . Wheel 14 , axle 22 and spokes 54 may be molded so as to form a single integral component.
After assembly, a portion of scroll wheel 14 rests within carriage 56 . Carriage 56 is a single, integral piece which can be molded. Carriage 56 includes axle guides 58 on both sides of carriage 56 . Each axle guide 58 may be formed between a pair of uprights 60 extending from (and integral to) carriage 56 . Although both axle guides 58 are shown in the drawings as having a “snap-in” configuration formed by an angled inlet between uprights 60 , other axle guide configurations are possible. For example, one axle guide 58 could be an enclosed hole (e.g., without a gap between the uprights 60 ) into which one end of axle 22 is inserted, with the other end of axle 22 being snapped into the other axle guide. Each axle guide 58 supports axle 22 for rotation, and is slightly larger in diameter than the portion of axle 22 that fits therein so as to allow rotation of axle 22 and wheel 14 .
Carriage 56 further has an integral follower arm 67 and follower 66 . Follower arm 67 projects inwardly towards scroll wheel 14 and is used to provide indexed wheel motion. After assembly, and as shown in FIG. 4 , follower 66 (located on the inwardly projecting end of follower arm 67 ) is in contact with the inner circumferential surface 50 . As wheel 14 is rotated within the wheel well 57 formed by carriage 56 , follower 66 is alternatively forced out of, and allowed to descend into, detents 52 . As follower 66 is forced out of a detent 52 , it is pushed radially inward against a radially outward bias of the spring force of follower arm 67 . In this manner, indexed rotation of scroll wheel 14 is obtained, and scroll wheel 14 is prevented from rotating except when such rotation is desired.
FIG. 9 is a perspective view of carriage 56 without scroll wheel 14 . FIG. 10 is an enlarged view of the region 10 of FIG. 9 , and shows exemplary dimensions for follower 66 and arm 67 . Dimensions may vary depending on material, scroll-wheel size, and other factors. As shown in FIG. 11 (which is a top view of the region shown in perspective in FIG. 10 ), the face 80 of arm 67 facing toward the detents may be straight when the follower 66 is centered within a trough (i.e., within a detent). As the dotted line shows, arm 67 flexes backward when force is exerted on follower 66 .
As shown if FIGS. 2-6 , carriage 56 may be mounted for pivotal movement within a mouse or other structure. Carriage 56 may include pivots 68 . Pivots 68 fit within pivot guides 70 formed in posts 72 , and are retained therein for pivotal movement. In the depicted embodiment, snap-fit pivot guides are shown; as with axle guides 58 , however, alternative arrangements are possible. Posts 72 are attached to (or formed as a part of) lower case 20 ′. Carriage 56 thereby pivots about an axis A passing through pivots 68 and pivot guides 70 . Located at the opposite end of carriage 56 is switch tab 74 . Switch tab 74 acts upon microswitch 76 when the user exerts downward force on wheel 14 ; switch tab 74 is thereby pressed against microswitch 76 , and actuates same. Microswitch 76 can be a self-biased switch such as a metallic beam switch, a metallic disc switch, or other type self-biasing switch which will support the carriage when not being pressed down by a user. As is known in the art, these types of switches are mechanically biased to an “off” state, and are only “on” when an external force is exerted on the switch. Although not shown, carriage 56 could alternatively be biased upward by a separate spring or resilient member. In such an alternative configuration switch 76 would not need to be self-biased.
FIG. 6 is an exploded front perspective view of the mouse and scroll wheel from an opposite side of the mouse. FIG. 5 is similar to FIG. 6 , but in an assembled condition and showing additional components. Encoder wheel 24 is attached to (or formed as a part of) the end of axle 22 . After assembly, and as shown in FIGS. 2 and 5 , encoder wheel 24 passes between a light emitting diode (LED) 42 and receptor(s) 46 . When scroll wheel 14 is rotated, the “spokes” of encoder wheel 24 alternatively allow and block light from LED 42 from reaching receptor(s) 46 , thereby facilitating detection of scroll wheel rotation. The details of such detection are known in the art, and are not critical to the present invention. The detents 52 could be configured such that, when the follower 66 rests within a detent, light from LED 42 reaches receptor(s) 46 . Alternatively, detents 52 could be configured so that, when the follower 66 rests within a detent, the encoder wheel 24 partially or completely blocks light from LED 42 from reaching receptor(s) 46 . LED 42 and receptor(s) 46 can be mounted upon a bracket 26 , which could in turn be mounted to circuit board 44 .
In one embodiment, hub 49 of scroll wheel 14 , axle 22 and spokes 54 may be integrally formed from any desired plastic such as an acetyl resin (for example, DELRIN®, available from E.I. duPont de Nemours and Company of Wilmington, Del.). If desired, a rubber-like thermoplastic elastomer such as SANTOPRENE® (available from Advanced Elastomer Systems of Akron, Ohio) may be overmolded or otherwise used to form an outer surface 15 of wheel 14 . Carriage 56 may also be molded from a plastic, for example Acrylonitrile Butadiene Styrene (ABS). The described materials are exemplary, however, and other materials and combinations are with thin scope of the invention. A small amount of lubricant_can be added to the connections between axles 22 and axle guides 58 and between follower 66 and detents 52 .
FIG. 7 is a top view of one embodiment of the invention installed on a mouse circuit board 44 , with certain components omitted. Although shown in certain figures as located directly opposite the pivots 68 , switch tab 74 could be located elsewhere. For example, switch tab 74 could be on one side of carriage 56 , shown as item 74 ′ in FIG. 7 . Circuit board 44 may also house components for tracking mouse movement across a surface, such as LED 91 and receptor 92 . Alternatively, mechanical encoder wheels and a captive rolling ball could be used, as could other motion tracking devices. FIG. 8 is a cutaway view taken along the line of sight 8 — 8 of FIG. 7 . Various components have been completely or partially removed so as to more clearly reveal detents 52 and follower 66 . As shown in FIG. 8 , a scroll wheel in one embodiment of the invention may have eighteen (18) evenly-spaced detents 52 distributed on inner circumferential surface 50 . FIG. 8A is an enlarged view of region 8 A of FIG. 8 , and has been rotated 90° counterclockwise for clarity. FIG. 8A shows dimensions for the embodiment of FIG. 8 , but the dimensions, shapes and positioning of the components may vary as desired. Follower 66 has a shape generally matching the trough shape. Fatigue on follower 66 and the follower arm 67 may be reduced if there is substantially no preload upon the follower. In other words, when the scroll wheel is assembled and follower 66 is substantially centered within a detent 52 , no significant force is exerted on follower 66 or arm 67 by wheel 14 .
As is clear from the above description, the invention provides numerous advantages over other scroll wheel configurations. Contained within a single part are the guides within which the scroll wheel axles rotate, the follower and the follower arm. Because there are a minimum number of parts, tolerances can be more easily and accurately maintained. This in turn enhances consistency in scroll wheel performance from mouse to mouse. Reducing the number of parts also reduces assembly time and expense. The invention further provides a consistent feel for a user rotating the scroll wheel in either direction. In other words, the forward and reverse rotational torque is more closely equal than is the case in other designs.
Although an example of carrying out the invention has been described, those skilled in the art will appreciate that there are numerous variations and permutations of the above described device that fall within the spirit and scope of the invention as set forth in the appended claims. As but one example, the detents could alternatively be located on an inner circumferential surface that is on a portion of the scroll wheel axle inside of the wheel hub, with the follower facing radially inward. As another example, the detents could be molded (or otherwise formed) on the outermost surface of the scroll wheel, the carriage modified, and the follower oriented to face radially inward. As yet another example, the axle could alternatively be molded as two half axles extending from either side of the carriage into the wheel well, with depressions molded into the scroll wheel for those half axles. As set forth above, the scroll wheel of the invention can be incorporated into other mouse designs, into other pointing devices (e.g., trackballs), and other input devices (e.g., keyboards). These and other modifications are within the scope of the invention, which is to be limited only by the claims. | A single-piece component rotatably supports a scroll wheel and includes an integral follower arm extending into a well within which the scroll wheel rotates. Formed on a circumferential surface of the scroll wheel are regularly spaced detents or other structures forming regularly spaced regions of alternating height. Located on an end of the follower arm is a follower which moves in and out of the detents as the scroll wheel rotates, with the arm biasing the follower against movement out of the detents. The carriage may also include pivots for relative movement of the carriage and scroll wheel assembly with respect to a housing, and a tab for actuating a switch. | 6 |
TECHNICAL FIELD
The present invention generally relates to a cooled vane component in a gas turbine engine. More specifically, the gas turbine vane has an improved cooling flow design and lower operating stresses.
BACKGROUND OF THE INVENTION
Gas turbine engines operate to produce mechanical work or thrust. Specifically, land-based gas turbine engines typically have a generator coupled thereto for the purposes of generating electricity. A gas turbine engine comprises an inlet that directs air to a compressor section, which has stages of rotating compressor blades. As the air passes through the compressor, the pressure of the air increases. The compressed air is then directed into one or more combustors where fuel is injected into the compressed air and the mixture is ignited. The hot combustion gases are then directed from the combustion section to a turbine section by a transition duct. The hot combustion gases cause the stages of the turbine to rotate, which in turn, causes the compressor to rotate.
The air and hot combustion gases are directed through a turbine section by turbine blades and vanes. These blades and vanes are subject to extremely high operating temperatures, often times upwards of 2800 deg. F. These temperatures often exceed the material capability from which the blades and vanes are made. Extreme temps also cause thermal growth in the component, which if not permitted, causes thermal stresses and can lead to cracking. In order to lower the effective operating temperature, the blades and vanes are cooled, often with air or steam. However, the cooling must occur in an effective way so as to use the cooling fluid efficiently.
SUMMARY
In accordance with the present invention, there is provided a novel configuration for a gas turbine vane assembly that provides effective cooling to gas-path surfaces while permitting movement of the platform. The vane assembly includes a plurality of airfoil cooling tubes and directed cooling to a vane platform.
In an embodiment of the present invention, a gas turbine vane assembly comprises an outer diameter pan coupled to an outer diameter platform, a hollow airfoil extending radially inward from the outer diameter platform, and an inner diameter platform connected to the hollow airfoil opposite the outer diameter platform such that the platforms are generally parallel to each other. The outer diameter platform has a trailing edge face spaced an axial distance from a leading edge face and includes a plurality of openings capable of receiving a plurality of cooling tubes and a tube collar associated with each of the plurality of openings. The plurality of cooling tubes extend radially inward from the outer diameter platform such that the tube collars are connected to each of the plurality of cooling tubes and the corresponding opening at the outer diameter platform. The plurality of cooling tubes extend through passages in the airfoil. The inner diameter platform includes a trailing edge face, a leading edge face, a plurality of corresponding openings for receiving the plurality of cooling tubes. A cover is fixed to each of the plurality of cooling tubes proximate the inner diameter platform and a forward pan is coupled to a forward end of the inner diameter platform while a meterplate is fixed to the inner diameter platform adjacent to the forward pan and is in fluid communication with an aft pan that is connected to an aft end of the inner diameter platform. The meterplate has a plurality of holes located therein capable of restricting a cooling fluid flow to a desired pressure and mass flow for a region of the holes positioned in the inner diameter platform and in fluid communication with the aft cavity. An aft cover is fixed to the aft end of the inner diameter platform to form an aft cavity. The inner diameter platform also includes a plurality of holes that receive a cooling fluid from the aft pan. An undercut is positioned in the inner diameter platform for providing increased flexibility to the inner diameter platform.
In an alternate embodiment, a flow restriction device capable of controlling a cooling fluid to an aft portion of an inner diameter platform of a gas turbine vane comprises an aft cover fixed to the inner diameter platform forming an aft cavity, a meterplate with a plurality of feed holes fixed to the inner diameter platform between a forward pan and the aft cover, a plurality of file cooling holes located in the inner diameter platform and in fluid communication with the aft cavity, and wherein the cooling fluid is capable of passing through the feed holes of the meterplate, into the aft cavity, and through the plurality of film cooling holes.
In yet another embodiment, an inner diameter platform of a gas turbine vane capable of increased thermal deflection comprise a gas path surface separated from a cold surface by a platform thickness, a forward pan, and an aft cover fixed to the cold surface. The platform thickness having an undercut extending between the gas path surface and cool surface, such that the undercut reduces stiffness of the inner diameter platform adjacent to the aft cover.
Additional advantages and features of the present invention will be set forth in part in a description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from practice of the invention. The instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The present invention is described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is an exploded view of the a gas turbine vane in accordance with an embodiment of the present invention.
FIG. 2A is a perspective view of an embodiment of the present invention including a plurality tube collars.
FIG. 2B is an alternate perspective view of an embodiment of the present invention that includes an outer diameter pan over the outer diameter platform.
FIG. 3 is a cross section view looking at the gas path surface of the outer diameter platform in accordance with an embodiment of the present invention.
FIG. 4 is a perspective view of a trailing edge cooling tube used in an embodiment of the present invention.
FIG. 5 is a perspective view of a mid-body cooling tube used in an embodiment of the present invention.
FIG. 6 is a cross section view looking at the gas path surface of the inner diameter platform in accordance with an embodiment of the present invention.
FIG. 7 is a perspective view looking at the cool surface of the inner diameter platform without the inner diameter pan in accordance with an embodiment of the present invention.
FIG. 8A is a detailed perspective view of a portion of FIG. 7 in accordance with an embodiment of the present invention.
FIG. 8B is a detailed perspective view similar to that of FIG. 8A but with the aft pan in place in accordance with an embodiment of the present invention.
FIG. 9 is a perspective view from the cool surface of the inner diameter platform with the inner diameter pan connected to the aft end of the inner diameter platform in accordance with an embodiment of the present invention.
FIG. 10 is a detailed perspective view of an inner diameter platform in accordance with an alternate embodiment of the present invention.
FIG. 11 is a cross section view of the airfoil of the vane assembly in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different components, combinations of components, steps, or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.
Referring to FIG. 1 , an exploded view of the gas turbine vane 100 , is depicted. An outer diameter pan 102 is affixed to the outer diameter platform 112 and has a plurality of holes 103 . Acceptable means for fixing the outer diameter pan 102 to the outer diameter platform 112 includes welding or brazing. The outer diameter platform 112 has a cool surface 111 and a gas path surface 113 . A plurality of cooling tubes 104 , 106 , and 108 extend from the outer diameter platform 112 . Specifically, the leading edge cooling tube 104 , mid-body cooling tube 106 , and the trailing edge cooling tube 108 are placed through openings in the outer diameter platform 112 , extending through the hollow airfoil 114 and reaching respective openings in the inner diameter platform 116 . Each opening in the outer diameter platform 112 has a respective tube collar 110 that is affixed to each of the cooling tubes 104 , 106 , and 108 and the corresponding opening. The outer diameter platform 112 has a leading edge face 112 A and a trailing edge face 112 B.
The cooling tubes 104 , 106 , 108 are capped at the inner diameter platform 116 . This embodiment illustrates three cooling tubes but the quantity of cooling tubes is not limited to exclusively three tubes. Covers 120 are affixed to the openings of the tubes to prevent cooling fluid from flowing from the airfoil 114 into the inner diameter platform 116 . The inner diameter platform 116 has a gas path surface 115 and a cool surface 117 that are separated by a platform thickness. The inner diameter platform 116 has a leading edge face 116 A and a trailing edge face 116 B.
Referring to FIGS. 8A and 8B , an undercut 118 is located within the inner platform thickness of the inner diameter platform 116 . The undercut 118 extends between the gas path surface 115 and the cool surface 117 along the thickness of the trailing edge face 116 B of the inner diameter platform 116 . By providing a greater opening within the thickness, an increase in the flexibility of the inner diameter platform 116 occurs, which helps to decrease the stress in the joint between the aft cover 126 and the inner platform 116 . Extending along the inner platform is a rail 119 that provides structural rigidity to the inner diameter platform 116 .
A meterplate 122 is affixed to the inner diameter platform 106 adjacent to a forward pan 124 . The meterplate 122 is oriented generally perpendicular to the inner diameter platform 116 so as to close an opening in the aft cavity while permitting a flow of the cooling fluid to enter the aft cavity generally parallel to the inner diameter platform 116 . The meterplate 122 restricts a supply of fluid flow to a desired pressure and mass flow for a region of film holes between a forward plenum and an aft plenum formed adjacent to the inner diameter platform 116 .
A forward pan 124 is affixed to the forward end of the inner diameter platform 116 and has a plurality of cooling holes 148 . An aft pan 126 is affixed to the aft end of the inner diameter platform 116 and does not have any cooling holes located therein. The aft pan 126 forms an aft cavity and has a generally flat portion and three sidewalls. Acceptable means for fixing the aft pan and the forward pan includes welding or brazing. In the gas turbine vane assembly 100 , the outer diameter platform 112 , the airfoil 114 , and the inner diameter platform 116 can be one single part, a welded assembly of parts, or any combination in between.
Referring to FIG. 2A , a view of the cool surface 111 of the outer diameter platform 112 without the outer diameter pan 102 , is depicted. The outer diameter platform has a trailing edge face and a leading edge face, where the outer diameter platform trailing edge face is spaced an axial distance from the outer diameter platform leading edge face. The openings for each of the cooling tubes is shown and fixed to the openings are the tube collars 110 for the corresponding cooling tubes. Referring to FIG. 2B , a view of the cool surface 111 of the outer diameter platform 112 with the outer diameter pan 102 , is depicted. The figure illustrates how the outer diameter pan 102 is affixed to the outer diameter platform 112 . The plurality of cooling holes 103 located on the outer diameter pan 102 are oriented at a surface angle relative to the outer diameter platform 112 .
Referring to FIG. 3 , a cross section view looking at the gas path surface 113 of the outer diameter platform 112 , is depicted. A plurality of cooling holes 121 are illustrated. Also, there are the openings for each of the cooling tubes. The cooling holes 103 located on the outer diameter pan 102 supply cooling fluid to pass through the cooling holes 121 to cool the gas path 113 surface of the outer diameter platform 112 .
Referring to FIG. 4 , an illustration of a trailing edge cooling tube 108 , is depicted. The trailing edge (TE) cooling tube 108 has an opening 128 , an opposing end 130 and a plurality of cooling holes 132 . The opening 128 receives cooling fluid from the outer diameter platform 102 with the cooling fluid passing through the tube 108 . The end 130 of the TE cooling tube 108 is closed by a cover 120 which prevents the cooling fluid from flowing into the inner diameter platform 116 . Since the cooling fluid is trapped in the body of the TE cooling tube 108 , the cooling fluid is forced out through the plurality of holes 132 . The cooling fluid exits the cooling tube and is directed towards an inner wall of the airfoil 114 and thus, cooling the airfoil 114 . The cooling fluid can be air or stream or a comparable cooling fluid. The TE cooling tube 108 also has raised surfaces 134 along the tube 108 . These raised surfaces 134 touch the inside of the airfoil and helps to hold the tube in place.
Referring to FIG. 5 , an illustration of a mid-body cooling tube 106 , is depicted. The mid-body cooling tube 106 has an opening 136 , and an opposing end 138 , and a plurality of cooling holes 140 . Similar to the TE cooling tube 108 , the mid-body cooling tube 106 directs cooling fluid from the outer diameter platform 112 and into the opening 136 of the mid-body cooling tube 106 . The cooling fluid is trapped in the body of the tube 106 because the end 138 is closed off with a cover 120 affixed at the inner diameter platform 116 . This forces the cooling fluid to pass through the plurality of holes 140 and onto the inner wall of the airfoil 114 .
Referring to FIG. 6 , a cross section view looking at the gas path surface 115 of the inner diameter platform 116 , is depicted. This view is from the gas path side 115 of the turbine vane. The inner diameter platform 116 can have a plurality of cooling holes 142 for directing a supply of cooling fluid along the gas path surface 115 of the inner diameter platform 116 . The cooling holes 142 could be oriented at a surface angle relative to the inner diameter platform 116 . This allows for improved cooling of the gas path surface 115 of the inner diameter platform 116 .
Referring to FIG. 7 , a view looking at the cool surface 117 of the inner diameter platform 116 without the inner diameter pan 124 , is depicted. The covers 120 are affixed to the cooling tubes to prevent cooling fluid from flowing into the cooling tubes 104 , 106 , and 108 from the inner diameter platform 116 . The meterplate 122 is shown affixed to an inner rail 119 of the inner diameter platform 116 .
Referring to FIG. 8A , a close up view of the sidewall portion and trailing edge face 116 B of the inner diameter platform 116 of FIG. 7 , is depicted. Located in the inner diameter platform 116 , and visible in FIG. 8A , is the undercut 118 , which for this embodiment, extends generally the axial length of the trailing edge face 116 B. The undercut 118 is slot-like in shape, where material of the inner diameter platform 116 has been removed so as to reduce stiffness of the inner diameter platform. FIG. 8A also illustrates an example of a sheet metal seal slot 146 along one of the side walls of the inner diameter platform 116 and outer diameter platform 112 . There are a plurality of cooling holes 144 extending through the inner diameter platform 116 . Cooling fluid is provided through the cooling holes 148 of the inner diameter pan 124 . The cooling fluid is passed through the plurality of holes 144 on the cool side of the inner diameter platform 116 . The cooling fluid then passes through the cooling holes 142 on the gas path surface 115 of the inner diameter platform 116 to help cool the gas path surface 115 of the turbine vane. The illustrated slot 146 is an example of the orientation and position of a sealing slot. A sheet metal seal fits into the slot 146 .
Referring to FIG. 8B , a similar view to FIG. 8A , but with the aft pan 126 included. The aft pan 126 receives the cooling fluid and directs the cooling fluid into the inner diameter platform 116 and through the plurality of cooling holes 144 located along the inner diameter gas path surface 115 .
Referring to FIG. 9 , a view looking at the cool surface 117 of the inner diameter platform 116 with the inner diameter pan 124 , is depicted. The inner diameter pan 124 can have a plurality of cooling holes 148 for receiving a supply of cooling fluid and directing the cooling fluid to holes 142 in the inner diameter platform. In this view of the inner diameter platform 116 , the undercut 118 , the meterplate 122 and the cooling tube covers 120 are visible.
Referring to FIG. 10 , a close up, cutaway section of the cool surface 117 of the inner diameter platform 116 , is depicted. In this view of the inner diameter platform 116 , the undercut 118 and the aft pan 126 are visible.
Referring to FIG. 11 , a view from the top of the cross section of the airfoil 114 , is depicted. The figure illustrates the three hollow cavities for holding the three cooling tubes 104 , 106 , and 108 . However, the invention is not limited to three cavities within the airfoil and can be more or less than three.
The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and within the scope of the claims. | A gas turbine vane to improve vane performance by addressing known failure mechanisms. A cooling circuit to the trailing edge of a vane airfoil is fed from the outer diameter platform, which prevents failure due to an oxidized and eroded airfoil trailing edge. The gas turbine includes an outer diameter platform, a hollow airfoil and an inner diameter platform with a plurality of cooling tubes extending radially through the airfoil. The cooling tubes are open at the outer diameter end and closed with covers at the inner diameter end. The inner diameter platform is also cooled and includes a meterplate for a portion of the cooling passageway and includes an undercut to improve thermal deflections of the inner diameter platform. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an improved three dimensional (3D) printing quoting tool and system. More particularly, the present invention relates a viewing and quoting tool that may be used internally over a local area network (LAN), over the internet, or by other similar means. The 3D printing tools contemplated are capable of taking information from and presenting information to customers in order for the customer to have selective input into various aspects of such design and fabrication which affect price of a customized 3D part, and the printer to accurately price a customized 3D part.
[0003] 2. Discussion of the Prior Art
[0004] U.S. Pat. No. 6,836,699 provides a automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part. The quotation module then provides the customer with the cost to manufacture the mold or a number of parts. The quotation is based in part upon mold manufacturing time as automatically assessed from the part drawings and based in part on the independent parameters selected by the customer. The customer's part is geometrically assessed so the system automatically selects appropriate tools and computes tool paths for mold manufacture. In addition to the part cavity, the system preferably assesses the parting line, the shutoff surfaces, the ejection pins and the runners and gates for the mold. The preferred system then generates CNC machining instructions to manufacture the mold, and the mold is manufactured in accordance with these instructions.
[0005] U.S. Pat. No. 7,120,510 provides method of executing a plurality of steps that are performed sequentially in temporal order under computer control. Each of the plurality of steps is executed by one of a plurality of terminal computers. When a terminal computer assigned to a step has completed the work in the step and is able to execute the work in the next step, it sends a work completion signal to a central processing computer. The central processing computer receives this work completion signal and prepares a work item notice that indicates that the next step can be started, such that the notice can be displayed on the screen of the terminal computer used for the next step. The terminal computer used for the next step allows the notice displayed on its screen to be clicked to start work on the next step assigned to it.
[0006] U.S. Pat. No. 7,590,466 Disclosed an automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturability. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part.
[0007] U.S. Pat. No. 8,014,889 is a method ( 10 ) for manufacturing a three-dimensional object. The method ( 10 ) includes receiving ( 14 ) digital information of the three-dimensional object over a communication line and building ( 30 ) the three-dimensional object based at least in part on the received digital information, where at least part of the three-dimensional object is built by rapid manufacturing, and where the three-dimensional object comprises an exterior surface. The method also includes vapor smoothing ( 32 ) at least a portion of the exterior surface of the three-dimensional object.
[0008] United States Patent Publication No. 20030126038 discloses an automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part. The quotation module then provides the customer with the cost to manufacture the mold or a number of parts. The quotation is based in part upon mold manufacturing time as automatically assessed from the part drawings and based in part on the independent parameters selected by the customer. The customer's part is geometrically assessed so the system automatically selects appropriate tools and computes tool paths for mold manufacture. In addition to the part cavity, the system preferably assesses the parting line, the shutoff surfaces, the ejection pins and the runners and gates for the mold. The preferred system then generates CNC machining instructions to manufacture the mold, and the mold is manufactured in accordance with these instructions.
SUMMARY OF THE INVENTION
[0009] A difficulty with presently available 3D Printing and Quoting Systems is that they often result in wildly inaccurate quotations for customers and potential customers. Current systems often merely approximate the amount of material to be used in printing and forming the 3D object and create a quotation based on the volume or mass of the object imported into the system. This method of quoting often results in manufacturers creating certain parts far below cost, cutting deeply into profitability. Or, in certain applications, creates a waste of materials and time on a 3D printing device (particularly important to certain companies/universities with internal 3D printing machines or departments). Oftentimes this is solved by manufacturers manually pricing a job, or by simply overpricing parts to avoid losses on any individual part. However those methods are generally inefficient, nor do they solve the underlying problem of having a non-optimized electronic quoting system. Thus, a the quoting systems and tools of the present invention are capable of accurately calculating the materials used, waste, time to completion, and other variable costs associated with 3D printing a particular physical object.
[0010] Such an application is capable of being used with several types of computer aided drafting (CAD) or representative 3D models that are imported into the system as files. In addition, the graphical user interface (GUI) of the system allows a user or consumer to view, rotate, and manipulate the file in 3D space allowing for rotation about the X, Y, and Z axes. This allows the user to verify their design was properly uploaded and scale the part to desired dimensions.
[0011] Typical 3D printers utilize one of four major types of 3D printing technology: Stereolithography (SLA), Selective Layer Sintering (SLS), Fused Deposition Modeling (FDM), PolyJet/InkJet 3D Printing and the system of the present invention is capable of modeling a printing tray for any of those process, as well as is capable of modeling newer and unique methods of 3D manufacture with only simple adjustments by the administrator or manufacturer.
[0012] Two issues that drive errors in typical 3D printing price quoting software are: 1) The amount of support structure used in printing; and 2) The time to completion for a print job. In 3D printing, portions of the part that are not vertically positioned over another part must be supported by a “support structure”, the material used in support structure is similar to that which is used in creating the actual part, but often requires a separate “printing head” to create the support structure as opposed to the actual portions of the printed object. Thus, if the amount of support structure is not accurately modeled the amount of material (support structure) used may be vastly over, or underestimated, as will the number of times the 3D printer will have to change printing heads, which can greatly increase time to completion.
[0013] Thus, the current system has several unique features that result in a more accurate pricing system, and even the ability to optimize the printing process. Firstly, the system can generate and define a buildable area that represents the 3D printing device to be used in the final process and can place a part in that area. The buildable area will have a support surface (build tray, floor) to which the software can snap the digital part to, “grounding” the part. The system also calculates the “envelope” for the desired part, the 3D box that contains the dimensions of the part along an X, Y, and Z axis, to ensure it can be constructed within the buildable area. This then allows the system to calculate the amount of support material needed (and display that to the user) and allow the user to re-orient the part inside the buildable area and visualize the support alongside the part. It can also simultaneously calculate the estimated time to completion for 3D printing the part. Then the system can calculate a price per piece based on the quantity desired by the customer/user and submit orders (if desired) to the manufacturer. Thus, this process is uniquely capable of pre-calculating time and wasted materials in ways that previous pricing tools cannot.
[0014] To achieve these objectives, a 3D Printing and CAD File Quoting System, methods, and tools having the following features is proposed.
[0015] A method for generating a quote for a three dimensional (3D) printed object, the method having at least the steps of: providing a user generated 3D model, importing said user generated 3D model into a 3D printing quote generation system, analyzing the user generated 3D model and generating a 3D envelope around said model, the 3D envelope corresponding to the X, Y, and Z dimensions of the user generated 3D model, instantiating a buildable area and a support surface in the quote generation system, displaying the user generated 3D model, buildable area, and support surface in a graphical user interface (GUI), orienting the user generated 3D model within the buildable area, snapping the user generated 3D model to the support surface and displaying such in the GUI, generating a digital support structure for the user generated 3D model based on the orientation of the user generated 3D model, and generating a quote for a three dimensional (3D) printed object based on the user generated 3D model.
[0016] In certain embodiments the user can manually reorient the user generated 3D model within the buildable area about the user generated 3D model's X, Y, or Z axis. In a preferred embodiment the quote generation system provides the user options for optimizing the orientation of the user generated 3D model to minimize support structure or price, and calculating the optimal orientation for the user's selected choice and displaying said orientation to the user in the GUI. Other features are contemplates such as: the user can selectively hide the support structure in the GUI, the manufacturer can customize a set of variables affecting the quote, scaling the user generated 3D model within the quote generation system, detecting defects in the user generated 3D model that would prevent proper manufacture of the three dimensional (3D) printed object, notifying the user of said defects, interrupting generation of the quote when said defects would prevent manufacture of the three dimensional (3D) printed object, sometimes the user is prompted to contact an administrator when generation of the quote is interrupted, a list of defects detectable may preferably be defects detected in the user generated 3D model are selected from the group comprising: thin walls; non-manufacturable holes; and non-manufactuable dimensions. Preferably there is a feature allowing for manufacturing the three dimensional (3D) printed object.
[0017] In a second embodiment the invention contemplates a method of manufacturing a three-dimensional (3D) object, the method comprising: providing a digital manufacturing system, the manufacturing system providing a graphical user interface (GUI) to a customer, receiving digital information from the customer wherein the digital information comprises: a digital representation of the 3D object, displaying the digital representation in the GUI, generating a digital support structure for the digital representation corresponding to a support structure for the 3D object, calculating a quotation for 3D printing the 3D object based upon a set of cost-affecting parameters determined by computer assessment of at least the 3D object and support structure, communicating the quotation to the customer, and upon acceptance of the computer calculated quotation by the customer, 3D printing the three dimensional object.
[0018] Preferably the method of manufacture may also include: generating a 3D envelope around the digital representation, the 3D envelope corresponding to the X, Y, and Z dimensions of the user generated 3D model, instantiating a buildable area and a support surface in the quote generation system; and displaying the buildable area, support surface, and 3D envelope in the GUI. Additionally the 3D envelope is automatically oriented in the buildable area such that it connects to the support surface, the digital support structure connects portions of the 3D object to the support surface. In other cases the customer can reorient the digital representation in the buildable area around the X, Y, or Z axis of the digital representation, and the digital manufacturing system automatically recalculating the amount of support structure required for a new orientation and displaying said new support structure in the GUI. The user can selectively hide the support structure in the GUI.
[0019] In a third embodiment the invention contemplates a method for generating a price quote for at least one three dimensional (3D) printed object comprising: receiving a customer's computer aided drafting (CAD) file corresponding to at least one 3D printable object, providing the customer with at least one computer menu of customer-selectable options for manufacturing the at least one 3D printable object, and allowing the customer to select one of the provided customer-selectable options assessing the customer's CAD file via computer to determine the volume of material in the at least one 3D printable object, the amount of support structure required to print the at least one 3D printable object; and the time required to print the at least one 3D printable object, computer calculating a price quote for 3D printing the at least one 3D printable object based on at least the material in the at least one 3D printable object, the amount of support structure required to print the at least one 3D printable object; and the time required to print the at least one 3D printable object, thereby generating a price quote, and communicating the quote to the customer via computer.
[0020] Preferably the method can also allow for computer calculating the price quote further comprises accounting for variables selected from the list comprising: the number of changes in printing heads, the amount of material wasted, and time thresholds. The method also includes generating a buildable area comprising an open area and a build tray, orienting the CAD file within the buildable area such that it is located on the build tray, and generating the support structure required to print the at least one 3D printable object corresponding the CAD file as oriented in the buildable area. The user can manually re-orient the CAD file along the X, Y, or Z axis of the CAD file, and then the computer recalculates the price quote based on the orientation of the CAD file. Preferably, the amount of support structure estimated has less than a five percent error when compared to the amount of support structure actually required to print the at least one 3D printable object.
[0021] Such embodiments do not represent the full scope of the invention. Reference is made therefore to the claims herein for interpreting the full scope of the invention. Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated or become apparent from, the following description and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Other features of my invention will become more evident from a consideration of the following brief descriptions of drawings:
[0023] FIG. 1 is a perspective view of a representative 3D Part shown within the price quoting system according to the present invention.
[0024] FIG. 2 is a perspective view of a representative 3D Part shown within the price quoting system with additional support structure shown according to the present invention.
[0025] FIG. 3 is a perspective view of the representative 3D Part of FIG. 1 reoriented within the price quoting system of the present invention.
[0026] FIG. 4 is a perspective view of the representative 3D Part reoriented as in FIG. 3 with rebuilt additional support structure.
[0027] FIG. 5 is a perspective view of a representative 3D Part shown within the price quoting system with functional options demonstrated.
[0028] FIG. 6 shows exemplary transactions for pricing a 3D printing job using the system of the present invention.
[0029] FIG. 7 is a representative quote as output by the current invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring now the drawings with more specificity, the present invention essentially provides a Three Dimensional (3D) Printing and CAD File Quoting System, or a viewer and quote engine for 3D parts corresponding to the 3D printing of those parts. Using the present invention a user may import a file from his computer into the 3D quoting system and receive a price quote from the system based on the size, scope, orientation, and other relevant factors related to the part. In addition the system can be programmed with several other variables and features discussed below.
[0031] Looking now to FIG. 1 a representative 3D Part 20 is show in the 3D quoting system's Graphical User Interface (GUI) 10 . Part 20 will typically represent a user's stereolithography (STL) format file, but other file formats are contemplated for use with the 3D quoting system through conversion and direct implementation. The GUI will typically involve drop down menus, radio buttons, and other conventional features that allow the user to select the process for making the part, color, density, finish, and other factors. In addition to conventional features of a 3D price quoting system the system of the present invention includes a representative printing tray or support surface 11 . The printing tray 11 can be scaled to represent the tray or surface of the 3D printing machine corresponding to the printing process the user selects (such as FDM, SLS, SLA, or other printing processes). Also unique to the present invention is the system's construction of an envelope or boxed border 30 around 3D Part 20 .
[0032] Envelope 30 shows a graphical representation of the X ( 31 ), Y ( 33 ), and Z ( 32 ) dimensions of the part as it is currently orientated. This envelope shows to the user the footprint of the part 20 within the build space 10 , and particularly the footprint on printing tray 11 . In certain configurations additional parts will be able to be manufactured simultaneously depending on the part's footprint, thereby affecting the price quote. In certain situations diagonals 34 are also shown in the envelope and may confer to the user additional information.
[0033] As can be seen in FIGS. 1 & 2 and additionally in other orientations in FIGS. 3 & 4 the price quotation system consistently can orient the part such that it is touching or adjacent to the printing tray 11 . This is a necessary step for generating support structure 40 which connects portions of piece 20 to tray 11 and supports them during the printing process. Support material is essential to the majority of modern 3D printing processes. A part (such as part 20 ) is printed one layer at a time, and without support material essential portions of the 3D printed part will fall to the base tray, into the undercuts, or through hollow features as the part is being printed. Thus, support material, or support structures 40 are used to hold layers in place and keep the base material out of the way.
[0034] Typical 3D printing quoting systems have no way of accurately modeling support material 40 . Mistakes in estimating the amount of support material used in printing often exceed 50% of the cost of printing the part. Thus, support structure (along with part size, time to print, and other factors) is a major factor in driving costs for the manufacturer and failures in estimation can cause major cost overruns. Thus as can be seen in FIGS. 2 & 4 the system of the current invention can generate and pre-render the support structure dynamically as the part is oriented within the space 10 . And as can be seen different support structures can be constructed for the same part depending on the orientation and reorientation of the part. The current system can estimate the total amount of support structure used with less than 10% error and typically in most cases the error is less than 5%.
[0035] One additional cost driver of present 3D printing processes is that printers typically must switch between separate printing heads when printing support material 40 and the part 20 . This is essential as the support material is constructed from a different composition for simple removal later (some implementations utilize chemical baths to dissolve support structure). Changing and cleaning printer heads takes time and thus increases the cost of manufacturing a part. For example, printing at boundary 21 (seen in FIGS. 2 & 4 ) requires a change from printing support structure 40 to part 20 necessitating a change in printer heads. Thus, one additional benefit of the current system is that by accurately rendering support structure 40 , the system can also accurately calculate the number of times the printer heads will have to trade off, and estimate the time and cost associated with those changes, greatly increasing the accuracy of the final price quote.
[0036] As can be seen with greater specificity in FIGS. 3 & 4 , one critical aspect of the current invention is the ability of the user to re-orient the 3D part 20 within the interface 10 and the system's ability to automatically reconfigure and recalculate the support structure 40 . The user can choose to reorient the part 20 around any of its X, Y, or Z axes thus giving the user total control over the printing process. While the system may also have an “auto orient” feature that will minimize the cost for the consumer, certain parts will have intricate features that a user may not want to be exposed to support structure. By way of example, a user may desire the orientation of FIGS. 3 & 4 as side 22 of the part 20 is not supported by support structure on the exterior. If there are details, such as a logo, being 3D printed on that side of the part, this orientation would preserve the integrity of those fine features.
[0037] Additional, optional, features of the invention are shown in FIG. 5 . One feature of preferred embodiments of the price quoting system is the ability to scale the model of within the system. Users can dynamically scale the model 20 , either by using the dimensions selecting tool (in, cm, mm, etc) or by selecting a percentage (%) of the current dimensions of the object as shown by arrows 15 . Certain dimensions of the part 20 such as edge 25 , width 26 , and height 27 can be dynamically extracted by the system and displayed to the user. Additionally, at certain stages the system will warn users that certain aspects of the model are not printable with the 3D printing process they have selected. Often this is due to excessive dimensions, thin walls, or unprintably small holes (as seen in FIG. 6 ).
[0038] Looking now with greater specificity to FIG. 6 exemplary actions, methods, and transactions for price quoting and order placement are show. In a typical transaction, as shown in FIG. 6 , the customer loads a file 102 on his computer 101 , preferably this is a STL file, but other files are often used. The user than sends the file 102 to the manufacturer's input terminal or processing system 103 . The system is equipped with a GUI 104 . The terminal 103 is pre-loaded with protocols 105 , manufacturing variables 106 , and design parameters 107 , such pre-loaded features are discussed in greater detail throughout the specification but may include material costs, manufacturing times, factory layout, etc.
[0039] The input terminal 103 then generates a buildable area 108 based on the design parameters and user preferences and displays them to the user in the GUI. The 3D file 102 is then displayed in the GUI and oriented 109 within the GUI and buildable area. The user may also selectively reorient 109 the model 102 according to his own preferences. The system then generates a 3D support structure 110 for the 3D file according to the orientation and size of the part and displays the support material and model to the user. In certain cases the user may then re-orient the model and the system will dynamically regenerate the 3D support structure 110 according to the new orientation of the part. The system also will conduct a series of tests 111 , such as hole detection, thin wall detection, and size detection 112 which may notify the user's computer 101 of possible manufacturing issues for the part as currently oriented and generated. The customer can then choose to re-orient and modify the part to fit within typical design parameters or submit the part to an administrator 114 for a manual price quote. If no errors are detected the system can automatically generate a price quote 113 for the customer 101 who can then submitted to the Administrator 114 for final approval and manufacture 115 .
[0040] An exemplary price quote output page is shown in FIG. 7 . Shown outputs include (but are not limited to) parts, quantity, file name and type, manufacturing process and manufacturing specifications, finish, unit price, total price, and other variables relevant to the consumer.
[0041] Accordingly, although the invention has been described by reference to certain preferred and alternative embodiments, it is not intended that the novel arrangements be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosures and the appended drawings. | A system and method for a three dimensional (3D) printing quoting tool and system is provided for in the present invention. The 3D printing tools contemplated are capable of taking information from and presenting information to customers in order for the customer to have selective input into various aspects of such design and fabrication which affect price of a customized 3D part, and the printer to accurately price a customized 3D part. | 6 |
This is a continuation in part of Ser. No. 548,522 filed Feb. 10, 1975, and now abandoned.
BACKGROUND OF THE INVENTION
The present invention concerns a method of making cold reduced Al-killed steel strips and sheet suitable for press forming by a continuous casting and continuous annealing process. More particularly, the present invention concerns a method of making a steel strip whose mechanical properties are not inferior to those of a steel sheet made by the batch type annealing process by means of controlling [N] %, Sol. Al. % and Sol.Al.%/[N]% ratio in the steel making stage.
A continuous casting process is advantageous in that the casting operation may be performed continuously with a consequent saving of manpower, the yield point is improved and uniform quality is obtainable. It has rapidly and widely come to be used in recent years. The steel widely used in continuous casting process for making cold reduced steel sheets is low carbon A1-killed steel having the general composition: C = 0.04 to 0.06%, Sol.AL. = 0.020 to 0.040%; N = 0.005 to 0.007%, Mn = 0.20 to 0.50%; P = 0.007 to 0.020%; and S = 0.010 to 0.030%.
Except for Sol. Al. and Mn, the above components are unavoidable in steel. The [N] is higher than that of Al-killed steel made in accordance with ordinary ingot making (0.003 to 0.005% [N]), because the molten steel is apt to come in contact with air more frequently between ladle and tundish, in the tundish and between the tundish and casting mold in the continuous casting process. The reason for controlling the Sol. Al content within the range of 0.020 to 0.040% is that advantageous results can be obtained in the form of steel sheet having excellent press-formability since the Lankford value is high and the yield point is low if the Sol. Al content is within said range. In the case of batch type annealing, when the aforementioned [N] range and Sol. Al range are used comparable results are not obtained. The reason for controlling the Mn content to 10 × [S]% to 0.50% is to avoid red shortness caused by S in steel by forming MnS.
The conventional continuous annealing process known in the art requires a shorter period of time for the steel to remain in the furnace than in the case of the batch type annealing process, and uses rapid heating and cooling. The steel sheet obtained by this annealing process has a low strain aging property and a high yield point and is not suitable for press forming. For these reasons, it is well known that it is mainly used for tin plate. However, the utility value of annealed cold reduced steel strip for press forming will be unlimited in view of the continuous annealing process, remarkable merits of the continuous annealing process for high efficiency in production and uniformity in quality once the above mentioned defects in the continuous annealing process have been rectified.
Until now the continuous process for obtaining a soft steel strip was proposed in U.K. Pat. No. 1,334,022 as a continuous annealing process for low carbon cold reduced soft steel strip for press forming which is characterized in that the cold reduced low carbon steel strip is heated, quenched, continuously passed through a furnace equipped with a heating zone, heated the strip up to 1,250° to 1,300° F. in said heating zone, quenched the same to below 1,000° F. from the above temperature range in said quenching zone, e.g. at a rate of 50° C.,/sec, and successively held the strip for at least 30 seconds within a temperature range of 800° to 1,000° F. in the shelf treating zone. However, the problem encountered in the above mentioned U.K. Patent process was that the shelf treatment continuous annealing given to continuously cast Al-killed steel having the above mentioned composition would never yield the steel sheet having the press formability of the commercial grade cold reduced steel sheet obtained by the batch type annealing process.
Generally, the properties required for a cold reduced steel sheet for press formability for it to be of commercial grade are as follows:
(1) it should have a low yield point (to be soft) and
(2) it should have excellent strain aging properties. The standards as regards the above mentioned properties of the commercial grade cold reduced steel sheet produced in the conventional batch type annealing process (Japanese Industrial Standards, G-3141, similar to ASTM A-109) are:
Yield Point = 22 to 23 kg/mm 2
After tempering = reappearance of yield point
elongation after 38° C. × 8 days aging is 1.5% or less.
If a steel continuously cast suitable for a continuous annealing process including shelf treating is developed under the present circumstances, process for the production of cold reduced steel strip from the steel making to the annealing is carried out by a continuous operation and its industrial merits will naturally be evaluated most highly.
SUMMARY OF THE INVENTION
The present invention aims to overcome the aforementioned and other problems and disadvantages of the prior art, and is characterized in that the Sol. Al content, the [N] content and the Sol.Al%/[ N] % ratio are controlled respectively within the specified ranges in the continuously cast Ai-killed steel.
An object of the invention is to provide an Al-killed steel strip made by a continuous casting and continuous annealing process having a press formability which is not inferior to that of the ordinary Al-killed steel made by batch type annealing process.
Another object of the invention is to make best use of the continuous annealing process for Al-killed steel made by the continuous casting process.
According to the present invention, there is provided a method of making an Al-killed cold reduced steel strip and sheet suitable for press forming which method comprises steel making, hot rolling including coiling at a high temperature therein, pickling and cold reducing, and continuous annealing including shelf treating therein, steel whose chemical composition is controlled as follows: [N] % = 0.005% ≦ [N] ≦ 0.007%; Sol. Al % = 10 x[N] % ≦ Sol.Al ≦0.12% and ratio Sol.Al%/[ N] % = 10 to 20.
It is preferable that coiling is performed at a temperature within the range of 700° C. to 780° C. and that the [N] % content and the ratio of Sol. Al%/[ N] % are controlled in the continuous casting step.
Other objects and advantages will be apparent from the following description and the accompanying drawing.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 shows the relationship between the Sol. Al and [N] contents in steels of the invention.
FIG. 2 shows the relationship between yield point and Sol. Al%/[ N] % ratio in the steel of the invention.
FIGS. 3 and 4 are typical continuous annealing cycles available in this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
From FIG. 1 it is apparent that the [N] content and the Sol. Al content in the steel should be: 0.005% ≦ [N] ≦ 0.007%; and 10 × [N] % ≦ Sol. Al ≦ 0.12%. In FIG. 1, the border line (A) corresponds to Sol. Al%/[ N] % = 10, and is based on the fact that the larger the Sol. Al%/[N] % ratio becomes the lower the yield point becomes. The relationship between such ratio and the yield point has its optimum range as shown in FIG. 2. If the ratio increases further, then it will cause the yield point to rise. In other words when the ratio of Sol. Al%/[ N] % is within the range of 2-15, the yield point will decrease as said ratio is increased and conversely if said ratio exceeds 15, it will gradually raise the yield point. Thus, it has been confirmed that the above mentioned ratio should be within the range of 10 to 20, to obtain the yield point of commercial grade cold reduced steel sheet. The border line (B) in FIG. 1 shows such an upper limit. It has been found that the yield point decreases as the Al%/[ N]% ratio is increased within the range of 2-15 because the increase in Sol.Al %/[ N]% ratio leads to the more sparse distribution of AlN precipitation and results in good grain growth during continuous annealing. It the ratio continues to be increased and exceeds 15, then solute Al content increases and solid solution hardening thereby tends to be brought about and, consequently, the raising of the yield point becomes unavoidable. The upper limit of the Sol. Al content was set in view of the raising of the yield point and operating efficiency at the time of continuous casting. That is to say, if the Sol. Al content exceeds 0.12% or the Sol.Al/[N] ratio exceeds 20, the nozzle for pouring the molten steel into the casting molds becomes clogged and causes difficulties in operation.
The lower limit of [N]% is rather high as shown in FIG. 1 as the border (C) ≧ 0.005%. It should be noted that the percents herein are in terms of weight unless otherwise stated. This is a requirement for reducing the deterioration of the properties at the coil ends. As will be discussed later, the outer and the inner peripheries of the coil, i.e. the coil ends are cooled faster than its middle portion when the steel is coiled at a high temperature after final hot rolling, and self-annealing effects of the coil become difficult to obtain and said [N] tends to be unable to precipitate as AlN completely. This exerts undesirable influences on the strain aging property. That is why [N] % in steel is controlled to [N]≧ 0.005%. However, too high a [N] content raises the yield point, consequently the same level in property as that of ordinary steel becomes difficult to obtain. Therefore, the upper limit is set at [N] ≦ 0.007%. This is shown in FIG. 1 as the border line (D). Thus, the range of 0.005% ≦ [N] ≦ 0.007% is the optimum range for making easy precipitation of AlN in the favourable self-annealing dependent upon coiling at a high temperature.
A similar consideration may be taken as for ordinary ingot making process in respect to C, P, S, and Mn, C, P and S contents should preferably be as low as possible and Mn should be 0.20 - 0.50% in order to avoid red shortness. In order to positively lower the C content, a degassing process may be included between the steel making process and the continuous casting process.
The continuously cast slab having the above mentioned composition is coiled at a high temperature after ordinary hot rolling. The coiling temperature here should be selected to be above 680° C. This is an indispensible requirement for the continuous annealing process which has little time to fix solute [N] in steel as AlN. The self-annealing of coil which has been coiled at such a high temperature leads to sufficient precipitation of AlN and the generation of strain aging may be prevented. This is quite the opposite of the ordinary batch type annealing. That is, in the batch type annealing, the strip is coiled at a temperature below 600° C. In order to restrain the precipitation of AlN in the hot rolling stage, and then AlN is precipitated during the ordinary annealing process. The high temperature coiling employed is markedly in contrast to the batch type annealing process and is one of the indispensible requirements of this invention.
The strip thus coiled at a high temperature is then subjected to pickling and cold-reducing processes. The pickling and cold reducing processes do not require any special care and may be performed in the ordinary manner. The cold reduced strip is annealled continuously. In the continuous annealing process in accordance with the present invention, a treating zone for precipitating carbide in steel is included. Various carbide precipitation treatments are known in the art, but the heat cycles recommended in this invention are represented by the curves in FIGS. 3 and 4. It is readily possible to obtain the properties of the commercial grade steel sheets with either one of the above cycles, the selection of either depending on the various conditions such as actual continuous annealing facilities. Details of the heat cycles will be discussed in relation to the following examples.
EXAMPLE 1
TABLE 1______________________________________Chemical Composition Sol.AlSol.Al [N] [N] C Mn P S______________________________________Steel 1 0.029 0.0058 5.0 0.052 0.35 0.009 0.022Steel 2 0.045 0.0055 8.2 0.043 0.30 0.012 0.018Steel 3 0.065 0.0068 9.6 0.049 0.33 0.011 0.020*Steel 4 0.078 0.0054 14.4 0.057 0.25 0.010 0.015*Steel 4-1 0.069 0.0057 12.2 0.052 0.17 0.010 0.017Steel 5 0.078 0.0079 9.9 0.055 0.38 0.013 0.023*Steel 6 0.079 0.0052 15.2 0.008 0.38 0.010 0.017*Steel 6-1 0.111 0.0060 18.5 0.045 0.20 0.012 0.020______________________________________ Note: *denotes inventive steels.
The continuously cast slabs having the above chemical compositions were subjected to hot rolling, high temperature coiling, pickling, cold reducing, continuous annealing and temper rolling.
The major requirements in respective stages are as follows:
______________________________________Hot rolling finishing thickness 3.2 mmHot rolling finishing temperature 850° CHot rolling coiling temperature 700° CCold reducing final thickness 0.8 mm______________________________________
Continuous annealing cycle (as shown in FIG. 3). That is
(1) Strip is heated to 720° C., from ambient temperature.
(2) It is held for 40 seconds at 720° C.
(3) it is cooled down to 595° C. at rate of about 7° C./sec.
(4) It is rapidly cooled down to room temperature from 595° C. by water quenching.
(5) It is re-heated to 490° C.
(6) it is cooled from 490° C. to 350° C. at rate of about 2° C./sec.
(7) It is cooled from 350° C. to ambient temperature at rate of about 5° C./sec.
Temper rolling = 1%.
The above is one example of the heat cycle as shown in FIG. 3. The next is an outline of respective steps in the continuous annealing cycle including shelf treating used in the present invention and the actual heat cycle should be selected from the following.
(1) The strip is heated from ambient temperature to a temperature above recrystallization temperature but below 800° C., preferably 700-730° C. in 30 to 90 seconds.
(2) The strip is held for 30 to 90 seconds at the above heating temperature.
(3) It is then cooled down to 550° to 650° C., at a rate of less than 30° C./sec.
(4) It is quenched from 550° to 650° C. to ambient temperature at a rate of more than 200° C./sec.
(5) It is re-heated to 300° to 500° C., preferably 400° to 500° C.
(6) it is then slowly cooled, but is held within this temperature. More precisely, the steel should be held for 30 to 180 seconds at a temperature within the range of 300 to 500° C.
(7) there is no specific limitation placed on the cooling rate from the above temperature to ambient temperature, but a rate of 3° to 17° C./sec is recommended.
In application of such shelf treatment process, requirements for respective steps are suitably selected and combined, and the above heat cycle is one example of such combination.
The steels 1 to 5 listed in Table 1 are slabs made by LD converter-continuous casting process. Steels 6 and 6-1 are slabs made by LD converter-DH degassing-continuous casting, with lower C content because of the degassing treatment. The mechanical properties of the steels 1,2 and 3 and steel 5 are not good because steel 1, 2 and 3 has too low Sol.Al/[N] ratio, and steel 5 has too high [N] content, while the inventive steels 4, 4-1, 6, 6-1 satisfy the range of the composition required of the invention.
The mechanical properties obtained are shown in Table 2.
TABLE 3______________________________________Properties Yield Point elon-Yield Total gation (%) afterPoint Tensile elon-(kg/- at ambient(kg/- strength gation temperature formm.sup.2) (kg/mm.sup.2) (%) 3 months.______________________________________Steel 1 25.5 35.6 45.8 0.2Steel 2 22.3 33.4 46.2 0.3Steel 3 23.0 34.0 45.3 0.2*Steel 4 21.2 33.0 45.5 0.4*Steel 4-1 21.7 33.1 45.9 0.2Steel 5 24.0 35.1 43.5 0.2*Steel 6 20.2 32.0 47.2 0.7*Steel 6-1 21.5 33.0 46.0 0.3______________________________________ Note: *denotes inventive steels.
The steels in accordance with the present invention all show low yield points of the commercial grade cold reduced steel sheet, and in particular inventive steel 4 having a high Sol.Al/[N] ratio and inventive steel 6 having low carbon content and a high Sol.Al/[ N] ratio show excellent mechanical properties. The steels 1,2,3 and 5 outside the range of the present invention were found unserviceable for the commercial grade cold reduced steel sheets because of their high yield points (more than 22.3 kg/mm 2 and above). Steels 4 and 6 have good yield point after aging. None of the steels presented problems in respect of strain aging properties.
EXAMPLE 2
The continuous annealing process including the shelf treating step in accordance with the following heat cycle as shown in FIG. 4 was given to the steels processed using the same requirements as those in EXAMPLE 1 up to the cold reducing.
(1) The strip is heated from ambient temperature to 710° C.
(2) it is held for 60 seconds at 710° C.
(3) it is rapidly cooled from 710° C. to 490° C. at rate of 15° C./sec.
(4) It is slowly cooled from 490° C. to 400° C. at a rate of 1° C./sec.
(5) It is cooled from 400° C. to ambient temperature at a rate of 5° C./sec.
Such a shelf treating step in the continuous annealing process is one example of actual heating cycles shown in FIG. 4, but basically it is similar to that used for Example 1 or FIG. 3. However, respective steps differ considerably from each other and may be summarized as:
(a) The starting temperature of rapid cooling for this example is higher than that of Example 1, i.e. 710° C.
(b) The rapid cooling rate is different from that of the water quenching in Example 1, and is within the range of the rate of accelerated cooling such as by gas.
(c) Because of the comparatively slow cooling rate, the control of the terminal temperature of cooling is easy, and accordingly it is possible to stop the cooling at the required temperature for carbide precipitation. The required carbide precipitation temperature is easily obtained and there is no need for re-heating as in the case of Example 1. In other words, the process is very suitable for application to the continuous annealing line which has no water quenching equipment and no re-heating zone.
The mechanical properties obtained by the above heat cycle and temper rolling of 1% are as follows.
TABLE 3.______________________________________Mechanical PropertiesYield Total Yield point elonga-Point Tensile Elon- tion (%) after aging(kg/- strength gation at ambient Temp. formm.sup.2) (kg/mm.sup.2) (%) 3 months.______________________________________Steel 1 25.1 35.3 46.0 0.4Steel 2 22.0 33.3 46.0 0.5Steel 3 22.5 33.0 45.5 0.5*Steel 4 20.8 32.5 45.8 0.4*Steel 4-1 21.2 32.7 45.9 0.5Steel 5 23.7 35.0 43.5 0.5*Steel 6 19.7 31.7 48.0 0.9*Steel 6-1 20.9 32.7 46.0 0.6______________________________________ Note: *denotes inventive steels.
The above table reveals that steels 1,2,3,5 whose compositions are outside the range of the present invention also show high yield points and are not suitable for commercial grade steel sheet even when they have been processed by the shelf treatment such as the present Example 2. Compared to Example 1, the recovery of yield point elongation after aging is found to be large. This naturally is based on the differences of the shelf treatment processes. Accordingly, it is suggested that Example 1, i.e. the shelf treating process in FIG. 3, should be applied when retarded-aging property is desired.
EXAMPLE 3
The continuously cast slab having the same chemical composition as that of Example 1 is subjected to hot rolling, high temperature coiling, pickling, cold reducing, continuous annealing including shelf treatment and temper rolling. The major requirements in respective processes are similar to those of Example 1 except in the hot rolling stage. The requirements in the hot rolling stage are as follows:
Finishing thickness 3.2 mm
Finishing temperature 870° C.
Coiling temperature 780° C.
The mechanical properties of the steel sheet thus obtained are shown in Table 4.
TABLE 4______________________________________Mechanical PropertiesYield Total Yield Point. Elonga-Point Tensile elon- tion (%) after aging(kg/- Strength gation at ambient temp formm.sup.2) (kg/mm.sup.2) (%) 3 months.______________________________________Steel 1 24.6 35.1 44.8 0.2Steel 2 21.4 32.9 45.5 0.1Steel 3 22.0 33.1 44.2 0.2*Steel 4 20.1 32.4 44.6 0.3*Steel 4-1 20.5 32.7 45.0 0.3Steel 5 23.7 34.7 41.6 0.3*Steel 6 19.4 31.1 47.9 0.5*Steel 6-1 20.7 32.9 44.9 0.3______________________________________ Note: *denotes inventive steels.
Table 4 reveals that the mechanical properties are better than those in the case of Example 1 if the coiling temperature is raised to 780° C. However, steels 1,2,3 and 5 which are outside the range of the present invention in chemical composition showed a high yield point, accordingly, not suitable for the above commercial grade cold reduced steel sheet even when the coiling temperature was raised to 780° C.
The above mentioned desription was not unfolded on condition of a continuous casting process. This reason lies in that the required [N]%, Sol. Al% and ratio of Sol.Al%/[ N] % are easily obtained in the continuous casting process as mentioned above. It is, however, needless to say that the above contents and ratio can be controlled in the steel making process and accordingly an ordinary ingot making and slabbing process also may be employed. In any case, when said [N] %, Sol. Al % and Sol.Al%/[ N] % ratio are controlled within the range of this invention, respectively, manufacture of a strip and sheet having good mechanical properties and not being inferior to the ordinary commercial base strip and sheet made by batch type annealing process is possible by a continuous annealing process with ease and stability.
The foregoing description is illustrative of the invention; numerous other embodiment and modifications thereof would be apparent to the worker skilled in the art. All such modifications and embodiments are to be considered to be within the spirit and scope of the invention. | When an Al-killed steel consisting of, specially, 0.005% ≦ [N] ≦ 0.007%; 10 × [N] ≦ Sol.Al. ≦ 0.12%; and the ratio Sol.Al.%/[N]% controlled within the range of 10 to 20, is continuously cast, hot rolled, coiled at a high temperature, cold reduced and finally continuously annealed under special requirements, the steel strip is not at all inferior to the commercial base strip in mechanical properties and is made under high productivity and exhibits excellent uniformity in qualities. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/805,380 filed on Mar. 22, 2004. The disclosure of this prior application is incorporated by reference in its entirety.
TECHNICAL FIELD
This invention relates to a cannula used for arthroscopic, endoscopic, or laproscopic surgery.
BACKGROUND
A cannula can be inserted into a portal in a tissue in cooperation with an obturator or trocar that is received in the cannula and has a tapered end that extends beyond the end of the cannula. Once the cannula has been inserted into the tissue, the obturator or trocar is removed and surgical instruments can be passed through the cannula into tissue to perform arthroscopic, endoscopic, or laproscopic surgery.
SUMMARY
According to one aspect of the invention, a medical assembly includes a cannula and a sealing cap releasably coupled to the cannula. The cannula and cap are configured to form a fluid-tight seal therebetween without the use of an additional element. Embodiments of this aspect of the invention may include one or more of the following features: The cannula has a wall with an inner surface defining a lumen, and the assembly further includes a shaft receivable in the lumen. The shaft includes a protrusion and the inner surface further defines a protrusion receiving formation, e.g., a slot.
The cap includes a body and a sealing member integrally molded with the body. The sealing member is, e.g., chemically bonded with the body. The cannula includes an annular shoulder and the sealing member includes an annular projection that is compressed against the annular shoulder to form the fluid-tight seal. The cannula defines a slot, e.g., a J-shaped slot, and the cap has a projection receivable in the slot to releasably couple the cap to the cannula.
The cap includes a member defining an opening for passage of a medical instrument therethrough in a fluid-tight manner. The member includes, e.g., a first portion surrounding the opening that is thickened to limit tearing of the first portion, and a second portion surrounding the first portion that is tapered down in thickness toward the first portion to increase flexibility of the member. According to another aspect of the invention, a medical assembly includes a cannula and a sealing cap releasably coupled to the cannula. The cap includes a body and a sealing member that is integrally molded with the body and configured to form a fluid-tight seal with the cannula.
According to another aspect of the invention, a medical assembly includes a shaft with a protrusion, and a cannula having a wall with an inner surface defining a lumen for receiving the shaft. The inner surface defines a protrusion receiving formation, e.g., a slot extending from a proximal end of the cannula. Embodiments of this aspect of the invention may include one or more of the following features. The shaft includes a second, opposing protrusion and the inner surface defines a second, opposing protrusion receiving formation, e.g., a second slot. The second protrusion receiving formation extends from the proximal end of the cannula. The lumen has, e.g, a constant diameter or is tapered.
According to another aspect of the invention, a medical cannula includes a wall with an inner surface defining a lumen. The inner wall defines a protrusion receiving formation, e.g., a slot, extending from a proximal end of the cannula.
Embodiments of this aspect of the invention may include one or more of the following features. The inner surface defines a second, opposing protrusion receiving formation, e.g., a second slot. The second protrusion receiving formation extends from the proximal end of the cannula. The wall has an outer surface defining an outer slot, e.g., a J-shaped slot, and a second, opposing outer slot, e.g., a second J-shaped slot. The medical cannula further includes an annular shoulder coupled to the wall for forming a fluid-tight seal with a cap. The wall has an outer surface that is threaded. The lumen has, e.g, a constant diameter or is tapered.
According to another aspect of the invention, a sealing cap includes a body for releasable attachment to a medical cannula and a sealing member integrally formed with the body and configured to form a fluid-tight seal with the cannula without the use of an additional element.
Embodiments of this aspect of the invention may include one or more of the following features. The sealing member is, e.g., chemically bonded with the body. The sealing member includes an annular projection that is compressible against the medical cannula to form the fluid-tight seal. The cap includes a projection for removably connecting the cap to the cannula. The cap includes an outer seal disposed over the body. The outer seal defines an opening for passage of a medical instrument therethrough in a fluid-tight manner. The outer seal includes a first portion surrounding the opening that is thickened to limit tearing of the first portion, and a second portion surrounding the first portion that is tapered down in thickness toward the first portion to increase flexibility of the member. The cap further includes an inner seal disposed within the outer seal. The inner seal includes an opening for passage of the medical instrument therethrough in a fluid tight manner.
According to another aspect of the invention, a seal includes a member defining an opening for passage of a medical instrument therethrough in a fluid-tight manner. A first portion of the member surrounds the opening and is thickened to limit tearing of the first portion. A second portion of the member surrounds the first portion and is tapered down in the thickness toward the first portion to increase flexibility of the member.
According to another aspect of the invention, a shaft includes an elongated body receivable in a medical cannula. At least two opposed protrusions extend from the body and are configured to mate with respective protrusion receiving formations in the cannula.
According to another aspect of the invention, a medical assembly includes a means for forming a channel for inserting a surgical instrument into a tissue, and a means for forming a fluid-tight seal with the means for forming a channel.
According to another aspect of the invention, a method includes inserting a cannula into tissue, and removing a sealing cap from the cannula as a single unit without leaving a loose element behind. Embodiments of this aspect of the invention may include one or more of the following features: removing tissue through the cannula after removing the sealing cap, and reattaching the cap to the cannula while the cannula remains in the tissue.
Advantages of the invention may include one or more of the following. The integral sealing member allows the cap to be removed from the cannula without the risk of the sealing member being separated from the cap. The integral sealing member also allows the cap to be reattached to the cannula without distorting the sealing member. The protrusions on the shaft and the corresponding protrusion receiving formations in the cannula facilitate the coupling of the shaft to the cannula such that a user can apply a torque to the shaft to turn the cannula. The thickened portion and the tapered portion of the outer seal facilitate the insertion of large surgical instruments through the cannula in a fluid-tight manner.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a medical assembly shown advanced into tissue.
FIG. 2A is a side view of a cannula of the assembly of FIG. 1 .
FIG. 2B is a cross-sectional view of the cannula of FIG. 2A along line 2 B- 2 B.
FIG. 3 is an end view of the cannula of FIG. 2 along line 3 - 3 .
FIG. 4 is a cross-sectional view of the removable sealing cap of the assembly of FIG. 1 .
FIG. 5 is an end view of the cap of FIG. 4 along line 5 - 5 .
FIG. 6 is a perspective view of the cap of FIG. 4 .
FIG. 7 is a perspective view of the cannula and removable cap of the assembly of FIG. 1 shown with the cap removed from the cannula.
FIG. 8 is a cross-sectional view of the cannula and removable cap of the assembly of FIG. 1 shown with the cap coupled to the cannula.
FIG. 9 is a side view of an obturator of the assembly of FIG. 1 .
FIG. 10 is a perspective view of the cannula and obturator of the assembly of FIG. 1 shown without the cap.
FIG. 11 is a cross sectional view of the assembly of FIG. 1 along line 11 - 11 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a medical assembly 10 includes a threaded cannula 20 , a sealing cap 40 removably coupled to cannula 20 , and a shaft, e.g., a trocar or obturator 80 , which is received within cannula 20 and cap 40 . Obturator 80 includes a tapered, threaded distal end 82 that extends beyond a distal end 27 of cannula 20 , and a proximal handle 84 that abuts against cap 40 . Obturator 80 is coupled to cannula 20 , as described below, such that turning proximal handle 84 of obturator 80 turns cannula 20 to insert cannula 20 into tissue 90 . When coupled, cap 40 and cannula 20 form a fluid-tight seal without the use of an additional sealing element, e.g., an O-ring, such that cap 40 can be removed from and re-coupled to cannula 20 by the user without the possibility of losing or dropping such an additional sealing element. The removal of cap 40 from cannula 20 permits, e.g., the removal of large pieces of tissue through cannula 20 .
Referring to FIGS. 2A , 2 B, and 3 , cannula 20 includes a proximal portion 22 , a stopcock portion 28 , a threaded distal portion 25 , and tapered distal end 27 , with a longitudinal bore or lumen 30 extending the length of cannula 20 . Proximal portion 22 has a cylindrical wall 21 with mating features 32 , 34 formed in outer and inner surfaces 33 , 35 , respectively, of wall 21 . Mating features 32 are, e.g., opposing J-shaped slots for releasably locking cap 40 to cannula 20 , as discussed below. Mating features 35 are, e.g., opposing protrusion receiving formations, such as opposing longitudinal slots 34 for receiving corresponding projections on obturator 80 , as discussed below. Between proximal portion 22 and stopcock portion 28 is an annular shoulder 29 for forming a fluid-tight seal with cap 40 , as discussed below. Stopcock portion 28 includes a cylindrical portion 23 defining a section of bore 30 , and a stopcock 26 in communication with bore 30 for aspirating fluid into bore 30 or for applying suction to bore 30 . Stopcock 26 includes a port 36 for attachment to a source of fluid aspiration or suction and a manually actuatable valve 38 for controlling the amount of fluid flow or suction.
Distal threaded portion 25 of cannula 20 includes threads 24 that facilitate inserting cannula 20 into tissue 90 by lifting the skin as the cannula is inserted into tissue 90 . Threads 24 also limit cannula 20 from pulling out of tissue 90 once cannula 20 has been inserted. Tapered distal end 27 also facilitates inserting cannula 20 into tissue 90 by gradually expanding the size of a portal 92 ( FIG. 1 ) in tissue 90 .
Distal end 27 has a length of approximately 2.5 mm and is tapered at an angle of approximately 15 degrees from the center line, with the length and taper angle chosen for manufacturability. Distal threaded portion 25 has a length of approximately 40 to 90 mm, an outer diameter of approximately 4.5 to 12 mm, with a thread depth of approximately 0.5 to 1.5 mm, a thread angle of approximately 60 degrees, and approximately 0.17 threads per mm. The length is selected according to the depth of the tissue being accessed. Cylindrical portion 23 of stopcock portion 28 has a length of approximately 13.5 mm and an outer diameter of approximately 9 mm. Proximal portion has a length of approximately 5 mm and an outer diameter of approximately 11 mm, to facilitate mating with cap 40 , as discussed below. Longitudinal bore 30 has a length of approximately 60 to 105 mm and a diameter of approximately 2.5 to 10 mm. The length of bore 30 varies according to the length of distal threaded portion 25 . Longitudinal bore 30 and distal threaded portion 25 each has a constant diameter or is tapered, e.g., at an angle of approximately 0.125 to 2 degrees, to facilitate manufacturing by molding. Longitudinal slots 34 each have a length of approximately 6.5 mm and a width of approximately 2 mm to facilitate mating with wings of obturator 80 , as described below.
Referring to FIGS. 4-6 , cap 40 is assembled from three components: a mating member or body 44 , an inner seal 70 , and an outer seal 60 . Mating member 44 has an inner wall 41 defining an opening 46 therethrough for receiving a surgical instrument, and a pair of projections 48 extending from wall 41 into opening 46 . Projections 48 are sized and configured to interlock with J-shaped slots 32 defined in proximal portion 22 of cannula 20 . As shown in FIGS. 7 and 8 , cap 40 is coupled to cannula 20 by aligning projections 48 with J-shaped slots 32 , pushing cap longitudinally in the direction of arrow 47 and then turning cap 40 in the direction of arrow 49 to lock cap 40 to cannula 20 . Cap 40 will then lock itself in place in J-slots 32 by moving slightly in the direction opposite to arrow 47 due to the expansion of a compressed sealing member 50 (discussed below). Cap 40 is removable from cannula 20 by pushing cap 40 in the direction of arrow 47 to compress sealing member 50 , turning cap 40 in a direction opposite to the direction of arrow 49 and pulling cap 40 in a direction opposite to the direction of arrow 47 .
Mating member 44 includes a locking ring 42 having a plurality of knurls 43 , which facilitate grasping cap 40 when coupling cap 40 to cannula 20 or removing cap 40 from cannula 20 . Two of knurls 43 are enlarged knurls 45 aligned with projections 48 , to facilitate aligning projections 48 with J-shaped slots 32 . Mating member 44 is made of a material having a strength similar to the strength of cannula 20 . For example, cannula 20 is made of a plastic material, such as polyester, having a tensile yield stress of approximately 45 MPa, while mating member 44 is made of a plastic material, such as acrylonitrile butadiene styrene (ABS) 2620 made by Dow Chemical, located in Midland, Mich., and having a tensile yield stress of approximately 41 MPa.
Mating member 44 includes a ring-shaped sealing member 50 that is integrally molded as a component of mating member 44 , such that mating member 44 and sealing member 50 are a unitary piece. Sealing member 50 is composed of an elastomeric material that is chemically bonded with mating member 40 . For example, sealing member 50 is composed of Versaflex® OM-9-802CL, manufactured by GLS Corporation of McHenry, Ill. Locking ring 42 has a flat face 58 with an indent 59 in which sealing member 50 is located. Sealing member 50 extends beyond flat face 58 to form an annular projection 52 . Sealing member 50 also includes opposing lateral extensions 57 that facilitate molding sealing member 50 into mating member 44 . As shown in FIG. 8 , when cap 40 is coupled to cannula 20 , sealing member 50 abuts against annular shoulder 27 of cannula 20 , and annular projection 52 is compressed to form a fluid-tight seal between cap 40 and cannula 20 . Because sealing member 50 is an integrally molded component of mating member 44 , cap 40 can easily be coupled to and decoupled from cannula 20 without sealing member 50 becoming separated from cap 40 and dropped or misplaced.
Inner wall 41 of mating member 44 defines two annular grooves 54 and 56 , for receiving inner seal 70 and outer seal 60 , respectively, in a snap-fit. Inner seal 70 includes a middle section 77 defining a diagonal slit 78 for passing a surgical instrument therethrough, a wall 72 defining an open region 71 for receiving the surgical instrument, and an annular depending skirt 74 defining an open region 73 and including an inwardly projecting rib 76 . Inner seal 70 snap-fits over mating member 44 with mating member 44 in open region 73 and inwardly projecting rib 76 received in annular groove 54 , thus forming a fluid tight seal therebetween. Slit 78 permits surgical instruments to be passed through top wall 72 of inner seal 70 while limiting fluid leakage from cap 40 .
Outer seal 60 includes a wall 61 and an annular depending skirt 62 defining an open region 69 and including an inwardly projecting rib 63 . Outer seal 60 snap-fits over inner seal 70 and over mating member 44 with inner seal 70 in open region 69 and inwardly projecting rib 63 received in bottom annular groove 56 , thus forming a second fluid tight seal with mating member 44 .
Inner seal 70 and outer seal 60 are composed of an elastomeric material, such as 30-50 durometer liquid injection molded silicone. Wall or member 61 of outer seal 60 includes an inner ring 64 defining an aperture 65 therethrough, a tapered ring 66 surrounding inner ring 64 , and a peripheral ring 67 surrounding tapered ring 66 . Peripheral ring 67 has a constant thickness T 1 , except for the region of chamfered surface 79 . Tapered ring 66 tapers from thickness T 1 to a thickness T 2 that is less than T 1 . Inner ring 64 is thickened along the outer side of seal 60 to form a reinforcing rib 68 , such that inner portion has a thickness T 3 that is greater than T 2 and less than T 1 . For example, T 1 is approximately 2.5 mm, T 2 is approximately 1 mm, and T 3 is approximately 1.5 mm. Tapered ring 66 is tapered on the outer surface of seal 60 at an angle of approximately 6 degrees over a length L 1 of approximately 6 mm. Tapered ring 55 is tapered on the inner surface of seal 60 at an angle of approximately 10 degrees. Reinforcing rib 68 has a length L 2 of approximately 1.5 mm. Aperture 65 allows surgical instruments to be passed through outer seal 60 while maintaining a seal to limit fluid leakage from cap 40 . Tapered ring 66 increases the flexibility of outer seal 60 to allow introduction of a surgical instrument therethrough while thickened reinforcing rib 68 limits tearing of outer seal 60 .
Referring to FIG. 9 , obturator 80 includes distal end 82 , an intermediate portion 83 , an elongated body or shaft portion 85 , and proximal handle 84 . Handle 84 includes a plurality of cut-outs 81 that make handle 84 lighter in weight. Intermediate portion 83 has a diameter D 2 that is the same as or slightly less than the diameter of bore 30 in order to form a seal that inhibits tissue from entering bore 30 while obturator 80 and cannula 20 are being inserted into tissue. Shaft portion 85 has a diameter D 1 that is the same as or less than the diameter of cannula bore 30 , in order reduce the weight of obturator 80 and to limit the stretching of outer seal 60 in cap 40 when shaft portion 85 is passed through cap 40 . Shaft portion 85 has a distal portion 86 including a plurality of lateral flanges 87 that taper proximally in diameter from D 2 to D 1 for a smooth transition between the different diameters of intermediate portion 83 and shaft portion 85 . Distal end 82 tapers from diameter D 2 of intermediate portion 83 to a distal point 88 to facilitate enlarging portal 92 ( FIG. 1 ) in tissue 90 . Distal end 82 is threaded to cooperate with threads 24 on cannula 20 to facilitate inserting cannula 20 into tissue 90 .
Referring also to FIGS. 10 and 11 , shaft portion 85 includes opposed lateral wings or protrusions 89 that are sized and configured to be received in longitudinal slots 34 in cannula 20 when obturator 80 is inserted into cannula 20 . Lateral wings 89 releasably couple obturator 80 to cannula 20 so that when obturator 80 is rotated by turning handle 84 , cannula 20 rotates with obturator 80 to facilitate inserting cannula 20 into tissue 90 .
Distal end 82 has a length of approximately 5 to 11.5 mm and is tapered at an angle of approximately 17.5 degrees to the center line. The threads on distal end 82 have a depth of approximately 0.5 to 1 mm, an angle of approximately 60 degrees and there are approximately 0.25 threads per mm. Intermediate portion 83 has a length of approximately 3 to 5 mm and a diameter D 2 of approximately 2.5 to 10 mm. Shaft portion 85 has a length of approximately 65 to 220 mm and a diameter of approximately 2.5 to 5.5 mm. Wings 89 are located on shaft portion 85 approximately 16.5 mm from a base 91 of handle 84 .
In use, referring to FIG. 1 , with cap 40 coupled to proximal end 22 of cannula 20 and obturator 80 located in cannula bore 30 with lateral wings 89 received in longitudinal slots 34 , the user inserts threaded distal tip 82 of obturator 80 into a small incision or portal 92 that has been made in tissue 90 to form a channel 95 in tissue 90 . The user then rotates handle 80 clockwise, inserting threaded distal portion 25 of cannula 20 into tissue 90 .
Once distal portion 25 of cannula 20 is inserted into tissue 90 , the user removes obturator 80 from tissue 90 and cannula 20 by pulling handle 84 while holding cannula 20 in place in tissue 90 . Fluid can be aspirated or suction can be applied through cannula 20 by attaching a source of fluid or suction to port 36 of stopcock 26 and adjusting the opening of valve 38 . The user passes surgical instruments into tissue 90 by passing them through outer seal 60 , inner seal 70 , and bore 30 in cannula 20 to perform an arthroscopic, endoscopic, or laproscopic surgical procedure. Outer seal 60 and inner seal 70 form a seal around the surgical instrument when the surgical instrument is located within cannula 20 , and seal off cannula 20 when no surgical instrument is located therein.
During the surgical procedure, the user can remove cap 40 from cannula 20 , e.g., to permit tissue that is too large to pass through cap 40 to be removed through cannula 90 . The user can reattach cap 40 to cannula 20 to again provide the sealing function of cap 40 . Cap 40 can be removed and reattached to cannula 20 as many times as desired during a surgical procedure. Once the user has completed the surgical procedure, the user removes cannula 20 from tissue 90 by rotating cannula counterclockwise.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the cannula can have a smooth outer surface rather than being threaded. The cannula also can have a valve other than a stopcock for aspirating fluid and applying suction. The distal threaded portion and the bore therethrough need not be tapered, e.g., when the cannula is manufactured by machining. The cannula can include more than two protrusion receiving formations. The protrusion receiving formations can be formed on an outer surface of the cannula.
The cap can be releasably coupled to the proximal end of the cannula by a mechanism other than a J-lock, such as a quick release or a spring loaded ball with a detent. The cap can be aligned with the cannula by other than an enlarged knurl on locking ring, such as by printed material or engraved lines on the cap. The cap can include protrusion receiving formations for receiving corresponding protrusions on the obturator to facilitate turning the cap and cannula assembly by turning the obturator. The cap can be tethered to the cannula, such as by a flexible tie, to avoid losing cap when it is detached from the cannula. The cap can include a smaller or larger number of seals to limit leakage of fluid when a surgical instrument is inserted therethrough. The integral sealing member can be mechanically attached to the mating member, such as be forming pin holes through the mating member and the sealing member including rod shaped projections extending through the pin holes and each being capped with a head.
The inner seal and outer seal can be attached to the cylindrical member by other than a snap-fit, such as by an adhesive. The inner seal can have an opening other than the slit therethrough, such as a circular or oblong aperture. The aperture through outer seal can have a shape other than circular, such as an elongated slot. The reinforcing rib on the outer seal can be on the inner side or the outer side of the outer seal, or both. The top wall of the outer seal also can include two or more reinforcing ribs surrounding the aperture. The top wall of the outer seal also can be of constant thickness.
The obturator can be of constant diameter throughout. The obturator can include a smaller or larger number of lateral projections that correspond to an equal or greater number of longitudinal slots inside the cannula. Other types of interlocking mechanisms between the obturator and the cannula can be used. The distal end of the obturator can be smooth and the handle can be solid.
In addition to the materials discussed above, the cannula, the cylindrical member, and the obturator can be made from any rigid biocompatible material such as a plastic, a metal, or a ceramic. Similarly, the integral seal, the inner seal, and the outer seal can be made of any elastomeric material such as latex or rubber.
In use, the obturator can be inserted into the cannula with the cap removed when the cannula is being inserted into the tissue. The obturator can be reinserted into the cannula at the end of the surgical procedure to facilitate removing the cannula from the tissue. These and other embodiments are within the scope of the following claims. | A medical assembly includes a cannula and a scaling cap releasably coupled to the cannula. The cap includes a body and a sealing member integrally molded with the body to form a fluid-tight seal between the cap and cannula. The cap includes a member defining an opening for passage of a medical instrument therethrough in a fluid-tight manner. The member includes a first portion surrounding the opening and being thickened to limit tearing of the first portion, and a second portion surrounding the first portion being tapered down in thickness toward the first portion to increase flexibility of the member. The assembly includes a shaft receivable in a lumen defined by an inner surface of the cannula. The shaft includes a protrusion and the inner surface further defines a protrusion receiving formation. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/330,969 filed on May 4, 2010, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to liquid level transducers, and more particularly to liquid level transducers having heating arrangements for heating the surrounding material to be measured.
[0003] Transducers for measuring liquid level are often used in vehicles, industrial equipment as well as other mobile and stationary systems and components. The electrical output of such transducers changes in response to a change in the liquid level being measured and is typically in the form of a change in resistance, capacitance, current flow, magnetic field, and frequency. These types of transducers may include variable capacitors or resistors, optical components, Hall Effect sensors, strain gauges, ultrasonic devices, reed switch arrays, and so on.
[0004] No matter what transducer type is used, the tank level measurement is most successful when the material being measured is in a liquid state as opposed to a semi-solid or frozen state. Although many fuels have a freezing point well below the operating temperature range of most vehicles and equipment, other fluids are subjected to freezing such as engine coolant and diesel exhaust fluid (DEF). DEF is especially problematic since it is used in vehicles equipped with Selective Catalytic Reduction (SCR) systems. DEF is a solution that typically comprises purified water and approximately 32.5 percent urea and is used to reduce nitrogen oxide (NOx) emissions from diesel-powered vehicles into nitrogen, water and carbon dioxide (CO 2 ). The DEF is kept in a tank on the vehicle and is automatically accessed during vehicle operation to reduce emissions. A liquid level transducer is often associated with the tank to indicate a level of the DEF to an operator or other observer. Unfortunately, the DEF can freeze when subjected to low temperature conditions and thus cannot be accurately measured or extracted from the tank until it is changed to a liquid state.
[0005] Prior art solutions have been inadequate in addressing these problems in a satisfactory manner. It would therefore be desirous to provide a heating arrangement associated with the liquid level transducer and/or liquid withdrawal or supply tubes of DEF tanks or the like so that the level of DEF can be more quickly ascertained and accessed during freezing conditions.
SUMMARY OF THE INVENTION
[0006] In accordance with one aspect of the invention, a transducer for determining the level of contents within a container wherein the contents are subjected to solidifying below a freezing temperature is provided. The transducer includes: a mounting head adapted for connection to the container; a liquid level sensor adapted to extend into the container from the mounting head; and a spiral-shaped heating unit comprising a first elongate tube extending through the mounting head. The first elongate tube is formed with at least one coil that surrounds at least a portion of the liquid level sensor and is adapted to circulate heating fluid therein to thereby heat the contents of the container at least in the vicinity of the liquid level sensor.
[0007] In accordance with a further aspect of the invention, a transducer for determining liquid level within a container includes: a mounting head adapted for connection to the container; a liquid level sensor adapted for extending into the container from the mounting head; and a heating tube extending through the mounting head. The heating tube has: first and second upright segments connected via a first lower bend; a third upright segment connected to the second upright segment via an upper bend; and a fourth upright segment connected to the third upright segment via a second lower bend. The first and fourth upright segments are adapted for fluid connection to a fluent heating source for heating the contents of the container.
[0008] In accordance with yet another aspect of the invention, a transducer for determining the level of contents within a container wherein the contents are subjected to solidifying below a freezing temperature is provided. The transducer includes: a mounting head adapted for connection to the container; a liquid level sensor adapted for extending into the container from the mounting head; and a heating unit extending through the mounting head and into the container. The heating unit has an outer tube and an inner tube extending inside and along a length of the outer tube. The outer and inner tubes are in fluid communication such that heating fluid is adapted to flow from one of the outer and inner tubes to the other of the outer and inner tubes to thereby heat the contents of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following detailed description of the preferred embodiments of the present invention will be best understood when considered in conjunction with the accompanying drawings, wherein like designations denote like elements throughout the drawings, and wherein:
[0010] FIG. 1 is a front isometric view of a liquid level transducer with a heat transfer unit connected to a tank in accordance with on embodiment of the present invention;
[0011] FIG. 2 is a side elevational view thereof;
[0012] FIG. 3 is a view similar to FIG. 1 with the tank removed;
[0013] FIG. 4 is a view similar to FIG. 3 with a mounting plate removed to reveal the details of an upper portion of the liquid level transducer;
[0014] FIG. 5 is top isometric view of the liquid level transducer;
[0015] FIG. 6 is a view similar to FIG. 5 with a housing portion removed to reveal the details of the upper portion of the liquid level transducer;
[0016] FIG. 7 is a view similar to FIG. 6 with a transfer block removed to reveal more details of an end portion of the liquid level transducer;
[0017] FIG. 8 is an enlarged bottom isometric view of the liquid level transducer;
[0018] FIG. 9 is a bottom perspective view of the liquid level transducer;
[0019] FIG. 10 is a front elevational view of a liquid level transducer with a heat transfer unit in accordance with a further embodiment of the present invention;
[0020] FIG. 11 is a rear elevational view thereof;
[0021] FIG. 12 is a top perspective view thereof;
[0022] FIG. 13 is a side perspective view of an upper portion of the liquid level transducer of FIG. 10 ;
[0023] FIG. 14 is a left side elevational view of an upper portion thereof;
[0024] FIG. 15 is a right side elevational view of an upper portion thereof;
[0025] FIG. 16 is a front elevational view of a lower portion of the liquid level transducer of FIG. 10 ;
[0026] FIG. 17 is left side elevational view of the lower portion thereof;
[0027] FIG. 18 is a top schematic view of a tank and the heat transfer unit of FIG. 10 for comparing the size of the opening with the heat transfer unit;
[0028] FIG. 19 is a front isometric view of a liquid level transducer with a heat transfer unit connected to a tank in accordance with a further embodiment of the present invention;
[0029] FIG. 20 is a sectional view of a heat transfer unit in accordance with yet another embodiment of the invention;
[0030] FIG. 21 is a sectional view thereof taken along line 21 - 21 of FIG. 20 ;
[0031] FIG. 22 is a front elevational view of a liquid level transducer with heat transfer unit in accordance with a further embodiment of the invention; and
[0032] FIG. 23 is an enlarged view of a portion of the heat transfer unit of FIG. 22 .
[0033] It is noted that the drawings are intended to depict only exemplary embodiments of the invention and therefore should not be considered as limiting the scope thereof. It is further noted that the drawings are not necessarily to scale. The invention will now be described in greater detail with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Referring now to the drawings, and to FIGS. 1 and 2 in particular, a liquid level transducer 10 according to an exemplary embodiment of the present invention is illustrated. The liquid level transducer 10 preferably extends into a container 11 , such as a fuel tank, oil reservoir, radiator, brake fluid chamber, or any other container for holding and/or transporting a liquid (not shown). In accordance with one preferred application of the invention, the transducer 10 is particularly useful for liquids that have a tendency to freeze at lower temperatures, such as diesel exhaust fluids (DEF) in a NOx emissions control system. Such fluids can include, but are not limited to, water, urea, ammonia, and combinations thereof.
[0035] With additional reference to FIGS. 3-5 and 9 , the transducer 10 preferably includes a mounting head 14 , an elongate sensing probe 12 extending through the mounting head 14 and downwardly therefrom, a heating unit 16 extending through the mounting head 14 and bending around the sensing probe 12 , and a fluid supply tube 18 extending through the mounting head 14 and along a substantial length of the heating unit 16 .
[0036] As best shown in FIGS. 2-4 and 6 - 8 , the sensing probe 12 preferably senses liquid level in a linear direction and, in accordance with one preferred embodiment of the invention, includes an outer sensor tube 22 with an upper end 24 that extends through the mounting head 14 and a lower end 26 with a support block 28 . A float 30 is preferably cylindrically-shaped and includes a central bore 32 (shown in FIG. 8 ) that is sized to receive the sensor tube 22 so that the float slides freely therealong. The support block 28 preferably holds the heating unit 16 , the lower end 26 of the sensor tube 22 , and preferably serves as a lower resting position for the float 30 in the event of a very low level or empty tank condition. A printed circuit board (PCB—not shown) is positioned within the sensor tube 22 and preferably extends along a substantial length thereof. A plurality of reed switches (not shown) are located along the length of the PCB. The reed switches are responsive to one or more magnets (not shown) located in the float 30 for creating a liquid level signal in a well-known manner as the float rides along the sensor tube 22 in response to a change in liquid level within the tank. Although not shown, insulating material, such as heat-shrink tubing, potting material, and so on, is preferably located between the PCB and the sensor tube 22 to insulate and protect the reed switches and other components against shock, vibration, and other harsh conditions to which the transducer 10 may be exposed. Potting material (not shown) may also be located at the upper end 24 of the sensor tube 22 to provide strain relief for the electrical wires 40 ( FIGS. 3 , 4 , 6 and 7 ) that extend between the PCB and an electrical connector 42 , as well as vibration protection for the PCB and its interface with the wires.
[0037] It will be understood that the sensor tube 22 can also contain other sensors besides liquid level, in particular temperature, which would provide information to the heating circuit for controlling circulation of the heating fluid through the heating unit 16 . Wiring connections and any circuitry required for the sensing is preferably located within the sensor tube and inside a sealed compartment within the mounting head 14 and sensor tube connection.
[0038] Although a reed-switch-type probe has been shown and described, it will be understood that the present invention is not limited thereto. It will be understood that other linear-type liquid level measurement sensors can be used, including but not limited to, capacitance, heated wire, ultrasonic, optical, and so on, as well as non-linear-type sensors such as resistance-type pivoting float arms.
[0039] As best shown in FIGS. 6-8 , the heating unit 16 preferably includes a single piece or length of tube that is bent into the tortuous shape as shown and includes a first upper segment 44 that extends generally horizontally and is fluidly connected to a fluent heat source (not shown) such as such as engine coolant, oil, hot exhaust gases and so on, in order to provide constant or selective intermittent circulation of heating fluid to warm the contents of the tank 11 ( FIG. 1 ). A first upright leg 46 extends generally vertically downwardly from the first upper segment 44 and is connected to a second generally vertically extending upright leg 48 via a first lower generally U-shaped bend 50 extending therebetween. A third generally vertically extending upright leg 52 is in turn connected to the second leg via an upper generally U-shaped bend 54 . Likewise, a fourth generally vertically extending upright leg 56 is in turn connected to the third leg 52 via a second lower generally U-shaped bend 58 that is vertically higher than the first bend 50 . The first and second lower U-shaped bends 50 , 58 are preferably connected to the support block 28 for providing stability at the lower end of the transducer 10 . The fourth leg 56 is in turn fluidly connected to a second generally horizontally extending upper segment 60 , which is in turn fluidly connected to the fluent heat source.
[0040] In order to eliminate the need for an internal tank restraint and provide greater structural integrity for the transducer 10 , the sensor tube 22 and fluid supply tube 18 are preferably securely connected to the heating tube 16 and to each other via clips 62 and 64 . However, it will be understood that the parts can be connected together through any well-known connection means, including but not limited to, adhesives, welding, other types of mechanical fastening, and so on.
[0041] A substantial portion of the fluid supply tube 18 preferably extends adjacent to the first leg 46 of the heating tube 16 . However, it will be understood that the supply tube 18 can alternatively be located adjacent to the fourth leg 56 . The supply tube 18 preferably includes a generally horizontally extending upper segment 68 that extends through the mounting head 14 . The supply tube 18 is adapted for connection to a pump (not shown) or the like in a well-known manner for delivering liquid from the tank 11 to a remote location. The supply tube 18 preferably extends to an empty level position inside the tank adjacent to the lower U-shaped bends 50 , 58 . If desired, a filter (not shown) can be located at the lower end of the supply tube 18 inside the tank.
[0042] The tortuous shape of the heating tube 16 is particularly advantageous since the four upright legs 46 , 48 , 52 and 56 increase the amount of heating tube surface area installed in the tank and create a space or volume 66 within the tank 11 that is more quickly heated than the surrounding area. When the heating tube carries warm fluid, such as engine coolant, the heat transferring from the heating tube is used to thaw or prevent freezing of the tank contents surrounding the sensor as well as the supply tube 18 located within the space 66 . Increasing the amount of surface area of the heating tube 16 increases the amount of heat transfer in a given amount of time. This reduces the potential for freezing of the tank contents in the area of the sensor and supply tubes at lower temperatures and causes quicker thawing of the contents at a given temperature than if the heating tube 16 were constructed with less segments.
[0043] As shown in FIGS. 3-6 and 9 , the mounting head 14 preferably includes a cover 70 connected to a mounting plate 72 which is in turn connected to the tank 11 ( FIG. 1 ). The cover 70 together with the mounting plate 72 create a hollow interior through which the segments 44 , 60 of the heating tube 16 and the segment 68 of the supply tube 18 preferably extend. A transfer block 74 is secured to the mounting plate 72 and includes passages for receiving the heating tube and supply tube segments, as well as an opening for receiving the electrical wires 40 and connector 42 . A valve assembly 76 extends into the transfer block 74 and is in fluid communication with the segment 44 of the heating tube and the fluent heating source (not shown).
[0044] Referring now to FIGS. 10 and 11 , a liquid level transducer 110 in accordance with a further exemplary embodiment of the invention is illustrated. The liquid level transducer 110 preferably extends into a container (not shown), such as a fuel tank, oil reservoir, radiator, brake fluid chamber, or any other container for holding and/or transporting a liquid (not shown). In accordance with one preferred application of the invention, the transducer 110 is particularly useful for liquids that have a tendency to freeze at lower temperatures, such as diesel exhaust fluids (DEF) in a NOX emissions control system. Such fluids can include, but are not limited to, water, urea, ammonia, and combinations thereof.
[0045] With additional reference to FIG. 12-15 , the transducer 110 preferably includes a mounting head 114 , an elongate sensing probe 112 extending through the mounting head 114 and downwardly therefrom, a helically-shaped heating unit 116 extending through the mounting head 114 and spiraling around the sensing probe 112 , a fluid supply tube 118 extending through the mounting head 114 and along a substantial length of the heating unit 116 , and a liquid return tube 120 extending through the mounting head 114 .
[0046] As best shown in FIGS. 10 , 11 , 13 , 16 and 17 , the sensing probe 112 preferably senses liquid level in a linear direction and, in accordance with one preferred embodiment of the invention, includes an outer sensor tube 122 with an upper end 124 that extends through the mounting head 114 and a lower end 126 with a stop flange 128 . A float 130 is preferably cylindrically-shaped and includes a central bore 132 (shown in hidden line in FIG. 16 ) that is sized to receive the sensor tube 122 so that the float slides freely therealong. The stop flange 128 provides a lower resting position for the float 130 in the event of a very low level or empty tank condition.
[0047] A printed circuit board (PCB) 134 is positioned within the sensor tube 122 and preferably extends along a substantial length thereof. A plurality of reed switches (not shown) are located along the length of the PCB 134 . The reed switches are responsive to one or more magnets (not shown) located in the float 130 for creating a liquid level signal in a well-known manner as the float rides along the sensor tube 122 in response to a change in liquid level within the tank.
[0048] Insulating material 136 , such as heat-shrink tubing, potting material, and so on, is preferably located between the PCB 134 and the sensor tube 122 to insulate and protect the reed switches and other components against shock, vibration, and other harsh conditions to which the transducer 110 may be exposed. Potting material 138 ( FIG. 13 ) is located at the upper end 124 of the sensor tube 122 to provide strain relief for the electrical wires 140 and vibration protection for the PCB 134 and its interface with the wires. A potting grommet 142 is received over the PCB 134 for limiting the height of the potting material during assembly and curing. A cushion 133 ( FIG. 17 ) is preferably located with the sensor tube 122 and surrounds the PCB 134 below the stop flange 138 for providing further protection against vibration and undesired forces that may otherwise be present on the PCB during shipping, installation and/or operation. The sensor tube 122 can also contain other sensors besides liquid level, in particular temperature, which would provide information to the heating circuit for controlling circulation. Wiring connections and any circuitry required for the sensing is preferably located within the sensor tube and inside a sealed compartment above the mounting head 114 and sensor tube connection.
[0049] Although a reed switch type probe has been shown and described, it will be understood that the present invention is not limited thereto. Other linear-type liquid level measurement sensors can be used, including but not limited to, capacitance, heated wire, ultrasonic, optical, pivoting float arm, and so on, as well as non-linear-type sensors such as resistance-type pivoting float arms.
[0050] As best shown in FIGS. 10 , 11 and 14 - 17 , the heating unit 116 is preferably in the form of a single, elongate tube with a first leg 144 and a second leg 146 and a generally U-shaped bend 148 extending therebetween. The first and second legs 144 and 146 include straight upper segments 150 and 152 , respectively, that extend through the mounting head 114 . The upper ends of the segments 150 , 152 are adapted for connection to supply and return conduits (not shown) of a fluent heat source, such as such as engine coolant, oil, hot exhaust gases and so on, in order to provide constant and/or intermittent circulation of heating fluid to warm the contents of the tank (not shown). In order to eliminate the need for an internal tank restraint and provide greater structural integrity for the transducer 110 , the sensor tube 122 is preferably securely connected to the heating tube 116 . When the sensor tube and heating tube are constructed of metallic material, such as stainless steel, the parts are preferably welded together. However, it will be understood that the parts can be connected together through any well-known connection means, including but not limited to, adhesives, ultrasonic welding, mechanical fastening, and so on.
[0051] A substantial portion of the fluid supply tube 118 is preferably connected to the first leg 144 of the heating tube 116 and thus spirals around the sensing probe therewith. However, it will be understood that the supply tube 118 can alternatively be connected to the second leg 146 . The supply tube 118 preferably includes a straight upper segment 154 that extends through the mounting head 114 . The supply tube 118 and return tube 120 are adapted for connection to a pump or the like in a well-known manner for delivering liquid from the tank (not shown) on which the transducer is mounted to a remote location and returning unused liquid back into the tank.
[0052] The extension of the fluid supply and return tubes into the tank can be inside of the helical heating tube 116 or parallel on the same diameter. The fluid return tube does not have to extend far into the tank, but can if desired. The supply tube 118 preferably extends into the tank to the empty level inside the tank adjacent the U-shaped bend 148 . If desired, a filter (not shown) can be located at the lower end of the supply tube 118 inside the tank.
[0053] As shown in FIGS. 10 and 18 , the helical configuration of the heating tube 116 is especially advantageous in that the helical coil can be made larger in diameter than the mounting head 114 ( FIG. 10 ) and the opening 156 ( FIG. 18 ) in the tank wall 158 to which the transducer 110 is mounted. As shown in FIG. 18 , the major or outside diameter C of the heating tube 116 is larger than the diameter A of the tank opening 156 , which is in turn larger than the minor or inside diameter B of the heating tube 116 . By way of example, and in accordance with a preferred embodiment of the invention, the maximum major diameter C can be calculated as follows:
[0000] C=A +( A−B )
[0054] For a 5-inch tank opening A and a 2.5-inch minor diameter B, the major diameter C of the heating tube 116 is approximately 7.5 inches, a significantly larger heating tube area that the contents of the tank will be exposed to over prior art solutions.
[0055] As shown in FIG. 10 , the distance or spacing 160 between adjacent coils is preferably greater than a thickness of the tank wall 158 ( FIG. 18 ) to which the transducer 110 will be mounted so that the thickness of the tank wall at the tank opening 156 can be cleared during the installation process. In this manner, the transducer 110 can be screwed into a tank opening 156 , preferably with the float lifted to the upper portion of the sensing tube 122 just below the mounting head 114 , with the tank opening being much smaller in diameter than the outside diameter of the coils of the helically-shaped heating tube 116 . With a larger diameter helically-shaped heating tube 116 , the amount of heater tubing surface area installed in the tank is significantly increased. When the coil carries warm fluid, such as engine coolant, the heat transferring from the coil is used to thaw or prevent freezing of the tank contents surrounding the sensor as well as the supply and return tubes. Increasing the amount of surface area of the heater tubing increases the amount of heat transfer in a given amount of time. This reduces the potential for freezing of the tank contents in the area of the sensor and supply tubes at lower temperatures and causes quicker thawing of the contents at a given temperature than if the coils of the heating tube 116 were constructed with a smaller diameter.
[0056] Referring now to FIG. 19 , a liquid level transducer 180 in accordance with yet another embodiment of the invention is illustrated. The liquid level transducer 180 preferably extends into a container 11 and preferably includes a mounting head 14 , an elongate sensing probe 12 extending through the mounting head 14 and downwardly therefrom with a float 30 movable along the length of the probe 12 as previously described, a first or inner heating unit 16 extending through the mounting head 14 and bending around the sensing probe 12 , a second or outer heating unit 116 spiraling around the inner heating unit 16 and a fluid supply tube 18 extending through the mounting head 14 and along a substantial length of the heating unit 16 . The inner and outer heating units are similar in construction to the heating units previously described, with the inner heating unit 16 being sized to slip through the tank opening and the outer heating unit 116 having an outer diameter, as previously described, that is larger than the tank opening so that the liquid level transducer 180 turned or twisted through the tank opening to install the transducer in the tank. With this arrangement, the inner and outer heating units provide more surface area for thawing or warming the fluid to be measured at an increased rate without increasing the overall size of the liquid level transducer so that it can fit within a standard tank opening.
[0057] Referring now to FIGS. 20 and 21 , a lower portion of a liquid level transducer 190 in accordance with a further embodiment of the invention is illustrated. The liquid level transducer 190 preferably includes a sensor tube 192 located within a heating unit which preferably includes an inner heating fluid return tube 194 which is in turn located within an outer heating fluid supply tube 196 . The sensor tube 192 is preferably connected to the outer supply tube 196 via a connector 198 that preferably includes a hub 200 that preferably encircles and connects to the inner return tube 194 and spokes 202 that extend radially outwardly from the hub 200 and connect to the outer supply tube 196 . A lower end 204 of the outer supply tube 196 preferably tapers toward the sensor tube 192 to create an internal chamber 206 that communicates with both the inner return tube and outer supply tube. In operation, heating fluid from a fluid source (not shown) such as previously described, is directed down into the outer supply tube 196 , as shown by arrows 208 , to thereby heat the outer tube and the contents within the tank in the vicinity of the outer tube, and then up into the inner return tube 194 , as shown by arrows 210 , 212 , where it exits the transducer 190 . It will be understood that the inner tube 194 can alternatively receive heating fluid and the outer tube 196 can function as the fluid return conduit without departing from the spirit and scope of the invention.
[0058] The inner return tube 194 and/or outer supply tube 196 can be constructed of stiff or flexible material. In accordance with one preferred embodiment of the invention, the inner tube 194 is constructed of a flexible material that is compatible to the heating fluid such as rubber, polyurethane, vinyl, and so on, while the outer tube 196 is constructed of a more rigid or stiff material such as stainless steel, aluminum, other metals, and so on. However, it will be understood that the inner and outer tubes can be constructed of any suitable materials without departing from the spirit and scope of the invention.
[0059] The sensor tube 192 preferably houses a liquid level probe such as a reed-switch-type probe as previously shown and described. However, it will be understood that the present invention is not limited thereto as other linear-type liquid level measurement sensors can be used, including but not limited to, capacitance, heated wire, ultrasonic, optical, and so on, as well as non-linear-type sensors such as resistance-type pivoting float arms
[0060] Referring now to FIGS. 22 and 23 , a liquid level transducer 220 in accordance with yet another embodiment of the invention is illustrated. The transducer 220 preferably includes a mounting head 222 , an elongate sensing probe 224 extending through the mounting head 114 and downwardly therefrom, and a helically-shaped heating unit 226 extending through the mounting head 222 and spiraling around the sensing probe 224 .
[0061] The sensing probe 224 is preferably similar in construction to the sensing probe 112 with float 130 as previously described. The heating unit 226 preferably includes an inner heating fluid return tube 228 located within an outer heating fluid supply tube 230 . The inner tube 228 is preferably constructed of a flexible material that is compatible to the heating fluid such as rubber, polyurethane, vinyl, and so on, while the outer tube 230 is constructed of a more rigid or stiff material such as stainless steel, aluminum or other metals, so that the heating unit 226 can be shaped in a quick and easy manner during manufacture through simple bending operations. A lower end 231 of the outer heating unit is sealed so that the heating fluid remains in the heating unit during use. The heating unit 226 in this embodiment is easier to manufacture and requires less material than the spiral heating tube previously described with reference to FIGS. 10 and 19 since the heating unit does not need to spiral back up as in the previous embodiments. As described in the FIG. 19 embodiment, the inner tube 228 of the present embodiment can alternatively receive heating fluid and the outer tube 230 can function as the fluid return conduit without departing from the spirit and scope of the invention.
[0062] In accordance with one preferred embodiment of the invention, the heating unit 226 has an outer diameter that is larger than the tank opening, as previously described with respect to FIG. 18 . In accordance with another preferred embodiment of the invention, the heating unit 226 has an outer diameter that is smaller than the tank opening so that the liquid level transducer 220 can be installed straight into the tank without the need to twist the transducer.
[0063] Rods 232 and 234 or other support structure can extend between the mounting head 222 and a lower base member 236 to provide added support to the liquid level transducer 220 .
[0064] It will be understood that the term “preferably” as used throughout the specification refers to one or more exemplary embodiments of the invention and therefore is not to be interpreted in any limiting sense.
[0065] It will be further understood that the term “connect” and its derivatives refers to two or more parts capable of being attached together either directly or indirectly through one or more intermediate members. In addition, terms of orientation and/or position as may be used throughout the specification denote relative, rather than absolute orientations and/or positions.
[0066] It will be further understood that terms of orientation and/or position as may be used throughout the specification, such as upper and lower, horizontal and vertical, inner and outer, and so on, refer to relative rather than absolute orientations and/or positions.
[0067] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims. | A transducer for determining the liquid level within a container that is subjected to at least partial solidification at or below a freezing temperature is provided. The transducer includes a mounting head adapted for connection to the container, a liquid level sensor adapted for extending into the container from the mounting head; and a heating unit extending through the mounting head. The heating unit is constructed of at least one tubular member that surrounds or encircles the liquid level sensor. Heated fluid from a fluid source is circulated through the at least one tubular member for heating the contents of the tank at least within the vicinity of the liquid level sensor. A fluid withdrawal tube can also be in close proximity to the at least one tubular member so that the contents of the tank surrounding the heating unit can be removed even when the remaining tank contents are in a frozen state. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/570,660, filed Sep. 30, 2009; which is a continuation of application Ser. No. 10/778,825, filed Feb. 13, 2004, now U.S. Pat. No. 7,616,247, the entire disclosures of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reproducing apparatus, an image data reproducing method, a program, and a storage medium each for reproducing image data obtained by an image pickup device.
2. Related Background Art
There is known an image pickup device which uses an image pickup element to photograph an object incident from an optical system and performs signal processing of the resultant image signal to convert the image signal into image information. An electronic still camera is a device to which the image pickup device is applied. Various kinds of electronic still cameras, which is arranged to record the image information on a recording medium which is composes of a memory card including a flash memory or a hard disk drive, have been proposed.
In the electronic still cameras of this type, there has been also proposed the electronic still camera in which a monitor is built in a camera body so as to reproduce the photographed image on the spot and which can perform enlargement reproduction of a part of photographed image, specified by a user on the compact monitor so that user can view details of the photographed image even if the monitor has the small number of pixels.
Further, the electronic still camera in which an attitude of the camera during photographing is detected, an image photographed in a lengthwise position of the camera is displayed by rotating the photographed image by 90 degrees during reproduction, and the image is normally displayed when the camera is in a widthwise position has been proposed. These functions improve operating ease of a user with respect to the image confirmation after photographing.
However, in the above conventional technologies, when the image is changed during enlargement reproduction, a display direction of the image is changed in accordance with a change in attitude information, but the change in the attitude information is not considered in an enlargement area reproduced at all. Accordingly, in case that the attitude is changed from the photographed image in the widthwise position to the photographed image in the lengthwise position when the image is changed during the enlargement reproduction, the same area, i.e. the widthwise position in this case is selected irrespective of the change in the attitude in the reproduction area where the enlargement reproduction is performed, so that the confirmation of the photographed image becomes very unnatural. The conventional technology in which the image is simply rotated according to the attitude during photographing can not provide the function with sufficient ease of use to users.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the invention to provide the reproducing apparatus, the image data reproducing method, the program, and the storage medium each of which improves convenience during reproducing the image data by performing reproduction processing according to the attitude state of the reproducing apparatus.
In order to achieve the above object, one aspect of the invention provides a reproducing apparatus comprising: an image processing device which extracts a part of an area of image data obtained by an image pickup device; a reproducing device which reproduces the part of the area of the image data extracted by the image processing device; and an attitude detection device which detects an attitude state of the reproducing apparatus, wherein according to detection result of the attitude detection device, the image processing device changes the part of the area of the image data to another part of the area and performs rotation processing of the another part of the area, and wherein the reproducing device reproduces the another part of the area, which was subjected to the rotation processing.
It is another object of the invention to provide a reproducing apparatus, an image data reproducing method, a program, and a storage medium each of which improves the convenience during reproducing the image data by performing the reproduction processing according to the attitude state of the image pickup device.
In order to achieve the above object, another aspect of the invention provides a reproducing apparatus comprising an input device which inputs image data obtained by an image pickup device and an attitude state of the image pickup device; an image processing device which extracts a part of an area of the image data; and a reproducing device which reproduces the part of the area of the image data extracted by the image processing device, wherein according to the attitude state, the image processing device changes the part of the area of the image data to another part of the area and performs rotation processing of the another part of the area, and wherein the reproducing device reproduces the another part of the area, which was subjected to the rotation processing.
The above-described objects of the present invention, and the advantages thereof, will become fully apparent from the following detailed description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram schematically showing a configuration of an electronic still camera according to a first to third embodiments of the invention;
FIGS. 2A , 2 B, and 2 C are views for illustrating a function of a lengthwise-or-widthwise position detection circuit in FIG. 1 ;
FIG. 3 is a flow chart showing camera operation in the first embodiment of the invention;
FIG. 4 is a flow chart showing reproduction operation in the first embodiment of the invention;
FIGS. 5A and 5B show one of display examples on an LCD monitor in the first embodiment of the invention;
FIG. 6 is a flow chart showing frame feeding operation in the first embodiment of the invention;
FIG. 7 is a flow chart showing enlargement reproducing operation in the first embodiment of the invention;
FIG. 8 shows a settable area of an enlargement area in the first embodiment of the invention;
FIG. 9 is a flow chart showing the frame feeding operation during enlargement reproduction in the first embodiment of the invention;
FIG. 10 shows one of enlargement display examples in the frame feeding operation during the enlargement reproduction in the first embodiment of the invention;
FIG. 11 is a flow chart showing the frame feeding operation during the enlargement reproduction in a second embodiment of the invention;
FIGS. 12A , 12 B, and 12 C show a parameter of image data used for calculation of enlargement position information in the second embodiment of the invention;
FIG. 13 is a flow chart showing the enlargement reproducing operation in a third embodiment of the invention;
FIG. 14 is a flow chart showing enlargement position selecting operation during the enlargement reproduction in the third embodiment of the invention; and
FIGS. 15A , 15 B, and 15 C show a change in enlargement position selecting sequence based on a photographing attitude in the third embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the invention will be described in detail below referring to the accompanying drawings.
First Embodiment
FIG. 1 is a block diagram schematically showing a configuration of an electronic still camera according to a first embodiment of the invention. In FIG. 1 , the electronic still camera includes a photographing lens 1 , an image pickup element 2 , a signal processing circuit 3 , a buffer memory 4 , am image processing circuit 5 , a recording circuit 6 , a memory card 7 , a drive circuit 8 , a control circuit 9 , an AF circuit 10 , an AE circuit 11 , an electronic dial switch 12 , an electronic sub-dial switch 13 , a lengthwise-or-widthwise position detection circuit 14 , a reproduction circuit 15 , an LCD monitor 16 , a release switch 17 , and a storage circuit 18 .
The image pickup element 2 includes, e.g., CMOS or a CCD image sensor which receives an object through the photographing lens 1 and photo-electrically converts the object. The signal processing circuit 3 converts a signal output from the image pickup element 2 into a digital signal. The buffer memory 4 temporarily stores the image data, and the image processing circuit 5 converts the image data stored in the buffer memory 4 into a predetermined video signal.
The recording circuit 6 records the video signal on a recording medium, the memory card 7 records the image thereon, and the drive circuit 8 drives the photographing lens 1 to a focal position. The control circuit 9 controls the signal processing circuit 3 , the image processing circuit 5 , recording circuit 6 , and the like.
The AF circuit 10 automatically detects the focal point, and the AE circuit 11 determines exposure of a photographed image. The electronic dial switch 12 is used to change reproducing areas during enlargement reproduction, and the electronic sub-dial switch 13 is a switch which is used for changing the reproducing images, the so-called frame feeding. The lengthwise-or-widthwise position detection circuit 14 detects the attitude of the electronic still camera, and the detail function of the lengthwise-or-widthwise position detection circuit 14 is described later. The reproduction circuit 15 reproduces the photographed image, the LCD monitor 16 displays the photographed image and various setting items, and the storage circuit 18 stores adjustment values and various settings of the electronic still camera.
FIGS. 2A , 2 B, and 2 C are views for illustrating the function of the lengthwise-or-widthwise position detection circuit 14 shown in FIG. 1 .
FIG. 2A shows that the electronic still camera is in a widthwise state, FIG. 2B shows that the electronic still camera is in a lengthwise state in which the release switch 17 of the electronic still camera is located on an upper side, and FIG. 2C shows that the electronic still camera is in the lengthwise state in which the release switch 17 of the electronic still camera is located on a lower side.
As shown in FIGS. 2A to 2C , two switches (or mercury switches) SW 3 and SW 4 in which a metal ball is movable are arranged in a camera body. As shown in FIG. 2A , in the case where the electronic still camera is in the widthwise state, the metal balls in the switches SW 3 and SW 4 proceed downward by gravity and both the switches SW 3 and SW 4 are turned on. As shown in FIG. 2B , in the case where the electronic still camera is in the lengthwise state in which the release switch 17 is located on the upper side, the switch SW 3 is turned on and the switch SW 4 is turned off. As shown in FIG. 2C , in the case where the electronic still camera is in the lengthwise state in which the release switch 17 is located on the lower side, the switch SW 3 is turned off and the switch SW 4 is turned on. The electronic still camera of the embodiment can detect the attitude of the camera including a position of the release switch 17 on the basis of on or off-state of the switches SW 3 and SW 4 .
The photographing operation of the electronic still camera will be described below referring to FIG. 3 .
The operation is started in Step S 100 . When the electronic still camera is started up by turning on the power with a power switch (not shown) in Step S 101 , the initial operation such as battery check, confirmation of mounting of the lens, or the like is performed in Step S 102 .
When a first stroke switch SW 1 of the release switch 17 is turned on in Step S 103 , an exposure value is determined in such a manner that the AE circuit 11 is activated by the control circuit 9 to perform photometric operation. Further, the AF circuit 10 is activated by the control circuit 9 to perform ranging operation.
In Step S 105 , it is decided on the basis of detection result of the lengthwise-or-widthwise position detection circuit 14 whether the attitude of the electronic still camera is in the widthwise state or in the lengthwise state. Further, in the case where the electronic still camera is in the lengthwise state, it is decided on the basis of detection result of the lengthwise-or-widthwise position detection circuit 14 whether the release switch 17 is located on the upper side or the lower side. In Step S 106 , in the case where the first stroke switch SW 1 is maintained to be in the on-state after completing photographing preparation, the photographing operation of the electronic still camera becomes a standby state to wait turn-on of a second stroke switch SW 2 of the release switch 17 while holding the attitude information, the ranging information, and the exposure value data, and then the photographing operation proceeds to Step S 107 . On the other hand, in the case where the first stroke switch SW 1 is in the off-state, the photographing operation proceeds to Step S 103 .
When the second stroke switch SW 2 is turned on in Step S 107 , the photographing operation is performed in Step S 108 . In Step S 108 , the object is exposed onto the image pickup element 2 by receiving the signal from the control circuit 9 to release a shutter mechanism (not shown), and the image of the subject is photo-electrically converted. Then, the photo-electrically converted object is converted into digital data by the signal processing circuit 3 and temporarily stored in the buffer memory 4 . In Step S 109 , the data stored in the buffer memory 4 is converted into predetermined image data by the image processing circuit 5 and recorded onto the memory card 7 by the recording circuit 6 . At this point, the attitude information detected onto Step S 105 is recorded in connection with the image data. Further, photographing number information indicating a photographed frame number is also simultaneously recorded. The photographing operation is ended in Step S 110 .
FIG. 4 is the flow chart showing the reproduction operation of the electronic still camera. The reproduction operation of the electronic still camera will be described below.
When a mode setting switch (not shown) is depressed to place the electronic still camera in a reproduction mode, the reproduction operation is started in Step S 200 . In Step S 201 , the final photographing number Nmax is set to a reproduced image number N which is displayed on the LCD monitor 16 . That is to say, immediately after the start of the reproduction operation, the photographed image data which has been finally photographed is selected as the reproduced image data.
In Step S 202 , the image data of the photographing number N which is recorded on the memory card 7 is read out and loaded in a predetermined format into the buffer memory 4 through the image processing circuit 5 .
In Step S 203 , it is decided whether the attitude information recorded in connection with the image data of the reproduced image number N is the widthwise position or not. In the case where the attitude information is the widthwise position, the reproduction operation proceeds to Step S 207 , the image data is transmitted to the reproduction circuit 15 and converted into the signal which can be displayed on the LCD monitor 16 , and the image data is displayed on the LCD monitor 16 .
In the case where the attitude information is not the widthwise position, the reproduction operation proceeds to Step S 204 , it is decided whether the release switch 17 is in the lower lengthwise state or not. In the case where the release switch 17 is located on the lower side, the reproduction operation proceeds to Step S 205 . In Step S 205 , the image data is rotated clockwise by 90 degrees, and the image data is transmitted to the reproduction circuit 15 . In Step S 207 , the image data is converted into the signal which can be displayed on the LCD monitor 16 , and the image data which has been rotated clockwise by 90 degrees is displayed on the LCD monitor 16 .
In the case where the release switch 17 is located on the upper side, the reproduction operation proceeds to Step S 206 . In Step S 206 , the image data is rotated counterclockwise by 90 degrees. In Step S 207 , the image data is transmitted to the reproduction circuit 15 and converted into the signal which can be displayed on the LCD monitor 16 , and the image data which has been rotated counterclockwise by 90 degrees is displayed on the LCD monitor 16 . When the lengthwise position image is displayed on the LCD monitor 16 , the conversion is performed by the reproduction circuit 15 so that the whole image data is displayed.
FIGS. 5A and 5B show one of display examples in which the widthwise position photographed image and the lengthwise position photographed image are reproduced on the LCD monitor 16 respectively.
In the widthwise position photographed image, as shown in FIG. 5A , the photographed image is displayed on the whole area of the LCD monitor 16 . In the lengthwise position photographed image, as shown in FIG. 53 , for example the image in which black images are added to both sides of the image is displayed on the whole area of the LCD monitor 16 so that the whole photographed image which has been rotated by 90 degrees is displayed.
In Step S 208 , it is decided whether the electronic sub-dial switch 13 is depressed or not. In the case where the electronic sub-dial switch 13 is depressed, the reproduction operation proceeds to Step S 209 , and frame feeding reproduction is performed according to the flow chart shown in FIG. 6 . Then, the frame feeding reproduction operation will be described referring to FIG. 6 .
When the flow chart of the frame feeding reproduction operation is started in Step S 300 , it is decided in Step S 301 whether the electronic sub-dial switch 13 is depressed in the clockwise direction or not. In the case where one click of the electronic sub-dial switch 13 is performed in the clockwise direction, the frame feeding reproduction operation proceeds to Step S 302 , and it is decided whether the reproduced image number N is equal to the final photographing number Nmax or not. In the case where the reproduced image number N is equal to the final photographing number Nmax, the frame feeding reproduction operation proceeds to Step S 305 , and the reproduced image number N is set to 1. In the case where the reproduced image number N is not equal to the final photographing number Nmax, the frame feeding reproduction operation proceeds to Step S 304 , and 1 is added to the reproduced image number N to update the reproduced image number N.
In the case where one click of the electronic sub-dial switch 13 is performed in the counterclockwise direction in Step S 301 , the frame feeding reproduction operation proceeds to Step S 303 , and it is decided whether the reproduced image number N is 1 or not. In the case where the reproduced image number N is 1, the frame feeding reproduction operation proceeds to Step S 306 , and the final photographing number Nmax is set to the reproduced image number N. In the case where the reproduced image number N is not 1, the frame feeding reproduction operation proceeds to Step S 307 , and 1 is subtracted from the reproduced image number N to upgrade the reproduced image number N. The frame feeding reproduction operation is ended in Step S 308 .
When the electronic sub-dial switch 13 is depressed during reproduction display, the reproduced image number is increased in each one click in the clockwise direction, and the image which has been photographed immediately after the image currently reproduced is selected. At this point, in the case where the image currently reproduced is the finally photographed image, the image initially photographed is selected.
Further, the reproduced image number is decreased in each one click in the counterclockwise direction, and the image which has been photographed immediately before the image currently reproduced is selected. At this point, in the case where the image currently reproduced is the initially photographed image, the finally photographed image is selected.
When the frame feeding operation is executed in Step S 209 , the reproduction operation proceeds to Step S 202 , and the image data of the reproduced image number N which is set by the frame feeding operation is read out from the memory card 7 and loaded in the predetermined format into the buffer memory 4 through the image processing circuit 5 .
In the case where the electronic sub-dial switch 13 is not depressed in Step S 208 , the reproduction operation proceeds to Step S 210 . In Step S 210 , an enlargement switch (not shown) is depressed to decide whether an enlargement reproduction mode is set or not. In the case where the enlargement reproduction mode is set, the reproduction operation proceeds to Step S 211 , and enlargement reproduction display is performed according to the flow chart shown in FIG. 7 . In the case where the enlargement reproduction mode is not set, the reproduction operation proceeds to Step S 212 . In Step S 212 , it is decided whether the end of the reproduction mode is selected by a mode setting switch (not shown) or not. In the case where the end of the reproduction mode is not selected, the reproduction operation proceeds to Step S 208 , and the reproduction of the image is continued. In the case where the end of the reproduction mode is selected, the reproduction operation is ended in Step S 213 .
The reproduction operation in the enlargement reproduction mode will be described referring to the flow chart shown in FIG. 7 and FIG. 8 . FIG. 8 shows one of relationships between the photographed image data and an enlargement area, when magnification is set to three times. The following description will be performed for the magnification of three times.
The operation is started in Step S 400 . In Step S 401 , an initial position is set as position information of the area where the enlargement display is performed on the LCD monitor 16 . At this point, an enlargement area P 5 which is of a divided image area corresponding to a central region of the image is set to the initial position. In Step S 402 , the set enlargement area of enlargement position information is extracted into a predetermined size from the image data stored in the buffer memory 4 .
In Step S 403 , it is decided whether the attitude information in photographing the image data is widthwise position or not. In the case where the attitude information is the widthwise position, the operation proceeds to Step S 407 , the extracted image data is converted into the signal which can be displayed on the LCD monitor 16 by the reproduction circuit 15 , and the enlargement image is displayed on the LCD monitor 16 .
In the case where the attitude information is not the widthwise position, the operation proceeds to Step S 404 , and it is decided whether the electronic still camera is in the lengthwise state in which the release switch 17 is located on the lower side or not. In the case where the electronic still camera is in the lengthwise state in which the release switch 17 is located on the lower side, the operation proceeds to Step S 405 . In Step S 405 , the extracted image data is rotated clockwise by 90 degrees, and the extracted image data is transmitted to the reproduction circuit 15 . In Step S 407 , the extracted image data is converted into the signal which can be displayed on the LCD monitor 16 , and the enlargement image which has been rotated clockwise by 90 degrees is displayed on the LCD monitor 16 .
In the case where the electronic still camera is in the lengthwise state in which the release switch 17 is located on the upper side in Step S 404 , the operation proceeds to Step S 406 . In Step S 406 , the extracted image data is rotated counterclockwise by 90 degrees, and the extracted image data is transmitted to the reproduction circuit 15 . In Step S 407 , the extracted image data is converted into the signal which can be displayed on the LCD monitor 16 by the reproduction circuit 15 , and the enlargement image which has been rotated counterclockwise by 90 degrees is displayed on the LCD monitor 16 .
In Step S 408 , it is decided whether the electronic dial switch 12 is depressed or not. In the case where the electronic dial switch 12 is depressed, the operation proceeds to Step S 409 . In Step S 409 , the enlargement area is changed in order from the central portion P 5 such as the order of P 5 →P 6 →P 7 →P 8 →P 9 →P 1 →P 2 →P 3 →P 4 → . . . in each one click in the clockwise direction of the electronic dial switch 12 . Then, the image data of the enlargement area change by the electronic dial switch 12 is extracted in Step S 402 .
Further, the enlargement area is changed in an order such as P 5 →P 4 →P 3 →P 2 →P 1 →P 9 →P 8 →P 7 →P 6 → . . . in each one click in the counterclockwise direction of the electronic dial switch 12 , and the selected image area is extracted in the similar manner. In the case where the electronic dial switch 12 is not depressed, the operation proceeds to Step S 410 , and it is decided whether the electronic sub-dial switch 13 is depressed or not. In the case where the electronic sub-dial switch 13 is depressed, the operation proceeds to Step S 411 , and the frame feeding reproduction operation during the enlargement reproduction is performed according to the flow chart shown in FIG. 9 .
The frame feeding reproduction operation during the enlargement reproduction will be described referring to the flow chart shown in FIG. 9 .
When the flow chart of the frame feeding reproduction display is started in Step S 500 , it is decided in Step S 501 whether the electronic sub-dial switch 13 is depressed in the clockwise direction or not. In the case where one click of the electronic sub-dial switch 13 is performed in the clockwise direction, the operation proceeds to Step S 502 , and it is decided whether the reproduced image number N is equal to the final photographing number Nmax or not. In the case where the reproduced image number N is equal to the final photographing number Nmax, the operation proceeds to Step S 505 , and 1 is set to the reproduced image number N. In the case where the reproduced image number N is not equal to the final photographing number Nmax, the operation proceeds to Step S 504 , and 1 is added to the reproduced image number N to update the reproduced image number N.
In the case where one click of the electronic sub-dial switch 13 is performed in the counterclockwise direction in Step S 501 , the operation proceeds to Step S 503 , and it is decided whether the reproduced image number N is 1 or not. In the case where the reproduced image number N is 1, the operation proceeds to Step S 506 , and the final photographing image number Nmax is set to the reproduced image number N. In the case where the reproduced image number N is not 1, the operation proceeds to Step S 507 , and 1 is subtracted from the reproduced image number N to update the reproduced image number N. Then, the operation proceeds to Step S 508 , and the image data of the photographing image number N which is recorded on the memory card 7 is read out and loaded in the predetermined format into the buffer memory 4 through the image processing circuit 5 .
In Step S 509 , it is decided whether the attitude information of the image data before the frame feeding is changed from the attitude information of the image data which is read after the frame feeding. In the case where the attitude information is changed, the operation proceeds to Step S 510 , and the information of the enlargement area is changed to the initial position P 5 . In the case where the change in the attitude does not occurs, the information of the enlargement area which is set to the reproduced image before the frame feeding is maintained.
Then, the operation proceeds to Step S 511 , and the frame feeding operation during the enlargement reproduction is ended. When the frame feeding operation during the enlargement reproduction is executed by the above flow chart, the reproduction operation in the enlargement reproduction mode proceeds to Step S 402 , and the enlargement area is extracted from the image data loaded into the buffer memory 4 . In Step S 407 , in the case where the extracted image data is the widthwise image, the selected enlargement area is displayed on the LCD monitor 16 . In the case where the extracted image data is the lengthwise image, the image data of the enlargement area which has been rotated by 90 degrees in the clockwise or counterclockwise direction according to the position of the release switch 17 is displayed on the LCD monitor 16
When the electronic sub-dial switch 13 is depressed during the reproduction display, the reproduced image number is increased in each one click in the clockwise direction, and the image which has been photographed immediately after the image currently reproduced is selected. Further, the reproduced image number is decreased in each one click in the counterclockwise direction, and the image which has been photographed immediately before the image currently reproduced is selected. In the case where the change in the attitude occurs during the frame feeding, the information of the area where the enlargement reproduction is performed is changed to the initial position.
As shown in FIG. 10 , when the enlargement display is performed in the area P 1 of the widthwise photographed image, in the case where the change in the attitude does not occur during the frame feeding, the same area P 1 is also displayed in the photographed image of the next frame. In the case where the widthwise photographed image is changed to the lengthwise photographed image, the area P 5 which is of the initial position is displayed. In the case where the enlargement image of the lengthwise photographed image is displayed, in order to match an aspect ratio of the enlargement image with the aspect ratio of the LCD monitor 16 , the image data in which the black images are added to the both sides of the display area is displayed on the LCD monitor 16 . In order to display the image on the whole LCD monitor 16 , it is also possible that, while the selected enlargement area is included, a wider enlargement area is extracted so that the image is displayed on the whole LCD monitor 16 . In the case where the electronic sub-dial 13 is depressed by the above operation in Step S 410 , the frame feeding operation in the enlargement reproduction is executed.
In the case where the electronic sub-dial 13 is not depressed in Step S 410 , the operation proceeds to Step S 412 , and it is decided whether the end of the enlargement reproduction is set by the mode setting switch (not shown) or not. In the case where the end of the enlargement reproduction is not set in Step S 412 , the operation proceeds to Step S 408 . In the case where the end of the enlargement reproduction is not set in Step S 412 , the operation proceeds to Step S 413 , and the enlargement reproduction operation is ended.
When the attitude information during photographing is changed in performing the frame feeding of the enlargement reproduction mode, the enlargement area automatically returns to the initial position. When the attitude information during photographing is not changed, the enlargement area is maintained. Accordingly, in the case where confirmation of details in the photographed image is continuously performed, even if the change in the photographing attitude occurs, the confirmation can be rapidly performed and natural operation feeling for the photographer can be realized.
In the embodiment, although the case in which the magnification is three times is described, the invention can be applied to an arbitrary magnification. Even in the case where trimming processing of the specified area is performed while the magnification is set to one time, the invention can be applied. Although the central portion of the image is shown as an example of the initial position in changing the attitude, for example, it is also possible that the initial position of the enlargement area is configured to be stored in the storage circuit 18 so that the user sets the initial position to a desired position.
Second Embodiment
A second embodiment of the invention will be described. The electronic still camera of the second embodiment has the substantially same configuration as the first embodiment shown in FIG. 1 , the attitude during photographing is detected by the lengthwise-or-widthwise detection circuit 14 , and the image data is recorded on the memory card 7 in connection with the attitude information.
FIG. 11 is the flow chart showing the operation involving the frame feeding during the enlargement reproduction of the electronic still camera of the embodiment. The frame feeding operation during the enlargement reproduction of the electronic still camera will be described below.
When the electronic sub-dial switch 13 is depressed during performing the enlargement reproduction of the image data of the reproduced image number N, the flow chart of the frame feeding reproduction display is started in Step S 600 . In Step S 601 , it is decided whether the electronic sub-dial switch 13 is depressed in the clockwise direction or not.
In the case where one click of the electronic sub-dial switch 13 is performed in the clockwise direction, the operation proceeds to Step S 602 , and it is decided whether the reproduced image number N is equal to the final photographing number Nmax or not. In the case where the reproduced image number N is equal to the final photographing number Nmax, the operation proceeds to Step S 605 , and 1 is set to the reproduced image number N. In the case where the reproduced image number N is not equal to the final photographing number Nmax, the operation proceeds to Step S 604 , and 1 is added to the reproduced image number N to update the reproduced image number N.
In the case where one click of the electronic sub-dial switch 13 is performed in the counterclockwise direction in Step S 601 , the operation proceeds to Step S 603 , and it is decided whether the reproduced image number N is 1 or not. In the case where the reproduced image number N is 1, the operation proceeds to Step S 606 , and the final photographing number Nmax is set to the reproduced image number N. In the case where the reproduced image number N is not 1, the operation proceeds to Step S 607 , and 1 is subtracted from the reproduced image number N to update the reproduced image number N.
Then, the operation proceeds to Step S 608 , and the image data of the photographing image number N which is recorded in the memory card 7 is read out and loaded in the predetermined format into the buffer memory 4 through the image processing circuit 5 .
In Step S 609 , it is decided whether the attitude information of the image data before the frame feeding is changed from the attitude information of the image data which is read after the frame feeding. In the case where the attitude information is not changed, the enlargement position information at the immediately preceding frame is maintained, and the operation proceeds to Step S 611 . In the case where the attitude information is changed, the operation proceeds to Step S 610 , and the enlargement position information is calculated.
FIGS. 12A , 12 B, and 12 C show a parameter of the image data used for the calculation of the enlargement position information. FIG. 12A shows the image data on a coordinate system in which an image data size in the widthwise position is set to Sx and Sy, an origin is located at the upper left of the image data, and the horizontal axis is set to an x1 axis and the vertical axis is set to a y1 axis. The coordinate of a starting point indicating the upper left of the enlargement area is set to (a1,b1) in the x1-y1 coordinate system. FIG. 12B shows the image data when the image data is rotated by 90 degrees in the clockwise direction, i.e. the image data picked up while the release switch 17 is located on the lower side is shown on the coordinate system in which the horizontal axis is set to an x2 axis and the vertical axis is set to a y2 axis. The coordinate of the starting point indicating the upper left of the enlargement area is set to (a2,b2) in the x2-y2 coordinate system. FIG. 12C shows the image data when the image data is rotated by 90 degrees in the counterclockwise direction, i.e. the image data picked up while the release switch 17 is located on the upper side is shown on the coordinate system in which the horizontal axis is set to an x3 axis and the vertical axis is set to a y3 axis. The coordinate of the starting point indicating the upper left of the enlargement area is set to (a3,b3) in the x3-y3 coordinate system.
Assuming that the magnification is set to three times, a method of calculating the enlargement area will be described.
Assuming that the photographing attitude of the image in which the enlargement reproduction is being performed is the widthwise position and the coordinate of the starting point of the selected enlargement area is (a1,b1) in the x1-y1 coordinate system, since the magnification is three times in the size of the enlargement area, the image data size in the x1 axis direction is Sx/3 and the image data size in the y1 axis direction is Sy/3. In the case where Sx/3 and Sy/3 are not integers, the fractional parts of Sx/3 and Sy/3 are rounded.
When the reproduced image is changed by the frame feeding operation, in the case where the attitude information of the image data immediately after the frame feeding is equal to the attitude information of the image data immediately before the frame feeding, i.e. in the case the image data immediately after the frame feeding is widthwise position, the starting point information and size of the enlargement area are maintained. In the case where the image data immediately after the frame feeding is the lengthwise position attitude in which the release switch 17 is located on the lower side, the coordinate system is changed to the x2-y2 coordinate system, and the starting point (a2,b2) of the enlargement area is calculated from the following equations 1 and 2.
a
2
=
Sy
Sx
*
a
1
Equation
1
b
2
=
Sx
Sy
*
b
1
Equation
2
The starting point of the enlargement area is determined so that ratios a1/Sx and b1/Sy of the image sizes Sx and Sy to the starting points a1 and b1 in the x1-y1 coordinate system before the conversion correspond to the ratios a2/Sx and b2/Sy of the image sizes to the starting points in the x2-y2 coordinate system after the conversion respectively. In the case where the calculation results of the equations 1 and 2 are not integers, the fractional parts of the calculation results are rounded.
In the case where the image data immediately after the frame feeding is lengthwise position attitude in which the release switch 17 is located on the upper side, the coordinate system is changed to the x3-y3 coordinate system, and the starting point (a3,b3) of the enlargement area is calculated from the following equations 3 and 4.
a
3
=
Sy
Sx
*
a
1
Equation
3
b
3
=
Sx
Sy
*
b
1
Equation
4
The starting point of the enlargement area is determined so that ratios a1/Sx and b1/Sy of the image sizes Sx and Sy to the starting points a1 and b1 in the x1-y1 coordinate system before the conversion correspond to the ratios a3/Sx and b3/Sy of the image sizes to the starting points in the x3-y3 coordinate system after the conversion respectively. In the case where the calculation results of the equations 3 and 4 are not integers, the fractional parts of the calculation results are rounded.
In the case where the magnification of the size of the enlargement area is three times and the camera attitude is in the widthwise position state, the image size in the x1 axis direction becomes Sx/3 and the image size in the y1 axis direction becomes Sy/3. In the case where the magnification of the size of the enlargement area is three times and the camera attitude is in the lengthwise position state in which the release switch 17 is located on the lower side, the image size in the x2 axis direction becomes Sx/3 and the image size in the y2 axis direction becomes Sy/3. In the case where the magnification of the size of the enlargement area is three times and the camera attitude is in the lengthwise position state in which the release switch 17 is located on the upper side, the image size in the x3 axis direction becomes Sx/3 and the image size in the y3 axis direction becomes Sy/3.
The enlargement position information after frame feeding is set by the above calculations, and the frame feeding operation in the enlargement is ended in Step S 611 . Even in the case where the attitude is changed from the lengthwise position to the widthwise position or even in the case where the position of the release switch 17 in the lengthwise position state is changed, the coordinate conversion and the calculation of the starting point of the extracting position are also performed on the basis of the concept described above.
The enlargement area is extracted from the image data by using the enlargement position information set by the above operation. In the case where the image data is the widthwise image, the selected enlargement area is displayed on the LCD monitor 16 . In the case where the image data is the lengthwise image, the image data of the enlargement area is rotated by 90 degrees in the clockwise direction or in the counter clockwise direction according to the position of the release switch 17 , and the image data of the enlargement area is displayed on the LCD monitor 16 .
When the electronic sub-dial switch 13 is depressed during the reproduction display, 1 is added to the reproduced image number in each one click in the clockwise direction, and the image which has been photographed immediately after the image currently reproduced is selected. Further, 1 is subtracted from the reproduced image number in each one click in the counterclockwise direction, and the image which has been photographed immediately before the image currently reproduced is selected.
In the case where the attitude information of the image data before the frame feeding corresponds to the attitude information of the image data after the frame feeding, the enlargement reproduction of the same position is performed. In the case where the attitude information of the image data before the frame feeding differs from the attitude information of the image data after the frame feeding, the enlargement reproduction of the position where positional relationship is relatively maintained is performed. That is to say, for example the upper left of the image in the widthwise position is enlarged and confirmed in the image before changing the images, so that the upper left of the image in the lengthwise position can be also confirmed even in the case where the reproduction direction after changing the images is changed to the lengthwise position.
When the frame feeding of the enlargement reproduction mode is performed, the confirmation of the image can be rapidly performed even if the attitude of the photographer is changed, and the natural operation feeling for the photographer can be realized. In the embodiment, although the case in which the magnification is three times is shown, the invention can be also applied to an arbitrary magnification and an arbitrary enlargement area.
Third Embodiment
A third embodiment of the invention will be described. The electronic still camera in the third embodiment has the substantially similar configuration as the first embodiment shown in FIG. 1 , the attitude during photographing is detected by the lengthwise-or-widthwise detection circuit 14 , and the image data is recorded in the memory card 7 in connection with the attitude information.
FIG. 13 is the flow chart showing the operation involving the enlargement reproduction of the electronic still camera of the embodiment. The enlargement reproduction operation and the changing operation of the enlargement position in the enlargement reproduction of the electronic still camera will be described referring to FIG. 13 .
When an enlargement switch (not shown) is depressed to select the enlargement reproduction mode during the reproduction mode, the enlargement reproduction operation is started in Step S 700 . The initial position information of the area where the enlargement display is initially performed on the LCD monitor 16 is set in Step S 701 . FIGS. 15A , 15 B, and 15 C show one of sequences of selecting the enlargement settable area and enlargement area, in case that the magnification is three times. In FIGS. 15A , 15 B, and 15 C, P 1 , P 2 , P 3 , P 4 , P 5 , P 6 , P 7 , P 8 , and P 9 are the area information for the image data and the information which is uniquely determined for the image data irrespective of the attitude information.
FIG. 15A shows the sequence in which the enlargement area is selected in the widthwise position. A(M) in FIG. 15A is the area selecting information in which selecting sequence information M is in connection with area information Pi. A relationship RA:Pi-A(M) between Pi and A(M) becomes P 1 -A( 6 ), P 2 -A( 7 ), P 3 -A( 8 ), P 4 -A( 9 ), P 5 -A( 1 ), P 6 -A( 2 ), P 7 -A( 3 ), P 8 -A( 4 ), and P 9 -A( 5 ). The central portion P 5 of the image data is set to the initial position in the enlargement area, the enlargement area is moved to the right side in a row direction, and the enlargement area is moved to the right end area. Then, the enlargement area is moved to the left end of the lower row.
FIG. 15B shows the sequence in which the enlargement area is selected in the lengthwise position in which the release switch 17 is located on the lower side. B(M) in FIG. 15B is the area selecting information in which the selecting sequence information M is in connection with the area information Pi. A relationship RB:Pi-B(M) between Pi and B(M) becomes P 1 -B( 8 ), P 2 -B( 2 ), P 3 -B( 5 ), P 4 -B( 7 ), P 5 -B( 1 ), P 6 -B( 4 ), P 7 -B( 6 ), P 8 -B( 9 ), and P 9 -B( 3 ). The central portion P 5 of the image data is set to the initial position in the enlargement area, the enlargement area for the image data rotated by 90 degrees in the clockwise direction is moved to the right side in the row direction, and the enlargement area is moved to the right end area. Then, the enlargement area is moved to the left end of the lower row.
FIG. 15C shows the sequence in which the enlargement area is selected in the lengthwise position in which the release switch 17 is located on the upper side, C(M) in FIG. 15C is the area selecting information in which the selecting sequence information M is in connection with the area information Pi. A relationship RC:Pi-C(M) between Pi and C(M) becomes P 1 -C( 3 ), P 2 -C( 9 ), P 3 -C( 6 ), P 4 -C( 4 ), P 5 -C( 1 ), P 6 -C( 7 ), P 7 -C( 5 ), P 8 -C( 2 ), and P 9 -C( 8 ). The central portion P 5 of the image data is set to the initial position in the enlargement area, the enlargement area for the image data rotated by 90 degrees in the counterclockwise direction is moved to the right side in the row direction, and the enlargement area is moved to the right end area. Then, the enlargement area is moved to the left end of the lower row.
The initial position set in Step S 701 is in the area where the selecting sequence information M is 1, and the central portion P 5 of the image data is selected irrespective of the attitude information. In Step S 702 , it is decided whether the attitude information in photographing the image data selected as the reproduced image is the widthwise position or not. In the case where the attitude information is the widthwise position, the operation proceeds to Step S 704 , and the area corresponding to the area selecting information A(M) is extracted from the image data stored in the buffer memory 4 into the predetermined size. In Step S 709 , the extracted image data is converted into the signal which can be displayed on the LCD monitor 16 by the reproduction circuit 15 , and the enlargement image is displayed on the LCD monitor 16 .
In the case where the attitude information is not the widthwise position, the operation proceeds to Step S 703 , and it is decided whether the attitude information is the lengthwise position in which the release switch 17 is located on the lower side or not. In the case where the attitude information is the lengthwise position in which the release switch 17 is located on the lower side, the operation proceeds to Step S 705 , and the area corresponding to the area selecting information B(M) is extracted from the image data stored in the buffer memory 4 into the predetermined size. In Step S 707 , the extracted image data is rotated by 90 degrees in the clockwise direction and transmitted to the reproduction circuit 15 . In Step S 709 , the image data is converted into the signal which can be displayed on the LCD monitor 16 by the reproduction circuit 15 , and the enlargement image which is rotated by 90 degrees in the clockwise direction is displayed on the LCD monitor 16 .
In the case where it is decided in Step S 703 that the attitude information is the lengthwise position in which the release switch 17 is located on the upper side, the operation proceeds to Step S 706 , and the area corresponding to the area selecting information C(M) is extracted from the image data stored in the buffer memory 4 into the predetermined size. In Step S 708 , the extracted image data is rotated by 90 degrees in the counterclockwise direction and transmitted to the reproduction circuit 15 . In Step S 709 , the image data is converted into the signal which can be displayed on the LCD monitor 16 by the reproduction circuit 15 , and the enlargement image which is rotated by 90 degrees in the counterclockwise direction is displayed on the LCD monitor 16 .
In Step S 710 , it is decided whether the electronic dial switch 12 is depressed or not. In the case where the electronic dial switch 12 is depressed, the operation proceeds to Step S 711 , and the enlargement position changing operation is performed according to the flow chart shown in FIG. 13 . Then, the enlargement position selecting operation will be described referring to the flow chart shown in FIG. 14 .
When the enlargement position selecting operation is started in Step S 800 , it is decided in Step S 801 whether the electronic dial switch 12 is depressed clockwise or not. In the case where the electronic dial switch 12 is depressed clockwise, the operation proceeds to Step S 802 , and it is decided whether the selecting sequence information M is 9 or not. In the case where the selecting sequence information M is 9, i.e. in the case where the selecting sequence information M is the maximum value, the operation proceeds to Step S 804 , and the initial value 1 is set to the selecting sequence information M. In the case where the selecting sequence information M is not the maximum value, the operation proceeds to Step S 805 , and the selecting sequence information M is changed by adding 1 to the selecting sequence information M.
In the case where the electronic dial switch 12 is depressed counterclockwise in Step S 801 , the operation proceeds to Step S 802 , and it is decided whether the selecting sequence information M is 1 or not. In the case where the selecting sequence information M is 1, i.e. in the case where the selecting sequence information M is the initial value, the operation proceeds to Step S 806 , and the initial value 1 is set to the selecting sequence information M. In the case where the selecting sequence information M is not the initial value, the operation proceeds to Step S 807 , and the selecting sequence information M is changed by subtracting 1 from the selecting sequence information M. Then, the enlargement position selecting operation is ended in Step S 808 .
When the enlargement position selecting operation in the flow chart shown in FIG. 14 is performed in Step S 711 , the operation proceeds to Step S 702 , and the enlargement area corresponding to the selecting sequence information M is extracted according to the attitude information to display the enlargement image on the LCD monitor 16 .
In the case where the electronic dial switch 12 is not depressed in Step S 710 , the operation proceeds to Step S 712 , and it is decided whether the end of the enlargement reproduction is set by the mode setting switch (not shown) or not. In the case where the end of the enlargement reproduction is not set, the operation proceeds to Step S 710 . In the case where the end of the enlargement reproduction is selected in Step S 712 , the operation proceeds to Step S 713 , and the enlargement reproduction operation is ended.
As described above, in the position selecting operation in the enlargement reproduction mode, the sequence of selecting the image data area is changed to the direction opposite to the direction of rotating the camera. Consequently, in the case of the widthwise image, each one click in the clockwise direction of the electronic dial switch 12 selects the area in order of P 5 →P 6 →P 7 →P 8 →P 9 →P 1 →P 2 →P 3 →P 4 → . . . . In the case of the lengthwise image in which the release switch 17 is located on the lower side, each one click in the clockwise direction of the electronic dial switch 12 selects the area in order of P 5 →P 2 →P 9 →P 6 →P 3 →P 7 →P 4 →P 1 →P 8 . . . . In the case of the lengthwise image in which the release switch 17 is located on the upper side, each one click in the clockwise direction of the electronic dial switch 12 selects the area in order of P 5 →P 8 P 1 →P 4 →P 7 →P 3 →P 6 →P 9 →P 2 → . . . . In any attitude on the LCO monitor 16 , the area is moved to the right side in the row direction by the clockwise click of the electronic dial switch 12 , and the area is moved to the left end of the lower row next to the right end in the row direction. Then, the area is moved to the left end of the uppermost row next to the right end of the lowermost row. Accordingly, the operating ease for the user can be also realized irrespective of the photographing attitude.
Although the case in which the magnification is three times is shown in the embodiment, the invention can be also applied to an arbitrary magnification and an arbitrary enlargement area.
According to the first and second embodiments of the invention, in performing the frame feeding of the enlargement reproduction mode in the electronic still camera, when the attitude information in taking the photograph is changed, the enlargement area is moved to the initial position previously set or the predetermined position determined by the calculation. Further, when the attitude information in taking the photograph is not changed, the enlargement area is maintained. Accordingly, the details of the photographed image can be continuously confirmed, and the natural operation feeling for the user can be realized even if the change in the photographing attitude occurs.
According to the third embodiment of the invention, the operational ease for the user can be also realized irrespective of the photographing attitude in such a manner that the order of selecting the area of the image data is changed according to the attitude information in the position selecting operation in the enlargement reproduction mode.
Needless to say, the object of the invention is also achieved, in such a manner that the storage medium in which program code of software realizing the function of the above embodiments is recorded is supplied to the system or the apparatus and a computer (or CPU or MPU) in the system or the apparatus reads out and executes the program code stored in the storage medium.
In this case, the function of the above embodiments is realized by the program code itself read out from the storage medium, and the program code itself and the storage medium storing the program code constitute the invention.
A flexible disk, a hard disk, an optical disk, a magneto-optical disk, CD-ROM, CD-R, magnetic tape, a nonvolatile memory card, ROM, and the like can be used as the storage medium for supplying the program code.
Needless to say, the invention includes not only the case in which the function of the above embodiment is realized by executing the program code read out by the computer, but also the case in which OS (basic system or operating system) which is running on the computer or the like performs a part of the actual processing or the whole actual processing on the basis of instructions of the program code and the function of the above embodiment is realized by the processing.
Needless to say, the invention includes the case in which, after the program code read out from the storage medium is written in a memory which is incorporated in a function enhancement board inserted in the computer or a function enhancement unit connected to the computer, CPU included in the function enhancement board or the function enhancement unit or the like performs a part of the actual processing or the whole actual processing on the basis of instructions of the program code and the function of the above embodiment is realized by the processing.
According to the embodiment, the enlargement target areas of the image data are properly changed according to the detection result of the attitude state of the reproducing apparatus, and the rotational displays of the enlargement target areas are performed, so that convenience can be improved in the enlargement reproduction of the image data.
As described above, although the invention was described by the preferred embodiment, the invention is not limited to the above embodiments, but various modifications can be made without departing from the spirit and the scope of the invention. | A reproducing apparatus, an image data reproducing method, a program, and a storage medium each detects an attitude state of the reproducing apparatus, extracts a part of an area of image data obtained by an image pickup device, and reproduces the part of the area of the extracted image data. According to the detection result, the part of the area of the image data is changed to another part of the area and rotation processing of another part of the area is performed, thereby reproducing the another part of the area which was subjected to the rotation processing. | 7 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to radiolabeled pyridazinone compounds, compositions thereof, methods of making such compounds and their use as imaging probes of Tau pathology especially as it relates to Alzheimer's Disease. Compounds of the present invention may be used for Positron Emission Tomography (PET) or Single Photon Emission Computed Tomography (SPECT) imaging.
DESCRIPTION OF RELATED ART
[0002] Alzheimer's disease (AD) is the most common cause of dementia in the elderly. It is definitively diagnosed and staged on the basis of post-mortem neuropathology. The pathological hallmark of AD is a substantial neuronal loss accompanied by deposition of amyloid plaques and neurofibrillary tangles (NFTs).
[0003] NFTs consist of filamentous aggregates composed of microtubule-associated protein tau. Much of the literature suggests that tau aggregates (NFTs) or NFT formation correlate more closely with AD progression than amyloid plaques (Braak, H. et al., Neuropathological Staging of Alzheimer-related Changes. Acta Neuropathologica, 82, 239-259, 1991). The tau aggregates or neurofibrillary lesions reportedly appear in areas (deep temporal lobe) decades before neocortical amyloid deposition and signs of dementia can be detected. The tau lesions occur before the presentation of clinical symptoms or signs of dementia and correlate with the severity of dementia. These attributes make tau aggregates a potentially superior approach for the early diagnosis of AD. Hence in vivo detection of these lesions or NFTs would prove useful for diagnosis of AD and for tracking disease progression.
[0004] One of the challenges in discovering NFT imaging probes is the selectivity for other protein aggregates (such as amyloid plaques) containing a cross beta-sheet conformation. Kudo et al. have recently screened compounds for selectivity to aggregated tau over amyloid in vitro. BF-170 and BF-158 were described as being ˜threefold selective for tau aggregates over Aβ1-42 amyloid:
[0000]
[0005] (Kudo, Y., et al., J. Neuroscience, 2005, 25(47):10857-10862). These compounds and other quinoline derivatives are also described in US 2005/0009865, now U.S. Pat. No. 7,118,730, as diagnostic probes for the imaging diagnosis of diseases in which tau protein accumulates. The probes can be labeled with a radionuclide.
[0006] WO2011/037985 describes aminothienopyridazine inhibitors of tau assembly.
[0007] However there still exist a need in the art for other compounds that can be used as imaging agents for NFTs. The present invention described below answers such a need.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a preparative HPLC chromatogram showing product 37* eluting at 12.8 min (top: UV channel at 254 nm, bottom: radioactivity channel).
[0009] FIG. 2 is an analytical HPLC chromatogram showing product 37* eluting at 7.2 min (top: UV channel at 254 nm, bottom: radioactivity channel).
[0010] FIG. 3 is an analytical HPLC chromatogram showing product 38* eluting at 6.8 min (top: UV channel at 254 nm, bottom: radioactivity channel).
[0011] FIG. 4 is an analytical HPLC chromatogram showing product 38* eluting at 6.8 min and spiked standard compound 19F-38 at 6.7 min (top: UV channel at 254 nm, bottom: radioactivity channel).
[0012] FIG. 5 depicts Histology of human AD tissue sections. Numerous tau+ NFTs (A-B, arrow) and Aβ+ plaques (E-F, arrow) were observed in AD tissue sections. In addition, NFTs (C, arrow) and neuritic plaques (D, arrow) were also observed in tissue sections labelled with Gallyas silver stain (E-F). 10×: A, C, E, scale bar 100 μM; 20×: B, D, F, scale bar: A, 25 μM.
[0013] FIG. 6 depicts Binding of novel compounds to NFTs and plaques in AD tissue. 38 (A, B) binds to both NFTs (A) and plaques (B) at high test concentrations. Similary, 105 (C, D) also binds to NFTs (C, D) and plaques (D) at high test concentrations. At lower concentrations, both compounds binds preferentially to NFTs (Table 3). Arrows=NFTs, *=plaques. A and C: 40×, B and D: 20×.
SUMMARY OF THE INVENTION
[0014] The present invention provides novel pyridazinone compounds for use as imaging probes of Tau pathology in Alzheimer's disease. The compounds of the inventions may be radiolabeled such that they may be used for in vitro and in vivo imaging purposes.
[0015] The present invention provides a compound of Formula I:
[0000]
[0000] wherein:
R 1 is alkyl or Ar, optionally substituted with at least one alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, amide, or alkoxyhalo;
R 2 is independently hydrogen, alkyl, alkynyl, ester, amino, amide, acid, aryl, heteroaryl, aminoalkyl, —C(═O)alkyl, —C(═O)aryl, —C(═O)heteroaryl, —C(═O)heterocycloalkyl, —C(═O)heterocycloalkylAr, —C(═O)(CH 2 ) p halo, —C(═O)(CH 2 ) p heterocyclyl, or —SO 2 Ar, optionally substituted with at least one alkyl, alkylhalo, halogen, nitro, aryl, heteroaryl, or heteroaryl(CH 2 ) p halo;
R 3 and R 4 are independently hydrogen, alkyl, alkenyl, alkynyl, acyl, aryl, heteroaryl;
Ar is an aryl, heteroaryl, cycloalkyl, heterocycloalkyl group;
p is an integer from 0-10; preferably, 0-5; more preferably, 0-3;
or a radiolabelled derivative thereof.
[0016] The present invention further provides a pharmaceutical composition comprising a compound of Formula (I) or a radiolabelled derivative thereof and a pharmaceutically acceptable carrier or excipient.
[0017] The present invention further provides a method of making a compound of Formula (I) or a radiolabelled derivative thereof.
[0018] The present invention further provides a method of imaging using a radiolabelled derivative of a compound of Formula (I) or a pharmaceutical composition thereof.
[0019] The present invention further provides a method of detecting tau aggregates in vitro and/or vivo using a radiolabelled derivative of a compound of Formula (I) or a pharmaceutical composition thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention provides pyridazinone compounds of Formula (I) as described herein.
[0021] In a preferred embodiment of the invention, a compound of Formula (I), as described above, is provided wherein Ar is:
[0000]
[0022] In a preferred embodiment of the invention, a compound of Formula (I), as described above, is provided wherein Ar of R 1 is:
[0000]
[0000] preferably
[0000]
[0023] The present invention provides a compound of Formula (I) having Formula (Ia):
[0000]
[0000] wherein:
R 1 is alkyl or Ar, optionally substituted with at least one alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, amide, or alkoxyhalo;
R 2 is independently hydrogen, alkyl, alkynyl, ester, amino, amide, acid, aryl, heteroaryl, aminoalkyl, —C(═O)alkyl, —C(═O)aryl, —C(═O)heteroaryl, —C(═O)heterocycloalkyl, —C(═O)heterocycloalkylAr, —C(═O)(CH 2 ) p halo, —C(═O)(CH 2 ) p heterocyclyl, or —SO 2 Ar, optionally substituted with at least one alkyl, alkylhalo, halogen, nitro, aryl, heteroaryl, or heteroaryl(CH 2 ) p halo;
R 3 and R 4 are independently hydrogen, alkyl, alkenyl, alkynyl, acyl, aryl, heteroaryl;
Ar is an aryl, heteroaryl, cycloalkyl, heterocycloalkyl group;
p is an integer from 0-10; preferably, 0-5; more preferably, 0-3;
or a radiolabelled derivative thereof.
[0024] The present invention provides a compound of Formula (I) having Formula (Ib):
[0000]
[0000] wherein:
[0025] R 2 , R 3 , and R 4 are each as defined herein for a compound of Formula (I);
[0026] R 5 is hydrogen, alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, or amide; and
[0027] n is an integer from 0-5; or a radiolabelled derivative thereof. The present invention provides a compound of Formula (I) having Formula (Ic):
[0000]
[0000] wherein:
[0028] R 2 is as defined herein for a compound of Formula (I);
[0029] R 5 is hydrogen, alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, or amide; and
[0030] n is an integer from 0-5;
[0000] or a radiolabelled derivative thereof.
The present invention provides a compound of Formula (I) having Formula (Ida), (Idb) or (Idc):
[0000]
[0000] wherein:
[0031] R 2 , R 3 , and R 4 are each as defined herein for a compound of Formula (I);
[0032] R 5 is hydrogen, alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, or amide; and
[0033] n is an integer from 0-5;
[0000] or a radiolabelled derivative thereof.
The present invention provides a compound of Formula (I) having Formula (Iea), (Ieb) or (Iec):
[0000]
[0000] wherein:
[0034] R 2 is as defined herein for a compound of Formula (I);
[0035] R 5 is hydrogen, alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, or amide; and
[0036] n is an integer from 0-5;
[0000] or a radiolabelled derivative thereof.
[0037] The present invention provides a compound of Formula (I) having Formula (If):
[0000]
[0000] wherein:
[0038] R 3 and R 4 are each as defined herein for a compound of Formula (I);
[0039] R 5 is hydrogen, alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, or amide;
[0040] n is an integer from 0-5;
[0041] R 6 and R 7 are independently hydrogen, alkyl, or alkynyl, or when taken together with the nitrogen to which they are attached form a heteroaryl or heterocycloalkyl optionally substituted with at least one alkyl, alkylhalo, halogen, hydroxyl, nitro, aryl, heterocycloalkyl, heteroaryl, or heteroarylhalo;
[0000] or a radiolabelled derivative thereof.
[0042] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0043] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0044] In one or more embodiments of the invention, the compound of Formula (I) is
[0000]
[0045] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0000] wherein I* is 123 I, 124 I, or 125 I; more preferably, 123 I or 125 I; more preferably, 123 I.
[0046] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0047] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0048] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0049] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0050] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0051] In one or more embodiments of the invention, the compound of Formula (I) is:
[0000]
[0052] According to the present invention, for a compound of the invention described herein, a halogen is selected from F, Cl, Br, and I; preferably, F.
[0053] The invention provides a radiolabelled derivative of a compound of the invention as described herein. According to the present invention, a “radiolabelled derivative” of a compound of the invention or a “radiolabelled derivative thereof” is a compound of the invention, as described herein, that comprises a radionuclide (i.e., a compound of the invention that is radiolabelled with a radionuclide. By way of example, a radiolabelled derivative of a compound of Formula (I) is a compound of Formula (I) as described herein wherein at least one of R 1 , R 2 , R 3 , R 4 and Ar comprises a radionuclide. The radionuclide shall mean any radioisotope known in the art. Preferably the radionuclide is a radioisotope suitable for imaging (e.g., PET, SPECT).
[0054] In one embodiment, the radionuclide is a radioisotope suitable for PET imaging. Even more preferably, the radionuclide is 11 C, 13 N, 15 O, 68 Ga, 62 Cu, 18 F, 76 Br, 124 I, or 125 I; even more preferably, the radionuclide is 18 F.
[0055] In one embodiment, the radionuclide is a radioisotope suitable for SPECT imaging. Even more preferably, the radionuclide is 99m Tc, 111 In, 67 Ga, 201 Tl, 123 I, or 133 Xe; even more preferably, the radionuclide is 99m Tc or 123 I.
Intermediates:
[0056] The present invention provides pre-cursor or intermediate compounds of Formula II:
[0000]
[0000] wherein:
R 1 is alkyl or Ar, optionally substituted with at least one alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, amide, alkoxyhalo or alkyoxyOPg;
R 2 is independently alkyl, alkynyl, ester, amino, amide, acid, aryl, heteroaryl, aminoalkyl, —C(═O)alkyl, —C(═O)aryl, —C(═O)heteroaryl, —C(═O)heterocycloalkyl, —C(═O)heterocycloalkylAr, —C(═O)(CH 2 ) p OPg, —C(═O)(CH 2 ) p halo, —C(═O)(CH 2 ) p heterocyclyl, or —SO 2 Ar, optionally substituted with an alkyl, alkylhalo, alkylOPg, halogen, nitro, aryl, heteroaryl, heteroaryl(CH 2 ) p halo, or heteroaryl(CH 2 ) p OPg;
R 3 and R 4 are independently hydrogen, alkyl, alkenyl, alkynyl, aryl, or heteroaryl;
Ar is an aryl, heteroaryl, cycloalkyl, or heterocycloalkyl group;
p is an integer from 0-10; preferably, 0-5; more preferably, 0-3;
Pg is H, a protecting or leaving group.
The protecting or leaving group may be any protecting or leaving group known in the art. Examples of suitable protecting or leaving groups include, but are not limited to, tosylate (OTs), BOC, Fmoc, Cbz, acetyl (Ac) and paramthoxybenzyl (PMB).
[0057] Examples of a pre-cursor or intermediate compounds of the invention include:
[0000]
[0058] The present invention further provides a pre-cursor or intermediate compound of the formula:
[0000]
Pharmaceutical or Radiopharmaceutical Composition
[0059] The present invention provides a pharmaceutical or radiopharmaceutical composition comprising a compound of the invention as described herein together with a pharmaceutically acceptable carrier, excipient, or biocompatible carrier. According to the invention when a compound of the invention is a radiolabelled derivative, the pharmaceutical composition is a radiopharmaceutical composition.
[0060] The present invention further provides a pharmaceutical or radiopharmaceutical composition comprising a compound of the invention as described herein together with a pharmaceutically acceptable carrier, excipient, or biocompatible carrier suitable for mammalian administration.
[0061] As would be understood by one of skill in the art, the pharmaceutically acceptable carrier or excipient can be any pharmaceutically acceptable carrier or excipient known in the art.
[0062] The “biocompatible carrier” can be any fluid, especially a liquid, in which a compound of the invention can be suspended or dissolved, such that the pharmaceutical composition is physiologically tolerable, e.g., can be administered to the mammalian body without toxicity or undue discomfort. The biocompatible carrier is suitably an injectable carrier liquid such as sterile, pyrogen-free water for injection; an aqueous solution such as saline (which may advantageously be balanced so that the final product for injection is either isotonic or not hypotonic); an aqueous solution of one or more tonicity-adjusting substances (e.g., salts of plasma cations with biocompatible counterions), sugars (e.g., glucose or sucrose), sugar alcohols (e.g., sorbitol or mannitol), glycols (e.g., glycerol), or other non-ionic polyol materials (e.g., polyethyleneglycols, propylene glycols and the like). The biocompatible carrier may also comprise biocompatible organic solvents such as ethanol. Such organic solvents are useful to solubilise more lipophilic compounds or formulations. Preferably the biocompatible carrier is pyrogen-free water for injection, isotonic saline or an aqueous ethanol solution. The pH of the biocompatible carrier for intravenous injection is suitably in the range 4.0 to 10.5.
[0063] The pharmaceutical or radiopharmaceutical composition may be administered parenterally, i.e., by injection, and is most preferably an aqueous solution. Such a composition may optionally contain further ingredients such as buffers; pharmaceutically acceptable solubilisers (e.g., cyclodextrins or surfactants such as Pluronic, Tween or phospholipids); pharmaceutically acceptable stabilisers or antioxidants (such as ascorbic acid, gentisic acid or para-aminobenzoic acid). Where a compound of the invention is provided as a radiopharmaceutical composition, the method for preparation of said compound may further comprise the steps required to obtain a radiopharmaceutical composition, e.g., removal of organic solvent, addition of a biocompatible buffer and any optional further ingredients. For parenteral administration, steps to ensure that the radiopharmaceutical composition is sterile and apyrogenic also need to be taken. Such steps are well-known to those of skill in the art.
Preparation of a Compound of the Invention
[0064] A compound of the invention may be prepared by any means known in the art including, but not limited to, nucleophilic aromatic substitution, nucleophilic aliphatic substitution, and click chemistry.
[0065] In one embodiment of the invention, a compound of the invention may be halogenated or radiolabeled with a radionuclide by nucleophilic aromatic substitution or nucleophilic aliphatic substitution of an appropriate leaving group with the desired halogen or radionuclide. Examples of suitable leaving groups for nucleophilic aromatic substitution include, but are not limited to, Cl, Br, F, NO 2 , ArI + and + N(R) 4 . Examples of suitable leaving groups for nucleophilic aliphatic substitution include, but are not limited to, I, Br, Cl, OTs (tosylate), OTf (triflate), BsO(brosylate), OMs(Mesylate), and NsO (nosylate).
[0066] In one embodiment of the invention, a compound of the invention may be directly labelled with 18 F via activated aromatic rings. This approach would require a protection of the essential amino group during radiolabelling.
[0067] In one embodiment, a compound of the invention may be prepared according to the following Scheme I:
[0000]
[0068] In one embodiment, a compound of the invention may be prepared according to the following Scheme II:
[0000]
[0069] In one embodiment, a compound of the invention may be prepared according to the following Scheme III:
[0000]
[0070] In one embodiment, a compound of the invention may be prepared according to the following Scheme IV:
[0000]
[0071] By way of example, the radioisotope [ 18 F]-fluoride ion ( 18 F − ) is normally obtained as an aqueous solution from the nuclear reaction 18 O(p,n) 18 F and is made reactive by the addition of a cationic counterion and the subsequent removal of water. Suitable cationic counterions should possess sufficient solubility within the anhydrous reaction solvent to maintain the solubility of 18F − . Therefore, counterions that have been used include large but soft metal ions such as rubidium or caesium, potassium complexed with a cryptand such as Kryptofix™, or tetraalkylammonium salts. A preferred counterion is potassium complexed with a cryptand such as Kryptofix™ because of its good solubility in anhydrous solvents and enhanced 18 F − reactivity. 18 F can also be introduced by nucleophilic displacement of a suitable leaving group such as a halogen or tosylate group. A more detailed discussion of well-known 18 F labelling techniques can be found in Chapter 6 of the “Handbook of Radiopharmaceuticals” (2003; John Wiley and Sons: M. J. Welch and C. S. Redvanly, Eds.). Similar methods may be used to radiolabel a compound of the invention with other radioisotopes including the PET and SPECT radioisotopes described herein.
Automated Synthesis
[0072] In one embodiment, the method to prepare a radiolabelled derivative of the invention, each as described herein, is automated. For example, [ 18 F]-labeled compounds of the invention may be conveniently prepared in an automated fashion by means of an automated radiosynthesis apparatus. There are several commercially-available examples of such platform apparatus, including TRACERlab™ (e.g., TRACERlab™ MX) and FASTlab™ (both from GE Healthcare Ltd.). Such apparatus commonly comprises a “cassette”, often disposable, in which the radiochemistry is performed, which is fitted to the apparatus in order to perform a radiosynthesis. The cassette normally includes fluid pathways, a reaction vessel, and ports for receiving reagent vials as well as any solid-phase extraction cartridges used in post-radiosynthetic clean up steps. Optionally, in a further embodiment of the invention, the automated radiosynthesis apparatus can be linked to a high performance liquid chromatograph (HPLC). The present invention therefore provides a cassette for the automated synthesis of a compound of the invention.
Imaging Method
[0073] The radiolabelled derivative of the invention, as described herein, may bind to NFTs or tau aggregates and aid in identifying the amount of NFTs/tau aggregates present which in turn may correlate with the stage of AD.
[0074] The present invention thus provides a method of imaging comprising the step of administering a radiolabelled derivative of the invention, as described herein, to a subject and detecting said radiolabelled derivative of the invention in said subject. The present invention further provides a method of detecting tau aggregates in vitro or in vivo using a radiolabelled derivative of the invention, as described herein. Hence the present invention provides better tools for early detection and diagnosis of Alzheimers disease. The present invention also provides better tools for monitoring the progression of Alzheimers disease and the effect of treatment.
[0075] As would be understood by one of skill in the art the type of imaging (e.g., PET, SPECT) will be determined by the nature of the radioisotope. For example, if the radiolabelled derivative of the invention contains 18 F it will be suitable for PET imaging.
[0076] Thus the invention provides a method of detecting tau aggregates in vitro or in vivo comprising the steps of:
i) administering to a subject a radiolabelled derivative of the invention as defined herein; ii) allowing said a radiolabelled derivative of the invention to bind to NFTs in said subject; iii) detecting signals emitted by said radioisotope in said bound radiolabelled derivative of the invention; iv) generating an image representative of the location and/or amount of said signals; and, v) determining the distribution and extent of said tau aggregates in said subject.
[0082] The step of “administering” a radiolabelled derivative of the invention is preferably carried out parenterally, and most preferably intravenously. The intravenous route represents the most efficient way to deliver the compound throughout the body of the subject. Intravenous administration neither represents a substantial physical intervention nor a substantial health risk to the subject. The radiolabelled derivative of the invention is preferably administered as the radiopharmaceutical composition of the invention, as defined herein. The administration step is not required for a complete definition of the imaging method of the invention. As such, the imaging method of the invention can also be understood as comprising the above-defined steps (ii)-(v) carried out on a subject to whom a radiolabelled derivative of the invention has been pre-administered.
[0083] Following the administering step and preceding the detecting step, the radiolabelled derivative of the invention is allowed to bind to the tau aggregates. For example, when the subject is an intact mammal, the radiolabelled derivative of the invention will dynamically move through the mammal's body, coming into contact with various tissues therein. Once the radiolabelled derivative of the invention comes into contact with the tau aggregates it will bind to the tau aggregates.
[0084] The “detecting” step of the method of the invention involves detection of signals emitted by the radioisotope comprised in the radiolabelled derivative of the invention by means of a detector sensitive to said signals, e.g., a PET camera. This detection step can also be understood as the acquisition of signal data.
[0085] The “generating” step of the method of the invention is carried out by a computer which applies a reconstruction algorithm to the acquired signal data to yield a dataset. This dataset is then manipulated to generate images showing the location and/or amount of signals emitted by the radioisotope. The signals emitted directly correlate with the amount of enzyme or neoplastic tissue such that the “determining” step can be made by evaluating the generated image.
[0086] The “subject” of the invention can be any human or animal subject. Preferably the subject of the invention is a mammal. Most preferably, said subject is an intact mammalian body in vivo. In an especially preferred embodiment, the subject of the invention is a human.
[0087] The “disease state associated with the tau aggregates” can be MCI (mild cognitive impairment), dementia or Alzheimers disease.
EXAMPLES
[0088] Unless set forth otherwise, all materials are commercially available. Abbreviations have the following meanings:
BINAP 1,2-di(naphthalen-2-yl)-1,1,2,2-tetraphenyldiphosphine BOP (benzotriazol-1-yloxy)tris(dimethylamino) phosphonium hexafluoro phosphate DCM Dichloromethane DIPEA N,N-diisopropylethylamine DMF Dimethylformamide DMSO DimethylSulfoxide HPLC High Performance Liquid Chromatography Kryptofix 4,7,13,16,21,24-Hexaoxa-1,10-diazabicyclo[8.8.8]hexacosane PBS Phosphate Buffered Saline QC HPLC Quality Control High-performance Liquid Chromatography TLC Thin Layer Chromatography TFA Trifluoroacetic acid
Example 1
[0101]
[0102] Fluorine-18 is produced in a cyclotron using the 18 O(p,n) 18 F nuclear reaction via proton irradiation of a target containing enriched [ 18 O]H 2 O. A Wheaton vial (3 mL) is charged with Kryptofix (5 mg, 13.3 mmol), potassium carbonate (1 mg, 7.2 mmol), acetonitrile (1 mL), and 18 F-containing water (100 μL, 335 MBq). The vial is heated to 100° C. and the solvent removed using a stream of nitrogen (100 mL/min) Acetonitrile (0.5 mL) is added and again evaporated to dryness using a stream of nitrogen. The procedure is repeated two times. The vial is cooled to room temperature and a solution of tosylate 38 (2.0 mg, 3.6 mmol) in anhydrous DMSO (0.2 mL) is added (Scheme A). The reaction mixture is heated for 15 minutes at 100° C. Purification by preparative HPLC (Luna C18 Phenomenex, 5μ, 50×4.6 mm, solvent A: H 2 O/0.1% TFA, solvent B: MeCN/0.1% TFA, flow rate 3.0 mL/min, UV: 254 nm, gradient: 20 to 90% B in 15 min) The isolated product ( FIG. 1 , non-corrected radiochemical yield=19%) is diluted with water (3 mL) and passed through a tC18 SepPak Light cartridge (Waters) that had been activated by flushing with ethanol (5 mL) and water (10 mL). The cartridge is eluted with water (5 mL) and flushed with nitrogen (1 min @ 100 mL/min) Elution with ethanol into a solution of PBS affords 18 F-37 or 37* (50 MBq) with 89% formulation recovery (corrected for decay). QC HPLC (Kinetex C18 Phenomenex, 2.6μ, 50×4.6 mm, solvent A: H 2 O/0.1% TFA, solvent B: MeCN/0.1% TFA, flow rate 1.0 mL/min, UV: 254 nm, gradient: 20 to 90% B in 15 min) shows 18 F-37 or 37* with a radiochemical purity of 98% ( FIG. 2 ).
Example 2
[0103]
[0104] [ 18 F]Fluoride is azeotropically dried in a Wheaton vial as described in Example 1. The vial is cooled to room temperature and a solution of tosylate 39 (2.0 mg, 3.7 mmol) in anhydrous DMSO (0.2 mL) is added (Scheme B). The reaction mixture is heated for 15 minutes at 100° C. Aliquots of the crude reaction mixture (10 mL) are quenched into HPLC mobile phase (100 mL, 35% solvent B) after 1 min, 5 min, and 15 min Analytical HPLC (Kinetex C18 Phenomenex, 2.6μ, 50×4.6 mm, solvent A: H 2 O/0.1% TFA, solvent B: MeCN/0.1% TFA, flow rate 1.0 mL/min, UV: 254 nm, gradient: 20 to 90% B in 15 min) reveals formation of 18 F-38 or 38* ( FIG. 3 ). Injection of cold reference compound confirms the radioactivity signal as product 18 F-38 or 38* ( FIG. 4 ).
Example 3
[0105] Fluorine-18 is produced and azeotropically dried in a Wheaton vial as described in Example 1. Alternative phase-transfer systems such as [ 18 F]tetrabutylammoniumfluoride hydrogen carbonate (TBAF) and [ 18 F]F − /KHCO 3 /Kryptofix are applied with tosylate 39 (2.0 mg, 3.7 mmol) dissolved in anhydrous DMSO (0.2 mL). The reaction mixtures are either heated to 100° C. or irradiated by microwave (50 W, set temperature 90° C.). Table 1 summarizes a time-course study for the radiochemistry optimization.
[0000]
TABLE 1
Comparison of analytical radiochemical yields of 18 F-38 or 38* under
different reaction conditions.
Reaction
1 min
5 min
15 min
5 s
10 s
15 s
No.
conditions
100° C.
100° C.
100° C.
MW
MW
MW
1
K 2 CO 3 /
31%
26%
28%
Kryptofix
2
TBAF
4%
10%
10%
3
TBAF
34%
33%
36%
4
KHCO 3 /
19%
23%
20%
Kryptofix
Example 4
Preparation of Compound 57
[0106]
4a. Preparation of Compound 55
[0107]
[0108] A mixture of 54 (250 mg, 0.788 mmol) (prepared according to Example 13d below), 2-(piperidin-4-yl)ethanol (122 mg, 0.94 mmol), and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (523 mg, 1.18 mmol) was dissolved in anhydrous DMSO (10 mL) and DIPEA (204 mg, 1.576 mmol, 0.27 mL) was added to it. The reaction mixture was stirred at room temperature for 16 h. The reaction mixture diluted with water (100 mL) and the resulting mixture was extracted with ethyl acetate (2×100 mL). The organic layer was washed with brine (100 mL), dried (Na 2 SO 4 ), filtered and evaporated under vacuum. The residue was stirred with diethyl ether overnight. The precipitate was filtered and allowed to dry to give 300 mg (85%) 55 as a yellow solid.
[0109] LC-MS: m/z calcd for C 21 H 24 N 4 O 4 S, 428, found 429.5 (M+H) +
[0110] 1 H NMR (300 MHz, CDCl 3 ): δ H 1.3 (2H, m, CH 2 C H 2 CH), 1.5 (2H, q, J=6 Hz, CHC H 2 CH 2 ), 1.8 (3H, m, C H 2 C H CH 2 ), 2.8 (1H, t, J=15 Hz, NC H 2 CH 2 ), 3.1 (1H, t, J=15 HzNC H 2 CH 2 ), 3.5 (1H, t, J=9 Hz, CH 2 O H ), 3.72 (2H, t, J=6 Hz, NC H 2 CH 2 OH), 3.86 (3H, s, ArOC H 3 ), 4.1 (1H, d, J=15 Hz, NC H 2 CH 2 ), 4.7 (1H, d, J=15 Hz, NC H 2 CH 2 ), 6.66 (1H, s, SC H ), 6.98 (2H, d, J=9 Hz, ArC H ) and 7.45 (2H, d, J=9 Hz, ArC H ).
4b. Preparation of Compound 56
[0111]
[0112] 55 (300 mg, 0.7 mmol) was dissolved in anhydrous Chloroform (20 mL) and diethylaminosulfur trifluoride (113 mg, 0.7 mmol) diluted with CHCl 3 (5 mL) was added dropwise at 0 C over 10 min. The reaction was monitored every 10 min by TLC. Thereafter reaction mixture was diluted with excess CHCl 3 (100 mL), washed with saturated NaHCO 3 (20 mL) and extracted with ethyl acetate (2×50 mL). The organic layer was filtered, dried (Na 2 SO 4 ) and concentrated to yield the crude product. The crude product was purified by Semi-prep HPLC using acetonitrile:methanol (50:50) and 20% ammonium acetate (pH 4.3). 1% HCl solution (5 mL) was added to the pooled fractions before freeze-drying to yield 40 mg (13%) as a yellow solid.
[0113] LC-MS: m/z calcd for C 21 H 23 FN 4 O 3 S, 430.50, found 431.4 (M+H) +
[0114] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.6 (7H, m, ringNCH 2 C H 2 C H 2 C H C H 2 CH 2 F), 2.73 (1H, t, J=15 Hz, NC H 2 CH 2 ), 3.05 (1H, t, J=15 Hz, NC H 2 CH 2 ), 3.77 (3H, s, ArOC H 3 ), 4.0 (1H, d, J=15 Hz, NC H 2 CH 2 ), 4.4 (1H, t, J=5 Hz, CH 2 C H 2 F), 4.5 (1H, t, J=5 Hz, CH 2 C H 2 F), 4.64 (1H, d, J=15 Hz, NC H 2 CH 2 ), 6.58 (1H, s, SC H ), 6.89 (2H, d, J=10 Hz, ArC H ) and 7.35 (2H, d, J=10 Hz, ArC H ).
4c. Preparation of Compound 57
[0115]
[0116] 55 (450 mg, 1.05 mmol) was dissolved in 1:1 mixture of DCM and Dioxane (20 mL) and N,N-Dimethylaminopyridine (256 mg, 2.1 mmol) was added. Methanesulphonyl chloride (120 mg, 1.05 mmol) diluted with dichloromethane (10 mL) was added over a period of 1 h. The reaction mixture was stirred at room temperature for 2 h. Thereafter the reaction mixture was diluted DCM (100 mL), washed with water (2×50 mL) and brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 90 mg (17%) of desired product.
[0117] LC-MS: m/z calcd for C 22 H 26 N 4 O 6 S 2 , 506.60, found 506.9 (M+H) + .
[0118] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.3 (4H, m, ringNCH 2 C H 2 CHC H 2 CH 2 ), 1.7 (3H, m, C H C H 2 CH 2 O Ms), 2.75 (1H, t, J=15 Hz, NC H 2 CH 2 ), 3.0 (3H, s, SO 2 C H 3 ), 3.1 (1H, t, J=15 Hz, NC H 2 CH 2 ), 3.8 (3H, s, ArOC H 3 ), 4.1 (1H, d, J=15 Hz, NC H 2 CH 2 ), 4.3 (2H, t, J=5 Hz, CH 2 C H 2 OH), 4.7 (1H, d, J=15 Hz, NC H 2 CH 2 ), 6.6 (1H, s, SC H ), 6.9 (2H, d, J=10 Hz, ArC H ) and 7.4 (2H, d, J=10 Hz, ArC H ).
Example 5
Preparation of Compound 59
[0119]
5a. Preparation of Compound 59
[0120]
[0121] 58 (100 mg, 0.29 mmol) (prepared according to Example 13f), was dissolved in DMF (10 mL), added 1N NaOH solution (17.4 mg, 0.43 mmol) and epifluorohydrin (26 mg, 0.348 mmol). The reaction mixture was stirred at 100 C for 3 h in microwave. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×100 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by silica gel chromatography to give 32 mg (26%) of the desired product.
[0122] LC-MS: m/z calcd for C 19 H 21 FN 4 O 4 S, 420.46, found 420.9 (M+H) + .
[0123] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.15 (6H, d, J=10 Hz, CH(C H 3 ) 2 ), 4.05 (4H, m, ArOC H 2 C H & C H (CH 3 ) 2 ), 4.46 (1H, m, FC H 2 CH), 4.56 (1H, m, FC H 2 CH), 5.5 (1H, s, CHO H ), 7.04 (2H, d, J=10 Hz, ArC H ), 7.18 (1H, s, SC H ), 7.5 (2H, d, J=10 Hz, ArC H ), 7.55 (2H, s, CHN H 2 ), 7.91 (1H, d, J=5 Hz, CON H ).
Example 6
Preparation of compound 60
[0124]
[0125] 58 (600 mg, 1.74 mmol) (prepared according to Example 13f) was dissolved in DMF (15 mL), Cesium carbonate (848 mg, 2.61 mmol) and glycidyl tosylate (397.3 mg, 1.74 mmol) are added. The reaction mixture was stirred for 15 h at room temperature. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×150 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 80 mg (11%) of the desired product.
[0126] LC-MS: m/z calcd for C 19 H 20 N 4 O 4 S, 400.12, found 401.2 (M+H) + .
[0127] 1 H NMR (300 MHz, CDCl 3 ): δ H 1.22 (6H, d, J=6 Hz, CH(C H 3 ) 2 ), 2.78 (1H, m, OC H 2 CH), 2.93 (1H, t, J=6 Hz, OC H 2 CH), 3.38 (1H, m, CH 2 C H CH 2 ), 4.0 (1H, m, ArOC H 2 ), 4.2 (1H, m, C H (CH 3 ) 2 ), 4.3 (1H, dd, J1=9 Hz, J2=3 Hz, ArOC H 2 ), 6.15 (2H, s, CN H 2 ), 6.9 (1H, d, J=9 Hz, CHN H ), 7.02 (2H, d, J=9 Hz, ArC H ), 7.44 (2H, d, J=9 Hz, ArC H ) and 7.58 (1H, s, SC H ).
Example 7
Preparation of Compound 61
[0128]
[0129] 58 (400 mg, 1.16 mmol) (prepared according to Example 130 was dissolved in DMF (15 mL), cesium carbonate (568 mg, 1.74 mmol) and bromofluoropropane (162 mg, 1.16 mmol) are added. The reaction mixture was stirred for 15 h. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×150 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 85 mg (18%) of 98.3% of the desired product.
[0130] LC-MS: m/z calcd for C 19 H 21 FN 4 O 3 S, 404.46, found 405.2 (M+H) + .
[0131] 1 H NMR (300 MHz, CDCl 3 ): δ H 1.22 (6H, d, J=6 Hz, CH(C H 3 ) 2 ), 2.15 (1H, q, J=6 Hz, C H 2 C H 2 CH 2 ), 2.24 (1H, q, J=6 Hz, C H 2 C H 2 CH 2 ), 4.15 (3H, m, ArOC H 2 & C H (CH 3 ) 2 ), 4.58 (1H, t, J=6 Hz, FC H 2 ), 4.74 (1H, t, J=6 Hz, FC H 2 ), 6.2 (2H, s, CN H 2 ), 6.9 (1H, d, J=9 Hz, CHN H ), 7.0 (2H, d, J=9 Hz, ArC H ), 7.42 (2H, d, J=9 Hz, ArC H ) and 7.57 (1H, s, SC H ).
Example 8
Preparation of Compound 62
[0132]
[0133] 58 (300 mg, 0.87 mmol) (prepared according to Example 13f) was dissolved in DMF (10 mL), cesium carbonate (283 mg, 0.87 mmol and 1,3-Propanediol di-p-tosylate (335 mg, 0.87 mmol) are added. The reaction mixture was stirred for 15 h. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×150 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 110 mg (23%) of the desired product.
[0134] LC-MS: m/z calcd for C 26 H 28 N 4 O 6 S 2 , 556.65, found 557.2 (M+H) + .
[0135] 1 H NMR (500 MHz, DMSO-d6): δ H 1.15 (6H, d, J=5 Hz, CH(C H 3 ) 2 ), 2.06 (2H, q, J=5 Hz, CH 2 C H 2 CH 2 ), 2.38 (3H, s, ArC H 3 ), 3.96 (2H, t, J=5 Hz, SO 3 C H 2 ), 4.06 (1H, m, C H (CH 3 ) 2 ), 4.22 (2H, t, J=5 Hz, ArOC H 2 ), 6.9 (2H, d, J=10 Hz, ArC H ), 7.19 (1H, s, SC H ), 7.42 (2H, d, J=10 Hz, ArC H ), 7.48 (2H, d, J=10 Hz, TsC H ), 7.55 (2H, s, N H 2 ), 7.78 (2H, d, J=10 Hz, TsC H ) and 7.88 (1H, d, J=5 Hz, N H CH).
Example 9
Preparation of Compound 64
[0136]
9a. Preparation of Compound 63
[0137]
[0138] 58 (400 mg, 1.16 mmol) (prepared according to Example 13f) was dissolved in a 1:1 mixture of dioxane and chloroform (25 mL) and dimethyl amino pyridine (221 mg, 1.74 mmol), di-tert-butyl dicarbonate (253 mg, 1.16 mmol) were added. The reaction mixture was stirred for 2 h. Thereafter the reaction mixture was diluted with water and extracted with dichloromethane (2×150 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 300 mg (58%) of the desired product.
[0139] LC-MS: m/z calcd for C 21 H 24 N 4 O 5 S, 444.50, found 444.3 (M+) + .
[0140] 1 H NMR (300 MHz, CDCl 3 ): δ H 1.25 (6H, d, J=6 Hz, CH(C H 3 ) 2 ), 1.60 (9H, s, NH(C H 3 ) 3 ), 4.2 (1H, m, C H (CH 3 ) 2 ), 6.92 (1H, d, J=9 Hz, N H CH), 7.3 (2H, d, J=9 Hz, ArC H ), 7.55 (2H, d, J=9 Hz, ArC H ) and 7.61 (1H, s, SC H ).
9b. Preparation of Compound 64
[0141]
[0142] 63 (30 mg, 0.067 mmol) was dissolved in Acetonitrile (15 mL),added cesium carbonate (33 mg, 0.101 mmol) and fluoroethyl tosylate (15 mg, 0.067 mmol) are added. The reaction mixture was stirred for 15 h. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×150 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 10 mg of the desired product.
[0143] LC-MS: m/z calcd for C 23 H 27 FN 4 O 5 S, 490.55, found 491.0 (M+) + .
[0144] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.2 (6H, d, J=5 Hz, CH(C H 3 ) 2 ), 1.45 (9H, s, O(C H 3 ) 3 ), 4.15 (1H, m, C H (CH 3 ) 2 ), 4.2 (1H, t, J=5 Hz, ArOC H 2 ), 4.24 (1H, t, J=5 Hz, ArOC H 2 ), 4.68 (1H, t, J=5 Hz, FC H 2 ), 4.78 (1H, t, J=5 Hz, FC H 2 ), 6.90 (1H, d, J=10 Hz, N H CH), 7.0 (2H, d, J=10 Hz, ArC H ), 7.40 (2H, d, J=10 Hz, ArC H ), 8.06 (1H, s, SC H ) and 10.0 (1H, s, N H Boc).
Example 10
Preparation of Compound 67
[0145]
10a. Preparation of Compound 65
[0146]
[0147] 5-bromo-2-fluoropyridine (1.5 g, 8.52 mmol) and sodium-tert-butoxide (1.22 g, 12.79 mmol) were dissolved in 1,4-Dioxane (30 mL), was added tert-butyl piperazine-1-carboxylate (1.58 g, 8.52 mmol), nitrogen gas was purged through the reaction mixture for 5 min, was added BINAP (0.318 g, 0.511 mmol) followed by Palladium(II)acetate (0.038 g, 0.17 mmol). The reaction mixture was stirred under reflux for 6 h. Thereafter the reaction mixture was diluted with water and extracted with ethyl acetate (2×200 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 1.0 g of the desired product.
[0148] LC-MS: m/z calcd for C 14 H 20 FN 3 O 2 , 281.33, found 281.9 (M+H) + .
[0149] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.4 (9H, s, O(C H 3 ) 3 ), 3.0 (4H, t, J=5 Hz, NC H 2 C H 2 N), 3.5 (4H, t, J=5 Hz, NC H 2 C H 2 N), 6.80 (1H, m, ArC H ), 7.3 (1H, m, ArC H ) and 7.7 (1H, s, ArC H ).
10b. Preparation of Compound 66
[0150]
[0151] 65 (650 mg, 2.31 mmol) was dissolved in dichloromethane (10 mL) and cooled to 5 C. 5 mL solution of 20% TFA in DCM was added dropwise to the reaction mass. The reaction mixture was stirred for 3 h. Thereafter the reaction mixture was diluted with excess DCM (100 mL) and washed with water wash (2×50 mL) followed brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give 500 mg of the desired product.
[0152] LC-MS: m/z calcd for C 9 H 12 FN 3 , 181.21, found 181.7 (M+H) + .
[0153] 1 H NMR (500 MHz, DMSO-d 6 ): δ H 3.26 (4H, m, NC H 2 C H 2 N), 3.38 (4H, m, NC H 2 C H 2 N), 7.1 (1H, m, ArC H ), 7.7 (1H, m, ArC H ), 7.9 (1H, s, ArC H ) and 9.0 (1H, s, N H )
10c. Preparation of Compound 67
[0154]
[0155] A mixture of 54 (300 mg, 0.945 mmol), 66(171 mg, 0.945 mmol) and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (627 mg, 1.418 mmol) in anhydrous DMSO (10 mL) was added DIPEA (244 mg, 1.891 mmol). The reaction mixture was stirred at room temperature for 16 h. The progress of the reaction mass was monitored by LCMS. The reaction mixture diluted with water (100 mL) and the resulting mixture was extracted with ethyl acetate (2×100 mL). The organic layer was washed with brine (100 ml), dried (Na 2 SO 4 ), filtered, and evaporated under vacuum. The residue was stirred with diethyl ether overnight. The precipitate was filtered and allowed to dry to give 60 mg (13%) of 67 as a yellow solid.
[0156] LC-MS: m/z calcd for C 23 H 21 FN 6 O 3 S, 480.51, found 481.0 (M+H) + .
[0157] 1 H NMR (500 MHz, DMSO-d 6 ): δ H 3.1 (2H, s, NC H 2 C H 2 N), 3.35 (2H, m, NC H 2 C H 2 N), 3.7 (2H, s, NC H 2 C H 2 N), 3.8 (5H, s, NC H 2 C H 2 N & ArOC H 3 ), 6.6 (1H, s, SC H CH), 6.98 (2H, d, J=10 Hz, ArC H ), 7.05 (1H, d, J=5 Hz, ArC H ), 7.4 (2H, d, J=5 Hz, ArC H ), 7.55 (2H, s, N H 2 ), 7.60 (1H, s, ArC H ) and 7.85 (1H, s, ArC H ).
Example 11
Preparation of Compound 70
[0158]
11a. Preparation of Compound 68
[0159]
[0160] Dissolved 5-bromo-2-nitropyridine (1.0 g, 4.92 mmol) and tert-butyl piperazine-1-carboxylate (1.1 g, 5.91 mmol) in N-methylpyrrolidine and stirred at 120 C for 18 h. Thereafter the reaction mixture was cooled to 30 C and diluted with water and extracted with ethyl acetate (2×200 mL). The combined organic extract was washed with brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give crude product. The crude product was purified by column chromatography to give 400 mg of the desired product.
[0161] LC-MS: m/z calcd for C 14 H 20 N 4 O 4 , 308.33, no ionization
[0162] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.4 (9H, s, O(C H 3 ) 3 ), 3.38 (4H, t, J=5 Hz, NC H 2 C H 2 N), 3.58 (4H, t, J=5 Hz, NC H 2 C H 2 N), 7.14 (1H, dd, J1=5 Hz, J2=10 HZ, ArC H ), 8.06 (1H, d, J=5 Hz, ArC H ) and 8.11 (1H, d, J=10 Hz, ArC H ).
11b. Preparation of Compound 69
[0163]
[0164] 68 (400 mg, 1.29 mmol) was dissolved in dichloromethane (10 mL), cooled to 5 C. 5 mL solution of 20% TFA in DCM was added dropwise. The reaction mixture was stirred for 3 h. Thereafter the reaction mixture was diluted with excess DCM (100 mL) and washed with water (2×50 mL) followed brine (50 mL). The organic layer was dried over sodium sulfate and concentrated under vacuum to give 200 mg (74%) of the desired product.
[0165] LC-MS: m/z calcd for C9H12N4O2, 208.22, found 208.7 (M+H) +
11c. Preparation of Compound 70
[0166]
[0167] A mixture of 54 (305 mg, 0.96 mmol), 69 (200 mg, 0.96 mmol) and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (637 mg, 1.44 mmol) in anhydrous DMSO (10 mL) was added DIPEA (0.67 mL, 3.84 mmol). The reaction mixture was stirred at room temperature for 12 h. The progress of the reaction mass was monitored by LCMS. The reaction mixture diluted with water (100 mL) and the resulting mixture was extracted with ethyl acetate (2×100 mL). The organic layer was washed with brine (100 ml), dried (Na 2 SO 4 ), filtered, and evaporated under vacuum. The crude product was purified by column chromatography to give 40 mg of the desired product.
[0168] LC-MS: m/z calcd for C 23 H 21 N 7 O 5 S, 507.52, found: 508.0 (M+H) + .
[0169] 1 H NMR (500 MHz, DMSO-d 6 ): δ H 3.55 (2H, s, NC H 2 C H 2 N), 3.7 (2H, s, NC H 2 C H 2 N), 3.75 (2H, s, NC H 2 C H 2 N), 3.8 (5H, s, NC H 2 C H 2 N & ArOC H 3 ), 6.74 (1H, s, SC H CH), 6.98 (2H, d, J=10 Hz, ArC H ), 7.4 (2H, d, J=10 Hz, ArC H ), 7.5 (1H, d, J=10 Hz, ArC H ), 7.56 (2H, s, N H 2 ), 8.18 (1H, d, J=10 Hz, ArC H ) and 8.26 (1H, d, J=5 Hz, ArC H ).
Example 12
Preparation of Compound 74
[0170]
12a. Preparation of Compound 71
[0171]
[0172] 4-Aminophenol (5 g, 45.87 mmol) was dissolved in a mixture of 37% hydrochloric acid (7 mL), ethanol (15 mL) and water (20 mL). The reaction mixture was cooled to 0 C in an ice-water bath before a solution of sodium nitrite (3.21 g, 45.87 mmol) in water (10 mL) was added dropwise. The resulting mixture was stirred at 0 C for 20 min Sodium acetate (24.95 g, 183.49 mmol) in water (50 mL) and ethyl acetoacetate (5.96 g, 45.87 mmol, 5.84 mL) were added and the reaction mixture was stirred at 0 C for 2 h. The precipitated solid was filtered, washed with water, and dried under high vacuum to provide 6 g (52%) of the desired product as brown solid.
[0173] LC-MS: m/z calcd for C 12 H 14 N 2 O 4 , 250.1, found 250.6 (M+H) + .
[0174] 1 H NMR (500 MHz, MeOD): δ H 1.35-1.41 (3H, m, OC H 3 ), 2.47 (3H, s, CH 2 C H 3 ), 4.30-4.39 (2H, m, O—C H 2 ), 6.82-6.88 (2H, m, phenyl-3 H and 5 H ) and 7.30-7.39 (2H, m, phenyl-2 H and 6 H )
12b. Preparation of Compound 72
[0175]
[0176] A mixture of 71 (2.0 g, 8 mmol), ethyl cyanoacetate (1.81 g, 16 mmol, 1.70 mL) and ammonium acetate (2.46 g, 31.91 mmol) in acetic acid (6 mL) was heated in microwave at 120 C for 45 min. The resulting mixture was diluted with water (50 mL) and extracted with ethyl acetate (3×100 mL). The combined organic extract was washed with water (30 mL), brine (30 mL), dried over sodium sulfate and evaporated under vacuum. The crude compound was washed with hexane (3×50 mL) and filtered to obtain 1.8 g (78%) as brown solid.
[0177] LC-MS: m/z calcd for C 15 H 13 N 3 O 4 299.0, found 298.5 (M−H) − .
[0178] 1 H NMR (500 MHz, CD3CN): δ H 1.26 (3H, t, J=5 Hz, CH 2 C H 3 ), 2.59 (3H, s, C H 3 ), 4.29 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.87 (2H, d, J=5 Hz, phenyl-2 H and 6 H ) and 7.30 (2H, d, J=5 Hz, phenyl-3 H and 5 H ).
12c. Preparation of Compound 73
[0179]
[0180] A mixture of 71 (2 g, 6.38 mmol), sulfur (0.30 g, 9.24 mmol), and morpholine (1.1 g, 12.67 mmol, 1.1 mL) in ethanol (6 mL) was heated in microwave to 120 C for 30 min After the mixture was cooled, the precipitate formed was filtered. Recrystallization from hot ethanol yielded 1.3 g (59%) as a pale brown solid.
[0181] LC-MS: m/z calcd for C 15 H 13 N 3 O 4 S, 331.0, found 331.9 (M+H) + .
[0182] 1 H NMR (500 MHz, DMSO): δ H 1.29 (3H, t, J=5 Hz, CH 2 C H 3 ), 4.31 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.83 (2H, d, J=5 Hz, phenyl-2 H and 6 H ), 7.08 (1H, s, SC H ), 7.26 (2H, d, J=5 Hz, phenyl-3H and 5H) and 7.59 (2H, s, N H 2 ).
12d. Preparation of Compound 74
[0183]
[0184] Lithium hydroxide monohydrate (0.1 g, 4.33 mmol) was added to a solution of 73 (2 g, 6.03 mmol) in tetrahydrofuran (20 mL) and water (20 mL). The reaction mixture was stirred at room temperature for 16 h. The progress of the reaction was monitored by LCMS. Thereafter the pH of the reaction mass was adjusted to 6 using 1 N HCl and the aqueous layer was extracted with ethyl acetate (3×50 mL). The combined organic layers were separated, dried over sodium sulfate and evaporated to yield 1.2 g (66%) of desired product as a yellow solid.
[0185] LC-MS: m/z calcd for C 13 H 9 N 3 O 4 S 303.3, found 303.9 (M+H) + .
[0186] 1 H NMR (500 MHz, DMSO): δ H 3.16 (1H, s, O H ), 6.80 (2H, d, J=5 Hz, phenyl-2 H and 6 H ), 7.14 (1H, s, SC H ), 7.22 (2H, d, J=5 Hz, phenyl-3 H and 5 H ) and 7.35 (2H, s, N H 2 ).
Example 13
Preparation of Compound 79
[0187]
13a. Preparation of Compound 75
[0188]
[0189] p-Anisidine (2 g, 16.23 mmol) was dissolved in a mixture of 37% hydrochloric acid (3 mL), ethanol (5 mL) and water (3 mL). The reaction mixture was cooled to 0 C in an ice-water bath before a solution of sodium nitrite (1.12 g, 16.23 mmol) in water (7 mL) was added in dropwise. The resulting mixture was stirred at 0 C for 20 min. Sodium acetate (8.61 g, 63.27 mmol) in water (20 mL) and ethyl acetoacetate (2.1 g, 16.13 mmol, 2 mL) were added and the reaction mixture was stirred at 0 C for 2 h. Then, the precipitated solid was filtered, washed with water and dried under high vacuum to provide 4 g (93%) as yellow solid.
[0190] LC-MS: m/z calcd for C 13 H 16 N 2 O 4 264.1, found 265.1 (M+H) + .
[0191] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.32 (3H, t, J=5 Hz, CH 2 C H 3 ), 2.51 (2H, s, OC H 3 ), 3.75 (3H, s, phenyl-OC H 3 ), 4.22-4.32 (2H, m, C H 2 CH 3 ), 6.84-6.88 (2H, m, phenyl-3 H and 5 H ), 7.20-7.25 (1H, m, phenyl-2 H ) and 7.29-7.32 (1H, m, phenyl-5 H ).
13b. Preparation of Compound 76
[0192]
[0193] A mixture of 75 (2.0 g, 7.57 mmol), ethyl cyanoacetate (1.71 g, 15.11 mmol, 1.61 mL) and ammonium acetate (2.33 g, 30.22 mmol) in acetic acid (5 mL) was irradiated in microwave at 120 C for 45 min. The resulting mixture was diluted with water (100 mL) and extracted with ethyl acetate (3×100 mL). The combined organic extract was washed with water (30 mL), brine (30 mL), dried (Na 2 SO 4 ) and evaporated under vacuum. The crude compound was heated in ethanol and filtered hot to yield 2 g (86%) as a dark yellow solid.
[0194] LC-MS: m/z calcd for C 16 H 15 N 3 O 4 313.3, found 312.5 (M−H) + .
[0195] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.39 (3H, t, J=5 Hz, CH 2 C H 3 ), 2.74 (3H, s, CNCCC H 3 ), 3.85 (3H, s, OC H 3 ), 4.41 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.99 (2H, d, J=5 Hz, phenyl-3 H and 5 H ) and 7.55 (2H, d, J=5 Hz, phenyl-2 H and 4 H ).
13c. Preparation of Compound 77
[0196]
[0197] A mixture of 76 (2 g, 6.38 mmol), sulfur (0.30 g, 9.24 mmol), and morpholine (1.1 g, 12.67 mmol, 1.1 mL) in ethanol (7 mL) was heated to 130 C in microwave for 25 min. The progress of the reaction mass was monitored by HPLC. Thereafter the mixture was cooled and the precipitate formed was filtered. The crude product was recrystallized from ethanol to give 0.530 g (24%) of product as a pale brown solid.
[0198] LC-MS: m/z calcd for C 16 H 15 N 3 O 4 S, 345.0, found 346.0 (M+H) + .
[0199] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.44 (3H, t, J=5 Hz, CH 2 C H 3 ), 3.87 (3H, s, OC H 3 ), 4.46 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.21 (1H, s, NH 2 ), 7.01 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.30 (1H, s, SC H ) and 7.51 (2H, d, J=5 Hz, phenyl-2 H and 4 H ).
13d. Preparation of Compound 54
[0200]
[0201] Lithium hydroxide monohydrate (0.1 g, 4.33 mmol) was added to a solution of 77 (0.50 g, 1.44 mmol) in tetrahydrofuran (10 mL) and water (10 mL). The reaction mixture was stirred at room temperature for 16 h. The progress of the reaction mass was monitored by HPLC. Thereafter pH of the reaction mass was adjusted to 6 using 1 N HCl and was extracted with ethyl acetate (3×50 mL). The combined organic layers were separated, dried (Na 2 SO 4 ) and evaporated to yield 0.35 g (77%) of desired product as a yellow solid.
[0202] LC-MS: m/z calcd for C 14 H 11 N 3 O 4 S, 317.3, found 318.6 (M+H) + .
[0203] 1 H NMR (500 MHz, MeOD): δ H 3.86 (3H, s, OC H 3 ), 6.80 (2H, s, NH 2 ), 7.02 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.20 (1H, s, SC H ) and 7.46 (2H, d, J=5 Hz, phenyl-2 H and 4 H ).
13e. Preparation of Compound 78
[0204]
[0205] A mixture of 54 (0.35 g, 1.10 mmol), iso-propylamine (0.13 g, 2.19 mmol, 0.18 mL), and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (0.73 g, 1.65 mmol) in anhydrous DMSO (5 mL) was added DIPEA (0.28 g, 2.16 mmol, 0.38 mL). The reaction mixture was stirred at room temperature for 16 h. The progress of the reaction mass was monitored by LCMS. The reaction mixture diluted with water (25 mL) and the resulting mixture was extracted with dichlormethane (3×75 mL). The organic layer was washed with brine (20 mL), dried (Na 2 SO 4 ), filtered, and evaporated under vacuum. The residue was stirred with diethyl ether overnight. The precipitate was filtered and allowed to dry to yield 0.30 g (90%) as a brown solid.
[0206] LC-MS: m/z calcd for C 17 H 18 N 4 O 3 S, 358.1, found 359.1. (M+H) + .
[0207] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.23 (6H, d, J=5 Hz, (C H 3 ) 2 CH3.84 (3H, s, OC H 3 ), 4.16-4.23 (1H, m, (CH 3 ) 2 C H ), 6.91-7.08 (5H, m, phenyl-3 H and 5 H , SC H , N H 2 ) and 7.40-7.46 (2H, m, phenyl-2 H and 4 H ).
13f. Preparation of Compound 58
[0208]
[0209] To 78 (0.22 g, 0.61 mmol), methane sulfonic acid (4 mL) and methionine (0.27 g, 1.81 mmol) were added and the reaction mixture was stirred for 3 days. The progress of the reaction mass was monitored by LCMS. Thereafter the reaction mass was poured into ice and the precipitated solid was recovered by centrifugation. The product was dissolved in ethyl acetate and was washed with aqueous bicarbonate solution (50 mL). The organic layer was separated, dried (Na 2 SO 4 ), filtered and evaporated under vacuum to yield 160 mg (80%) as a brown solid.
[0210] LC-MS: m/z calcd for C 16 H 16 N 4 O 3 S, 344.0, found 345.0 (M+H) + .
[0211] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.14 (6H, d, J=5 Hz, 2×(C H 3 ) 2 CH), 4.05 (1H, q, J=10 Hz (CH 3 ) 2 C H ), 6.82 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.17 (1H, s, SC H ), 7.34 (2H, d, J=5 Hz, phenyl-2 H and 4 H ), 7.52 (2H, s, N H 2 ) and 7.87 (1H, d, J=5 Hz, N H )
13 g. Preparation of Compound 79
[0212]
[0213] To 58 (0.30 g, 0.08 mmol) in anhydrous acetonitrile (20 mL), cesium carbonate (0.42 g, 1.29 mmol) and ethylene ditosylate (0.39 g, 1.02 mmol) were added. The reaction mixture was heated to 60 C for 16 h. The reaction mixture was diluted with water (25 mL) and the resulting mixture was extracted with dichlormethane (2×100 mL). The organic layer was washed with brine (20 mL), dried (Na 2 SO 4 ), filtered, and evaporated under vacuum. The crude compound was purified using semi-prep with water and ammonium acetate as gradient solvents. The fractions were freeze-dried to yield 77 mg (16%) as yellow solid.
[0214] LC-MS: m/z calcd for C 25 H 26 N 5 O 6 S 2 , 542.1, found 542.9 (M+H) + .
[0215] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.22 (6H, d, J=5 Hz, NHCH(C H 2 ) 3 ), 2.46 (3H, s, C H 3 ), 4.16-4.23 (3H, m, NHC H (CH 2 ) 3 and SO 2 OC H 2 CH 2 ), 4.37-4.43 (2H, m, SO 2 OCH 2 C H 2 ), 6.13 (2H, s, NH2), 6.89 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.28-7.49 (2H, m, tosylphenyl-3 H and 5 H ), 7.58 (1H, s, SC H ), 7.73 (2H, d, J=5 Hz, phenyl-2 H and 6 H ) and 7.83 (2H, d, J=5 Hz, tosyl phenyl-2 H and 6 H ).
Example 14
Preparation of Compound 81
[0216]
14a. Preparation of Compound 80
[0217]
[0218] tert-Butyl 4-(hydroxymethyl)piperidine-1-carboxylate (50 mg, 0.23 mmol) was taken in a 50:50 mixture of ether and methanol (10 ml) and conc. HCl (1 mL) added to it dropwise over a period of 10 min. The reaction mixture was stirred for 1 h. The solvents were evaporated. Water was removed as an azeotrope with anhydrous acetonitrile (3×20 mL) to give the free amine as a hydrochloride salt. 54 (50 mg, 0.15 mmol) (prepared according to Example 13d) was dissolved in DMSO (2 mL) and piperidin-4-ylmethanol hydrochloride (36 mg, 0.23 mmol), DIPEA (40.7 mg, 0.31 mmol, 0.05 ml) and ((1H-benzo[d][1,2,3]triazol-1-yl)oxy)tris(dimethylamino)phosphonium hexafluorophosphate(V) (105 mg, 0.23 mmol) were added. The reaction mixture was stirred for 16 h at room temperature. The progress of the reaction was monitored by LCMS. The reaction mixture was diluted with water (50 mL) and extracted with ethyl acetate (2×15 mL). The organic layer was filtered, dried (Na 2 SO 4 ) and concentrated to yield 35 mg (46%) of desired product as brown solid.
[0219] LC-MS: m/z calcd for C 20 H 22 N 4 O 4 S 414.1, found 415.1 (M+H) + .
14b. Preparation of Compound 81
[0220]
[0221] 80 (350 mg, 0.84 mmol) was dissolved in anhydrous chloroform (20 ml) and diethylaminosulfur trifluoride (0.11 mL, 0.84 mmol) diluted with CHCl 3 (5 ml) was added at 0 C in drops over 10 min. The reaction was monitored every 10 min by TLC. Thereafter reaction mixture was washed with saturated NaHCO3 (20 mL) and extracted with ethyl acetate (2×50 mL). The organic layer was filtered, dried (Na 2 SO 4 ) and concentrated to yield the crude product. The crude product was purified by Semi-prep HPLC using acetonitrile:methanol(50:50) and 20% ammonium acetate (pH 4.3). 1% HCl solution (5 mL) was added to the pooled fractions before freeze-drying to yield 50 mg (13%) of required compound as yellow solid.
[0222] LC-MS: m/z calcd for C 20 H 21 FN 4 O 3 S 416.1, found 417.1 (M+H) + .
[0223] 1 H NMR (300 MHz, DMSO): δ H 1.07-1.28 (2H, m, FCH 2 CHC H 2 CH 2 ), 1.61-1.83 (2H, m, FCH 2 CHCH 2 C H 2 ), 1.88-2.07 (1H, m, CH), 2.74-2.91 (2H, m, ONC H 2 CH 2 ), 3.03-3.17 (ONCH 2 C H 2 ), 3.79 (3H, s, OC H 3 ), 4.30 (2H, dd, J=3 Hz and 15 Hz, C H 2 F), 6.62 (2H, s, N H 2 ), 6.99 (2H, d, J=3 Hz, phenyl-2 H and 6 H ), 7.38 (2H, d, J=3 Hz, phenyl-3 H and 5 H ) and 7.54 (1H, s, SC H ).
Example 15
Preparation of Compound 82
[0224]
[0225] 78 (50 mg, 0.14 mmol) was dissolved in 5 mL anhydrous dimethylformamide and cesium carbonate (90 mg, 0.28 mmol) added to it. The reaction mixture was maintained at 0 C and methyl iodide (39 mg, 0.28 mmol, 0.017 mL) dissolved in DMF (3 mL) and added slowly in drops over 10 min. The reaction mixture was allowed to stir at room temperature for 16 h. The reaction mixture was diluted with water (30 mL) and extracted with ethyl acetate (3×20 mL). The combined organic layers were dried (Na 2 SO 4 ) and evaporated under vacuum. Purification was carried over neutral alumina eluting with hexane (A): ethyl acetate (B) (0-30%) (B), 8 g, 12 mL/min to give desired product 19 mg (35%) as a pale yellow solid.
[0226] LC-MS: m/z calcd for C 19 H 22 N 4 O 3 S, 386.1, found 386.9 (M+H) + .
[0227] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.22 (6H, d, J=5 Hz, NHCH(C H 3 ) 2 ), 3.14 (6H, s, N(C H 3 ) 2 ), 3.85 (3H, s, OC H 3 ), 4.15-4.27 (1H, m, NHC H (CH 3 ) 2 ), 6.94-7.04 (3H, m, SC H and phenyl-3 H and 5 H ), 7.43 (2H, d, J=5 Hz, phenyl-2 H and 6 H ) and 8.02 (1H, s, CON H ).
Example 16
Preparation of Compound 87
[0228]
16a. Preparation of Compound 83
[0229]
[0230] 77 (100 mg, 0.28 mmol) was dissolved in dioxane (7 mL) and 4-dimethylaminopyridine (0.35 mg, 0.02 mmol) was added to it. Boc anhydride (69 mg, 0.32 mmol) dissolved in dioxane (3 mL) was added dropwise to the reaction mixture at room temperature and allowed to stir for 4 h. The progress of the reaction mass was monitored by HPLC, dioxane was distilled off and the crude reaction mixture was diluted with water (15 mL) and extracted with ethyl acetate (3×15 mL). The combined organic extracts were dried (Na 2 SO 4 ) and distilled under vacuum to obtain the crude compound. Purification was carried over neutral alumina eluting with hexane (A): ethyl acetate (B) (0-15%) (B), 8 g, 12 mL/min to give desired product 55 mg (43%) as a pale yellow solid.
[0231] LC-MS: m/z calcd for C 21 H 23 N 3 O 6 S 445.3, found 445.9 (M+H) + .
[0232] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.43 (3H, t, J=5 Hz, CH 2 C H 3 ), 1.53 (9H, s, O(C H 3 ) 3 ), 3.85 (3H, s, OC H 3 ), 4.46 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.97-7.01 (2H, m, phenyl-3 H and 5 H ), 7.47-7.51 (2H, m, phenyl-2 H and 6 H ), 7.78 (1H, s, SC H ) and 10.17 (1H, s, N H ).
16b. Preparation of Compound 84
[0233]
[0234] 83 (55 mg, 0.12 mmol) was dissolved in 2 mL in anhydrous dimethylformamide and cesium carbonate (48 mg, 0.15 mmol) added to it. Methyl iodide (19 mg, 0.13 mmol, 0.008 mL) dissolved in 1 mL of DMF was added to the reaction mixture dropwise at 0 C. The reaction mixture was stirred at room temperature for 4 h. The reaction mixture was diluted with water (3×20 mL) and extracted with ethyl acetate (3×50 mL). The combined organic extracts were dried (Na 2 SO 4 ) and distilled under vacuum to obtain the crude compound. Purification was carried over neutral alumina eluting with hexane (A): ethyl acetate (B) (0-25%) (B), 8 g, 12 min/min to give desired product 30 mg (53%) as a pale yellow solid.
[0235] LC-MS: m/z calcd for C 22 H 25 N 3 O 6 S 459.1, found 459.9 (M+H) + .
[0236] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.32-1.40 (12H, m, CH 2 C H 3 and O(C H 3 ) 3 ), 3.26 (3H, s, NC H 3 ), 3.77 (3H, s, OC H 3 ), 4.39 (2H, q, J=10 Hz, C H 2 CH 3 ), 6.89-6.93 (2H, m, phenyl-3 H and 5 H ), 7.39-7.43 (2H, m, phenyl-2 H and 6 H ) and 8.26 (1H, s, C H ).
16c. Preparation of Compound 85
[0237]
[0238] 84 (30 mg, 0.06 mmol) was dissolved in a mixture of water and tetrahydrofuran (3 mL, (1:1)) and lithium hydroxide (4.7 mg, 0.19 mmol) was added to it. The reaction mixture was allowed to stir at room temperature for 16 h. The progress of the reaction was monitored by HPLC. Tetrahydrofuran was distilled off and 1N HCl was added to it till pH 6 was reached. The aqueous layer was extracted with ethyl acetate (2×50 mL). The combined organic layers were dried (Na 2 SO 4 ) and distilled to obtain the desired 22 mg (78%) product as a pale yellow solid.
[0239] LC-MS: m/z calcd for C 20 H 21 N 3 O 6 S 431.1, found 431.9 (M+H) + .
[0240] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.44 (9H, s, O(C H 3 ) 3 ), 3.33 (3H, s, NC H 3 ), 3.83 (3H, s, OC H 3 ), 6.96 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.41 (2H, d, J=5 Hz, phenyl-2 H and 6 H ) and 8.49 (1H, s, SC H ).
16d. Preparation of Compound 86
[0241]
[0242] 85 (22 mg, 0.05 mmol), iso-propylamine (4.5 mg, 0.07 mmol, 0.006 mL), and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (45 mg, 0.10 mmol) were suspended in anhydrous DMSO (2 mL) and DIPEA (13 mg, 0.10 mmol, 0.017 mL) was added to it. The reaction mixture was stirred at room temperature for 16 h. The progress of the reaction was monitored by LCMS. The reaction mixture diluted with water (10 mL) and the resulting mixture was extracted with ethyl acetate (2×50 mL). The organic layer was washed with brine (10 mL), dried (Na 2 SO 4 ), filtered, and evaporated under vacuum. The residue was stirred with diethyl ether overnight. The crude compound 19 mg (91%) was taken directly for the next reaction.
[0243] LC-MS: m/z calcd for C 23 H 28 N 4 O 5 S 472.1, found 472.9 (M+H) + .
[0244] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.24 (9H, s, O(C H 3 ) 3 ), 1.43-1.49 (6H, m, NHCH(C H 3 ) 2 ), 3.31 (3H, s, NC H 3 ), 3.85 (3H, s, OC H 3 ), 4.18-4.26 (1H, m, NHC H (CH 3 ) 2 ), 6.99-7.02 (2H, m, phenyl-3 H and 5 H ), 7.42-7.45 (2H, m, phenyl-2 H and 6 H ) and 8.68 (1H, s, SC H ).
16e. Preparation of Compound 87
[0245]
[0246] 86 (19 mg, 0.04 mmol) was dissolved in 10 mL anhydrous dichloromethane and 1 mL trifluoroacetic acid added to it. The reaction was allowed to stir at room temperature for 4 h. The reaction mixture was quenched with water (10 mL) and extracted with dichloromethane (5 mL). The aqueous layer was neutralized with saturated sodium bicarbonate solution and extracted with dichloromethane (2×45 mL). The combined organic layers were dried (Na 2 SO 4 ) and distilled to obtain 12 mg of crude compound. This was re-crystallized using ethyl acetate and hexane to give 9 mg (58%) of desired product.
[0247] LC-MS: m/z calcd for C 18 H 20 N 4 O 3 S 372.1, found 372.9 (M+H) + .
[0248] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.22 (6H, d, J=5 Hz, NHCH(C H 2 ) 3 ), 3.04 (3H, d, J=5 Hz, NHC H 3 ), 3.86 (3H, s, OC H 3 ), 4.14-4.27 (1H, m, NHC H (CH 2 ) 3 ), 6.93 (1H, s, SC H ), 6.99 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.43 (2H, d, J=5 Hz, phenyl-2 H and 6 H ) and 7.52 (1H, s, CON H ).
Example 17
Preparation of Compound 91
[0249]
17a. Preparation of Compound 88
[0250]
[0251] 1-Boc-piperazine (1 g, 5.37 mmol) and 2,6-difluoropyridine (0.61 g, 5.37 mmol) were dissolved in dry DMF (20 mL) and triethylamine (0.81 g, 8.05 mmol, 1.12 mL) was added. The mixture was heated at reflux for 16 h. On cooling, the reaction was quenched with saturated sodium bicarbonate solution (15 mL). After 10 min this was diluted with water (60 mL) and the mixture extracted with ethyl acetate (3×60 mL). The combined organic layer were washed with water (2×50 mL), brine (50 mL), dried (Na2SO4), filtered and evaporated. The dark oil was put under high vacuum overnight to remove residual DMF prior to column chromatography on silica gel eluting with hexane (A): EtOAc (B) (0-15% (B), 12 g, 12 mL/min) to give the desired product 0.8 g (53%) as a viscous yellow oil.
[0252] LC-MS: m/z calcd for C 14 H 20 FN 3 O 2 , 281.2; found, 282.1 (M+H) + .
17b. Preparation of Compound 89
[0253]
[0254] 88 (700 mg, 2.49 mmol) was dissolved in anhydrous dichloromethane (30 mL) and trifluoroacetic acid (10 mL) added to it. The reaction mixture was allowed to stir at room temperature for 4 h. The reaction was quenched with water, neutralized with saturated sodium bicarbonate solution. The aqueous layer was extracted with DCM (2×50 mL). The combined organic layers were dried (Na 2 SO 4 ), filtered and evaporated to obtain the desired product 330 mg (73%) as a yellow oil.
[0255] LC-MS: m/z calcd for C 9 H 12 FN 3 , 181.1; found, 181.9 (M+H) + .
17c. Preparation of Compound 90
[0256]
[0257] To a mixture of 54 (0.39 g, 1.23 mmol) (prepared according to Example 13d), 89 (0.33 g, 1.84 mmol), and benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate reagent (0.81 g, 1.84 mmol) in anhydrous DMSO (10 mL), DIPEA (0.32 g, 2.45 mmol, 0.43 mL). was added and the reaction mixture was stirred at room temperature for 16 h. The progress of the reaction was monitored by LCMS. The reaction mixture diluted with water (25 mL) and the resulting mixture was extracted with dichloromethane (2×50 mL). The organic layer was washed with brine (20 mL), dried (Na 2 SO 4 ), filtered and evaporated under vacuum. Purification was carried over neutral alumina eluting with hexane (A): ethyl acetate (B) (0-40%) (B), 8 g, 12 mL/min, to give desired product 0.29 g (47%) as yellow solid.
[0258] LC-MS: m/z calcd for C 23 H 21 FN 6 O 3 S, 480.1, found 480.9 (M+H) + .
[0259] 1 H NMR (500 MHz, DMSO): δ H 3.48-3.77 (8H, N(C H 2 ) 2 (C H 2 ) 2 N), 3.80 (3H, s, OC H 3 ), 6.31 (1H, s, SC H ), 6.72 (2H, s, N H 2 ), 7.00 (2H, d, J=5 Hz, fluoropyridyl-3 H and 5 H ), 7.42 (2H, d, J=5 Hz, phenyl-3 H and 5 H ), 7.56 (2H, s, phenyl-2 H and 6 H ) and 7.70 (1H, d, J=5 Hz, fluoropyridyl-4 H ).
17d. Preparation of Compound 91
[0260]
[0261] 90 (60 mg, 0.12 mmol) was dissolved in dioxane (5 mL) and 4-dimethylaminopyridine (1.2 mg, 0.012 mmol) was added to it. Boc anhydride (30 mg, 0.13 mmol) dissolved in dioxane (3 mL) was added dropwise to the reaction mixture and heated at 50 C for 2 h. Dioxane was distilled off and the crude reaction mixture was dissolved in dichloromethane (50 mL) and washed with water (15 mL), brine (5 mL). The organic layer was dried (Na 2 SO 4 ) and evaporated under vacuum to obtain the crude compound. Purification was carried over neutral alumina eluting with hexane (A): ethyl acetate (B) (0-20%) (B), 8 g, 12 mL/min to give desired product 10 mg (13%) as a pale yellow solid.
[0262] LC-MS: m/z calcd for C 28 H 29 FN 6 O 5 S 580.1, found 580.9 (M+H) + .
[0263] 1 H NMR (300 MHz, CDCl3): δ H 1.54 (9H, s, O(C H 3 ) 3 ), 3.58-3.69 (4H, m, ON(C H 2 ) 2 (CH 2 ) 2 N), 3.77-3.82 (2H, m, ON(CH 2 ) 2 C H 2 CH 2 N), 3.86 (3H, s, OC H 3 ), 3.89-3.95 (2H, m, ON(CH 2 ) 2 CH 2 C H 2 N), 6.22 (1H, dd, J=3 Hz and 6 Hz, fluoropyridyl-3 H ), 6.42 (1H, dd, J=3 Hz and 6 Hz, fluoropyridyl-5 H ), 6.94 (2H, d, J=3 Hz, phenyl-3 H and 5 H ), 7.31 (1H, s, SC H ), 7.43 (2H, d, J=3 Hz, phenyl-2 H and 6 H ), 7.56 (1H, q, J=6 Hz, fluoropyridyl-4 H ) and 10.13 (1H, s, N H ).
Example 18
Preparation of 5-amino-N-(2-fluoroethyl)-3-(4-methoxyphenyl)-4-oxo-3,4-dihydrothieno[3,4-d]pyridazine-1-carboxamide (92)
[0264]
[0265] 5-amino-3-(4-methoxyphenyl)-4-oxo-3,4-dihydrothieno[3,4-d]pyridazine-1-carboxylic acid (75 mg, 0.24 mmol), BOP (157 mg, 0.36 mmol) and 2-fluoroethanaminium chloride (47.1 mg, 0.47 mmol) were dissolved in anhydrous DMSO (1.5 mL) and DIPEA (0.17 ml, 0.95 mmol) added. The solution was stirred at 20° C. for 24 h. Added water (20 mL) and extracted with DCM (3×10 mL). Washed combined DCM with brine (10 mL) dried over anhydrous sodium sulfate filtered and evaporated. The residue was purified by chromatography on silica gel eluting with dichloromethane (A): methanol (B) (0.5-10% B, 10 g, 25 CV, 30 mL/min) to give the product as a yellow solid (50 mg, 58%).
[0266] LC-MS: calcd for C 16 H 15 FN 4 O 3 S, 362.1; found, 363.3 (M+H) + .
[0267] 1 H NMR (301 MHz, CHLOROFORM-D) δ H 7.54 (s, 1H, S—C H ), 7.48-7.38 (m, 2H, Ar— H ), 7.04-6.95 (m, 2H, Ar— H ), 6.14 (br s, 2H, N— H 2 ), 4.56 (dt, J=48 Hz & 4.8 Hz, 2H, F—C H 2 ), 3.85 (s, 3H, OC H 3 ), 3.80-3.59 (m, 2H, NC H 2 ) and 3.49 (d, J=5.1 Hz, N H ). 13 C NMR (76 MHz, CHLOROFORM-D) δ C 163.2 ( C —NH2), 161.1 (NH C ═O), 159.8 ( C —OMe), 159.1 ( C ═O), 134.4, 133.5, 127.4 (2×Ar— C H), 126.8, 114.2 (2×Ar— C H), 107.4, 106.0 (S C H), 82.6 (d, J=168.1 Hz, C —F), 55.7 (O C H 3 ) and 39.8 (d, J=20.3 Hz, NH C H 2 ).
Example 19
Preparation of (R)-7-amino-4-(3-fluoropyrrolidine-1-carbonyl)-2-(4-methoxyphenyl)thieno[3,4-d]pyridazin-1(2H)-one (93)
[0268]
[0269] 5-amino-3-(4-methoxyphenyl)-4-oxo-3,4-dihydrothieno[3,4-d]pyridazine-1-carboxylic acid (75 mg, 0.24 mmol), BOP (157 mg, 0.36 mmol) and (R)-3-fluoropyrrolidin-1-ium chloride (29.7 mg, 0.24 mmol) were dissolved in anhydrous DMSO (1.5 ml) and DIPEA (0.17 ml, 0.95 mmol) added. The solution was stirred at 20° C. for 24 h. Added water (20 mL) and extracted with DCM (3×10 mL). Washed combined DCM extracts with brine (10 mL) dried over anhydrous sodium sulfate filtered and evaporated. The residue was purified by chromatography on silica gel eluting with dichloromethane (A): methanol (B) (0.5-10% B, 25 g, 25 CV, 40 mL/min) to give the product as a yellow solid (60 mg, 65%).
[0270] LC-MS: calcd for C 18 H 17 FN 4 O 3 S, 388.1; found, 389.2 (M+H) + .
Example 20
Preparation of (S)-7-amino-4-(3-fluoropyrrolidine-1-carbonyl)-2-(4-methoxyphenyl)thieno[3,4-d]pyridazin-1(2H)-one (94)
[0271]
[0272] 5-amino-3-(4-methoxyphenyl)-4-oxo-3,4-dihydrothieno[3,4-d]pyridazine-1-carboxylic acid (75 mg, 0.24 mmol), BOP (157 mg, 0.36 mmol) and (S)-3-fluoropyrrolidin-1-ium chloride (29.7 mg, 0.24 mmol) were dissolved in anhydrous DMSO (1.5 ml) and DIPEA (0.17 ml, 0.95 mmol) added. The solution was stirred at 20° C. for 24 h. Added water (20 mL) and extracted with DCM (3×10 mL). Washed combined DCM with brine (10 mL) dried over anhydrous sodium sulfate filtered and evaporated. The residue was purified by chromatography on silica gel eluting with dichloromethane (A): methanol (B) (0.5-10% B, 25 g, 25 CV, 40 mL/min) to give the product as a yellow solid (50 mg, 55%).
[0273] LC-MS: calcd for C 18 H 17 FN 4 O 3 S, 388.1; found, 389.2 (M+H) + .
Example 21
Preparation of Compound 99
[0274]
21a. Preparation of Compound 95
[0275]
[0276] 76 (4 g, 12.7 mmol) (prepared according to Example 13b) was suspended in a mixture of ethanol (66 mL) and water (25 mL). 0.511 g (12.7 mmol) of the sodium hydroxide was added to the reaction mass. The reaction was stirred at room temperature for 16 h. The reaction mass was concentrated under vacuum to remove the ethanol. The residue was dissolved in water (100 mL) and washed with ethyl acetate (100 mL) to remove the impurities. The pH of the aqueous reaction mass was adjusted the pH 2 by adding 1N HCl. The precipitate obtained was filtered and kept under the oven at 60 C to give 2.4 g (63%) of the desired product.
[0277] LC-MS: m/z calcd for C 14 H 11 N 3 O 4 , 285.1; found, 285.8 (M+H) +
[0278] 1 H NMR (500 MHz, DMSOD 6 ): δ H 2.65 (3H, s, C H 3 CCCN), 3.83 (3H, s, O—C H 3 ), 7.09 (2H, d, J=5 Hz, Ar-3-C H and Ar-5-C H ), 7.51 (2H, d, J=10 Hz, Ar-2-CH and Ar-6-CH)
21b. Preparation of Compound 96
[0279]
[0280] 95 (2 g, 7.01 mmol) was suspended in a mixture of t-butanol:DMF (40 mL, (1:1)). To this reaction mass, triethylamine (1.06 g, 10.52 mmol, 1.458 mL) was added. The reaction mass was cooled and added triphenylphosphoryl azide (2.31 g, 8.41 mmol). The reaction mass was stirred at a 0 C from another 10 min and started heating at 100 C for another 5 h. The reaction mass was quenched with water (30 mL) and extracted with ethyl acetate (5×30 mL). The organic layer was washed with water (3×20 mL) and dried over anhydrous Na 2 SO 4 (15 g).The organic layer was evaporated and purified through chromatography on alumina column eluting with hexane (A): ethyl acetate (B), (0-40% (B), 8 g, 12 mL/min) to give the pure product 1.0 g (40%) as yellow solid.
[0281] LC-MS: m/z calcd for C 18 H 20 N 4 O 4 , 356.1; found, 357.15 (M+H) +
[0282] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.53 (9H, s, OC(C H 3 ) 3 ), 2.55 (3H, s, CNCCC H 3 ), 3.87 (3H, s, O—C H 3 ), 6.60 (1H, bs, N H COOC(CH 3 ) 3 ), 6.98 (2H, d, J=10 Hz, Ar-3-C H and Ar-5-C H ) and7.53 (2H, d, J=10 Hz, Ar-2-C H and Ar-6-C H )
21c. Preparation of Compound 97
[0283]
[0284] 96 (0.50 g, 1.4 mmol) was taken in dry di methyl formamide (10 mL), added sodium hydride (0.04 g, 1.54 mmol) followed by the addition of fluoro ethyl tosylate (0.46 g, 2.11 mmol). The reaction mass was heated to 95 C for 12 h. Thereafter the reaction mass was quenched with water (10 mL) and extracted with ethyl acetate (4×20 mL).The organic layer was washed with water (3×20 mL) and dried over anhydrous Na 2 SO 4 (15 g) and evaporated under vacuum. The crude material was purified by chromatography on alumina column eluting with hexane (A): ethyl acetate (B), (0-50% (B), 8 g, 12 mL/min) to give the pure product 0.30 g (53%) as brown liquid.
[0285] LC-MS: m/z calcd for C 20 H 23 FN 4 O 4 , 402.1; found, 402.9 (M+H) +
[0286] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.49 (9H, bs, OC(C H 3 ) 3 ), 2.50 (3H, s, CNCCC H 3 ), 3.89 (3H, s, O—C H 3 ), 3.95-4.25 (2H, bs, NC H 2 CH 2 F), 4.46 (2H, m, NCH 2 C H 2 F),7.01 (2H, m, Ar-3-C H and Ar-5-C H ) and 7.55 (2H, m, Ar-2-C H and Ar-6-C H )
21d. Preparation of Compound 98
[0287]
[0288] 97 (0.29 g, 0.716 mmol) was suspended in ethanol (5 mL), sulphur (0.03 g, 1.07 mmol) and morpholine (0.14 g, 1.43 mmol, 0.14 mL) was added it. The reaction mass was then heated at 100 C in microwave for 35 min. The ethanol was evaporated from the reaction mass and then partitioned between ethyl acetate (3×10 mL) and water (3×10 mL). The combined organic layer then dried over anhydrous Na 2 SO 4 (10 g) and evaporated to dryness. The crude material the purified by chromatography on alumina column eluting with hexane (A): ethyl acetate (B), (0-60% (B), 8 g, 12 mL/min) to give the pure product 0.15 g (48%) as brownish liquid.
[0289] LC-MS: m/z calcd for C 20 H 23 FN 4 O 4 S, 434.14; found, 434.9 (M+H) +
[0290] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.45 (9H, s, OC(C H 3 ) 3 ), 3.86 (3H, s, O—C H 3 ), 3.98 (1H, t, J=5 Hz, NC H a H b CH 2 F), 4.03 (1H, t, J=5 Hz, NCH a H b CH 2 F), 4.59 (1H, t, J=5 Hz, NCH 2 C H a H b F), 4.68 (1H, t, J=5 Hz, NCH 2 CH a H b F), 6.14 (2H, bs, SCN H 2 ), 6.44 (1H, s, CC H S), 6.99 (2H, m, Ar-3-C H and Ar-5-C H ) and 7.48 (2H, m, Ar-2-C H and Ar-6-C H ).
21e. Preparation of Compound 99
[0291]
[0292] 98 (0.150 g, 0.345 mmol), was dissolved in dry dichloromethane (1.5 mL), cooled to 0 C using ice- salt mixture. To the reaction mass, trifluoroacetic acid: dichloromethane (5 mL, 1:1) was added. The reaction mass was stirred at RT for 12 h. Quenched with water (5 mL) and basified with saturated solution of NaHCO 3 (5 mL). The organic layer was extracted with DCM (4×5 mL) and dried over anhydrous Na 2 SO 4 (5 g) and evaporated to dryness. The crude material then purified by chromatography on alumina column eluting with hexane (A): ethyl acetate (B), (0-60% (B), 8 g, 12 mL/min) to give the pure product 0.06 g (54%) as off-white solid.
[0293] LC-MS: m/z calcd for C 15 H 15 FN 4 O 2 S, 334.1; found, 334.8 (M+H) +
[0294] 1 H NMR (500 MHz, CDCl 3 ): δ H 3.66 (1H, m, NC H a H b CH 2 F), 3.72 (1H, m, NCH a H b CH 2 F), 3.86 (3H, s, OCH 3 ), 4.42 (1H, bs, FCH 2 CH 2 N H ), 4.62 (1H, t, J=5 Hz, NCH 2 C H a H b F), 4.72 (1H, t, J=5 Hz NCH 2 CH a H b F), 6.20 (2H, bs, SCN H 2 ), 6.37 (1H, s, CC H S), 6.97 (2H, d, J=10 Hz, Ar-3-C H and Ar-5-C H ) and 7.55 (2H, d, J=10 Hz, Ar-2-C H and Ar-6-C H ).
Example 22
Preparation of Compound 100
[0295]
[0296] 96 (0.2 g, 0.561 mmol) was taken in ethanol (2 mL), added sulfur (0.027 g, 0.84 mmol) and morpholine (0.098 g, 1.12 mmol, 0.098 mL). The reaction mass was then heated at 100 C in microwave for 35 min. The ethanol was evaporated from the reaction mass and then partitioned between ethyl acetate (3×15 mL) and water (3×15 mL). The combined organic layer then dried over anhydrous Na 2 SO 4 (10 g) and evaporated to dryness. The crude material the purified by chromatography on alumina column eluting with hexane (A): ethyl acetate (B), (0-60% (B), 8 g, 12 mL/min) to give the pure product 0.07 g (32%) as brown solid.
[0297] LC-MS: m/z calcd for C 18 H 20 N 4 O 4 S, 388.1; found, 388.9 (M+H) +
[0298] 1 H NMR (500 MHz, CDCl 3 ): δ H 1.53 (9H, s, OC(CH 3 ) 3 ), 3.85 (3H, s, OCH 3 ), 6.65 (1H, bs, N H COOC(CH 3 ) 3 ), 6.76 (1H, s, CC H S), 6.98 (2H, d, J=10 Hz, Ar-3-C H and Ar-5-C H ) and 7.48 (2H, d, J=10 Hz, Ar-2-C H and Ar-6-C H ).
Example 23
Preparation of Compound 104
[0299]
23a. Preparation of Compound 101
[0300]
[0301] p-Anisidine (2 g, 16.23 mmol) was dissolved in a mixture of 37% hydrochloric acid (3 mL), ethanol (5 mL) and water (3 mL). The reaction mixture was cooled to 0 C, and a solution of sodium nitrite (1.12 g, 16.23 mmol) in water (7 mL) was added dropwise. The resulting mixture was stirred at 0 C for 20 min. Sodium acetate (8.61 g, 63.27 mmol) in water (20 mL) and t-Butyl acetoacetate (2.56 g, 16.23 mmol, 2 mL) were added and the reaction mixture was stirred at 0 C for 2 h. The precipitate formed was filtered, washed with water, and dried under high vacuum to give 4.08 g (80%) as brown solid.
[0302] LC-MS: m/z calcd for C 13 H 16 N 2 O 4 278.2, found 277 (M).
[0303] 1 H NMR (500 MHz, CDCl3): δ 1.6 (5H, s, C(CH3)3), 1.62 (4H, s, C(CH3)3), 2.48 (1.67H, s, COCH3), 2.56 (1.27H, s, COCH3), 6.9 (2H, m, phenyl-CH), 7.26 (1H, d, j=10 hz, phenyl-CH) and 7.33 (1H, d, J=10 hz, phenyl-CH).
23b. Preparation of Compound 102
[0304]
[0305] A mixture of 101 (4.0 g, 14.39 mmol), ethyl cyanoacetate (3.25 g, 28.78 mmol, 1.61 mL) and ammonium acetate (4.43 g, 57.56 mmol) in t-Butanol (5 mL) was irradiated in microwave at 100 C for 45 min. The resulting mixture was distilled to remove t-Butanol and then diluted with water (100 mL) and extracted with ethyl acetate (3×100 mL). The combined organic extract was washed with water (30 mL), brine (30 mL), dried over sodium sulfate and evaporated under vacuum. The crude compound was heated in ethanol and filtered hot to yield 2.8 g (60%) as a dark yellow solid.
[0306] LC-MS: m/z calcd for C 16 H 15 N 3 O 4 327.12, found 328.1 (M+H) +
[0307] 1 H NMR (500 MHz, CDCl3): δ 1.62 (9H, s, C(CH3)3), 2.72 (3H, s, CNCCCH3), 6.9 (2H, d, J=10 hz, ArCH), 7.4 (2H, d, J=10 Hz ArCH3)
23c. Preparation of Compound 103
[0308]
[0309] A mixture of 102 (2.8 g, 8.56 mmol), sulfur (0.42 g, 12.40 mmol) and morpholine (1.3 g, 17.12 mmol, 1.1 mL) in tert-Butanol (7 mL) was heated to 100 C in microwave for 30 min After the mixture was cooled, the precipitate formed was filtered and washed using ethanol to yield 0.76 g (25%) as a pale brown solid.
[0310] LC-MS: m/z calcd for C 16 H 15 N 3 O 4 S 359.09, found 360.09 (M+H) + .
[0311] 1 H NMR (500 MHz, CDCl 3 ): δ 1.55 (9H, s, C(C H 3 ) 3 ), 6.64 (1H, s, ArC H ), 6.8 (2H, d, J=10 Hz, Ar H ), 7.0 (1H, s, SC H ), 7.3 (2H, d, J=10 Hz, Ar H )
23d. Preparation of Compound 104
[0312]
[0313] A mixture of 103 (0.76 g, 2.12 mmol), fluoroethyltosylate (0.92 g, 4.24 mmol) and Cesium carbonate (1.22 g, 6.35 mmol) in DMF (10 mL) was stirred at ambient temperature for 16 h. The reaction was quenched in to 25 mL of water and extracted using dichlomethane (25 mL×2). The organic layer was dried using sodium sulfate and concentrated to dryness to yield 0.42 g of crude product.
[0314] LC-MS: m/z calcd for C19H20FN3O4S 405.12, found 406.12 (M+H) + .
[0315] 1H NMR (500 MHz, CDCl3): δ 1.64 (9H, s, C(CH3)3), 4.24 (1H, t, J=5 hz, OCH2), 4.3 (1H, t, J=5 Hz,OCH2), 4.75 (1H, t, J=5 Hz, FCH2), 4.85 (1H, t, J=5 Hz, FCH2), 7.02 (2H, d, J=10 Hz, ArCH), 7.15 (1H, s SCH), 7.55 (2H, d, J=10 Hz Ar CH).
Example 24
Preparation of Compound 105
[0316]
[0317] Compound 105 was prepared using the same route as that shown in Example 13, starting with 4-nitroaniline rather than p-anisidine.
Example 25
Preparation of Compound [ 18 F]56
[0318]
[0319] [ 18 F]Fluoride is azeotropically dried in a Wheaton vial as described in Example 1. The vial is cooled to room temperature and a solution of mesylate 57 (2.0 mg, 3.9 mmol) in anhydrous DMSO (0.2 mL) is added. The reaction mixture is heated for 15 minutes at 100° C. The reaction product [ 18 F]56 is isolated and formulated as described in Example 1.
Example 26
Preparation of Compound [ 18 F]59
[0320]
[0321] Compound [ 18 F]59 is obtained by nucleophilic ring opening reaction of epoxide 60 using [ 18 F]fluoride/Kryptofix in tert-amyl alcohol following a published protocol (R. Schirrmacher et al., Tetr. Lett. 52 (2011) 1973-1976).
Example 27
Preparation of Compound [ 18 F]106
[0322]
[0323] A solution of [ 18 F]2-fluoroethylamine (100 μL acetonitrile; obtained following a method by M. Glaser et al., J. Label. Compd. Radiopharm. 2012, 55, 326-331) is added to a mixture of acid 54 (2.0 mg, 6.3 mmol), BOP (4.2 mg, 9.4 mmol), DIPEA (57 μL, 325 μmol). After incubation for 30 min at room temperature the amide [ 18 F]106 is isolated by preparative HPLC.
Example 28
Preparation of Compounds [ 18 F]67 and [ 18 F]90
[0324]
[0325] Compound [ 18 F]90 is obtained by reacting nitro precursor 70 with the K[ 18 F]F-K 222 -carbonate complex in DMSO following the procedure as described by A. Maisonial et al. ( J. Med. Chem. 54, 2011, 2745-2766). Compound [ 18 F]67 is prepared in a similar fashion.
Example 29
Preparation of Compound [ 18 F]92
[0326]
[0327] The labelling reagent [ 18 F]fluoroethyl tosylate is obtained following a published protocol as described by W. Wadsak et al. (Nucl. Med. Biol. 34, 2007, 1019-1028). The subsequent N-alkylation and deprotection provides [ 18 F]92 in a similar fashion as described by E. Schirrmacher et al. ( Bioorg. Med. Chem. Lett. 13, 2003, 2687-2692).
Example 30
Preparation of Compounds [ 18 F]93 and [ 18 F]94
[0328]
[0329] Compounds [ 18 F]93 and [ 18 F]93 are obtained from the corresponding mesylate precursors by reacting with the K[ 18 F]F-K 222 -carbonate complex in DMSO following the procedure as described by X.-S. He et al. ( J. label. Cpd. Radiopharm. 33, 1993, 573-581).
Example 31
General
[0330] A number of novel compounds were screened for their ability to bind tau+ neurofibrillary tangles in Alzheimer disease brain tissue, in vitro ADME properties and brain uptake in vivo. Taken together, the results demonstrate that a selection of compounds of the invention bind preferentially to tangles, are metabolically stable in vitro, can be radiolabelled, and have a high brain uptake in rodent models. Thus, such compounds display the desired characteristics for a tau imaging agent.
1 Material and Methods
1.1 Human Tissue
[0331] Human brain tissue samples from the entorhinal cortex of patients with Alzheimer's disease (AD) and healthy controls were obtained from Tissue Solutions (Tissue Solutions Ltd, Glasgow, UK). Tissue samples were collected after informed written consent, and specimens were dissected at the tissue bank and snap-frozen for cryopreservation at a time interval of between 3 and 18 h after death. The frozen tissue was embedded in TissueTek® (VWR) and sectioned using a Microm HM560 cryostat (Thermo Scientific). Serial 12 μm sections were mounted onto SuperFrost®+ glass slides (VWR) and stored a −70° C.
1.2 Immunohistochemistry
[0332] To confirm presence and location of tau+ neurofibrillary tangles (NFTs) and β-amyloid (Aβ)+ plaques in the human tissue sections, every 20 th tissue section throughout the specimens was processed for immunohistochemical labelling with antibodies raised against aggregated and hyperphosphorylated tau, and aggregated Aβ.
[0333] Briefly, tissue sections were defrosted and fixed in ice-cold 70% ethanol. All tissue sections were rinsed with PBS after fixation and between all subsequent incubation steps. Following fixation, tissue sections were incubated first with H 2 O 2 (EnVision™ kit, Dako). Tissue sections to be processed for Aβ immunohistochemistry were further treated for antigen retrieval by incubation in 70% formic acid (Sigma-Aldrich) for 10 min. All tissue sections were then incubated with 10% normal goat serum (Vector Labs) to block non-specific labelling. After the blocking steps, the tissue sections were incubated with primary antibodies raised against tau (AT8, mouse monoclonal antibody, 1:20 dilution, Invitrogen) or Aβ (4G8, mouse monoclonal antibody, 1:100 dilution, Covance) for 1 h at room temperature (RT).
[0334] Following incubation with primary antibodies, the tissue sections were incubated with secondary antibodies conjugated to horseradish peroxidase (HRP) directed against mouse IgG for 30 min at RT. This was followed by incubation with the chromogen 3,3′-diaminobenzidine (DAB) for 2-3 min. EnVision™ HRP kits were used for secondary labelling (Dako). Finally the sections were counterstained with haematoxylin (Merck), dehydrated and mounted in DPX mounting media (VWR). Images of tissue sections labelled with tau and Aβ were captured using a Nikon digital camera connected to a Leica microscope and using the NIS Elements D software (Nikon). Images were further processed with the Photoshop® software (Adobe).
1.3 Gallyas Silver Stain
[0335] Conventional immunohistochemistry rely on the presence and detection of specific antigen by primary antibodies. For example, the tau antibody (AT8) used for the immunohistochemical detection of NFTs in 1.2 detects a specific conformation of hyperphosphorylated tau aggregates, but it will not detect less mature tau aggregates (Augustinack et al., 2002). Likewise, further phosphorylation results in conformational changes and loss of the AT8 specific tau antigen (Augustinack et al., 2002, Jeganathan et al., 2008). It has therefore been suggested that using a different method, such as Gallyas silver stain, that doesn't rely on one antigen is a more sensitive and accurate method to detect and label NFTs (Rosenwald et al., 1993, Cullen et al., 1996, Uchihara et al., 2001, Uchihara, 2007). Therefore, in addition to tau+ and Aβ+ immunohistochemistry, tissue sections adjacent to the slides used for immunohistochemistry where processed for Gallyas silver stain.
[0336] Briefly, tissue sections were defrosted and fixed for 10 min in neutral buffered formalin (VWR) and washed first in PBS and then dH 2 O. Unless stated otherwise, tissue sections were rinsed in dH 2 O between each of the subsequent incubation steps. First, the tissue sections were incubated in 5% periodic acid for 5 min, and then for 1 min in an alkaline silver iodide solution. This was followed by a 10 min wash in 0.5% acetic acid, and then the tissue sections were incubated in developer solution for 5-30 min. The tissue sections were then washed in 0.5% acetic acid and rinsed in dH 2 O. This was followed by incubation for 5 min in a 0.1% gold chloride solution, and then 5 min in 1% sodium thiosulphate solution. The tissue sections were then rinsed in tap water and counterstained with 0.1% nuclear fast red for 2 min.
[0337] Finally, the tissue sections were rinsed in tap water, dehydrated and mounted in DPX mounting media (VWR). All reagents for the Gallyas silver stain were procured from Sigma-Aldrich unless otherwise stated. Images of tissue sections labelled with tau and Aβ were captured using a Nikon digital camera connected to a Leica microscope and using the NIS Elements D software (Nikon). Images were further processed with the Photoshop® software (Adobe).
1.4 Tissue Binding Assay
[0338] The binding of compounds to tau+NFTs and Aβ+ plaques in human AD tissue were evaluated based on fluorescence. All test compounds have an innate fluorescence, and binding of the compounds to NFTs/plaques in AD tissue can therefore be detected using a fluorescence microscope. Two reference compounds were included in the screen; PiB (Pittsburgh compound B (PiB) and FDDNP (fluorescent probe 2-(1-(2-(N-(2-fluoroethy)-N-methylamino)-naphthalene-6-yl)-ethylidende)-malononitrile). PiB has been reported to bind with a preference to Aβ+ plaques (Ikonomovic et al., 2008), whereas FDDNP binds to both NFTs and plaques (Agdeppa et al., 2001). In addition, an aminothienopyrazidine compound (ATPZ), a tau aggregation inhibitor first reported by Ballatore et al (Ballatore et al., 2010), was also screened on tissue.
[0339] Briefly, tissue sections were defrosted and fixed in ice-cold 70% ethanol. All tissue sections were rinsed with PBS after fixation and between all subsequent incubation steps. To quench autofluorescence, tissue sections were incubated first with 0.25% KMnO 4 (Sigma-Aldrich) in PBS for 12 min, and then with 0.1% K 252 O 5 /0.1% oxalic acid (both reagents from Sigma-Aldrich) in PBS for 1 min. The tissue sections were blocked with 2% BSA in PBS for 10 min, and then incubated with the test compounds at 100 μM concentration for 1 h at RT. Compounds with positive binding at 100 μM was further tested in subsequent assays using lower test concentrations, 10 μM and 1 μM. Finally the tissue sections were rinsed in PBS, and mounted in SlowFade® mounting media (Invitrogen). Images of labelled tissue sections were captured using a Nikon digital camera connected to a Leica microscope and using the NIS Elements D software (Nikon). Images were further processed with the Photoshop® software (Adobe).
1.5 In Vitro ADME Screening
[0340] Test compounds were screened using a panel of in vitro ADME assays for prediction of in vivo properties. The following assays were used; parallel artificial membrane permeability assay (PAMPA) to determine cell membrane passage, compound stability in the presence of human or rat plasma, compound stability in the presence of human or rat liver microsomes, and determination of binding to proteins in human plasma and rat brain homogenates. To enable comparison with two compounds reported to have high brain uptake in vivo, PiB (Ikonomovic et al., 2008) and ATPZ (Ballatore et al., 2010) were included in the screen.
1.5.1 PAMPA
[0341] The PAMPA assay is used to determine how well a compound crosses a cell membrane by measuring its passage through a phosphotidyl choline barrier. A permeability coefficient >−6 indicates high permeability across lipid membranes and is indicative of a compounds ability to cross the blood brain barrier.
[0342] A 10 μM solution was incubated on a PDVF membrane coated with a 2% phoshotidyl choline solution for 5 h at RT. Membrane penetration was measured using LC-MS.
1.5.2 Protein Binding Assays
[0343] The protein binding assays provide an estimate of free (unbound) fraction of the compound in the blood or brain in vivo. High protein binding of a compound within the blood indicates that it is potentially unavailable for passage across the blood brain barrier and could compromise its metabolism or excretion, whereas high binding to proteins in the brain is indicative of non-specific binding and slow excretion. The desirable criterion for this assay is <99% of test compound bound.
[0344] Test compounds were first dissolved in DMSO to a concentration of 50 μM. This was followed by incubation in samples of human plasma and rat brain homogenates (final test concentration 1 μM). Binding of compounds to proteins was determined in the samples by rapid equilibrium dialysis after 5 and 30 min of incubation.
1.5.3 Liver Microsome Stability Assay
[0345] The liver microsome stability assay provides an estimate of compound stability and rate of metabolism in vivo. The desirable criterion for this assay is >50% parent compound after 30 min.
[0346] A 1 μM compound solution was incubated with rat or human liver microsomes (20 mg/ml) at 37° C. and the amount of parent compound remaining following the incubation was determined after 5 and 30 min of incubation using LC-MS.
1.6 In Vivo Cold Bio-Distribution
[0347] All animal studies were in compliance with local rules and regulations. Test compounds were administered by intravenous (i.v) injection through the tail vein of naïve male Wistar rats (50 μg test compound/rat). The animals were sacrificed by dislocation of the neck at 2, 10, 30, 60 min post-injection (p.i). The brain and plasma were collected from each animal. The concentration of test compound was measured in the plasma and brain homogenates using LS-MS, and calculated as % compound/g (% ID/g).
[0000] 1.7 In Vivo Bio-Distribution with Radiolabelled Compounds
[0348] All animal studies were in compliance with local rules and regulations. [ 18 F]-radiolabelled compounds were injected i.v through the tail vein of naïve male C57B1/6 mice (2 MBq/mouse). The animals were sacrificed by dislocation of the neck at 2, 10, 30 and 60 min p.i. Next, the animals were dissected and the radioactivity of organs, tissue and blood was measured using a Wallac γ counter (Perkin-Elmer). The compound concentration in the specimens was calculated as % ID/g.
2 Results
[0349] 2.1 Histology of human AD tissue
[0350] Every 20 th section was labelled for tau or Aβ to confirm the presence and extent of tau+ NFTs and Aβ+ plaques in the human tissue sections. Adjacent tissue sections were processed using Gallyas silver stain, which is a sensitive method for labelling of NFTs and neuritic plaques that is not relying on antibodies for detection.
[0351] Numerous tau+ NFTs and neuritic plaques, as well as Aβ+ plaques, were observed in all AD specimens. In contrast, no NFTs or plaques were observed in tissue sections from a control subject. NFTs and neuritic plaques were also observed in tissue sections labelled with Gallyas silver stain. More mature NFTs were detected with Gallyas silver stain compared to tau+ immunohistochemistry. Typical morphology of NFTs and plaques are demonstrated FIG. 5 .
2.2 Screening of Compound Binding to Human AD Tissue
[0352] The binding of compounds to tau+ NFTs and Aβ+ plaques in human AD tissue were evaluated based on fluorescence. All test compounds have an innate fluorescence, and binding of the compounds to NFTs/plaques in AD tissue can therefore be detected using a fluorescence microscope. The results from the tissue assays are summarized Table 2, Table 3, and Table 4.
[0353] At high test concentration, binding of both reference compounds (PiB and FDDNP) was detected to both NFTs and plaques (Table 2). At lower test concentrations, PiB only bound to plaques. These results are as expected and are supported by reports in the literature (Agdeppa et al., 2001, Ikonomovic et al., 2008, Thompson et al., 2009).
[0354] Some of the tested novel compounds were observed to bind to NFTs (Table 2, Table 3, and Table 4). Most notably are test compounds 38 and 105 (Table 1, FIG. 6 (38 A-B, 105 C-D)), which at high test concentrations bind to both NFTs and plaques but at lower test concentrations bind with a preference for NFTs.
2.3 In Vitro ADME Screening
[0355] Selected compounds were screened using multiple in vitro assays for prediction of in vivo properties.
[0356] The results are summarized in Table 3. The data suggest that the majority of the screened novel compounds from this class fulfil the desired in vitro criteria for an imaging agent, and these compounds are predicted to cross BBB and to be metabolically stable in vivo.
2.4 Cold Bio-Distribution
[0357] Selected compounds were screened using cold bio-distribution in rat to determine brain uptake. The results are summarized in Table 6. The data demonstrates uptake >0.2% ID/g at 2 min p.i. for 38 and 99, which suggest significant brain uptake, but low brain uptake of 106. In addition, the clearance ratio for 38 and 99 demonstrates rapid brain uptake followed by rapid clearance. For cold bio-distribution in rats, the benchmark criteria for an imaging agent are a brain uptake >0.2% ID/g at 2 min p.i. and a clearance ratio >2.
[0000] 2.5 Biodistribution with [ 18 F]-Radiolabelled Compounds
[0358] Selected compounds were radiolabelled and used for bio-distribution in mice to determine brain uptake. The results are summarized in Table 7. The data demonstrate uptake >1% ID/g at 2 min p.i. for [ 18 F]-38 (i.e., 38*). In addition, the clearance ratio for [ 18 F]-38 (i.e., 38*) demonstrates a rapid brain uptake followed by rapid clearance. For bio-distribution of radiolabelled compounds in mice, the minimum criteria required for an imaging agent are a brain uptake >1% ID/g at 2 min p.i. and a clearance ratio >2.
[0000]
TABLE 2
Results from tissue binding assay.
Compound
Structure
Concentration (μM)
NFTs
Plaques
PIB
100 10 1
+++ + −
+++ ++ ++
FDDNP
100 10 1
+++ ++ +
+++ ++ +
ATPZ
100 10 1
+++ ++ +
+ − −
38
100 10 1
+++ ++ +
++ + −
14
100 10 1
+ − −
+ − −
105
100 10 1
++ + −
++ −
82
100
+
++ − −
90
100
(+)
−
63
100
−
(+)
91
100
−
−
− No staining;
+ weak staining;
++ moderate staining;
+++ intense staining
[0000]
TABLE 3
Results from tissue binding assay
Concentration
Compound
Structure
(μM)
NFTs
Plaques
64
100
−
−
56
100
−
−
81
100
−
106
100 10 1
−
87
−
−
107
100
−
+ − −
108
100
−
−
99
100
ND 1
ND 1
67
100
−
−
1 Not possible to determine binding due to test compound fluorescence in the UV range
− No staining;
+ weak staining;
++ moderate staining;
+++ intense staining
[0000]
TABLE 4
Results from the tissue binding assay
Concentration
Compound
Structure
(μM)
NFTs
Plaques
59−
100
−
−
61
100
−
−
104
100
−
−
− No staining;
+ weak staining;
++ moderate staining;
+++ intense staining
[0000]
TABLE 5
Summary of results from in vitro ADME screen
Protein binding
Liver stability
PAMPA
Human
Rat
Rat (% PCP)
Human (% PCP)
Com-
Log Pe
plasma
brain
>50%
>50%
>50%
>50%
pound
>−6
<99%
<99%
5 min
30 min
5 min
30 min
PiB
−5.41
99.82
98.26
57.18
5.01
66.99
14.54
ATPZ
−5.24
99.02
90.94
97.06
70.19
98.9
68.29
38
−5.02
93.58
57.2
81.7
56.4
87.2
74.4
14
−4.89
94.78
61.7
92.8
64.0
92.1
61.3
105
−5.10
98.0
88.8
81.29
58.8
91.5
73.2
58
−7.52
93.2
49.4
90.03
79.3
100.9
83.4
90
−5.51
99.16
88.84
72.67
53.0
44.62
2.57
56
−5.16
96.28
55.2
94.88
92.06
80.98
52.10
81
−5.12
95.02
41.07
60.12
32.54
91.63
73.10
[0000]
TABLE 6
Results from cold bio-distribution in rat
Clearance
Brain uptake % ID/g p.i (min)
ratio
Compound
2
10
30
60
2:30 min
38
0.28
0.081
0.021
0.011
13.3
106
0.014
0.001
0.004
0.001
3.5
99
0.31
0.092
0.013
0.001
23.8
[0000]
TABLE 7
Results from bio-distribution of radiolabelled compounds in mouse
Clearance
Brain uptake % ID/g p.i (min)
ratio
Compound
2
10
30
60
2:30 min
[ 18 F]-38
6.50
3.26
2.83
2.35
2.3
[ 18 F]-61
9.84
5.77
3.46
1.51
2.8
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[0000]
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Augustinack J C, Schneider A, Mandelkow E M, Hyman B T (2002) Specific tau phosphorylation sites correlate with severity of neuronal cytopathology in Alzheimer's disease. Acta Neuropathol 103:26-35.
Ballatore C, Brunden K R, Piscitelli F, James M J, Crowe A, Yao Y, Hyde E, Trojanowski J Q, Lee V M, Smith A B, 3rd (2010) Discovery of brain-penetrant, orally bioavailable aminothienopyridazine inhibitors of tau aggregation. J Med Chem 53:3739-3747.
Cullen K M, Halliday G M, Cartwright H, Kril J J (1996) Improved selectivity and sensitivity in the visualization of neurofibrillary tangles, plaques and neuropil threads. Neurodegeneration 5:177-187.
Ikonomovic M D, Klunk W E, Abrahamson E E, Mathis C A, Price J C, Tsopelas N D, Lopresti B J, Ziolko S, Bi W, Paljug W R, Debnath M L, Hope C E, Isanski B A, Hamilton R L, DeKosky S T (2008) Post-mortem correlates of in vivo PiB-PET amyloid imaging in a typical case of Alzheimer's disease. Brain: a journal of neurology 131:1630-1645.
Jeganathan S, Hascher A, Chinnathambi S, Biernat J, Mandelkow E M, Mandelkow E (2008) Proline-directed pseudo-phosphorylation at AT8 and PHF1 epitopes induces a compaction of the paperclip folding of Tau and generates a pathological (MC-1) conformation. J Biol Chem 283:32066-32076.
Rosenwald A, Reusche E, Ogomori K, Teichert H M (1993) Comparison of silver stainings and immunohistology for the detection of neurofibrillary tangles and extracellular cerebral amyloid in paraffin sections. Acta Neuropathol 86:182-186.
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Uchihara T (2007) Silver diagnosis in neuropathology: principles, practice and revised interpretation. Acta Neuropathol 113:483-499.
Uchihara T, Nakamura A, Yamazaki M, Mori O (2001) Evolution from pretangle neurons to neurofibrillary tangles monitored by thiazin red combined with Gallyas method and double immunofluorescence. Acta Neuropathol 101:535-539.
[0369] All patents, journal articles, publications and other documents discussed and/or cited above are hereby incorporated by reference. | Pyridazinone compounds of Formula I: (I) wherein: R′ is alkyl or Ar, optionally substituted with at least one alkyl, halogen, hydroxyl, alkoxy, haloalkoxy, acid, ester, amino, nitro, amide, or alkoxyhalo; 2 R is independently alkyi, alkynyl, ester, amino, amide, acid, aryl, heteroaryl, aminoalkyl, —C(=0)alkyl, —C(=0)aryl, —C(=0)heteroaryl, —C(=0)heterocycloalkyl, —C(=0)heterocycloalkylAr, —C(=0)(CH 2 ) n halo, —C(═O)(CH 2 )nheterocyclyl, or —SĈAr, optionally substituted with at least one alkyi, alkylhalo, halogen, nitro, aryl, heteroaryl, or heteroaryl(CH 2 )nhalo; R 3 and R 4 are independently hydrogen, alkyi, alkenyl, alkynyl, aryl, heteroaryl; Ar is an aryl, heteroaryl, cycloalkyl, heterocycloalkyl group; n is an integer from 0-10; or a radiolabeled derivative thereof. The compounds are useful as imaging probes of Tau pathology in Alzheimer's disease are described. Compositions and methods of making such compounds are also described. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to an arrangement for bundling newspaper and, more particularly, to such an arrangement which both stores and bundles newspapers and in addition can be made aesthetically pleasing in appearance.
In recent years, environmental concerns have resulted in an increased awareness of the need to recycle certain materials in order to save dwindling natural resources. One such material is paper, typically in the form of newspaper. In fact, many municipalities have recently instituted mandatory recycling programs which require that residents save and bundle their newspapers, which are then taken to a recycling center for processing.
Typically, municipalities require that the residents bundle their newspapers in stacks of height from 6" to 9", which bundles are then secured by twine, paper tape, or the like. In order to comply with these requirements, many homeowners merely place their newspapers in a pile until the pile reaches the desired stack height. The pile of newspapers is then secured. For many people, such as the aged and physically handicapped, this is a difficult task, since a 9" stack of newspaper weighs a considerable amount and it is difficult to manipulate so as to put the twine or paper tape beneath the bundle during the securing process. Accordingly, it is a primary object of the present invention to provide an arrangement which assists in the bundling of newspapers.
As was previously mentioned, prior to securing the newspapers in a bundle, they must be somehow stored. It is therefore another object of this invention to provide a newspaper bundling arrangement that provides storage for the newspapers prior to bundling.
A supply of previously read newspapers can be rather unsightly. It is therefore a further object of this invention to provide a newspaper bundling and storage arrangement so designed as to provide an aesthetically pleasing appearance.
SUMMARY OF THE INVENTION
The foregoing and additional objects are attained in accordance with the principles of this invention by providing apparatus for bundling newspapers and the like which comprises a base and a pair of upstanding side members. A support is mounted for rotation on each of the side members in a cantilevered manner. The supports extend toward each other with their axes of rotation being co-linear, there being a space between the supports, which space is bridged by a newspaper supported by the supports. When the desired amount of newspaper is held by the supports, the bundling material (i.e., twine or paper tape or the like) is secured to the newspaper and the supports are rotated about their co-linear axes, with the bundling material passing between the supports in the space which separates them, the bundling material thereby encircling the stack of newspapers.
In accordance with an aspect of this invention, there is further provided means for securing the newspapers to the supports so that the supports along with the newspapers supported thereby may be rotated as a unit without the newspapers falling therefrom.
In accordance with a further aspect of this invention, there is further provided an arrangement whereby the supports are releasable secured against rotation.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings in which like elements in different figures thereof have the same reference numeral and wherein:
FIG. 1 is a perspective view of a first embodiment of a newspaper storage and bundling arrangement, combined with a magazine rack, according to the present invention;
FIG. 2 is a top plan view of the arrangement shown in FIG. 1;
FIG. 3 is an exploded perspective view of the arrangement shown in FIG. 1 illustrating the rotational mounting of the supports on the side members;
FIG. 4 is an perspective view of the arrangement shown in FIG. 1 with a supply of bundling tape partially extracted from a storage compartment;
FIG. 5 is a perspective view of the arrangement shown in FIG. 1 wherein newspapers are supported by the supports and secured thereto, a supply of bundling tape is supported on the base, and tape is partially pulled out from the supply;
FIG. 6 is a perspective view like FIG. 5 showing partial rotation of the supports with tape from the supply secured to the newspapers;
FIG. 7 is a perspective view like FIG. 6 after sufficient rotation of the supports that the bundling tape completely encircles the newspaper; and
FIG. 8 is a perspective view of a second embodiment of an arrangement constructed in accordance with the principles of this invention.
DETAILED DESCRIPTION
Referring now to the drawings, FIGS. 1-7 illustrate a first embodiment of apparatus constructed in accordance with the principles of this invention. As shown therein, such apparatus, designated generally by the reference numeral 10, includes a base 12 and a pair of side members 14 and 16 which are supported on the base 12. The side members 14 and 16 extend upwardly from the base 12 on opposite ends thereof. On each of the side members 14, 16 there is mounted for rotation in a cantilevered manner a respective support member 18, 20. As illustrated herein, each of the support members 18, 20 includes a respective planar wall 22, 24 and newspaper containment structure 26, 28 on one side of each of the respective walls 22, 24.
The support members 18, 20 are mounted for rotation on their respective side members 14, 16 and extend toward each other, leaving a space 30 separating them. The axes of rotation of the support members 18, 20 are co-linear and, as illustrated in FIG. 3, the rotational mounting structure may include axles 32, 34 supported on the side members 14, 16 and extending parallel to the walls 22, 24 which are mounted thereon by structure not shown.
As shown in FIGS. 1-7, the newspaper containment structure 26, 28 illustratively takes the form of a three sided rack open toward the top and the space 30 so that newspaper 36 supported thereby spans the space 30. Illustratively, according to the first embodiment, on the other side of each of the planar walls 22, 24 there is provided a four sided magazine rack 38, 40. When the support members 18 and 20 are holding newspapers and magazines, it is desirable to secure the support members against undesirable rotation to prevent the newspapers and magazines from falling out. Accordingly, there may be provided between the support members 18, 20 and their respective walls 14, 16 detent means 42, 44 which may take the form of a spring loaded ball and socket arrangement.
In use, when newspapers are ready for recycling, they are placed in the newspaper containment structure 26, 28, bridging the space 30, as shown in FIG. 5. At the same time, magazines may be stored in the magazine racks 38 and 40. Since magazines are typically more pleasant in appearance than used newspapers, the storage and bundling unit 10 may be so placed in a person's home that the newspaper storage side is against the wall and the magazine storage side is outwardly disposed so as to be visible, thereby presenting a more aesthetically pleasing appearance.
When a sufficient amount of newspaper 36 fills the newspaper containment structure 26, 28, the unit 10 is used for bundling the newspaper so that it may be more easily handled for transport to a recycling center. A preferred material for securing a stack of newspaper into a bundle is paper tape, since this material need not be separated from the newspaper in the recycling process. Accordingly, as shown in FIG. 4, the unit 10 is provided with a storage compartment 46 behind the wall 22 for storing a supply 48 of paper tape. The tape supply 48 preferably comprises a standard roll of masking tape which is mounted for rotation on a plate member 50 which in turn is mounted on a base member 52 which forms a part of the cover of the storage compartment 46. The other part of the storage compartment cover is a member 54 hingedly mounted on the open side of the storage compartment 46. The base member 52 is provided with an extension 56 and the cover member 54 is provided with a recess 58 complemental to the extension 56. Thus, the extension 56 may be placed in the recess 58 and the base and cover members 52, 54 may together close off the storage compartment 46 with the supply of tape 48 contained therein. The base 12 of the unit 10 is provided with a recess 60 along an edge and aligned with the space 30. The recess 60 is also complemental to the extension 56 so that the extension 56 may be inserted therein to support the supply of tape 48 on the base 12 in line with the space 30, as shown in FIG. 5.
In accordance with this invention, there is also provided means for securing the newspaper 36 to the newspaper containment structure 26, 28 so that it is retained therein when the support members 18, 20 are rotated to effect the bundling operation. Since the embodiment shown in FIGS. 1-7 also includes magazine racks 38, 40, the magazines must also be secured within their racks. Toward this end, there is provided a pair of elastic cords 62, 64 secured at one end to the newspaper containment structures 26, 28, respectively. The other end of each of the elastic cords 62, 64 is terminated by a hook member 66, 68, respectively. Thus, as shown in FIGS. 5-7, when the newspaper 36 is ready for bundling, the elastic cords 62, 64 are extended over the newspaper 36 held within the newspaper containment structure 26, 28 and also over the magazines held in the magazine racks 38, 40. The hook members 66, 68 are then hooked over a rail of a respective magazine rack. Thus, the support members 18, 20 may be rotated as a unit with the newspapers and magazines supported thereby being secured against falling therefrom.
Accordingly, after a sufficient supply of newspaper 36 is contained within the newspaper containment structure 26, 28 the supply of tape 48 is removed from the storage compartment 46 and mounted on the base 12, as shown in FIG. 5. The elastic cords 62, 64 are then utilized to secure the newspapers to the containment structure 26, 28. Tape is pulled from the supply 48 and adhered to the newspaper 36. This adherence is within the space 30. Next, the support members 18, 20 along with the newspaper 36 are rotated as a unit so that the tape 48 encircles the newspaper 36 within the space 30 without interference from any of the structure of the unit 10, as shown in FIGS. 6 and 7. By the time the support members 18, 20 are returned to their original orientation, the tape 48 has completely encircled the newspaper 36, providing a secured bundle suitable for transport. The elastic cords 62, 64 are then released and the bundle of newspaper may be removed. The supply of tape 48 may then be returned to the storage compartment 46 and storage of newspaper may be resumed.
FIGS. 1-7 illustrate an embodiment of the invention suitable for use in a residence. FIG. 8 illustrates an embodiment of this invention which is suitable for use in an office environment to hold trade papers, computer paper, and the like, for recycling. As shown in FIG. 8, the inventive arrangement includes a base 70 and side members 72, 74. Paper support trays 78, 80 are mounted in a cantilevered manner for rotation on the side members 72, 74, respectively, about a common axis 82. The trays 78, 80 are separated by a space 84, below which a supply of tape 86 is mounted on the base 70. The trays 78, 80 are releaseably secured against rotation by means not shown, and there is also provided, although not shown, some means for securing paper contained within the trays 78, 80 from falling from the trays when the trays together with the paper are rotated. Operation of the embodiment shown in FIG. 8 is similar to that for the embodiment shown in FIGS. 1-7 and no further description thereof need be given.
Although the described embodiments have been shown with supplies of paper tape, other bundling material may be provided such as, for example, twine.
Accordingly, there have been disclosed arrangements for storing and bundling recyclable material. While several illustrative embodiments have been disclosed, it will be apparent to one of ordinary skill in the art that various modifications and adaptations to the disclosed embodiments can be made without departing from the spirit and scope of this invention, which is only intended to be limited by the appended claims. | Apparatus for storing and bundling recyclable material includes rotatable containment members separated by a space, which support the recyclable material spanning the space. Rotation of the containment members allows bundling material lined up with the space to completely encircle the recyclable material without interference from the structure of the storage and bundling apparatus. | 1 |
FIELD OF THE INVENTION
The present invention relates to a non-invasive technique designed to help an individual lose weight by burning calories from fatty deposits in the body without strenuous exercise. More particularly, the invention relates to a non-invasive thermal-wrap therapy for inducing calorie burning and weight loss. The thermal-wrap therapy helps burn over 5,000 calories per week without strenuous exercise, is effective without radical dieting, pills or medication, is non-invasive and safe, and achieves the desired results after just one week of treatment with bi-weekly sessions.
BACKGROUND OF THE INVENTION
Cellulite has been defined as “deposits of subcutaneous fat within fibrous connective tissue (as in the thighs, hips and buttocks) that give a puckered and dimpled appearance to the skin surface.” The origin of the term is French, where it literally means accumulation of subcutaneous fat, cellulitis, from cellule (cell) and ite (itis). The medical definition of cellulite is “deposits of subcutaneous fat within fibrous connective tissue (as in the thighs, hips and buttocks) that give a puckered and dimpled appearance to the skin surface.” Cellulite is known as localized lipodystrophy, meaning misshapen fat in one or several specific areas of the body.
“Cellulite” is not a medical term. In the past, cellulite has been widely interpreted as a fat disorder. However, medical research has discovered that it is, in fact, primarily a disease of the circulatory system that deforms the connective tissue. Though infrequently found in males, it is found in some 95% of women today. It is seen more commonly in males with androgen-deficient states such as Klinefelter's syndrome, hypogonadism, post-castration states and in those patients receiving estrogen therapy for prostate cancer.
Medical authorities agree that cellulite is simply ordinary fatty tissue. In testing, cellulite has been found to be indistinguishable from ordinary fat. Strands of fibrous tissue connect the skin to deeper tissue layers and also separate compartments that contain fat cells. When fat cells increase in size, these compartments bulge and produce a waffled appearance of the skin.
Cellulite follows a predictable path of development. It typically starts with a few broken veins or tiny areas of discoloration and a tendency to bruise easily. This early stage may be missed, but it soon develops into the distinctive “orange peel” appearance as the tissue under the skin becomes swollen and distended. If left unchecked, this frequently develops into the “mattress skin” stage in which the skin feels cool. After this, the tissues deteriorate further into islands of concentrated blood flow that feel hot and are surrounded by cold cellulite tissue. The lack of circulation in the damaged cellulite tissues finally results in more fat along with fluid retention to produce a honeycomb structure of swollen lumpy tissue, known as steatomes, that disfigures the body profile.
Cellulite is caused by damage to the delicate capillary or drainage system in the fat layer under the skin. It begins when the circulation in the capillaries, veins or lymphatic drainage vessels under the skin slows down. This leads to sluggish or even static regions of blood or lymph flow, which allow highly reactive chemicals, known as free radicals, to attack the walls of the capillaries, veins or lymph vessels as well as the surrounding tissues. Once damage has occurred in one of the circulatory systems in this fatty layer, it spreads to the others, leading to accumulation of lymph in the tissues.
As the circulation slows and lymph accumulates in the fatty tissue under the skin, more and more protein fibers are formed. Normally, cells known as fibroblasts would dissolve these abnormal protein fibers, but as the circulation and drainage deteriorate, these fibroblasts become defective because they are starved of oxygen and nutrients. Instead of removing the protein fibers and maintaining a network of fine, elastic, supporting fibers, they build thicker, less flexible webs of fiber around groups of fat cells. These fibers give rise to a lumpy appearance on the skin that is the beginning of the cellulite cycle.
Fat cells have fat-storing and fat-releasing receptor sites. Different parts of the body have fat cells with more fat storing sites or more fat-releasing sites. This is why many women tend to store fat on certain parts of the body and lose it on other parts, frequently giving rise to the familiar “pear shaped” body or “Gynoid” conformation.
Cellulite areas usually have fat cells with more fat-storing sites. This means that any fatty substances in the lymph surrounding the damaged tissues are quickly taken up by the fat cells and stored. During exercise, the body demands energy from the fat cells to release fat into the blood for consumption by the muscles. The damaged cellulite tissues, however, are not able to respond due to the damaged circulation. As a result, fat from other areas is used and the cellulite areas continue to build up fatty deposits.
Research has identified two types of cellulite. The first type of cellulite is from any “pinch” or “compression” of tissue in the thighs or buttocks. This type of cellulite is gender-typical to almost all women of various ages.
The second type of cellulite is the “mattress” or “orange peel” appearance that a woman may have in her natural stance or when lying down. An example of this type is the “mattress” look in thighs when crossing legs while seated. The combination of thick, rigid fibers and increasing fat along with distended tissues caused by fluid retention gives rise to the “orange peel” appearance of the skin that is associated with the first stages of cellulite. Without appropriate and preventative treatments, the cycle of damages accelerates causing patches of isolated fatty tissue that feel cold, separated by “hot” zones where blood circulation is concentrated. This is known as the “mattress skin” stage, which progresses to the formation of steatomes.
It was thought previously that cellulite was related to obesity, yet it is found on skinny women and men.
A. Genetic
It is well known that women possessing the Mediterranean conformation, or “Gynoid” conformation (“pear shaped” body), or both, have localized cellulite and fat on their hips and thighs.
B. Damaged Circulation
There are many ways that the very delicate microcirculation and lymph drainage vessels under the skin can be damaged. It is certain that free radicals play a role in this damage and it is likely that physical damage or restriction is also involved in starting the cycle of deterioration that results in cellulite. Examples of this physical damage or restriction are: sitting for long periods, wearing tights, over exertion while training, etc.
If either the incoming fresh blood, or the outgoing “used” blood is restricted, free radicals start to build up and oxygen becomes scarce. This causes more damage to the circulation as well as impairing the function of the cells, known as fibroblasts, that manage the structure of the connective tissue.
When fibroblasts malfunction, they cause two problems: (1) they weaken the fibers that hold the fat cells in place; and (2) they coat clumps of fat cells with impenetrable protein layers that prevent the circulation from reaching these areas.
C. Free Radicals
Free radicals are highly reactive chemicals that are found everywhere in the environment and in our bodies. They react with almost everything they come in contact with and are very damaging. Besides cellulite, they are responsible for aging and cause many of the worst diseases we suffer from, including cancer, heart disease, and Alzheimer's disease. Free radicals are the main agents of damage to our circulatory system that results in cellulite.
We are constantly taking in free radicals from the environment as well as creating them within every cell in our body. Free radicals are leftover pieces of molecules which include oxygen but are lacking one or more electrons. Our immune system may use them to destroy unwanted elements such as bacteria, viruses, and cancer cells. Unfortunately, the destruction of these invaders includes considerable collateral damage, as the free radicals are not specific and react with anything that can supply the electrons they need.
Whether we create the free radicals or absorb them from our food or environment, the results are the same: cell walls are weakened and the genetic DNA molecules become damaged. Over time, this may lead to slow circulation, a factor in the production of cellulite, heart attacks, strokes, Alzheimer's, cancer, etc.
Our bodies protect themselves from the continuous onslaught of free radicals with agents known as antioxidants; these include vitamins, enzymes and many herbal extracts. They are abundantly available in fresh herbs, fruit, and vegetables, particularly immediately after they have been harvested and when they have been organically grown. Vitamins C and E, as well as beta-carotene (the building block for vitamin A), have been found to be particularly effective. Even more powerful are certain herbal extracts that act as antioxidants.
D. Over Exertion
Over exertion causes a build-up of free radicals in the tissues. Tissues under the skin are vulnerable to damage, particularly in women, so any accumulation of excess free radicals in this area may cause damage to the microcirculation and vessels. The body can manage free radicals caused during short bursts or over exertion, such as those expended in team or competitive sports and weight or resistance training. If over exertion is sustained, however, as in long distance running and competitive athletics, damage from free radicals may begin to accumulate.
E. Digestion and Bad Diet
When partially chewed food reaches the large intestines, where digestion occurs through the action of friendly bacteria, clumps of unprocessed food attract unfriendly bacteria and provide a rich medium for them to multiply. This results in the production of poorly digested food molecules that not only damage the intestine, but also are absorbed into the body. These toxic residues are delivered to the liver where they are broken down into harmless molecules and removed from the body via the gall bladder or kidneys. Our livers, can, however, only deal with a limited amount of these toxins, and any excess is sent to the fat cells where they are held so as to protect the body from damage. These toxins cause fluid and fat retention in the cells, which then swell up and reduce blood circulation and block the lymph from draining properly. Reduced lymph drainage and poor blood circulation causes fat accumulation, stretching of the connective fibers under the skin and the bulging pattern of the skin characteristic of cellulite.
As the circulation in the skin deteriorates with the early onset of cellulite, these toxic residues become isolated and are implicated in the development of cellulite as the familiar “orange peel” and “mattress skin” takes shape.
F. Hormonal Imbalances
The female hormone Estrogen is responsible for shortening the fibrous tissue that closes the womb just before delivering a baby. An excess of Estrogen or contraceptive pills are believed to cause weakening of the connective tissue which allows fat to bulge up into the skin. Excess Estrogen is thought to be one of the main causes of cellulite.
G. Chemicals and Artificial Products
Drugs, artificial hormones and artificial products can cause cellulite, as the body does not have the capability of naturally eliminating such chemicals. One of the only means of eliminating chemicals from the body is to store them in fat tissue. It is well known that the chemical compound, DDT, used many years ago to destroy mosquitoes and other insects remains to this day deposited in the fat cells of people who were exposed to it.
Efforts have been employed to reduce cellulite. Liposuction is not very successful in treating cellulite and may actually worsen the dimpled skin appearance. Biochemicals such as aminophylline, caffeine and theophyilline, members of a group known as methylxanthines, are present in many cellulite creams. These agents can enhance the body's ability to break down stored fat, a process known as lipolysis. When applied topically to the skin, however, the cellulite cream must be able to penetrate the skin and dermis and reach the target fat tissue before being absorbed by the tissue. Yet, to be effective, these creams would have to have a sufficient concentration in the subcutaneous fat layer for an ample length of time, which partially explains their lack of consequential cellulite removal. While studies have shown a small reduction in thigh girth when using such creams, there has not been a substantial reduction in the presence of cellulite.
It has been claimed that the only effective way to reduce cellulite is the same one which reduces ordinary fat, that is, exercise. The inventor is not aware, however, of any proven method, system or study that has proven the efficacy of strenuous exercise in reducing cellulite, local or generalized fat, but are aware that there is research showing that strenuous exercise can be useless and can, in fact, exacerbate the presence and appearance of cellulite. In addition, strenuous exercise can pose a danger for women after the menopausal stage and men after age 55, particularly causing back, joint and muscle problems. In any event, the available data and/or statistics support the position that more than 75% of the population of the Western hemisphere does not engage in regular exercise.
The method of the invention provides a means of losing weight, reducing inches and the burning of more than 5,000 calories in one week with bi-weekly sessions without strenuous exercise using thermal wrap therapy. This therapy uses a conductive heating system encased in a specifically designed fabric. This system works as a localized “mini sauna” to enhance sweating and detoxification. The thermal-wraps can either be applied locally to thighs, hips and abdomen or over the entire body for more generalized results. Its effectiveness is increased by instituting a Mediterranean alkalinizing eating plan that is customized to each individual's needs. The weight loss of this technique consists of over 78% from fatty deposits while increasing the body's water content. What this means is that not only is the percentage of fat that is burned maximized, but the loss of lean muscle and water is minimized. In addition to the significant weight loss, it was also observed that this integrative approach has other benefits including detoxification, relaxation to diminish stress, and anti-aging and alkalinizing benefits.
More particularly, the method and technique of the invention provides a means of losing weight, reducing inches and the burning of more than 5,000 calories in one week with bi-weekly sessions utilizing the invention without strenuous exercise using thermal wrap therapy. The inventor has been able to demonstrate using the disclosed technique that the weight loss observed consists of over 78% from fatty tissue while increasing the body water content.
Adipose tissue, also known as local fat, is primarily located beneath the skin, but is also found around internal organs. The fat layer of skin is located in the subcutaneous layer of tissue called the hypodermis. In the skin, it accumulates in the deepest level, the subcutaneous layer, providing insulation from heat and cold. Around organs, it provides protective padding. It also functions as a reserve of nutrients.
In overweight and obese persons, excess adipose tissue hanging downward from the abdomen is referred to as a panniculus (or pannus). A panniculus complicates surgery of the morbidly obese, and may remain as a literal “apron of skin” if a severely obese person quickly loses large amounts of weight.
There are two types of adipose tissue: white adipose tissue and brown adipose tissue. White adipose tissue, also known as white fat, constitutes as much as 20% of body weight in men and 25% of body weight in women. Brown adipose tissue, also known as brown fat, is present in many newborns.
Generally speaking, when a person introduces the right amount of caloric intake into the daily diet, in other words, eats with moderation and exercises regularly, that person has a greater chance of keeping weight under control. The problem is that, as set forth above, many people do not exercise regularly and tend to eat too much. Moreover, certain foods are lacking in nutrients and water. Other causes of overweight or obesity today are: genetic, metabolic, psychological, socio-cultural, lifestyle, hormone dysfunction, over eating, and high caloric intake. The inventor has been able to demonstrate that, with just two 50-minute thermal wrap sessions in accordance with the invention per week, the subject would burn over five times the calories as jogging on a treadmill, as demonstrated by FIG. 8 .
In the clinical setting, overweight and obesity are typically evaluated by measuring BMI (body mass index) and waist circumference. The BMI, developed by the Belgian Adolphe Quetelet, is calculated by dividing the subject's weight in kilograms by the square of his/her height in meters (BMI=kg/m 2 ). The current definitions commonly in use establish the following values:
Group A—a BMI of 18.5-24.9 is normal weight;
Group B—a BMI of 25.0-29.9 is overweight;
Group C—a BMI of 30.0-39.9 is obese; and
Group D—a BMI of 40.0 or higher is severely (or morbidly) obese.
Due to the size restrictions of the body wraps, more fully discussed below, Groups A and B are the preferable subjects for the treatment outlined in the invention.
The eating plan preferably combined with the thermal wrap technology is a versatile, comprehensive program, modeled on the Mediterranean diet, for altering an individual's eating patterns in order to both meet nutrient requirements and help control weight in a healthy, satisfying manner. The plan allows the individual to tailor food choices to personal preferences. Designed to conform to the U.S. Dietary Guidelines, it emphasizes choosing fiber-rich fruits, vegetables, and whole-grain products, but does not exclude nutrient-rich choices from the dairy and protein food groups, thus ensuring a wide variety of nutrient sources.
With just two 50-minute thermal-wrap sessions per week, over five times the amount of calories are burned then would be burned while jogging on a treadmill. Table I set forth above sets forth the comparison in calories burned.
SUMMARY OF THE INVENTION
In accordance with the invention, a method is provided for treating cellulite and reducing the volume of fat cells localized in the subcutaneous areas by the use of heat applied to the affected areas. The application of heat results in a restoration and improvement of the lymphatic and blood circulation to the tissues. The fat deposits lying under the epidermal cells are stimulated by the heat applications. Heat applied to the human body has the effect of drawing fresh blood with nutrients and oxygen closer to the surface of the skin. In so doing, the fat deposits are drawn out of the tissues, thereby neutralizing the build-up of damaging positive ions and creating an environment that allows the blood supply to be rebuilt by the body. The method for reducing cellulite, local or generalized fat in accordance with the invention utilizes variable temperatures and comprises the following steps in the sequence which follows:
(a) applying a heat source, having a temperature, i.e., the heat source (thermal wrap) has been preheated to a temperature within the temperature range of about 104° F. to about 108° F. (first temperature), to the area on the body of a person affected with cellulite or local fat; (b) increasing the temperature of said heat source over approximately the next twelve to fifteen minutes to a second temperature in the range of about 122° F. to about 128° F., and preferably about 124° F. to about 126° F.; (c) decreasing the temperature of said heat source over approximately the next one and one-half minutes to a third temperature differing from said second temperature by having a lower value than said second temperature and being in the range of about 112° F. to about 120° F., and preferably about 110° F. to about 114° F.; (d) increasing the temperature of said heat source over approximately the next three and one-half minutes to a temperature differing from said third temperature by having a value higher than said third temperature and being in the range of about 122° F. to about 128° F., and preferably about 124° F. to about 126° F., and most preferably increasing the temperature to a value substantially equivalent to the second temperature (step (b), above); and (e) repeating a cycle of the steps (c) and (d) nine or ten times until a period of about 45 minutes to about 60 minutes has elapsed from the time that said heat source was applied to said affected area.
Most, preferably, the method for reducing cellulite, local or generalized fat in accordance with the invention comprises the following steps in the sequence which follows:
(f) applying a heat source, having a temperature, i.e., the heat source (thermal wrap) has been preheated to a temperature within the temperature range of about 104° F. to about 114° F., and preferably about 106° F. to about 108° F. (first temperature), to the area on the body of a person affected with cellulite or local fat; (g) increasing the temperature of said heat source over approximately the next ten to fifteen minutes to a second temperature in the range of about 123° F. to about 127° F.; (h) decreasing the temperature of said heat source over approximately the next one and one-half minutes to ten minutes to a third temperature differing from said second temperature and being in the range of about 113° F. to about 119° F., and preferably about 110° F. to about 114° F.; (i) increasing the temperature of said heat source over approximately the next three and one-half minutes to a temperature differing from said third temperature and being in the range of about 123° F. to about 127° F., and preferably about 124° F. to about 126° F.; and (j) repeating a cycle of the steps (c) and (d) nine or ten times until a period of about 50 minutes to about 55 minutes has elapsed from the time that said heat source was applied to said affected area.
The method, in accordance with another preferred embodiment of the invention, may include showering at a certain temperature or range of temperatures for specified time periods following the heat applications. Also, the method may preferably include the adherence to an eating plan.
The actual wrap employed (Thermal-Wrap 5000™, Vivinlinea Corporation, Great Neck, N.Y.) has been shown to be safe with no adverse effects (Lovisolo, G. A., Marino C., c/o ENEA Labs, Casaccia Research Center, report available upon request). Its design uses a conductive heating system with resistive elements causing the heat to gently penetrate deeper into the skin in a safe and controlled manner.
During use, the researchers observed an increase of 7° F. or more on the superficial layer of the skin and up to 10 mm of depth. Core temperatures increased 0.6° F., typical of that observed during sporting activity.
The apparatus of the invention can be characterized as a conductive heating system utilizing variable temperatures and comprises 2 parts: (1) a controller or control board to be operated by a trained individual; and (2) 3 heating structures, called “thermal wraps,” that induce modulated and gentle heat in cutaneous and subcutaneous areas. The heating structure may comprise 3 separate wraps or be consolidated into a single body wrap. The maximum extremely low-frequency electric field (ELF) was 11 μT.
Each thermal wrap contains a series of insulated electrical resistances that the controller to provide a 50 to 60 Hz current at 24V and a power of 600 W at maximum.
The conductive heating system and method for reducing cellulite of the invention utilizing variable temperatures also provides for an apparatus for reducing cellulite, local or generalized fat, comprising (a) a heat source and (b) an electrical energy supplying device for regulating an electrical current to produce a first temperature of the heat source of about 104° F. to about 114° F., and preferably about 104° F. to about 108° F., the aforesaid electrical energy supplying device is connected to said heat source and provides a first temperature rise from said first temperature to a second temperature of about 123° F. to about 127° F., and preferably about 124° F. to about 126° F., during a first period of about 10 to 15 minutes, and thereafter in a second period of about three and one-half minutes increases the temperature of said heat source by providing a third temperature of about 122° F. to about 128° F., preferably about 124° F. to about 126° F., said second and third temperatures differing one from the other and said third temperature being lower than said second temperature, increasing to a temperature differing from said third temperature and being in the range of about 124° F. to about 126° F., and cycling between said second and third temperatures repetitively nine to ten times, preferably seven to eight times, wherein each repetition involving said second and third temperature takes place during a period of about five minutes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplar series of wraps 10 , wherein a left wrap, a right wrap and a top wrap are employed as three individual wraps.
FIG. 2A is a plan view showing interior features of an exemplar body wrap in accordance with the invention.
FIG. 2B is a cross-section of the body wrap of FIG. 2A .
FIG. 3 is an illustration of how the control panel and wraps are connected.
FIG. 4 is a cross-section of the electrical protection wire.
FIG. 5 is a plan view showing interior features of the exemplar body wrap in accordance with the invention.
FIG. 6 is a chart that graphically depicts the variable temperature of the wraps during the heat treatment process, the normal skin temperature, and the average skin temperature during the treatment process.
FIG. 7 illustrates two examples of eating plans that are preferably prescribed in accordance with the invention.
FIG. 8 illustrates a comparison between calories burnt by the thermal therapy of the present invention and jogging.
DETAILED DESCRIPTION OF THE INVENTION
At the first session with the subject whose body evidences cellulite, localized or generalized fat, the subject's height and weight measurements are taken, as well as measurements of the subject's waist, hips, right thigh and right knee. Such measurements, for best results, are taken at the beginning of the first session and again every subsequent six sessions. The subject's weight is recorded in the subject's chart at each session and will show the effects as to the extent to which the subject has or has not followed the prescribed eating plan outlined below.
Also at the first session, a Body Composition Test is performed by use of a BIA 450 Bioimpedance analyzer on the wrist and ankle of the subject. Resistance and reactance, the two components of impedance, are measured directly from the body. Using regression analysis, the analyzer assesses the lean body weight, fat mass (or fat body weight), body mass index (BMI), basal metabolic rate (BMR), total body water (TBW), and the ratios: TBW/body weight and TBW/fat-free mass.
In reporting the results of the Body Composition Test, recommendations are made as to the following suggested targets: body fat percentage, total weight, fat weight, lean weight, weight to lose, body water percentage and basal metabolic rate. The Body Composition Test is preferably repeated at the end of the program.
A heat source that can be placed on the subject (including, for example, a patch, cuff, bandage or preferably wrap and most preferably the thermal wrap) is used to apply heat to the affected areas (that is, those areas on the subject's body which exhibit the presence of cellulite, localized or generalized fat). While the wraps may be purchased commercially (at least two different types of wraps are commercially available: localized body wraps and generalized body wraps) and typically comprise a polyurethane layer, wraps specifically designed for use in accordance with the invention and providing a significant measure of safety are described below with reference to FIG. 2A to FIG. 6 .
Referring to FIG. 1 , a subject is placed in a series of body wraps ( 10 ). The exemplar body wraps have three localized body wraps as shown. A left wrap ( 2 ) is employed to cover at least the upper portion of the left leg of the subject, whereas a right wrap ( 4 ) is employed to cover at least the upper portion of the right leg of the subject and a top wrap ( 6 ) is employed to cover a substantial portion of the upper body of the subject. The three independent wraps can be used independently (not shown) or jointly (as shown in FIG. 1 ). The three wraps have their own respective temperature controls, allowing the user to customize the temperature or heating profiles. The wraps also have safety features detailed in FIGS. 2A to 6 . Preferably, the localized wraps are not placed around the subject so as to have overlapping regions, as it gives more comfort to the subject during the procedure. Further, the left and right wraps around the legs can either cover the entire the leg or only a (upper) portion of the legs. Preferably, the left and right wraps cover a significant portion of the upper portion of the legs, where most of the fat is likely to accumulate. More preferably, the left and right wraps leave the areas of the knees uncovered, so that the subject can bend or the move the knees if desired while being wrapped. Localized wraps 2 , 4 and 6 are exemplar localized body wraps, which are used for individuals exhibiting cellulite or local fat and are placed around parts of the body, such as thighs (wrap 2 and 4 ), or hips and the abdomen (wrap 6 ).
The sizes or dimensions of the localized wraps in FIG. 1 are only for illustration purpose. The localized body wraps are available in various sizes, for example for thighs, wraps between 32 inches to 42 inches by 12 inches to 20 inches are available, and for abdomens, wraps between 46 inches to 60 inches by 18 inches to 28 inches are available.
Typically, a localized body wrap measuring between 32 inches to 42 inches by 12 to 20 inches is placed on the thigh and a wrap measuring between 46 inches to 60 inches by 18 inches to 28 inches is placed on the abdomen and hips.
Optionally, generalized body wraps for use with subjects whose body shows generalized fat can be used for a large size individual and for individuals of average weights, and are placed substantially around the entire body in three sections, including top, the middle and the lower part of the body. The top section typically extends from the shoulders to the abdomen, the middle section extends from the abdomen to below the knees; and the lower section extends from below the knees to the toes. Each of three sections of a generalized body wrap typically measures 22 inches by 56 inches.
In accordance with the invention, both localized body wraps and generalized body wraps are connected to an electrical current source (not shown) using a device configured to regulate an electrical current sufficient to produce the temperature of the wraps, as described below. The device preferably includes a selector for selectively configuring the device to supply current to either a first heat source comprising a localized body wrap or a second heat source comprising a generalized body wrap. Preferably, the localized wraps have independent variable temperature controls, which allow the user to regulate the temperatures independent of other wraps.
The wrap contains electrical circuits with low voltage (24 volts) throughout. They may be secured to the subject's body by Velcro connections. An example of a commercially manufactured wrap is set forth in United States Patent Application Publication No. US 2004/0073258 published on Apr. 15, 2004, the disclosure of which is incorporated by reference herein in its entirety.
Referring to FIG. 2A , a body wrap 30 , in accordance with the invention, may be of generally rectangular shape having a length L of approximately 59 inches and a width W of approximately 20 inches. A thermostat (not shown), having a set temperature at a maximum of 85° C. provides maximum temperature protection. The provided sensor and thermostat provide for the required temperature control. The regulation of the temperature of wrap 30 is as more fully described below.
Referring to FIG. 2B , the layers of wrap 10 are shown in cross-section, a top layer 24 may be formed of polyurethane fabric. An expanded fabric 26 , as for example formed of polyester, may be bonded to layer 24 . A layer 28 made of a blend of polyester yarn and fibers is disposed below layer 26 . An additional expanded fabric layer 32 , formed of polyester, is sandwiched between layer 28 and a further woven or non-woven layer 34 . Layers 28 , 32 , and 34 form a quilted insert between the combination of layers 24 and 26 on one side, and a bottom layer 36 on the other side, formed of a polyurethane fabric. The various layers described above are bonded together, especially at the periphery of the wrap 10 , by any of several well known techniques, such as by the use of adhesives, which may be activated under heating under pressure and by sewing the previously arranged plies.
Cable 82 in FIG. 2A can further connect to a control panel as shown in FIG. 3 . The control panel includes at least a temperature sensor wire connected to power an analog circuit. The analog circuit is further connected to a micro controller. The temperature sensor wire is one of the exemplar safety features of the present invention.
The temperature sensor wire for receiving and making electrical connections is shown in FIG. 3 .
In one embodiment of the present invention (see FIG. 4 ), the temperature sensitive wire includes at least the following: a resistive heating wire wound around an insulating polyester core of coaxially arranged wire. A coaxial insulator separates resistive heating wire from an electrical protection wire wound around the insulator. An outer insulator surrounds the wire and forms the outer covering of the cable. All of these components of the temperature sensitive wire are flexible to allow for easy routing of the wire through the wrap in any required arbitrary path. Insulators may be formed so as to be heat shrinkable, with heat being applied after winding of the wire on the core and the wire on the insulator, respectively.
The foregoing arrangement helps to further assure safety. The wire may be connected to a system ground in controller 50 (not shown). If there is a break in the heating wire and insulator, any risk of shock is avoided, because generally, there will be contact of the heating wire with the protection wire, thus establishing a short circuit. This contact is detected as a sudden change in resistance measured by power circuit (not shown), which may be configured to shut down power.
FIG. 5 illustrates a cross section view of another alternative embodiment of the safety features of the present invention. The safety features as shown include at least a temperature sensor layer and an insulation layer which are sandwiched in between two external insulation layers.
FIG. 2A and FIG. 5 illustrate, respectively, a wrap 20 suitable for use around the thigh ( FIG. 2A ) and a wrap 30 suitable for use around the lower and middle torso (abdominal section) of the body ( FIG. 5 ). Wrap 30 comprises an electrical connection 88 , electrical resistance 86 , supply wire 82 , thermostat 84 and connector 12 .
Although the general shapes and dimensions of wraps 20 and 30 in FIGS. 2A and 5 are different, the construction and principles of operation are essentially the same as described with respect to the embodiment of FIG. 2A to FIG. 5 . Wrap 20 has a V shape, but may have a dimension of L of approximately 32.7 inches and dimension L′ of approximately 16.5 inches. It may consume about 90 watts. Wrap 30 may have major dimensions of length L″ equal to 54.3 inches and an extended width W″ of 22.8 inches, and may also operate at a power of approximately 90 watts. A portion of wrap 30 may extend over the midriff section of a user, or slightly above ( FIG. 2A ).
The wraps, and in particular the wraps in accordance with the invention, are preheated during a “warm-up” phase to approximately 104° F. to 108° F., and preferably 106° F. to 108 F. After the wraps are pre-heated to the 104° to 108° F. range, the wraps are placed on the subject. Between the wraps and the subject's skin, there is placed a sheet of plastic, preferably made of low-density polyethylene, for hygienic purposes to prevent perspiration from the subject's body from coming into contact with the wraps. The thermal wrap temperature in accordance with the invention increased to a temperature associated with a fever and namely 98.6° F.
After placement of the pre-heated wraps on the subject, the treatment begins with the startup cycle for approximately the next twelve to fifteen minutes, but preferably ten to fifteen minutes, wherein the temperature of the wraps is increased to a temperature with the range of 122° F. to 134° F., and preferably within a range of 124° F. to 126° F.
At the end of the startup cycle, the first five-minute treatment cycle will commence. For approximately the next three and one half minutes, the temperature of the wraps is increased again to a value within the range of approximately 122° F. to 134° F., and preferably a temperature within the range of 124° F. to 126° F.
The treatment cycle by variable temperature that characterizes the invention has two phases:
(1) turning off the current in the wraps until the temperature of the wraps decreases to a temperature value of between 112° F. to 120° F., but generally only as low as 110° F. to 114° F. over the following approximately two-minute period, as influenced by the maximum temperature and by environmental considerations, the temperature being different and having a lower value than the value in step (2); and (2) increasing the temperature over an approximate three minute period to a value between 122° F. and 134° F.;
and is repeated until the ninth or tenth repetition of such treatment cycle.
At the end of the ninth or tenth repetition of such treatment cycle, approximately between 50 and 55 minutes will have elapsed from the time that the wraps were initially placed on the subject's body. At room temperature, the average temperature of the skin is typically at approximately 98° F. During the treatment cycle, the average skin temperature is approximately 110° F.
The steps outlined above are shown in FIG. 6 .
At the end of the ninth or tenth repetition of the treatment cycle, the wraps and the plastic are removed from the subject's body and the subject remains in a prostrate position for the next three to five minutes to reestablish his or her blood pressure, which typically is lowered during the treatment.
The heat source temperature cycles and specifically the conductive heating system by variable temperature of the invention produce the results as set forth in the following:
The application of the heat treatment outlined above increases the subject's circulation and induces the flow of blood to the surface of the skin. Blood that is transported to the surface of the skin is richer in oxygen and nutrients and gives the skin the appearance of normality, as opposed to the orange tinge that appears as a result of the presence of cellulite. Also, the presence of additional oxygen in the blood activates a pumping mechanism (the ATP pump) located on the membrane of the fat cell. Fat that is deposited into the cell is expelled from the cell, as a result of the pumping action of the ATP pump, into the lymphatic system and eventually to the liver.
Preferably, following the subject's five to ten minute resting period, the subject takes a shower in three phases: (1) the first phase, lasting approximately 1.5 minutes, with the water temperature at approximately 95° F.; (2) the second phase, lasting approximately 40 seconds, with the water temperature at approximately 75° F.; and (3) the third phase, lasting for approximately 30 seconds, with the shower just on the legs at a cold water temperature, preferably between 41° F. and 59° F.
The shower has multiple beneficial effects, including the slowing or stopping of perspiration by the subject, a toning of the body, reinforcement of the immune system, aid in circulation of the subject's blood and overall enhancement of the process of reducing cellulite.
Preferably, no more than one to three days should elapse between the end of this treatment and the next session with the subject, at which time, the steps outlined above are repeated. The treatments are continued, preferably with 24 hours to 72 hours between every two sessions, until such time as the subject has reached his or her targets set forth in the recommendations resulting from the Body Composition Test.
The treatment may also involve, before or following the removal of the wraps, but in any event before the shower, additional treatments such as manual or vibratory massage, lymphatic drainage, seaweed mud, fango- or thalassotherapy, ionophoresis, ultrasound, electrostimulation or hot spring water baths.
Preferably, the treatment outlined above is performed in conjunction with an appropriate eating plan. Such plan provides for the daily intake of between 1,300 and 2,000 calories, and the consumption of a minimum of 25 to 30 grams of fiber.
In this plan, the main courses, lunch and dinner, commence with two to three servings of raw mixed salad, rich in radishes (preferably organic), and dressed with one tablespoon of extra virgin olive oil and lemon.
The plan also provides that certain categories of food are preferably consumed together, in regulated portions, at any one meal. Thus, complex carbohydrates or starches (for example, bread, pasta, potatoes and other foods falling within this category) are preferably not consumed in a proportion greater than 20% by weight of either animal protein (for example, fish, poultry, meat, eggs and other foods falling within this category) or vegetable protein (for example, beans, chickpeas, lentils and other foods falling within this category) that is consumed during the same meal.
Thus, if 10 ounces of animal protein or vegetable protein are consumed during a meal, it is preferable that no more than two ounces of complex carbohydrates (and even more preferably no more than one ounce of the latter) be consumed during the same meal. Conversely, if 10 ounces of complex carbohydrates are consumed, then no more than two ounces of animal protein or vegetable protein (and more preferably no more than one ounce) should be consumed during the same meal. At least three quarters of a cup of steamed, cooked or baked vegetables is preferably consumed at any meal where animal protein or complex carbohydrates, or both, are consumed.
Optimally, the majority of the food consumed at breakfast or lunch is composed of complex carbohydrates or vegetable protein. Preferably, protein consumption at dinner should alternate, for example, vegetable protein should be consumed on Monday, Wednesday and Friday, and animal protein consumed on Tuesday, Thursday, Saturday and Sunday.
Foods within the fruit group are preferably consumed as snacks, without food from other groups, and are not consumed with vegetables or animal protein or complex carbohydrates.
As an example of eating plans, Plan One, set forth in FIG. 7 , is preferably followed during the work week. Plan One includes a hearty breakfast, a light lunch, dinner and two or three snacks according to the following regimen: Snack (60 to 80 calories in the fruit group); Breakfast (165 to 440 calories); Light Lunch (340 to 440 calories); Snack (80 calories in the fruit group); Dinner (780 to 1,470 calories); and Snack (10 to 80 calories in the fruit group). As noted, it is preferable that the daily caloric intake be a minimum of 1,300 calories and a maximum of 2,000 calories.
Plan Two, as set forth in FIG. 7 , is preferably followed during weekends and includes a light breakfast, lunch, dinner and three snacks according to the following regimen: Snack (60 to 80 calories in the fruit group); Light Breakfast (10 to 80 calories); Snack (80 calories in the fruit group); Lunch (690 to 1,040 calories); Dinner (725 to 1,470 calories); and Snack (10 to 80 calories in the fruit group). As with Plan One, it is preferable that the daily caloric intake be a minimum of 1,300 and a maximum of 2,000.
Plans One and Two are complemented with a selection by the subject of a “Cleansing Day” where the subject chooses one day a week to detoxify his or her body by having five or six fresh fruit snacks, two servings each, every two hours through the day and two (2) three-serving salads, one at lunch with one-third cup of almonds (6-8) and another at dinner with one-half medium avocado.
Preferably, the eating plan includes a prescription that at least 16 ounces of natural filtered water be consumed daily between main courses, preferably on an empty stomach.
The inventors are aware that adherence to the method and treatment outlined above can result in the burning of up to 2,500 calories from localized fat deposits at any given session of treatment.
The combination of the heat treatment outlined above and adherence to the eating plan produces a synergistic effect in reducing cellulite, local or generalized fat in a healthy, non-invasive manner in total relaxation.
It has been found to be important to have adequate skin care during a weight reduction program. A skin care product line such as that produced by Gruppo Biofarma Via Castelliere, of Italy, and imported into the United States by VIVNLINEA CORP. of Great Neck, N.Y., may be used. These products, suitable for home-use, have been developed for specific areas of the body, such as: waist, hips, abdomen, bust, shoulders, arms, legs, thighs and knees. They complement the treatment provided as disclosed herein. The principal benefits include hydrating, nourishing, softening and firming skin, as well as slowing or halting aging of the skin. The principal natural ingredients of these creams include sweet almond oil, wheat germ oil, focus, vesiculosus, kelpadelie, rhodysterol, codium tomentosum, alga rosa, corallinea officinalis, kaolin and horse chestnut, as well as extracts of: hops, horsetail, fenu-Greek, green coffee, guaraná, green tea and butcher broom. Also included may be a mix of essential oils such as origanum, rosemary, lemon, bergamot and ylang.
The skin care products may be used during or after a session, and may be used at home for long-term maintenance.
Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, the invention may be embodied in other forms or carried out in other ways without departing from the spirit and scope of the invention. Therefore, the claims that follow should not be limited to the preferred embodiments described herein. | A method for reducing cellulite, local or generalized fat comprising applying thermal body wraps, which are cycled in temperature, is provided. Based on a body composition test, suggested targets for body fat percentage, total weight, fat weight, lean weight, weight to lose, body water percentage and basal metabolic rate are calculated. The thermal body wraps are described and may comprise layers of synthetic material, such as polyurethane and polyester fabric. The body wraps may have a heating circuit including a coaxially arranged heating cable, and a control loop including a negative temperature coefficient thermistor. The heating cable may have a protection wire, coaxially surrounding and insulated from a heating wire, so that if a break in the heating wire is detected, current flow to the heating wire is suspended. A thermostat in the wrap provides additional safety. | 6 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates generally to a structure and process for a semiconductor device which provides improved ESD protection for internal active semiconductor devices and more particularly to a semiconductor SCR like device which when used with shallow trench isolation, provides improved parasitic bipolar characteristics resulting in improved ESD protection performance.
[0003] (2) Description of Prior Art
[0004] The discharge of electrostatic energy from the human body or other sources known as electrostatic discharge (ESD) into the input or output pads of integrated circuit semiconductor devices has shown to cause catastrophic failures in these same circuits. This is becoming more important as modern metal oxide semiconductor (MOS) circuit technology is scaled down in size and increased in device and circuit density. Prevention of damage from ESD events is provided by protection devices or circuits on the input or output pads of the active logic circuits which shunt the ESD energy to a second voltage source, typically ground, thereby bypassing the active circuits protecting them from damage. Various devices such as silicon controlled rectifiers (SCR) have been utilized to essentially shunt the high ESD energy and therefore the ESD stress away from the active circuits.
[0005] Isolation is required between these ESD protection devices and the active circuit devices as well as between the active devices themselves. Originally areas of local thick oxide, often called LOCOS or field oxide, have been used to provide this isolation. While having good isolation properties, this isolation method uses more surface area, or “real estate”, than an alternative isolation method using shallow, relatively narrow trenches filled with a dielectric, typically silicon oxide (SiO 2 ), called shallow trench isolation (STI).
[0006] While providing good isolation properties, the STI structure has limiting effects on the current triggering and capacity of the SCR ESD protection devices. During STI formation, the STI region is exposed to the etching process, leading to non-planer STI edges where the silicon region extends above the isolation edge. The non-planer STI edge is called “STI pull-down”. The impact of STI pull-down, and the interaction with the silicide process typically used in current contact technology, as well as junction depth reduction of the diode elements bounded by the STI devices, all degrade ESD protection capabilities by reducing the parasitic bipolar current gain, beta, (β). This increases the holding voltage and trigger current of the lateral SCR, reduces lateral heat transfer capability, and possibly limits the type of ESD networks implemented. Among other things, this can result in device failure before the SCR is fully on, or a high on-resistance for the SCR reducing the ESD failure threshold.
[0007] [0007]FIG. 1A is a simplified cross section of a typical prior art SCR ESD protection device. Shown is a P substrate 8 , with an N-well 10 and which contains contact regions N+ 16 and P+ 18 . The N-well 10 contact regions are isolated and bounded by the shallow trench isolation (STI) structures 12 A, 12 B and 12 C. The N-well 10 is also bounded by STI elements 12 A and 12 C. The P substrate 8 also contains N+ contact 20 bounded by STI elements 12 C and 12 D, and P+ contact 22 bounded by STI structures 12 D and 12 E. Also depicted in FIG. 1A are parasitic vertical PNP bipolar transistor T 1 and lateral NPN bipolar transistor T 2 with parasitic resistors R 1 and R 2 . The P+ contact 18 is the anode end of the device and is connected to the active circuit input or output pad 4 as well as to the N-well N+ contact 16 by conductor 24 A.
[0008] The junction between the P+ contact region 18 and the N-well 10 is the first junction of the SCR, and the P+ contact region 18 forms the SCR device anode. The N-well 10 and the P substrate 8 form the second junction. The third device junction is formed by the P substrate 8 and substrate N+ contact 20 , which also is the cathode terminal of the device. N+ contact 20 is connected to a second voltage source, typically ground, and also to substrate P+ contact 22 by conductor element 24 B.
[0009] [0009]FIG. 1B shows the horizontal topography of the prior art device showing the N-well 10 with associated N+ contact 16 , P+ contact 18 , and related STI structures 12 A, 12 B, and 12 C represented by the dashed lines. Also represented in FIG. 1B are the substrate N+ contact 20 and P+ contact 22 as well as the STI structures 12 D and 12 E. The contact elements often use a silicide, or salicide, to improve the silicon to metal contact conductivity. The salicides are typically formed from refractory metals such as titanium (Ti), tungsten (W), tantalum (Ta), or molybdenum (Mo). The typical process is to provide a barrier such as SiO 2 to prevent salicide formation in unwanted areas, deposit the metal followed by a heat process, to form the salicide, and then remove the metal from the unwanted or non-contact areas.
[0010] [0010]FIG. 1C represents the electrical schematic of the prior art device showing the parasitic vertical bipolar PNP transistor T 1 and parasitic lateral NPN bipolar transistor T 2 as well as the resistors R 1 and R 2 . A positive ESD voltage event will cause the T 1 base-collector junction to go into avalanche conduction, turning on T 2 and providing the regenerative conduction action shunting the ESD current to the second voltage source, typically ground. A negative ESD voltage pulse will forward bias the base-collector junction of T 1 , which is formed by the N-well 10 and P-substrate 8 junction, again shunting the current to the second voltage source.
[0011] However, for positive ESD events as indicated above, the STI isolation structures inhibit lateral current conduction near the surface, lower the parasitic bipolar semiconductor current gain, and can interfere with device thermal characteristics.
[0012] [0012]FIG. 2 represents another prior art protection device, a low voltage trigger SCR (LVTSCR). There is no STI between the N-well N+ contact 16 and SCR P+ anode 18 , and the STI structure 12 C formerly straddling the N-well 10 and Substrate 8 boundary has been shifted to the left and a N+ region 28 has been added straddling the lateral boundary. A FET gate 26 has been inserted between the N+ region 28 and the N+ region 20 which essentially become the drain and source of a NFET respectively. The NFET source region 20 also functions as the SCR cathode. The prior art LVTSCR device operational trigger voltage is reduced by the NFET device breakdown voltage. The remaining STI elements still reduce the desirable ESD protection characteristics as previously discussed.
[0013] The invention in various embodiments allows the reduced use of STI elements while improving ESD protection by the use of an oxide layer, often called resistor protection oxide, for a silicide block.
[0014] The following patents describe ESD protection devices.
[0015] U.S. Pat. No. 6,172,403 (Chen) shows an ESD circuit with a process involving AA, isolation areas, and silicide.
[0016] U.S. Pat. No. 5,012,317 (Rountree) shows a conventional SCR-ESD circuit protection device with parasitic bipolar transistors.
[0017] U.S. Pat. No. 5,629,544 (Voldman et al.), U.S. Pat. No. 6,236,087 (Daly et al.), U.S. Pat. No. 5,903,424, (Taillliet), and U.S. Pat. No. 5,530,612 (Maloney) are related ESD patents.
[0018] The following technical reports discuss ESD protection circuits and STI bound ESD protection networks.
[0019] “Basic ESD and I/O Design” by S. Dabral et al., 1998 pps 38, 57, 62, and 247.
[0020] “Designing Power Supply Clamps for Electrostatic Discharge Protection of integrated Circuits” by T. J. Maloney, Microelectronics Reliability 38 (1998) pp. 1691-1703.
SUMMARY OF THE INVENTION
[0021] Accordingly, it is the primary objective of the invention to provide a novel, effective structure and manufacturable method for protecting integrated circuits, in particular field effect transistor devices, from damage caused by electrostatic discharge (ESD) events during normal operation.
[0022] It is a further objective of the invention to improve ESD protection involving SCR elements employing shallow trench isolation (STI).
[0023] It is yet another object of the invention to provide an ESD protection structure while maintaining the required operating characteristics of the active devices being protected.
[0024] The above objectives are achieved in accordance with the embodiments of the invention that describes a novel structure and process for a SCR like ESD protection device. The device is situated on a semiconductor substrate, typically P doped, and containing a N-well with P+ and N+ contact regions. A STI structure straddles one N-well to substrate lateral boundary. The same STI abuts the N-well N+ contact region lateral boundary near the substrate surface. A second STI structure defines a device lateral boundary near the surface for the P+ substrate contact.
[0025] A N-well P+ contact and a N+ substrate contact are also defined. The N-well P+ element forms the anode of the SCR device, and is electrically connected to the N+ N-well contact and to the active logic device input or output pad. The substrate N+ element forms the SCR cathode and is electrically connected to the substrate P+ contact and to a second voltage source, typically ground.
[0026] A feature of the invention is the use an oxide element in strategic locations on the substrate surface, often called resistor protection oxide (RPO), in place of the STI elements, to mask off silicide from areas where it is not desired. This enables the use of fewer STI elements, improving the ESD characteristics of the SCR ESD protection device.
[0027] In alternative invention embodiments, the RPO is utilized in low voltage trigger SCR (LVTSCR) devices and also in silicon on insulator (SOI) device design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] [0028]FIG. 1A is a cross sectional representation of a prior art SCR ESD protection device structure showing the isolation elements and parasitic bipolar elements.
[0029] [0029]FIG. 1B is a representation of the horizontal topography of the prior art SCR ESD protection device.
[0030] [0030]FIG. 1C represents the electrical schematic of the prior art SCR ESD protection device.
[0031] [0031]FIG. 2 represents a prior art low voltage trigger SCR (LVTSCR) protection device cross section.
[0032] [0032]FIG. 3A is a representation of the cross section of one embodiment of the invention for a SCR ESD protection device.
[0033] [0033]FIG. 3B is top view of one embodiment of the invention for a SCR ESD protection device showing the horizontal topography of the invention.
[0034] [0034]FIG. 4 is a simplified cross section of another embodiment of the invention for a LVTSCR.
[0035] [0035]FIG. 5 is a simplified cross sectional representation of another embodiment of the invention for a silicon on insulator device design.
[0036] [0036]FIG. 6 is a flow diagram of the invention process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] [0037]FIG. 3A shows a simplified cross section of one embodiment of the invention. A P doped substrate 108 with typical doping concentration of between 1E14 and 1E16 atoms/cm 3 (a/cm 3 ) contains an N-well 110 with a typical dopent concentration between 1E16 and 1E18 a/cm 3 . The N-well 110 is bounded at and near the surface by shallow trench isolation (STI) element 112 A, typically between 0.2 to 1 um wide and 0.4 to 2 um deep. The STI element 112 A is filled with a dielectric, typically silicon oxide (SiO 2 ). Within the N-well 110 region are a N+ 116 and P+ 118 contact regions, with typical dopent concentrations of between 1E19 and 1E21 a/cm 3 . The N+ region 116 is bounded on the side away from the P+ contact 18 by the STI 112 A. The substrate 110 has N+ contact 120 and P+ contact 122 , with a typical dopent concentration of between 1E19 and 1E21 a/cm 3 of donor and receptor dopent respectively. The outside edge of substrate P+ contact 122 is bounded by STI element 112 E.
[0038] The N-well N+ region 116 and P+ region 118 typically have specific contact areas where the silicon to metallurgy interface contains a salicide to reduce contact resistance. The salicides are typically formed from refractory metals such as titanium (Ti), tungsten (W), tantalum (Ta), or molybdenum (Mo). There is a blanket metal evaporation followed by a thermal annealing process, typically done at a temperature between 450 and 650° C., that forms the salicide. Unwanted unreacted metal is then selectively removed by use of an etchant that does not attack the salicide, the silicon substrate or the SiO 2 . A typical substance used for this etchant is a mixture of deionized water, hydrogen peroxide (H 2 O 2 ), and ammonium hydroxide (NH 4 OH) in a 5:1:1 mixture. Following the removal of unreacted metal, typically a stabilization anneal is performed with a temperature of between 800 and 900° C. to further reduce resistivity.
[0039] A unique feature of the invention is a protective oxide layer 132 , often called resistor protection oxide (RPO), overlaying the surface in non-contact areas, between the N-well N+ contact 116 , P+ contact 118 , and substrate N+ contact 120 and substrate P+ contact 122 . The oxide 132 is thermally deposited to a thickness between 1000 and 3000 Å. This oxide is a barrier or mask to prevent the salicide used to reduce the contact resistance between the silicon and the metallurgy system, typically aluminum or aluminum doped with silicon, from being formed in or on unwanted areas.
[0040] The RPO layer enables the proper device salicide processing without having to use the STI elements of prior art. As previously discussed, the STI elements can be detrimental to the ESD protection capability of the device by reducing the parasitic bipolar current gain, beta, (β), and can also reduce lateral heat transfer capability.
[0041] Processing is continued in a conventional manner to complete the devices on the substrate. The P+ contact 18 is the anode of the SCR device, and is electrically connected to the. N+ contact 116 , and the active device input or output pad 104 by conductor 124 A. The N+contact 120 is the SCR cathode and is electrically connected to the substrate P+ contact 122 , and a second voltage source, typically ground, by conductor 124 B. Not shown in the figure for clarity, but typically the device surface is covered by a passivation layer, either SiO 2 or silicon nitride (Si 3 N 4 ), or a borophosphorus silicate glass with a thickness of between 3000 and 7000 Å for protection against scratching, moisture or other damage.
[0042] [0042]FIG. 3B shows the device horizontal topography with the RPO depicted by the area 132 . It is noted that the invention does not require the prior art STI elements 12 B, 12 B, 12 C and 12 D, as depicted by the dotted lines in the plan view of prior art FIG. 1B.
[0043] Another embodiment of the invention is shown in FIG. 4. The unique design of the invention further improves the ESD protection of a LVTSCR device by enabling the elimination of STI elements 12 C and 12 D shown in FIG. 2 for prior art. The N+ doped region 128 straddling the lateral boundary between the N-well 110 and the substrate 108 has a dopent concentration typically between 1E19 and 1E21 a/cm 3 . This N+ difussion region 120 serves as the drain of a N-channel thin oxide field effect transistor (FET) with associated gate 126 . The FET N+ drain 128 connects internally to the N region N-well 110 base of the SCR and the FET N+ source 120 , which also serves as the SCR cathode. The cathode 120 , FET gate 126 , and substrate P+ contact 122 are connected to a second voltage source, typically ground, by conductor 124 B. This arrangement has the effect of lowering the trigger voltage of the SCR by the design of the channel length and/or the gate oxide thickness of the FET to provide a LVSCR element. The N-well P+ contact 118 is the device anode and is connected to the N-well N+ contact 116 and the active circuit I/O pad by conductor 124 A.
[0044] The unique structure of the invention design places a protective oxide layer 132 , or RPO layer, over the device surface except for the specific contact areas, to prevent the formation of salicide in areas not required. This eliminates the need for the prior art STI structures shown in FIG. 2 as STI elements 12 B and 12 C between the SCR anode and cathode. Again, the elimination of these STI improves the ESD performance of the SCR device.
[0045] Again, not shown in the figure for clarity, but typically the device surface is covered by a passivation layer, either SiO 2 or silicon nitride (Si 3 N 4 ), or a borophosphorus silicate glass with a thickness of between 3000 and 7000 Å to provide device protection.
[0046] In yet another embodiment depicted in FIG. 5, the invention is applied to a silicon on insulation (SOI) SCR protection device. There are several techniques in achieving an SOI structure well known in the art such as using sapphire as the insulator or using oxide as the insulator by using a heavy oxygen implant to create the oxide layer. As depicted in FIG. 5, a silicon wafer 108 has received an implant of oxygen to form a buried layer of SiO 2 134 as the insulation layer below the wafer surface. Typically, a high dosage of oxygen ions (O + ), between 1E18 and 5E18 a/cm 2 with an implant energy between 150 and 180 KeV is used to create the insulation layer. The insulation layer is typically between 0.3 and 0.5 microns below the surface. The wafer is typically heated between 350 and 450° C. during the implant process to insure that the surface maintains its crystallinity. A post implant anneal is performed at a temperature between 1050 and 1200° C. for 3 to 5 hours to form the buried layer of SiO 2 . The anneal step also allows excess oxygen in the surface silicon to out-diffuse, increasing the dielectric strength of the buried oxide layer. After the anneal, an additional layer of epitaxial silicon is deposited to assure that a single crystal active device region 136 of at least 0.5 um or greater in depth exists for the fabrication of active devices.
[0047] The use of trench isolation with SOI technology can be restrictive as the trench can contact the insulation element. When STI elements are used for isolation between SCR elements this can completely block device current flow around STI regions located between the SCR anode and cathode.
[0048] As depicted in FIG. 5, the invention embodiment for SOI technology, the SCR structure is composed of an N-well 110 with N+ contacts 116 and SCR anode P+ contact 118 . Adjacent to the N-well 110 is a P-well 114 with N+ contact 120 forming the device cathode and a P+ contact 122 . The heavily doped electrical contact areas typically contain a silicide or salicide between the silicon surface and the aluminum metallurgy conductor elements 124 A and 124 B. The SCR device is bounded on one side by STI element 112 A and on the other side by STI element 112 E, and there are no STI elements within the SCR active device area. The device anode 118 is electrically connected to the N-well 110 P+ contact 116 and the I/O node 104 by a metallurgical conductor element 124 A, typically aluminum, or silicon doped aluminum. The device cathode 120 is electrically connected to the P-well 114 P+ contact 122 and a second voltage source, typically ground, by a similar metallurgical conductor element 124 B. The electrical contact at the silicon surface typically contains a refractory metal salicide, such as TiSi 2 , to reduce electrical contact resistivity and prevent unwanted metallurgical annealing with the silicon.
[0049] As shown in FIG. 5, this invention embodiment provides an insulating RPO layer 132 on the device surface in non-contact areas to prevent salicide formation in those areas. This feature enables the reduction in the use of STI structures improving device ESD performance, or enabling an SCR ESD protection structure in situations not possible before. As in other embodiments, the N-well N+ contact 116 , N-well 110 , P-well 114 and P-well P+ contact 122 , effectively form a PN diode that is useful for shunting negative ESD energy occurring at the input terminal 104 away from the active devices.
[0050] Not shown in the figure for clarity, but the device surface is typically covered by a passivation layer, either SiO 2 or silicon nitride (Si 3 N 4 ), or a borophosphorus silicate glass with a thickness of between 3000 and 7000 Å
[0051] The process to develop an embodiment of the invention for an SCR on a P doped silicon substrate is outlined in the flow diagram of FIG. 6. Starting with a P doped substrate, a N-well 50 is created, typically by doping with an implant of phosphorous (P) with a dosage between 1E15 and 1E18 atoms/cm 2 and with an energy of between 30 and 80 KeV to produce an N-well with a dopant concentration of between 1E16 and 1E18 a/cm 3 . The creation of STI elements 52 is typically performed using an etching process such as a dry anisotropic plasma etch to form the trenches to a depth between 0.4 and 2 um deep and between 0.2 and 1 um wide. The trenches are then filled with a dielectric, typically SiO 2 , by LPCVD, or by an APCVD, or by a high-density plasma process. After filling, the STI elements are planarized by either an etch process, or, more typically, a chemical mechanical polish (CMP) process.
[0052] As indicated in FIG. 6, the creation of the N+ contact regions 54 is done by using a donor element such as arsenic (As), with a dosage level between 1E13 and 1E15 a/cm 2 , and with an energy between 20 and 40 KeV. This results in contact dopent regions with a concentration of between 1E19 and 1E21 a/cm 3 . The P+ contact regions in the N-well and substrate are similarly created by an implant process but using an acceptor element, typically boron (B), with a dosage of between 1E12 and 1E13 a/cm 2 , and an implant energy of between 40 and 80 KeV resulting in a dopent concentration of between 1E19 and 1E21 a/cm 3 .
[0053] As indicated by the flow element 58 in FIG. 5, the creation of the thermal oxide layer 58 is typically done with a thermal process at a temperature of between 700 and 1100° C. The oxide, frequently called resistor protection oxide, is etched at the appropriate contact areas to open the oxide to the contact regions. The refractory metal evaporation 60 , is performed to produce a blanket of the metal, typically metal such as titanium (Ti), tungsten (W), tantalum (Ta), or molybdenum (Mo).
[0054] After the evaporation, an anneal is done at temperatures between 450 and 650° C. to form the salicide in the contact areas. Removing unwanted unreacted metal 62 from the device is typically done by an etch such as a mixture of DI H 2 O, 30% H 2 O 2 , and NH 4 OH in a 5:1:1 mixture. A stabilization anneal is performed at a temperature between 800 and 900° C. Continued device processing 64 includes creating conductor elements by evaporating metal, typically aluminum doped with 1% silicon, patterning and etching to remove metal from unwanted areas, and providing a passivation layer such as SiO 2 , or silicon nitride (SiN), or borophosphorus silicate glass (BPSG). For BPSG, deposited SiO 2 is doped with boron from a diborane source and doped with phosphorous from a phosphine source at a temperature between 400 and 500° C. followed by a densification between about 700 and 900° C. to form BPSG.
[0055] While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various chances in form and details may be made without departing from the spirit and scope of the invention. | A novel device structure and process are described for an SCR ESD protection device used with shallow trench isolation structures. The invention incorporates an SCR device with all SCR elements essentially contained within the same active area without STI elements being interposed between the device anode and cathode elements. This enhances ESD performance by eliminating thermal degradation effects caused by interposing STI structures, and enhances the parasitic bipolar characteristics essential to ESD event turn on. Enabling this unique design is the use of an insulation oxide surface feature which prevents the formation of contact salicides in unwanted areas. This design is especially suited to silicon-on-insulator design, as well as conventional SCR and LVTSCR designs. | 7 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a method for detecting an end point of etching, and more particularly, to a method for detecting an end point of dry-etching using a plasma emission spectrum.
Description of the Related Art
In conventional dry-etching, the desired amount of etching is controlled by the etching time. Practically, in the case where etching reproducibility is good, no problems occur with the use of time controlled etching. However, in cases where etching reproducibility is inadequate, with time controlled etching, different over-etching times occur for every substrate in batch processing, or in single wafer processing, thereby resulting in decreased etching precision. Therefore, in such cases, the control of the amount of etching has been performed by inspection. However, it is necessary that a worker always observe the etching condition during etching, which burdens the production of semiconductor devices.
More recently, a plasma emission spectrum intensity has been monitored in reactive ion etching (hereinafter referred to as RIE) as a method for etching control. More specifically, the RIE method detects an end point of etching at the time when a film, not covered with an etching mask, is completely etched.
The prior art end point detection of etching will be described with reference to FIG. 5 as an example for etching an Al or Al alloy film formed on an insulating film. In this case, samples a and b having the same structure are continuously etched by a single wafer processing etcher under the same etching condition, and their spectrum intensities are measured by the wavelength 396 nm of Al. FIG. 5 shows a variation in the spectrum intensities of Al with respect to the etching time. In FIG. 5, t 0 indicates the time when etching of Al starts, and t 3 denotes the time when the etching is actually finished by worker inspection, i.e., t 3 denotes the end point of etching.
The etching end time provided by the waveform of FIG. 5 is obtained, for example, by the sample a. First, an average (It 1a +It 2a )/(It 2a -It 1a ) of the emission spectrum intensity I in a range between t 1a and t 2a , in which a variation in the emission spectrum intensity is relatively low, is obtained. The time when the emission spectrum intensity I is reduced to 70% of the average is defined as the etching end time t 3a of the sample a. Similarly, the etching end time of the sample b is given by t 3b . However, the actual etching end times of both the samples a and b are t 3 and differs from t 3a and t 3b obtained from the waveforms shown in FIG. 5. Since the waveform of the emission spectrum intensity I lacks reproducibility, an appropriate etching end point cannot be defined even by monitoring the wavelength of Al.
Therefore, even if the substrates have the same structure and of the etching end points determined by inspection are the same, there is little or the no reproducibility of etching. In the case of etching substrates having different structures or etching patterns, etching reproducibility is even less likely. Accordingly, even if the emission spectrum intensity of Al is used, it is difficult to detect the etching end point with high precision and to etch substrates having different structures.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for detecting an end point of dry-etching with high reproducibility.
Another object of the present invention is to stably and automatically perform etching with high precision.
A feature of the present invention is that an end point of etching is detected with high reproducibility by monitoring an emission spectrum intensity of helium in dry-etching, using an etching gas including a helium gas.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel and distinctive features of the invention are set forth in the claims appended to the present application. The invention itself, however, together with further objects and advantages thereof may best be understood by reference to the following description and accompanying drawings in which:
FIG. 1 is a schematic view showing a structure of a dry-etching apparatus for use in a method for detecting an etching end point according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view of a material to be etched according to the embodiment of the present invention;
FIG. 3 is a graph showing a variation in emission spectrum intensity of helium with respect to etching time;
FIG. 4 is a graph showing a variation in emission spectrum intensity of helium with respect to etching time of each of three materials to be etched; and
FIG. 5 is a graph showing a variation in emission spectrum intensity of aluminum with respect to etching time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described, with reference to the accompanying drawings.
FIG. 1 shows a dry-etching apparatus having a parallel-plate electrode structure. A chamber 1 includes an upper electrode 2 and a lower electrode 3, which are arranged in parallel with each other and connected to a high-frequency power supply 4. An etching gas is introduced from holes of the upper electrode 2 into the chamber 1 and exhausted from an exhaust port 6 provided at a lower portion of the chamber 1. A sample 5 is placed on the upper surface of the lower electrode 3. An emission spectrum filter 7 is attached to the chamber 1 to detect an emission spectrum of the etching gas.
The sample 5 will be described in detail with reference to FIG. 2. An SiO 2 film 12 is formed on a silicon substrate 11. An Al film 13 is deposited over the substrate surface as a wiring layer by sputtering, and an etching mask 14 having a desired wiring pattern is formed on the Al film 13. The Al film 13 formed on the SiO 2 film 12 has a thickness of 10000 Å. The Al film 13 is composed of, for example, an Al-Si-Cu alloy.
The Al film 13, which is not covered with the etching mask 14, is etched down to the SiO 2 film 12. The process condition is given by an etching gas: SiCl 4 /Cl 2 /He=50/100/400[SCCM], a pressure: 100 [Pa], and a power: 300 [W].
For detecting an end point of etching, the emission spectrum of wavelength 439 nm of helium is monitored. The wavelength of helium is monitored through the emission spectrum filter 7. FIG. 3 shows a variation in the emission spectrum intensity of the helium with respect to the etching time. In FIG. 3, t 0 indicates the etching start time, and t 3 represents the etching end time. The emission spectrum intensity of the helium has a single peak at the end of the etching. This is because the wavelength of Al is the highest during the etching of the Al film 13 and the wavelength of helium becomes extremely high after the etching of the Al film 13 is finished. The etching end time determined by the single peak correctly coincides with the etching end time defined by the inspection.
Furthermore, three samples a, b and c having the same structure as that of the sample 5 are continuously etched under the same condition as that of the sample 5. A variation in the emission spectrum intensity of helium in this case is shown in FIG. 4. Although the etching end times of the three samples differ from one another, the emission spectrum intensity of helium of each of the samples has a single peak, and the etching end times t 3a , t 3b and t 3c corresponding to the peaks are easily detected. In other words, even if the samples having the same structure are etched in sequence and the etching end times of the samples do not coincide with one another, the etching end points can be easily detected with high precision, since the single peak of the emission spectrum intensity of helium of each sample always appears at the end of the etching.
As another embodiment, the present invention can be applied to a case where an insulating film such as an SiO 2 film is etched. The etching apparatus is the same as that shown in FIG. 1, and the process condition is given by an etching gas: CHF 3 /SF 6 /He=50/10/200[SCCM], a pressure: 100[Pa], and a power: 500 [W]. Since, in this embodiment, the emission spectrum intensity of helium has a single peak, an etching end point can be detected.
In the above embodiments, the emission spectrum intensity of helium has a single peak during etching, and high-precision etching can be performed. Since the emission spectrum of a helium gas is used, an etching end point can be easily detected, irrespective of the structure (etching pattern) of a substrate or a material to be etched. Not only the high-precision etching can be attained, but also the etching process can be stabilized. Further, since good etching reproducibility is obtained, the etching process can be automated.
The present invention is applied to etching of the Al film and the insulating film, as described above. However, it can be applied to all dry-etching using a process gas containing a helium gas irrespective of a material to be etched.
It is further understood by those skilled in the art that the foregoing description is only of the preferred embodiments and that various changes and modifications may be made in the invention without departing from the spirit and scope thereof. | For dry-etching a material such as an aluminum alloy layer, a helium gas is added to an etching gas to detect an end point of etching in the material. When the dry-etching of the material has been completed, an emission spectrum intensity of helium having a single peak occurs. | 7 |
TECHNICAL FIELD
The present invention relates to a starter system for an internal combustion engine, and in particular to an engine starter system equipped with an improved structure for mounting the same on an engine.
BACKGROUND OF THE INVENTION
Conventionally, various starters for cranking an internal combustion engine have been known. For instance, as disclosed in Japanese patent laid open publication No. 61-53568, and U.S. Pat. Nos. 4,604,907, 4,561,316, 4,573,364, 4,520,285, 4,510,406, and 4,528,470, a pinion is selectively meshed with a ring gear of the engine to crank the same according to the on-off action of an electromagnetic switch with a DC motor which drives the pinion via a planetary gear reduction unit.
In such a starter, the casing accommodating the pinion is fitted into a mounting bore of a crank case of an engine and is secured therein by fastening threaded bolts passed through a flange portion of the casing in order to ensure the high precision of the meshing between the ring gear and the pinion. Further, a mounting end surface for securing purpose is provided in the flange portion around each of the holes for passing a threaded bolt as a planar surface perpendicular to the axial line of the output shaft, and this mounting end surface is brought into contact with an associated mounting surface of the crank case so that the misalignment of the output shaft at the time of mounting may be avoided.
When the pinion is meshed with the ring gear to crank the engine, the load acting on the pinion is transmitted to the mounting end surface through a certain lever action with the fitted portion or a circumferential mounting surface of the starter casing serving as a fulcrum. According to the above described conventional structure, since the fitting boss portion serving as the mounting circumferential surface extends continuously from the mounting flange portion provided with the mounting end surfaces, a substantial bending moment acts upon the flange and a relatively large load acts upon the mounting end surfaces due to the reaction force acting on the pinion as it cranks the engine. Therefore, in order to ensure a sufficient rigidity of the flange portion, it was necessary to increase the thickness and size of the flange to an undesirable extent.
In assembling such a starter, the casing is supported typically by placing a pair of mounting end surfaces for securing purpose, provided in flanges disposed in diagonally opposing positions on the casing accommodating a pinion, on an assembly jig. Since the mounting end surfaces are provided in diagonally opposing, 180 degree opposed positions around the drive shaft, the axial force applied to the drive shaft when fitting it into the bearing of the casing may be supported by the mounting end surfaces in a stable fashion.
In terms of the freedom in designing the mounting structure between the starter and the engine, it is preferable to arrange holes for passing fastening bolts in mutually asymmetric positions with respect to the drive shaft. However, if the mounting end surfaces defined around such mounting holes are arranged in mutually asymmetric positions with respect to the drive shaft, the force applied to the drive shaft to fit the drive shaft into a bearing provided in the casing while supporting its mounting surfaces with an assembly jig produces a moment, and it impairs the efficiency of the assembly work.
BRIEF SUMMARY OF THE INVENTION
In view of such problems of the prior art, a primary object of the present invention is to provide an engine starter system which can ensure a sufficient rigidity without increasing the size of the mounting end surface.
A second object of the present invention is to provide an engine starter system which can increase the freedom in designing the mounting structure between the starter and the engine without impairing the efficiency of assembly work.
These and other objects of the present invention can be accomplished by providing a starter system for an internal combustion engine, comprising: an electric motor having an output shaft; a power transmission unit including an output shaft carrying a pinion for meshing with a ring gear of an internal combustion engine, an input end of the power transmission unit being coupled to the output shaft of the electric motor; and a casing accommodating the power transmission unit therein, and provided with an opening exposing the pinion gear; the casing being provided with a mounting circumferential surface, for instance, of a cylindrical shape adapted to be substantially closely fitted into an associated bore provided in the engine or a transmission housing associated therewith, and a mounting flange extending radially from the casing and provided with a mounting end surface extending perpendicularly to a longitudinal line of the output shaft of the power transmission unit and spaced from the mounting circumferential surface along the longitudinal line.
Thus, the distance of the step defined between the mounting circumferential surface and the mounting end surface for securing the starter system in the mounting bore of the engine increases the length of the arm of the bending moment between the fulcrum point of the fitted portion and the mounting end surface, and the force acting upon the mounting end surface is reduced, thereby ensuring a sufficient rigidity without increasing the size of the mounting end surface.
Preferably, the mounting flange consists of at least a pair of mutually asymmetrically disposed flange portions extending radially from the casing, each of the flange portions being provided with means for securing the same to an associated mounting surface of the engine or the transmission case, the casing further comprising a counter support surface disposed in a part of the casing diametrically opposed to the mounting flange portions with respect to the output shaft of the power transmission unit.
Thus, by supporting the two mounting end surfaces for securing purpose and the counter support surface serving as a jig seat surface for assembling purpose with associated parts of an assembly jig, it becomes possible to support the case at three points against the force applied to the output shaft or the drive shaft as it is being fitted into the casing, and allows the assembly work to be carried out in a stable fashion while increasing the freedom in designing the mounting structure between the starter and the engine as the mounting end surfaces are not required to be provided in mutually symmetric positions with respect to the output shaft or the drive shaft.
For the convenience of machining, the mounting end surfaces of the mounting flange portions and the counter support surface are disposed on a common plane.
BRIEF DESCRIPTION OF THE DRAWINGS
Now the present invention is described in the following with reference to the appended drawings, in which:
FIG. 1 is a longitudinal sectional view of a preferred embodiment of the starter system according to the present invention;
FIG. 2 is a front view of the starter system illustrated in FIG. 1;
FIG. 3 is an enlarged side view of a part of the starter system illustrated in FIG. 1; and
FIG. 4 is a side view illustrating the process of installing the drive shaft in the pinion cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 generally shows a starter 1 equipped with a reduction gear unit given here as an embodiment of the starter system for an internal combustion engine according to the present invention, and this starter 1 powered by a DC motor 2 produces a rotational power for cranking an engine. As seen in FIG. 1, the right end of the motor shaft 2a of the DC motor 2 is rotatably supported by a ball bearing 5 secured to an end cover 4 covering a commutator 3, and the left end of the motor shaft 2a is supported by a metal bearing 7 secured to a separator 6 serving as an end plate of the motor 2.
To the left side of the motor shaft 2a as seen in FIG. 1 is provided a planetary gear unit 9 serving as a reduction gear unit, and a sun gear 9a is mounted on the left free end of the motor shaft 2a. Planetary gears 9b mesh with the sun gear 9a. On the left end of the separator 6 is placed a center bracket 11 defined with a small and a large axial cylindrical portion. The larger cylindrical portion of the center bracket 11 receives an internal gear 9c, and the planetary gear unit 9 is received in the space defined between the separator 6 and the center bracket 11.
The separator 6 and the center bracket 11 are fixedly secured between a pinion cover 13 serving as a casing for receiving a pinion 12 which is described hereinafter and a casing 2b of the motor 2. The two ends of a drive shaft 16 are supported by a metal bearing 14 fixedly secured to the left free end of the pinion cover 13 as seen in FIG. 1 and a roller bearing 15 fitted in the smaller cylindrical portion of the center bracket 11, coaxially with the motor shaft 2a, respectively. The planetary gears 9b are pivotally supported by a radial flange portion provided at the right end of the drive shaft 16 as seen in FIG. 1 and received in the center bracket 11.
A clutch outer member 18 of an overrunning clutch consisting of a one-way roller clutch is coupled to the outer circumferential surface of an intermediate part of the drive shaft 16 by way of a spline coupling portion 17 consisting of a helical spline, and a clutch inner member 19 thereof is rotatably and axially slidably fitted on the drive shaft 16. The pinion 12 for driving a ring gear 30 of an internal combustion engine is integrally formed in the axially left end of the clutch inner member 19 as seen in FIG. 1.
The clutch outer member 18 is provided with an annular recess 21 around its circumference, and a bifurcated working end 22a of a shift lever 22 engages with this annular recess 21. The shift lever 22 is received in a radially extending peninsular portion 13a integrally formed with the pinion cover 13, and a middle part of the shift lever 22 is pivotally supported by a support bracket 25 interposed between a yoke 24 of an electromagnetic switch 23 connected to the peninsular portion 13a and the peninsular portion 13a itself. A plunger 26 of the electromagnetic switch 23 is engaged by a free end of a spring 27 which is supported by a support bracket 25 at an intermediate part thereof and engaged to a part of the shift lever 22 intermediate between the pivot shaft and the working end portion 22a. The free end 22b of the shift lever 22 remote from the working end 22a is also bifurcated, and is elastically engaged to the end of the spring 27 adjacent the plunger 26. The thus constructed shift means allows the rotative motion of the shift lever 22 according to the movements of the plunger 26 under the attractive force of the electromagnetic switch 23 when it is energized and the restoring force of the return spring in the electromagnetic switch when the latter is not energized.
A battery connecting terminal 28 of the electromagnetic switch 23 is electrically connected to a battery not shown in the drawings, and a switch terminal 20 is electrically connected to an ignition switch not shown in the drawings while a motor connection terminal 29 is electrically connected to the motor 2. When the ignition switch is turned to the starter-on position, the electromagnetic switch 23 is energized, thereby causing the plunger 26 to be attracted thereto and the shift lever 22 to be rotated in clockwise direction in the sense of FIG. 1 by way of the spring 27. As the working end 22a of the shift lever 22 pushes out the clutch outer member 18, at the same time, causing it to rotate by means of the spline coupling portion 17 provided in the drive shaft 16, the clutch inner member 19 or the pinion 12 comes into mesh with the ring gear 30 of the engine. The attracted movement of the plunger 26 causes an internal contact set to be closed and thereby the motor 2 to be rotated, and the rotation of the motor 2 is reduced in speed by the planetary gear unit 9 and is transmitted to the pinion 12 which drives the ring gear 30 and cranks the engine.
Since, even when the plunger 26 has been activated but the pinion 12 has failed to mesh with the ring gear 30 by striking the end surface of the gear teeth of the ring gear 30, the plunger 26 can be completely attracted by the electromagnet because of the deflection of the spring 27, and the contact set of the electromagnetic switch 23 is closed in any case and the motor 2 is rotated so that the pinion 12 can continue to be rotated by the motor 2, and can eventually mesh with the ring gear 30 in a reliable manner.
A part adjacent the base end of the pinion cover 13 of the thus constructed starter 1 on the right hand side of FIG. 1 is provided with a cylindrical fitting boss portion 31 having an outer circumferential surface serving as a mounting circumferential surface coaxial with the drive shaft 16 for fitting the fitting boss portion 31 into a mounting bore 32a provided in the transmission case 32 of the engine, and a pair of mounting flange portions 33a and 33b projecting radially and outwardly on the base end of the fitting boss portion 31 of the pinion cover 13 as illustrated in FIG. 2. A projecting end portion of one of the mounting flanges 33a is provided with a bolt passing hole 34 while the other mounting flange portion 33b is provided with a threaded hole 35, each for securing purpose. In this embodiment, the mounting bore 32a is provided in the transmission case, but may also be provided in the engine itself.
The pinion cover 13 is provided with a smoothly finished mounting end surface 36a or 36b for securing purpose around the hole 34 or 35 of each of the mounting flange portions 33a and 33b, and a jig seat surface 38 for assembly purpose for supporting the pinion cover 13 with an assembly jig as described hereinafter at three points in cooperation with the mounting end surface 36a or 36b when installing the output shaft 16 into the pinion cover 13. In other words, the jig seat surface 38 serves as a counter support surface. In this embodiment, the three surfaces 36a, 36b and 38 are defined in a common plane for the convenience of machining, but they may also be placed in mutually different planes if necessary. Also, the mounting circumferential surface defined around the fitting boss portion 31 is preferred to be cylindrical in shape, but may also have other shapes if desired.
As illustrated in FIG. 3, when the starter 1 is mounted on the transmission case 32, the fitting boss portion 31 is fitted into the mounting bore 32a of the transmission case 32, and the mounting end surfaces 36a and 36b prevent any misalignment of the axial line of the starter 1 during assembly in cooperation with the associated mounting surface 32b of the transmission case 32.
In this starter 1, a step of distance a is defined between an end portion 31a of the fitting boss portion 31 adjacent the mounting end surfaces 36a and 36b and the mounting end surfaces 36a and 36b. Therefore, as shown in FIG. 3, when the pinion 12 is meshed with the ring gear 30 when cranking the engine, and a reaction load F acts upon the pinion 12, a force R acts upon the mounting end surfaces 36a and 36b due to the moment generated around a fulcrum defined by the fitting boss portion 31. The directions of the load F and the action force R are indicated only for the purpose of illustration.
Since the length of the arm of the moment as measured between the fitting boss portion 31 serving as the fulcrum of the moment and each of the mounting end surfaces 36a and 36b can be found as the radial distance from the center of the drive shaft 16 and the distance a of the step, the magnitude of the action force R is reduced as opposed to the case where the arm length is given as the radial distance alone. Therefore, the radial distance between the axial center of the drive shaft 16 and each of the mounting end surfaces 36a and 36b can be relatively reduced, whereby the mounting flange portions 33a and 33b may be safely reduced in size without requiring the mechanical rigidity and strength of the mounting flange portions 33a and 33b and the overall size of the starter 1 can be minimized.
In assembling the starter 1 to the transmission case 32, the fitting boss portion 31 is first fitted into the associated mounting bore 32a of the transmission case 32, and the starter 1 is fixedly secured by fastening threaded bolts passed through the bolt passing hole 34 and the threaded hole 35. Parts of the mounting flange portions 33a and 33b facing the mounting surface of the transmission case 32 and surrounding the associated mounting holes 34 and 35 are provided with the mounting end surfaces 36a and 36b, respectively, as planar surfaces extending perpendicularly to the axial line of the drive shaft 16 for the purpose of controlling the misalignment of the pinion cover 13 as described above. Further, the pinion cover 13 is additionally provided with the jig seat surface 38 for assembling purpose on another side of the drive shaft 16 from that of the mounting end surfaces 36a and 36b for securing purpose as a planar counter support surface extending on a same plane as the mounting end surfaces 36a and 36b.
According to this starter 1, the opening angle of the two mounting holes 34 and 35 with respect to the axial center of the drive shaft 16 is determined as approximately 120 degrees, and the two mounting end surfaces 36a and 36b are arranged at mutually asymmetric positions with respect to the drive shaft 16. Therefore, as opposed to the conventional starter having a pair of mounting threaded holes and mounting end surfaces for securing purpose at mutually 180 degree opposed positions with respect to the drive shaft, the freedom in designing the mounting structure between the starter and the engine is much increased, and by determining the opening angle according to the change in the shape of the side surface of the engine a favorable mounting structure can be ensured for each specific engine design.
Furthermore, in installing the drive shaft 16 into the pinion cover 13 during the process of assembling the starter 1, since the two mounting end surfaces 36a and 36b as well as the jig seat surface 38 are placed on the assembly jig 37 as illustrated in FIG. 4, and a free end of the drive shaft 16 is fitted into the metal bearing 14 of the pinion cover 13, the pinion cover 13 is supported at three points against the force to force the drive shaft 16 into the metal bearing 14, and a stable assembly process is made possible without tilting the pinion cover 13 as the drive shaft 16 is installed in the pinion cover 13.
Thus, according to the present invention, since an additional length is added to the length of the arm between the fitted portion serving as a fulcrum point and the mounting end surfaces by means of the provision of the step, even when the radial distance between the drive shaft and the mounting end surfaces is reduced, a sufficient rigidity can be ensured to the mounting end surfaces against the action force acting on the mounting end surfaces when cranking the engine, and the overall size of the starter system can be minimized.
Further, since a pair of mounting end surfaces for securing purpose may be provided at mutually asymmetric positions with respect to the drive shaft, and the two mounting end surfaces can be arranged in a favorable fashion for each different engine design, the freedom in designing the mounting structure for the engine starter system is increased, and this can be accomplished without impairing the efficiency of the assembly work by supporting the casing at the three points on the two mounting end surfaces and the jig seat surface in a stable fashion.
Although the present invention has been described in terms of a preferred embodiment thereof, it is obvious to a person skilled in the art that various alterations and modifications are possible without departing from the scope of the present invention which is set forth in the appended claims. | A starter system for an internal combustion engine having a casing provided with a mounting circumferential surface adapted to be substantially closely fitted into an associated mounting bore provided in the engine or a transmission housing associated therewith, and a mounting flange extending radially from the casing and provided with a mounting end surface perpendicular to a longitudinal line of the output shaft of the starter system and spaced from the mounting circumferential surface along the longitudinal line. Because of the presence of the distance between the mounting end surface of the mounting flange and the mounting circumferential surface of the starter casing closely fitted into the mounting bore, the reaction force acting on the pinion is prevented from being amplified and transmitted to the mounting surfaces by means of an undesirable lever action. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to the field of injection molding of plastic articles, such as blowable plastic parisons. The parisons are typically formed by injecting molten plastic around a set of central core pins, and subsequently cooling the array of parisons while on the core pins. The cooled parisons next are stripped of the gate or tail portion of the parison and collected for subsequent blow molding into containers.
The art of container forming by blow molding a previously injection molded parison has advanced to the state where several thousand such containers can be formed per hour from a presupplied stock of parisons. In such a rapid production rate system, it is necessary to require that the parisons, from which the containers are ultimately blown, are themselves formed rapidly, inexpensively and with a high quality in each parison so that the total reject rate from the parison formation step is minimized. Accordingly in the injection molding process, which forms the parison for subsequently blow molding, it has become critical to reduce the overall cycle time of the injection molding cycle while increasing parison quality and reducing injection molding machine down time.
Currently available injection molding machines have not provided the overall desirable features disclosed above. For example, most currently available injection molding machines include a bipartate injection mold which terminates in flat space which houses an inlet port. An injection nozzle, which is connected to an injector assembly, which supplies molten thermoplastic material, fits into the inlet port with a very snug fit in the port. Also, current injection molding machines provide for a long tail or sprue section on the parison which must be removed prior to blow molding of the parison into a finished container. This provides for more waste plastic, which must be recylced, at a significant cost or discarded. Further, such an approach provides for high crystallinity in the parison sprue which is disadvantageous to the performance of the final blown container.
A number of problems are inherent in the above approach to injection molding of parisons. The large sprue or tail area on the bottom of the parison allows highly crystallizable materials, for example, polyethylene terephthalate, to crystallize as the parison is being cooled in the injection mold station. When the sprue is a crystallized plastic, it does not stretch well when the parison is being biaxially oriented to produce strong pressure resistant plastic containers such as those suitable for soft drink and beer packaging. Accordingly, the sprue must be removed in a subsequent station by a sprue removal device to provide a blowable parison for container fabrication. Such a step in parison fabrication requires additional cycle time thereby lowering the overall production of the injection molding machine. Further, in many cases, residual crystallinity remains in the sprue area of the bottom of the parison which is translated into a poorly oriented centrally located heel area on the bottom of the finished container. Such a poorly oriented heel area in the container is substantially less pressure resistant and provides an inferior container for holding pressurized fluids.
Further, when attempts were made to militate against the formation of highly crystalline sprue portions on parisons by moving the injection nozzle to intimate contact with the bottom of the parison, within the injection mold halves, further problems occurred. Namely, when the parison molds were opened, drooling or stringing of the injected plastic occurred which was detrimental to high quality parison production. A related, and very serious, problem occurred when the injection nozzle was placed such that the mold halves closed around the injection nozzle. Upon repeated clamping of the injection mold halves onto the hollow injection nozzle, as injection cycles occurred, the nozzles stress-cracked and were no longer useful. Further, at the end of the machine cycle and at the beginning of the cycle, as the molds heated and cooled they expanded and contracted. The nozzle also expanded and contracted, but usually at a different rate, since it was of a different metal alloy and in intimate thermal contact with the hot plasticizer. This situation led to crushing of the nozzle within the mold halves as differential thermal expansion and contraction occurred. This also caused premature replacement of the nozzles due to metal fatigue and subsequent failure.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of previous injection molding systems, and resultant parison problems, through an injection molding system which includes an injector assembly for supplying molten plastic through manifold assembly into a plurality of horizontally spaced apart injection nozzles. The injection nozzles are insertable into bipartate injection mold housing. The injection mold housing accepts the nozzle through a mold recess which includes a generally cylindrical indwelling portion or recess wall which terminates at an angled mating surface, which angles inwardly of the injection mold and terminates in a centrally located flat central mating surface. A passageway or gate is located at the center of the flat central mating surface to provide plastic passage through the gate into the centrally located hollow parison formation cavity. The injection nozzle includes a generally annular base portion which supports a generally cylindrical hollow sidewall portion. The sidewall portion terminates at its upper end in an inwardly beveled heat transfer control portion. The beveled heat transfer control portion is connected to an angled mating portion which is of complementary angle to the angled mating surface of the mold recess. The angled mating portion terminates at a flat central mating surface which is of complementary geometry and dimensions to the flat mating surface of the injection mold. The flat central mating surface includes a centrally located outlet port which merges with the gate of the mold to thereby provide a continuous passage for molten plastic from the injector assembly, through the manifold, through the injection nozzle and into the parison formation cavity.
In one embodiment of the invention, the total length of the sprue or tail on the heel portion of the parison bottom is sixty-thousandths of an inch or less, thereby militating against the need to remove the sprue before blow molding the parison into a container. Such a limited sprue dimension is achieved by limiting the added lengths of the gate and outlet port to the desired dimension. It has been discovered according to the present invention that such a short sprue cools quickly enough to remain a amorphous plastic. Such an amorphous plastic is easily blow molded into a molecularly oriented bottom portion of the container without any significant residual crystallinity. Prior large sprue portions could not be cooled quickly enough to avoid crystallization, which resulted in the problems described above.
In another embodiment of the apparatus for forming parisons according to the present invention, the angled mating portion of the injection nozzle is formed of a roughened surface finish, such as a vapor honed finish, to minimize heat transfer from the end of the injection nozzle adjacent the injection mold gate into the mold. The vapor honing may be achieved by any conventional technique. This embodiment of the invention allows further heat withdrawal from the injection mold gate area and the nozzle outlet port area to rapidly cool an amorphous parison sprue. Alternatively, the surface may be roughened by conventional acid etching techniques. Either technique provides a roughened surface to minimize heat transfer from the nozzle to the mold.
In another embodiment of the invention, a heater band with an insulated covering shroud therearound is provided on the exterior of the generally cylindrical hollow sidewall portion of the nozzle to assist in maintaining the plastic passageway of the injection nozzle molten during parison formation.
A number of advantages are presented by the present invention including improved cycle time, on the order of 20% compared to conventionally available parison injection molding machines. Also, an increased percentage of acceptable parisons due to amorphous sprue formation are had. Further, the lightweighting of parisons is allowed since the amorphous sprue portion may be blown into a highly molecular oriented bottom portion for the container, militating against a thick, less oriented container bottom to achieve the same gas permeation characteristics. Further, the present invention provides increased nozzle and injection molding machine lifetime since the matched angle of the mating portions of the injection mold and the injection nozzle prevent crushing of the injection nozzle during heat-up and cool-down of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will become readily manifest to one skilled in the parison and container-forming art from reading the following detailed description of the preferred embodiments of the invention, when considered in view of the accompanying drawings, in which:
FIG. 1 is a perspective view of a hollow, organic, thermoplastic parison prepared according to the present invention;
FIG. 2 is a schematic plan view of a parison injection molding device incorporating the features of the present invention;
FIG. 3 is a side elevational view taken along the lines 3--3 of FIG. 2;
FIG. 4 is a perspective view of the injection nozzle and shut-off pin according to the present invention;
FIG. 5 is a cross-sectional view of the injection mold in operating engagement with the injection nozzle and shut-off pin of the present invention;
FIG. 6 is a perspective view of an alternative embodiment of an injection nozzle according to the present invention; and
FIG. 7 is a perspective view of an alternative embodiment of the injection nozzle according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, particularly at FIG. 1, there is illustrated an organic, thermoplastic parison 20 which is formed by the parison forming apparatus according to the present invention. The parison 20 includes a threaded neck finish 22 which in integral with an outstanding finish ledge 24. Continuous with and immediately below the finish ledge 24 is an outwardly tapered shoulder portion 26. Immediately below and integral with the shoulder portion 26 is a main cylindrical body portion 28. The body portion 28 terminates at its lower end in a generally hemispherical bottom portion 30. A centrally located heel 32 is in the geometric center of the generally hemispherical bottom 30 of the parison 20. A sprue 34 extends radially outwardly from the center portion of the heel portion 32 of the bottom 30 of the parison 20. The parison 20 formed according to the present invention is blown by conventional blow molding techniques into a finished container. Preferably, the organic, thermoplastic parison 20 is fabricated from a highly orientable plastic. The plastic, when blow molded into a finished hollow container, is stretched to induce biaxially molecular orientation to yield a final container having excellent anti-gas permeability properties and mechanical strength properties. Particularly preferred for the parison 20 according to the present invention is a polyethylene terephthalate plastic material of an inherent viscosity of greater than 0.6.
Referring to FIG. 2 there is illustrated a schematic plan view of a parison injection molding system incorporating the advantageous features of the present invention. A rotary injection molding machine 36 is provided which includes a centrally located rotatable turret 38. The turret 38 rests upon a rotary support shaft 40 which is rotated about its longest axis by a conventional drive means, not shown. The rotary molding machine 36 includes a parison injection staion 42, a parison cooling station 44 and a parison ejection station 46. Each station includes a plurality of horizontally spaced-apart core poins 48. Each core pin 48 includes an alignment boss 50 which properly positions the core pin 48 within the injection molds, described hereinafter. The parison injection station 42 includes a bipartate injection mold, shown only in top plan view in FIG. 2 and described in detail hereinafter, which accepts molten plastic from a reciprocating screw plasticizer 52. The plasticizer 52 is connected, via a hollow coupling 54, to a plastic distribution manifold 56. The manifold 56 includes a plurality of horizontally spaced-apart nozzle housings 58 which support injection nozzles 60. The injection nozzles 60 fit within the injection molds, as illustrated in detail hereinafter, to supply molten plastic to the injection molds. In operation, liquid plastic is moved under pressure from reciprocating screw plasticizer 52 through the coupling 54 and into the manifold 56. The plastic is delivered from the manifold 56 through the nozzle housings 58 into the injection nozzles 60 for delivery into the integral cavities of the injection mold around the core pins 48 and form the parisons 20. After formation of the parisons, and with sufficient mold residence time for solidification of the liquid plastic, the injection molds are split vertically to allow rotation of the newly formed parisons 20 on the core pins 48 to the parison cooling station 44. It will be appreciated that the injection nozzle 60, and complementary recess described in detail hereinafter, can be used equally well with a conventional injection blow molding apparatus.
After removal of the newly formed parisons 20, the injection molds are again closed about the nozzles 60 to receive a new charge of molten plastic from the plasticizer 52. At the parison cooling staion 44, the still warm parisons 20 on the core pins 48 are subjected to a high pressure cold air blow via a high speed air pump 62 which supplies a high velocity of air, for example, a thousand feet per minute through an air transfer manifold 64 to the air nozzles 66. The air nozzles 66 are arranged such their output of cold air is directed to blow upon the sprue portions 34 of the parisons 20 as well as the heel portions 32. After sufficient time has elapsed for substantial cooling of the sprues 34 and heel portions 32 of the parisons 20, the turret 38 is rotated about the rotary support shaft 40 to index the parisons 20 to the parison ejection staton 46. Obviously, such rotation of the cooled parisons 20 bring the next group of newly injection formed parisons 20 into the cooling station 44. At the parison ejection station 46 a shuttle bar 69, driven by a pair of drive rails 70 and 72, moves the parisons horizontally to remove them from the core pins 48 to a collection station, not shown.
FIG. 3 illustrates a side elevational view showing, in more detail, the parison injection station 42 and the plasticizer 52 in operative relationship to the distribution manifold 56, injection nozzle 60 and plasticizer 52. A bipartate, vertically separable, parison mold 74 includes an upper mold half 76 and a lower mold half 78. The lower mold half 78 rests upon a mold retainer block 80 and is secured thereto by conventional means. The mold retainer block 80 is supported on and secured to a stationary base plate 82. The upper mold half 76 is secured to and elevated by a mold retainer block 84 which is secured to and elevated by a mold elevation platen 86. The mold elevation platen 86 is moved upwardly by conventional elevation means, not shown. The center of the injection mold 74 is hollow and accepts the core pin 48 and provides an intervening space wherein the parison 20 is formed by injection molding. The mold halves 76 and 78 may be internally channeled to accept mold coolant to aid in rapid cooling of the injected plastic. Such cooling aids in retarding unwanted crystallization of the plastic. The injection mold 74 includes a gate 88 which communicates with a mold recess 90 which accepts and mates with the injection nozzle 60, as more clearly illustrated in FIGS. 4 and 5. The injection nozzle 60 is secured to the manifold 56 by the nozzle housing 58. An internally disposed shut-off pin 92, described in detail hereinafter, which is moved by a shut-off pin transfer means 94 provides means for stopping plastic flow through the injection nozzle 60 when sufficient plastic from the plasticizer 52 has been passed into the mold 74. As illustrated in the drawing, the plasticizer 52 is connected to the distribution manifold 56 by a hollow coupling 96.
FIG. 4 illustrates a perspective view of the injection nozzle 60 and the shut-off pin 92 according to the present invention. The shut-off pin 92 includes a main shaft portion 98 which is connected to the pin transfer means 94. The main shaft 98 terminates in a beveled intermediate portion 100 which in turn terminates in a flexible shaft portion 102. The flexible shaft portion 102 can have a flat end portion 104 as illustrated. Alternatively, the end portion 104 can be chamferred or rounded to minimize misalignment impact damage.
The injection nozzle 60 includes a base portion 106 which is continuous with an acutely angled, beveled upper base edge portion 108. The edge portion 108 is continuous with a generally flat face portion 110. A generally cylindrical hollow main body portion 112 rests upon and is integral with the base portion 106 of the injection nozzle 60. At the upper-most end of the hollow main body 112 is a transfer control portion 114 which merges into an acutely angled mating surface 116. The angled mating surface 116 merges into a flat central portion 118 which accommodates an outlet port 120. Internal of the injection nozzle 60 is a generally cylindrical plastic passageway 122, illustrated in phantom, extending through the base portion 106 and the hollow main body 112 and terminating at an angle passageway end portion 124 which merges with the outlet port 120. The diameter of the flexible shaft 102 is 0.001-0.0012 thousandths of an inch in diameter less than the diameter of the outlet port 120 in the preferred practice of the invention, such that the leading portion of the flexible shaft 102 fits snugly within the outlet port 120, but provides minimal metal-to-metal contact. The angles passageway end portion 124 acts as a guide means to assure proper entry of the flexible shaft 102 into the outlet port 120 as the main shaft 90 is advanced toward the outlet port 120. Typically, a maximum flex of 0.020 inches is sufficient to allow proper insertion into the outlet port 120. The entire shut-off pin 92 is preferably fabricated from H-13 commercially available tool steel of a hardness of 50-55 Rockwell C. Generally the flexible shaft 120 is flame hardened for increased service life. A clearance of 0.0006 inches per side with the outlet port 120 is sufficient to allow complete shut-off of plastic flow when crystallizable plastics are used.
As best illustrated in FIG. 5, the mold recess 90 includes a recess wall 126 which is spaced apart from the main body 112 of the injection nozzle 60 to form a annular void 128. The void 128 provides air insulation between the mold recess 90 and the majority of the surface area of the injection nozzle 60. The mold recess 90 further includes an acutely angled mating surface 130 which is of complementary angled to the angled mating surface 116 of the injection nozzle 60. The angled mating surface 130 terminates at a centrally located, flat mating surface 132 which is of the same radial distance as the flat central portion 118 of the injection nozzle 60, such that the portions 118 and 132 match identically in geometry.
The acute angle used for these mating surfaces is determined by the injection nozzle's motion relative to the mold mating surface during the systems start up and shut down thermal cycles. The angle is set so that the nozzles horizontal and vertical motion components determine the acute angle such that the nozzle backs out of its taper location as it slides past the mating surface.
One of the important features of the present invention is the provision of the void 128 which separates the mold recess wall 126 contact with the main body portion 112 of the injection nozzle 60. During start-up procedures for the injection molding system the injection nozzle 60 and the mold 74 are heated and accordingly thermally expand. In currently available injection molding systems the injection nozzle 60 would be in intimate frictional contact with the mold 74 and be subjected to substantial stresses in the event it did not expand at an identical rate to the mold 74 during heat-up procedures. Conversely, during cool-down procedures when the injection molding system would contract due to thermal cooling, the injection nozzle 60 would not contract at the same rate as the mold 74 and would again be subjected to crushing stresses as the metal of the mold 74 contracted around the injection nozzle 60. Such problems have caused substantial difficulties in long term operations of high temperature injection molding machines in the past. The present invention militates against such problems by providing the void 128 intermediate the mold recess 90 and the main body portion 112 of the injection nozzle 60 thereby lengthening injection nozzle lifetimes by preventing contraction of the mold 74 around the base 112 of the injection nozzle 60.
Another important feature of the present invention is the provision of a beveled heat transfer control portion 114 intermediate the main body portion 112 and the angled mating surface 116 of the injection nozzle 60. The beveled heat transfer control portion, as clearly illustrated in FIG. 5, is not in direct thermal contact with the angled mating surface 130 of the mold 74. Accordingly, heat which is contained in the portion 114 is not transferred from the hot nozzle 60 through the portion 114 after the shut-off pin 92 has been moved forward to close the outlet port 120 to stop hot plastic flow into the mold 74. Such elimination of heat flows through portion 114 to mold 74 accelerates the cooling of the sprue 34 of the parison 20. This militates against crystallization of the plastic in the sprue 34. Thus a more amorphous sprue is formed which can be blown and oriented to become part of the bottom of the container.
After molten injected plastic has passed through the passageway 122 into the mold 74 and the flexible shaft 102 of the shut-off pin 92 has been moved into position in the outlet port 120, it is important to quickly transfer heat from the sprue 34, without requiring extra cooling of the remainder of the mold 74. Such rapid heat transfer out of the sprue 34 quickly cools the material so as to allow minimal crystallization in the sprue area 34. The heat which is contained in the molten charge resident in the pasageway 122 is dissipated through the portion 114, after flow is stopped, which portion 114 is not in mechanical contact, yet is in thermal contact, with the hot surface 130 of the mold 74.
Thus, the sprue 34 can be cooled rapidly once the influx of molten plastic charge has been stopped and yet the plastic charge in passageway 122 need not be cooled adjacent the outlet port 120 since substantial heat is retained in the nozzle 60 via portion 114, such heat not entering the mold 74.
It has been discovered according to the present invention that by causing the total distance of the gate 88, indicated at FIG. 5 by area G and the outlet port 120 indicated at FIG. 5 by area OP, to equal sixty thousandths of an inch or less and by the provision of the beveled heat transfer control portion 114, that an essentially amorphous sprue portions 34 can be formed on the parison 20. By such an expedient, the sprue portion 34 can be blown as an integral part of the container body without requiring any sprue removal step in an injection molding cycle. This presents a substantial advantage over conventionally used injection molding systems by lowering net cycle time and removing one set of mechanical devices, namely sprue cutters, from the system.
In an alternative embodiment of the invention, illustrated in FIG. 6, the portions 118, 116 and 114 of the injection nozzle 60 are caused to be roughened to decrease the effective heat transfer surface area they present to the mold 74. In the preferred embodiment, the roughening up or pitting of the surface is accomplished by any conventional vapor-honing or acid-etching technique to roughen the surfaces 118, 116 and 114.
In the embodiment of the invention illustrated in FIG. 7, a heater band 134 is disposed about the middle of the main body portion 112 of the injection nozzle 60 to provide extra heat into the passageway 122 so that the minimal amount of heat dissipated by the portion 114 or the roughened portions 118, 116 and 114 will not adversely affect that portion of the molten plastic which is maintained at the ready in the passageway 122 after the shut-off pin 92 has been moved into position in the outlet port 120 to stop the plastic flow at the end of an injection cycle. While it is important to quickly cool the sprue 34 in the outlet port 120 and the gate 88, it is equally important in some applications to maintain the plastic in the passageway 122 at a sufficiently high temperature that when the shut-off pin 98 is withdrawn from the outlet port 120 the injection of the plastic through the passageway 122 occurs rapidly to shorten injection cycles. In the preferred embodiment of the invention illustrated in FIG. 7, a cover shroud 136 fabricated of an insulated material surrounds the entire heater band 134 to effectively direct substantially all of the heat generated in the heater band 134 into the passageway 122. In FIGS. 6 and 7, like reference numerals define identical structures to the injection nozzle 60 illustrated at FIG. 4. Similarly, a set of conventional thermal pins or so-called heat pipes may be inserted via bored holes in to the main body portion 112 parallel to the main body portion 112 to provide heat.
Alternatively, in another preferred embodiment of the invention, when using the embodiments of the invention illustrated in FIGS. 6 and 7, the shut-off pin 92 may be removed from the apparatus, or held stationary in a position slightly retracted from its full shut-off position, to allow for a thermal shut-off means. When the shut-off pin 92 is maintained in a partially retracted position it acts as a thermal pin, discussed above, to maintain the molten plastic at the proper pre-injection temperature. According to this embodiment of the invention, the roughened surface of the portions 118, 116 and 114 maintain heat in the nozzle 60 and facilitate removal of heat from the sprue 34 of the parison 20 in the outlet port 120 to essentially stop plastic flow and quickly cool the sprue 34 when the parison cavity has been filled and no more material flows through the outlet port 120. The material finally collected in the outlet port 120 when the parison 20 is fully formed within the mold 74 quickly cools because of the surface roughened effect keeping heat from the nozzle 60 from flowing into the mold 74, which provides greater heat dissipation from the sprue 34 by minimizing heat transfer from the molten charge into the sprue 34 and accordingly provides a thermal shut-off for the plastic flow through the passageway 122. Such thermal shut-off simplifies manifold design. Alternatively, the embodiment of the invention illustrated in FIG. 7 provides a substantial plastic viscosity difference between that portion of the plastic which is in the relatively colder outlet port 120, surrounded by the relatively cold surfaces 118, 116 and 114 compared to the plastic in the area of the heater band 134. Accordingly, the viscosity differential between the hot area under the heater band 134 and that material in the colder area of the outlet port 120 causes such a flow distortion as to shut off the plastic flow when the parison 20 is fully formed.
Either embodiment of the invention, using the shut-off pin 92 or a thermal shut-off mechanism without the shut-off pin 92 have been found to be fully offerable with the invention.
In accordance with the provisions of the patent statutes, I have explained the principals and best mode of operation of the preferred embodiments of my invention, and have illustrated and described in the typical embodiments what I consider to be the best embodiments. | An injection nozzle for use in an injection molding apparatus including a generally annular base portion which supports a generally cylindrical hollow side wall portion. The hollow side wall portion terminates at its upper end portion in an inwardly beveled heat transfer control portion. The beveled heat transfer control portion terminates in an angled mating portion which is of complementary angle to the angled mating surface of an injection nozzle accepting recess in the injection mold portion of the apparatus. The injection nozzle structure provides for controlled heat transfer control from the sprue portion of an injection molded parison to prevent crystallization in the sprue portion of the parison. | 1 |
DESCRIPTION
Background of the Invention
The invention relates to a lubricating device, in particular for a universal joint spider, of the type comprising a conduit which communicates with an inlet for lubricant under pressure.
In universal joints, a conduit extends through each trunnion of the spider and usually opens onto the end of the associated bearing bush by way of a portion of enlarged diameter constituting a reservoir. When filling with the lubricant, the pressure provided by the lubricant pump is such that the lubricant is projected onto the ends of the bearing bush without completely filling the reservoir of the spider. The lubricant then continues its travel along each bearing bush and the needles of the rolling bearing and traps a certain amount of air under pressure in the reservoir. The filling is then incomplete and may be found to be insufficient in use, the air under pressure moreover accentuating the initial losses of lubricant.
Further, in the course of the rotation of the joint, a part of the lubricating grease contained in the conduits is discharged under the effect of centrifugal force until a balance is reached between the interior of the reservoirs and the interior chamber of the rolling bearings, which corresponds as a rule to a filling of the reservoir from the end of the bearing bushes to the region of the sealing devices of the latter.
However, in operation, the temperature of the universal joint may rise considerably owing to the temperature of the neighbouring elements (engine, exhaust pipe, etc.), and this increases the fluidity of the lubricant within the spider. Consequently, during periods of inactivity after operation, there is always at least one trunnion which is drained under the effect of gravity into the opposite trunnion located below. Then, when the joint again starts to rotate, the lubricant contained in the lower trunnions does not return into the original trunnions. Indeed, the excess lubricant is discharged by way of the sealing devices under the action of the centrifugal force. The level of the lubricant is therefore re-established in the region of the seals in the considered trunnions, whereas the trunnion or trunnions which were previously drained contain practically no lubricant.
It will be understood that with a repetition of this phenomenon, a spider could rapidly be drained of a large part of its lubricant.
SUMMARY OF THE INVENTION
An object of the invention is to provide a lubricating device which ensures very cheaply a complete and durable filling of the conduit, ie. without an air bubble.
The invention therefore provides a lubricating device of the aforementioned type, wherein there are disposed in the conduit combined means forming a constricted passage and a stop valve, these means comprising a first part whose section is slightly less than the section of the associated portion of the conduit, and a second part forming a flexible skirt extending in the downstream direction and having a diameter at rest which exceeds the diameter of the associated portion of the conduit, and the conduit includes means for retaining such means during the filling of the conduit.
The aforementioned combined means may advantageously comprise a moulded member of plastics material comprising, in succession, the first part, the skirt and a third part which projects from the skirt and is adapted to bear against a transverse surface onto which the conduit opens.
Another object of the invention is to provide a universal joint, of the type comprising a spider which connects two fork elements, each trunnion of which spider carries a bearing bush, the spider being provided with a lubrication connector which communicates with four radial conduits, each of which opens onto the end of a bearing bush, wherein each conduit is part of a lubricating device such as defined hereinbefore.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinafter in more detail with reference to the accompanying drawings which show only one embodiment of the invention and wherein
FIG. 1 is a sectional view of a universal joint according to the invention;
FIG. 2 is a partial sectional view of a part of this universal joint.
DETAILED DESCRIPTION OF THE INVENTION
The universal joint 1 shown in FIG. 1 comprises a spider 2 each trunnion 3 of which carries a bearing bush 4 which is connected to one end 5 of one of the two fork elements 6, 7 of the joint. Each bearing bush 4 is rotatably mounted on its trunnion 3 by a needle bearing 8, the sealing being ensured by a sealing device 9 located at the inner end of the bearing bush 4.
Radially extending from the center of the spider 2 are four lubricating conduits 10 each of which is coaxial with a trunnion 3. Each conduit 10 comprises an inner portion 11 of small diameter which extends roughly to the region of the corresponding sealing device 9, and then a frustoconical shoulder 12 which connects this portion 11 to an outer portion 13 of larger diameter. The portion 13 constitutes a lubricant reservoir and opens onto the end surface of the trunnion 3, ie. directly onto the end 14 of the bearing bush 4.
Extending from the center of the spider 2 is moreover an additional conduit 15 which communicates with the exterior of the spider between two trunnions 3 by way of a connector 16.
Disposed in each conduit 10 is a member 17, preferably moulded from a plastics material, which comprises three successive coaxial parts:
a cylindrical inner part 18 whose diameter is slightly less than the diameter of the portion 11 of the conduit and which has a frustoconical nose portion 19;
a skirt or flexible diaphragm 20 having a V-shaped section and extending from the outer end of the part 18 and diverging outwardly, ie. away from this part 18, to a maximum diameter exceeding the diameter of the reservoir 13 of the conduit 10; and
an outer part 21 which extends outwardly from the center of the skirt 20, axially projects from the latter and has a small diameter, eg. less than the diameter of the part 18.
The member 17 is inserted in the conduit 10 before the bearing bush 4 is placed in position. After assembly, its part 18 is received almost fully in the portion 11 of the conduit of which it occupies the major part of the section. The skirt 20 cooperates frictionally with the wall of the reservoir 13 of the conduit, which bends it slightly, and is located at a short distance from the shoulder 12, and consequently outwardly of the sealing device 9. Part 21 abuts against the end 14 of the bearing bush 4.
When the lubricant is introduced under pressure by way of the connector 16 and the conduit 15, the constricted passage constituted by the part 18 retards the stream of lubricant in each conduit 10. The lubricant retarded in this way reaches the skirt 20, moves the latter away from the wall of the reservoir 13 and thus reaches the reservoir which it gradually fills by expelling any air contained therein. During the filling operation the member 17 is retained axially by the abutment of its part 21 against the end of the bearing bush.
When the filling of the reservoir 13 and the needle bearing 8 has terminated, the injection of the lubricant is stopped. The skirt 20 once again applies itself against the wall of the reservoir 13 and performs the function of a stop valve which prevents the lubricant, even when the latter is rendered very fluid by a rise in temperature, from passing from the reservoir 13 into the portion 11 of the conduit and thence into another conduit 10.
Thus, in the course of operation, after a first partial discharge of lubricant produced by centrifugal force, each conduit 10 is filled up to the region of the sealing device 9 (in travelling toward the center of the spider), ie. in the considered embodiment, up to a little beyond the skirt 20. When stationary, only the amount of lubricant located beyond the skirt 20 can pass into another trunnion 3 located at a lower position. After a certain number of utilization of the universal joint, there is consequently obtained a stabilization of the filling of the reservoir 13 in the region of the skirt 20 of each trunnion. The consumption of lubricant on the part of the universal joint is thus considerably reduced.
In the course of operation, the shoulder 12 performs the function of retaining means for the member 17 in the direction toward the lubricant inlet 15-16.
It will be understood that the invention may be applied to the lubrication of mechanisms different from a universal joint. | Each trunnion of a spider is provided with an axial lubricating conduit having an outer portion forming a reservoir of increased diameter. Each conduit contains a combined device having an upstream part forming a constricted passage with the narrow portion of the conduit and an intermediate part in the form of a skirt and forming a stop valve. In order to ensure the positioning of this device, the skirt cooperates with a shoulder of the conduit, and a third part of the device cooperates with the end of an associated bearing bush. In this way, formation of air bubbles in the course of the filling of the conduits is avoided and the lubricant is retained in the reservoir during the course of operation. | 5 |
The present invention concerns novel indanyl derivatives, a process for their preparation and pharmaceutical preparations containing them as active ingredients.
SUMMARY OF THE INVENTION
It is an object of this invention to provide new compounds having valuable pharmacological properties.
Upon further study of the specification and appended claims, further objects and advantages of this invention will become apparent to those skilled in the art.
These objects have been achieved by providing indanyl derivatives of Formula I ##STR2## wherein R 1 is hydrogen, methanesulfonyl, or acetyl,
R 2 and R 3 jointly mean oxo, oximino, or separately two hydrogen atoms, or
R 2 is hydrogen and R 3 is hydroxy or amino, and when R 3 is amino, the physiologically acceptable acid salts thereof.
DETAILED DESCRIPTION
Suitable physiologically acceptable acids for preparing the physiologically acceptable salts include hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, oxalic acid, malonic acid, tartaric acid and citric acid.
The process of this invention for preparing the novel indanyl derivatives of this invention can be conducted conventionally, e.g., under the conditions set forth in the U.S. Pat. No. 4,244,960 whose disclosure is incorporated by reference herein.
For example, the indanyl derivatives of this invention can be prepared in a conventional manner by condensing a compound of Formula II ##STR3## wherein R 1 , R 2 , and R 3 are as defined above, with methanesulfonic acid chloride, and optionally reducing indanyl derivatives wherein R 2 and R 3 represent an oxo group or an oximino group, or acetylating indanyl derivatives of Formula I wherein R 1 is hydrogen.
The compounds of Formula II are preparable by conventional process disclosed in U.S. Pat. No. 4,244,960.
As compared with the indanyl derivatives described in European Application 9544 (except for the compounds of Formula I wherein R 2 and R 3 are oximino which are preferably employed as intermediates for preparation of other compounds of this invention), the compounds of this invention are distinguished by superior anti-inflammatory efficacy, as demonstrated by the results of the adjuvant arthritis test described below:
Female and male rats of the Lewis (LEW) strain in a weight span between 110 and 190 g were utilized. The animals received drinking water and "Altromin" pressed feed ad libitum.
Ten rats were used for each dosage group.
Mycobacterium butyricum by Difco, Detroit, was used as the irritant. A suspension of 0.5 mg of Mycobacterium butyricum in 0.1 ml of thinly fluid paraffin (DAB [German Pharmacopoeia]7) was injected in a subplantar fashion into the right hind paw.
The test compounds were administered orally and daily over 4 days starting with the 11th day of the trial. The compounds were given as a clear aqueous solution or crystalline suspension with the addition of "Myrj" 53 (85 mg-%) in an isotonic sodium chloride solution.
The rats were subdivided into various groups as uniformly as possible regarding their body weights. After plethysmographic volume measurement of the right hind paw, 0.1 ml of adjuvant was injected in a subplantar manner into this hind paw.
The right hind paws were measured starting from the 14th day of the trial until the end of the experiment. The duration of the trial was three weeks.
The healing of the right paw of the animal was determined in dependence on the dose of test compound applied.
The Table set forth below demonstrates the results obtained in this test with compounds 3 through 5 of this invention as compared with the structurally analogous indanyl derivatives 1 and 2 previously known from U.S. Pat. No. 4,244,960 which corresponds to the European Patent Application No. 0 009 554. The results show that the compounds of this invention are of good efficacy at doses which are so low that the comparison compounds show practically no efficacy at all at them.
______________________________________ % Com- Heal- pound ing of mg/kg RightNo. Compound Animal Paw______________________________________1 N--[6-(4-Fluorophenoxy)-5-indanyl]- 4 × 0.1 0methanesulfonamide 4 × 0.3 02 N--[6-(2,4-Dichlorophenoxy)-5- 4 × 0.1 0indanyl]methanesulfonamide 4 × 0.3 33 N--[6-(2,4-Difluorophenoxy)-5- 4 × 0.1 33indanyl]methanesulfonamide 4 × 0.3 404 N--Acetyl-N--[6-(2,4-difluoro- 4 × 0.1 28phenoxy)-5-indanyl]methanesulfonamide 4 × 0.3 385 6-(2,4-Difluorophenoxy)-5-methyl- 4 × 0.1 36sulfonyl-1-indanone 4 × 0.3 42______________________________________
Accordingly, the novel compounds of this invention are suitable in combination with carriers customary in galenic pharmacy for the treatment of diseases of the spectrum of rheumatic disorders (such as ostearthritis or ankylosing spondylitis), bronchial asthma, hay fever, and others.
It is furthermore remarkable that the indanyl derivatives of this invention are also suitable for the treatment of migraine and dysmenorrhea and reduce the risk of thrombosis.
There may also be compounds among the indanyl derivatives of this invention which may possess, in addition to the antiinflammatory efficacy, a pronounced antiulcerogenic as well as tumor-inhibiting effectiveness.
The useful medicinal preparations (pharmaceutical compositions) are produced in fully conventional fashion by converting the active agents with suitable additives, vehicles, and e.g., flavor-ameliorating agents into the desired forms of administration, such as tablets, dragees, capsules, solutions, inhalants, etc.
For oral administration, tablets, dragees, and capsules are especially well suited, containing, for example, 1-250 mg of active ingredient and 50 mg to 2 g of a pharmacologically inert vehicle, such as, for example, lactose, amylose, talc, gelatin, magnesium stearate, and similar materials, as well as the customary additives.
The typical daily dosage for administration an antiinflammatory is 2-200 mg/kg/day for mammals, including humans. The compounds can be administered for such purposes by analogy to the conventional agent indometacine e.g., by considering the normal factors such as differential potency using fully conventional protocols.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. In the following examples, all temperatures are set forth uncorrected in degrees Celsius; unless otherwise indicated, all parts and percentages are by weight.
EXAMPLE 1
(a) 10.1 g of 5-bromo-6-nitroindan, 4.1 g of copper(I) chloride, 7.1 g of potassium tert.-butanolate, and 8.5 g of 2,4-difluorophenol were refluxed in 210 ml of tert.-butanol for 7 hours. After cooling, dilution with ether, filtration, concentration, taking up the residue in ether, washing of the ether solution with 1N hydrochloric acid, as well as drying and concentration, 10.5 g of a crude product was obtained which was chromatographed over a silica gel column with hexane-ethyl acetate. Yield: 6.3 g of 5-(2,4-difluorophenoxy)-6-nitroindan, mp 65°-68° C. (from hexane).
(b) 14.6 g of 5-(2,4-difluorophenoxy)-6-nitroindan was combined in 300 ml of dioxane-ether 1:1 with 10 g of Raney nickel and thereafter at 40° C. with 4.86 of hydrazine hydrate. After another 30 minutes at 50° C. and 30 minutes under reflux, the mixture was cooled, filtered, and concentrated. Yield: 13 g of crude 6-(2,4-difluorophenoxy)-5-indanylamine.
(c) At 0° C., 13.1 g of 6-(2,4-difluorophenoxy)-5-indanylamine in 60 ml of pyridine was combined with 4.0 ml of methanesulfonyl chloride. After 3 hours at 0° C. and 16 hours at 20° C., the mixture was concentrated, the residue was taken up in chloroform, the solution was washed with 1N hydrochloric acid, and concentrated. Recrystallization of the residue from ethanol yielded 8.1 g of N-[6-(2,4-difluorophenoxy)-5-indanyl]methanesulfonamide, mp 85°-87° C.
EXAMPLE 2
3 g of N-[6-(2,4-difluorophenoxy)-5-indanyl]-methanesulfonamide in 30 ml of pyridine was combined at 0° C. within 10 minutes under nitrogen with 1.5 ml of acetic anhydride and stirred for 3 hours at 0° C. and for 13 hours at room temperature. The mixture was concentrated, the residue taken up in chloroform, extracted three times with 1 N hydrochloric acid and once with water, the organic phase was dried over calcium sulfate, concentrated, and the residue was recrystallized from ethanol.
Yield: 3.1 g of N-acetyl-N-[6-(2,4-difluorophenoxy)-5-indanyl]methanesulfonamide, mp 160° C.
EXAMPLE 3
12.8 g of 5-amino-6-(2,4-difluorophenoxy)-1-indanone in 95 ml of pyridine was combined at 0° C. with 8.3 ml of methanesulfonyl chloride. After 3 hours at 0° C. and 16 hours at 20° C., the mixture was concentrated, the residue taken up in chloroform, the solution washed with 1 N hydrochloric acid, and concentrated. Chromatography of the residue over silica gel with dichloromethane-ethyl acetate yielded 1.2 g of 6-(2,4-difluorophenoxy)-5-bis(methylsulfonyl)amino-1-indanone, mp 190° C. (from toluene) and subsequently 8.9 g of 6-(2,4-difluorophenoxy)-5-methylsulfonylamino-1-indanone, mp 153° C. (from ethanol).
The starting compound for this synthesis step can be obtained in two ways:
Method 1
(a) 13.9 g of 6-(2,4-difluorophenoxy)-5-indanylamine in 93 ml of acetic acid was combined at 30° C. with 40 ml of acetic anhydride. Thereafter a solution of 11 g of chromium trioxide in 27 ml of water and 17 ml of acetic acid was added dropwise at 50° C. After another 40 minutes at 50° C., the mixture was cooled, poured on ice water, and vacuum-filtered. The residue was chromatographed over silica gel with dichloromethane-ethyl acetate, thus obtaining 9 g of 5-acetylamino-6-(2,4-difluorophenoxy)-1-indanone, mp 153° C., and subsequently 4 g of the isomeric 6-acetylamino-5-(2,4-difluorophenoxy)-1-indanone, mp 199° C.
(b) 12.9 g of 5-acetylamino-6-(2,4-difluorophenoxy)-1-indanone was refluxed in 210 ml of ethanol with 22 ml of concentrated hydrochloric acid for 2 hours. The mixture was then concentrated, the residue was combined with water and ammonia solution (pH 8), and the solid 5-amino-6-(2,4-difluorophenoxy)-1-indanone was vacuum-filtered. Yield: 11.1 g, mp 132° C.
Method 2
(a) 4.58 g of 5-(2,4-difluorophenoxy)-6-nitroindan and 8.2 g of bis(dimethylamino)tert.-butoxymethane were stirred in 5 ml of dimethylformamide for 60 minutes at 140° C. Concentration under vacuum yielded crude 1-dimethylaminomethylene-5-(2,4-difluorophenoxy)-6-nitroindan.
(b) This product was dissolved in chloroform, and ozone was introduced at -40° C. (12 minutes, rate: 4.5 g per hour). After nitrogen purging, the mixture was poured on ice water, brought to pH 3 with hydrochloric acid, washed with sodium bisulfite solution, and concentrated. Chromatography of the residue over silica gel with chloroform produced 250 mg of 5-(2,4-difluorophenoxy)-6-nitro-1-indanone, mp 145° C. (from ethanol).
(c) This product was dissolved in 5 ml of ethanol-dioxane 1:1, 250 mg of Raney nickel was added thereto and the mixture was then combined at 45° C. with 100 mg of hydrazine hydrate. After 30 minutes of refluxing the mixture was cooled, filtered, and concentrated. Yield: 240 mg of 5-amino-6-(2,4-difluorophenoxy)-1-indanone, mp 153° C. (from ethanol).
EXAMPLE 4
2.82 g of 6-(2,4-difluorophenoxy)-5-methylsulfonylamino-1-indanone was combined in 30 ml of pyridine with 1.57 g of acetyl chloride. After 20 hours at 20° C., the mixture was concentrated, combined with water, brought to pH 6 with hydrochloric acid, and extracted with chloroform. The chloroform extract was washed neutral, concentrated, and the residue chromatographed over silica gel with toluene-ethanol 99:1.
Yield: 2.50 g of 5-(N-acetyl-N-methylsulfonylamino)-6-(2,4-difluorophenoxy)-1-indanone, mp 182° C. (from ethanol).
EXAMPLE 5
3.53 g of 6-(2,4-difluorophenoxy)-5-methylsulfonylamino-1-indanone was dissolved in 35 ml of methanol and 10 ml of 1 N sodium hydroxide solution and, at 5° C., combined in incremental portions with 0.8 g of sodium borohydride. After 16 hours at 20° C., the mixture was concentrated, mixed with 40 ml of water and 26 ml of 1 N hydrochloric acid, and vacuum-filtered. Recrystallization from ethanol yielded 3.07 g of N-[6-(2,4-difluorophenoxy)-1-hydroxy-5-indanyl]methanesulfonamide, mp 127° C.
EXAMPLE 6
7.06 g of 6-(2,4-difluorophenoxy)-5-methanesulfonylamino-1-indanone was refluxed in 100 ml of methanol and 40 ml of water with 3.40 g of sodium acetate trihydrate and 4 g of hydroxylaminohydrochloride for 3 hours. After cooling, the mixture was vacuum-filtered and dried. Yield: 6.16 g of N-[1-hydroxyimino-6-(2,4-difluorophenoxy)-5-indanyl]methanesulfonamide, mp 240° C.
EXAMPLE 7
3.68 g of N-[1-hydroxyimino-6-(2,4-difluorophenoxy)-5-indanyl]methanesulfonamide was dissolved in 100 ml of ethanol. The solution was saturated with gaseous ammonia, 1 g of Raney nickel was added, and hydrogenation was carried out at 90° C. Cooling, filtering, concentrating, combining with ethanolic hydrochloric acid, concentrating, and crystallizing with ether yielded 2.99 g of N-[1-amino-6-(2,4-difluorophenoxy)-5-indanyl]methanesulfonamide, hydrochloride, mp 220° C.
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples. From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | Compounds of the formula ##STR1## wherein R 1 is hydrogen, methanesulfonyl, or acetyl,
R 2 and R 3 jointly mean oxo, oximino, or separately two hydrogen atoms, or
R 2 is hydrogen and R 3 is hydroxy or amino, and when R 3 is amino, the physiologically acceptable acid salts thereof
possess valuable pharmacological properties. | 2 |
[0001] This application claims the benefit of U.S. Provisional Appl. No. 60/371,780, filed Apr. 11, 2002 by Laura Lynn McGreal and Timothy Richard McGreal entitled “Smoke Alarm Mounting/Installation/Removal From a Distance System and Method”.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed toward securing devices and more particularly toward mounting smoke alarms to support surfaces which are difficult to reach.
[0003] The use of various structures to secure devices at desired locations is, of course, well known in the prior art. Known prior art securing devices include, for example, U.S. Pat. No. 5,149,038; U.S. Pat. No. 4,702,452; U.S. Pat. No. 5,186,653; U.S. Pat. No. 5,188,332; U.S. Pat. No. 5,153,567; U.S. Pat. No. 5,563,766, U.S. Pat. No. 5,577,696 and U.S. Pat. No. Design 246,635.
[0004] While these devices fulfill their respective objectives and requirements, the aforementioned patents have limited utility in allowing for smoke alarms to be mounted to support surfaces which are difficult to reach, particularly where the smoke alarms must be accessed from time to time for servicing, as to replace a battery, or for regular cleaning per all smoke detector manufacturer instructions, or to replace defective units, or upgrade an entire system by replacing all units. It should also be noted that for all embodiments of the present invention, the system can be installed without the use of a ladder, with the exception of hard-wired systems which require an electrical connection to the mounting plate.
[0005] The present invention is directed toward overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
[0006] In one aspect of the present invention, a smoke detecting apparatus which is releasably securable to a support surface from a distance is provided, including a smoke detector, a support plate securable to the support surface, a longitudinal member having a proximate end graspable by a user and a distal end releasably securable to the smoke detector, a first releasable connection requiring a force of R on the smoke detector to connect the support plate and the smoke detector, and a second releasable connection between the smoke detector and the longitudinal member distal end.
[0007] In one form of this aspect of the invention, the support plate and the smoke detector are connectable at different relative angular orientations about a center, with a first electrical contact provided on one of the support plate and smoke detector and a second electrical contact provided on the other of the support plate and smoke detector. The first electrical contact is annular with a selected radius about the center and the second electrical contact is spaced the selected radius from the center whereby the first and second electrical contacts are in contact in all of the different relative angular orientations.
[0008] In another form of this aspect of the present invention, the first and second releasable connections are threaded engagements and the second releasable connection is releasable by a force of S, where R and S are torques and S>R. In one form of this aspect of the invention, the second releasable connection includes a snap releasable with a relative torque of S between the smoke detector and the longitudinal member distal end. In another form, the first and second releasable connections include matching threaded connections whereby a torque applied to the longitudinal member by a user unscrews one of the connections and screws together the other of the connections. In this form, a snap connection may also be provided between the smoke detector and the longitudinal member distal end, where the snap connection requires a torque of S to disconnect and a torque of R screws together the first releasable connection until the smoke detector threaded connection is seated in the support plate threaded connection.
[0009] In other forms of this aspect of the present invention, the first and second releasable connections are releasable snap connectors. The second releasable connection may include first and second selectable connectors on the longitudinal member distal end, where the first and second selectable connectors are releasably connectable to the smoke detector. In another form, the first connection has a separating force of Y, the first selectable connector is secured to the smoke detector by a separating force no greater than X, the second selectable connector is secured to the smoke detector by a separating force no less than Z, at least one of X<(Y−W) and X<Y is true, and at least one of Y<Z and (Y−W)<Z is true, where W is the weight of the smoke detector. X<(Y−W)<Z when the support surface is a ceiling, and X<Y<Z when the support surface is a wall. In a further form, the first and second connectors may be slotted balls receivable in a socket in the smoke detector, with the first connector slotted ball having wider slots than the second connector slotted ball, and the selected one of the first and second connectors, the smoke detector socket, and the detector plate are aligned along the axis.
[0010] In still another form of this aspect of the present invention, the support plate includes a first magnet releasably securable by a magnetic force greater than W to the smoke detector. In another form, the smoke detector includes a second magnet, the first and second magnets being circular. In still another form, the first releasable connection has a separating force of Y, the longitudinal member distal end includes a third magnet magnetically attracted to the smoke detector, a selectable spacing member is adapted to space the third magnet from the smoke detector by a distance A, wherein the magnetic attraction between the second magnet and the smoke detector is Z when adjacent and X when spaced apart a distance A, and at least one of X<(Y−W) and X<Y is true and at least one of Y<Z and (Y−W)<Z is true, where W is the weight of the smoke detector.
[0011] In another aspect of the present invention, a smoke detecting apparatus releasably securable to a support surface from a distance is provided, including a smoke detector weighing W with a detector plate, a support plate securable to the support surface and releasably securable to the detector plate where the support plate and detector plate release from one another with a separating force of Y, and a longitudinal member having a proximate end graspable by a user and a distal end releasably securable to the smoke detector. The distal end includes a selectable first connector releasably securable to the smoke detector for mounting the smoke detector to the support plate and a selectable second connector securable to the smoke detector for detaching the smoke detector from the support plate. The first connector is secured to the smoke detector by a separating force no greater than X and the second connector is secured to the smoke detector by a separating force no less than Z, where Y>W, at least one of X<(Y−W) and X<Y is true, and at least one of Y<Z and (Y−W)<Z is true.
[0012] In one form of this aspect of the invention, the support plate and the detector plate are releasably securable at different relative angular orientations about a center, with a first electrical contact provided on one of the support plate and detector plate and a second electrical contact provided on the other of the support plate and detector plate. The first electrical contact is annular with a selected radius about the center and the second electrical contact is spaced the selected radius from the center whereby the first and second electrical contacts are in contact in all of the different relative angular orientations.
[0013] In another form of this aspect of the invention, the releasable securing of the support plate and the detector plate comprises a releasable snap connector, and/or the first and second connectors comprise snap connectors. In further forms, the first and second connectors comprise slotted balls or two balls of differing diameters receivable in a socket in the smoke detector, the first connector slotted ball having wider slots than the second connector slotted ball.
[0014] In a further form, the selected one of the first and second connectors, the smoke detector socket, and the detector plate are aligned along the longitudinal member axis.
[0015] In still another form of this aspect of the invention, the support plate includes a first magnet releasably securable to the detector plate, wherein the detector plate and first magnet are securable together by a magnetic attraction force greater than W. In a further form, the detector plate is a magnet and both the first magnet and the detector plate are circular.
[0016] In yet another form of this aspect of the invention, the longitudinal member distal end includes a second magnet magnetically attracted to the smoke detector, and a selectable spacing member is adapted to space the second magnet from the smoke detector by a distance A, wherein the magnetic attraction between the second magnet and the smoke detector is Z when adjacent and X when spaced apart a distance A.
[0017] In another form, the support plate has a concave conical mating surface, and the detector plate has a convex conical mating surface.
[0018] In still another aspect of the present invention, a kit for releasably securing a smoke detector to a support surface from a distance is provided, including a support plate securable to the support surface, a longitudinal member having a proximate end graspable by a user and a distal end releasably securable to the smoke detector, and first and second releasable connecting members. The first releasable connecting member is adapted to connect the support plate and the smoke detector, with the first connecting member securing a connected support plate and smoke detector against disconnecting when subjected to a separating force up to Y. The second releasable connecting member is adapted to connect the smoke detector and the longitudinal member distal end, and includes selectable first and second connectors. The first connector is secured to the smoke detector by a separating force no greater than X and the second connector is secured to the smoke detector by a separating force no less than Z, where at least one of X<(Y−W) and X<Y is true, where W is the weight of the smoke detector, and at least one of Y<Z and (Y−W)<Z is true.
[0019] In one form of this aspect of the invention, the second releasable connection includes first and second selectable connectors on the longitudinal member distal end, where the first and second selectable connectors releasably connectable to the smoke detector. In a further form, the first releasable connection and the second releasable connection comprise snap connectors. In a still further form, the first and second connectors comprise slotted balls receivable in a socket in the smoke detector, with the first connector slotted ball having wider slots than the second connector slotted ball.
[0020] In another form of this aspect of the invention, the smoke detector weighs W, the first releasable connection has a separating force of Y, and the second releasable connection includes a magnet on the longitudinal member distal end which is magnetically attracted to the smoke detector and a selectable spacing member adapted to space the magnet from the smoke detector by a distance A, where the magnetic attraction between the second magnet and the smoke detector is Z when adjacent and X when spaced apart a distance A, where X<(Y−W)<Z.
[0021] In yet another aspect of the present invention, a kit for releasably securing a smoke detector to a support surface from a distance is provided, including a support plate securable to the support surface, a longitudinal member having a proximate end graspable by a user and a distal end releasably securable to the smoke detector, a first releasable connection requiring a force of R on the smoke detector to connect the support plate and the smoke detector, and a second releasable connection between the smoke detector and the longitudinal member distal end. The first releasable connection and the second releasable connection are threaded engagements and the second releasable connection is releasable by a force of S, where R and S are torques and S>R.
[0022] In one form of this aspect of the invention, the second releasable connection includes a snap releasable with a relative torque of S between the smoke detector and the longitudinal member distal end.
[0023] In another form of this aspect of the invention, the first releasable connection and the second releasable connection comprise matching threaded connections whereby a torque applied to the longitudinal member by a user unscrews one of the first releasable connection and the second releasable connection and screws together the other of the first releasable connection and the second releasable connection. In a further form, a snap connection is provided between the smoke detector and the longitudinal member distal end, where the snap connection requires a torque of S to disconnect and a torque of R screws together the first releasable connection until the smoke detector threaded connection is seated in the support plate threaded connection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a perspective view of a first embodiment of the present invention;
[0025] [0025]FIG. 2 is a perspective, cross-sectional view illustrating the imminent removal of a smoke detector from a supporting surface using the first embodiment of the present invention;
[0026] [0026]FIG. 3 is a perspective view of an alternate support plate usable with the first embodiment of the present invention;
[0027] [0027]FIG. 4 is a perspective view of an alternate pole attachment structure usable with the first embodiment of the present invention;
[0028] [0028]FIG. 5 is an exploded view of the FIG. 4 pole attachment structure;
[0029] [0029]FIG. 6 is a perspective, cross-sectional view illustrating a second embodiment of the present invention;
[0030] [0030]FIG. 7 is an exploded view of the second embodiment of the present invention;
[0031] [0031]FIG. 8 is an enlarged, exploded partial view of the lower connection of a smoke detector and pole according to the second embodiment of the present invention;
[0032] [0032]FIG. 9 is an exploded perspective view of the lower screw plate and lower nut plate of the second embodiment of the present invention;
[0033] [0033]FIG. 10 is a side view of the second embodiment of the present invention;
[0034] [0034]FIG. 11 is a cross-sectional view taken along line 11 - 11 of FIG. 10;
[0035] [0035]FIG. 12 is a side, partial cross-sectional view of a third embodiment of the present invention;
[0036] [0036]FIG. 13 is an exploded view of the third embodiment of the present invention; and
[0037] [0037]FIG. 14 is an enlarged perspective view of the pole attachment structure of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] In accordance with the present invention, a smoke detector can be selectively decoupled from a remote support surface to permit an individual to service or silence the smoke detector from a distance or for regular cleaning per all smoke detector manufacturer instructions, or to replace defective units, or upgrade an entire system by replacing all units. It should also be noted that for all embodiments of the present invention, the system can be installed without the use of a ladder, with the exception of hard-wired systems which require an electrical connection to the mounting plate.
[0039] One embodiment of the mounting structure for a smoke alarm or smoke detector 30 according to the present invention is shown in FIGS. 1 - 3 . This embodiment uses magnetic couplings between the smoke detector 30 and the support surface 32 , and between the smoke detector 30 and the longitudinal member 34 , such as a pole, which may be used during installation and/or servicing to reach the smoke detector 30 mounted in a hard to reach location, such as a ceiling or high on a wall. For simplicity of illustration, only the smoke detector housing is illustrated in the figures, with the internal operating components thereof omitted.
[0040] In accordance with this embodiment, a support plate 36 may be suitably secured to a desired location on a support surface 32 , such as a ceiling or a wall. The support plate 36 may be secured to the support surface 32 by any suitable support means, including means such as adhesive or a self-drilling fastener which may allow installation without requiring that the installer us a ladder, step stool, or the like. To accommodate a suitable fastener such as a screw or a self-drilling fastener, one or more mounting apertures 38 may be provided in the plate 36 .
[0041] A magnet 40 is suitably secured to the support plate 36 , as by a mechanical fastener or an adhesive. Alternatively, the support plate magnet 40 may include a mounting aperture directed therethrough as shown in the drawings permitting selective securement of the magnet 40 directly to the support surface 32 if so desired. The support plate 36 may also include suitable contacts or terminals 44 which may be connected as desired (e.g., for hard wired power or remote communication of the smoke detector 30 ). The terminals 44 are connected to downwardly facing ring connectors 45 (see FIG. 3) which may be connected at any point around their lengths to smoke detector contacts 46 to provide a detachable electrical connection between the support plate 36 and the smoke detector 30 in any angular orientation between the two.
[0042] A mating top magnet 50 is also suitably attached to the smoke detector 30 , as by adhesive or mechanical fasteners, which magnet 50 may be selectively coupled to the support plate magnet 40 as described hereafter. When positioned adjacent one another, the magnets 40 , 50 provide an attractive force therebetween whereby they may only be separated by a separating force of Y. It should be appreciated, therefore, that so long as Y is greater than the weight (W) of the smoke detector 30 , the smoke detector 30 may be detachably or releasably secured via the support plate 36 to the support surface 32 which is horizontal (such as a ceiling).
[0043] Further, it should be appreciated that the illustrated cylindrical geometry of the magnets 40 , 50 will enable the smoke detector 30 to be reliably connected to the support plate 36 no matter the annular orientation relative to each other. Further, it should be recognized that by selecting magnets 40 , 50 which have opposite poles which extend laterally relative to the smoke detector 30 (i.e., not vertically in a ceiling mounted smoke detector 30 ), the magnets 40 , 50 may be used to bias the smoke detector 30 about its central axis to a specific rotational position. This may therefore assist in ensuring, for example, that contacts will be suitably self-aligned during mounting where such alignment is desired or necessary.
[0044] Another releasable magnetic connection is also provided between the opposite (bottom) side of the smoke detector 30 and a mounting pole 34 .
[0045] Specifically, a lower smoke detector magnet 56 is suitably attached to the bottom of the smoke detector 30 (e.g., by adhesives or mechanical fasteners). A mating pole magnet 60 is suitably secured to the end of the pole 34 in a retainer 62 which has a gap cap 64 which may be selectively capped onto the retainer 62 whereby the magnet 60 may be used to provide two different releasable connectors to the smoke detector 30 as described below. In an alternate embodiment, the pole magnet 60 may be an electromagnet suitably powered, as by a battery mounted in the pole.
[0046] Specifically, when installing a smoke detector 30 , the cap 64 may be snapped over the magnet 60 whereby the upper surface of the cap 64 is a selected distance (A) from the upper surface of the magnet 60 . The smoke detector 30 may then be placed with its lower magnet 56 adjacent the cap 64 , whereby the magnetic force therebetween having a separating force X will securely hold the smoke detector 30 on the end of the pole 34 . As illustrated in FIG. 1, the pole 34 may be provided with an adjustable elbow 66 as well as a resilient member 68 to reduce the sensitivity of the system to planar misalignments and to facilitate handling of the pole 34 and attached smoke detector 30 .
[0047] The installer may then use the pole 34 to position the smoke detector 30 adjacent the support plate 36 mounted to the support surface 32 as previously described, with the support plate magnet 40 and upper smoke detector magnet 50 adjacent each other whereby their attractive magnetic force will secure them together in the desired position as previously noted. It should be appreciated that the magnetic force securing the smoke detector 30 to the pole 34 is selectively less than the magnetic force securing the smoke detector to the supporting plate 36 , so that when the installer pulls the pole 34 away from the smoke detector 30 , the smoke detector 30 will remain secured to the support plate 36 due to its greater securing force. In the case of a conventional horizontal ceiling mount, this would require that X<(Y−W), where the separating force (Y) of the support plate connection should be sufficient to overcome both the separating force (X) of the pole 34 when it is pulled down and the weight (W) of the smoke detector.
[0048] Alternatively, where the smoke detector is to be mounted to a horizontal wall, the magnets could be selected whereby X<Y, since the support plate magnetic connection need not also support the weight of the smoke detector 30 . For example, the smoke detector 30 may be received within a cup portion of a support plate where there is a mechanical interference between the side of the cup portion and the smoke detector 30 which supports the smoke detector 30 , with the magnetic attraction (X) required only to be enough to prevent the smoke detector 30 from tipping out of the cup portion. If the wall connection does not have such a mechanical interference supporting the smoke detector 30 , then the friction forces between the vertical surfaces must be sufficient to support the smoke detector. Of course, the friction forces in such a case would be a function of the magnetic attraction force between the magnets 40 , 50 and the coefficient of friction.
[0049] When it is later desired to remove the smoke detector 30 from the support surface 32 , such as for servicing (e.g., replacing batteries), the cap 64 may be removed from the top of the retainer 62 (a suitable snap may be provided along the side of the pole 34 to hold the cap 64 clear of the retainer 62 ), whereby the service person may reach up with the pole 34 and position the magnet 60 adjacent the bottom smoke detector magnet 56 , without the spacing (A) therebetween caused by the cap 64 . It will be appreciated that the magnetic attraction force, and the force required to separate the magnets, is a function, inter alia, of the proximity of the magnets 56 , 60 . In accordance with this embodiment of the present invention, the separating force (Z) of the magnets 56 , 60 when directly adjacent one another (i.e., without the spacing A provided by the cap 64 ) is sufficient to overcome the separating force between the magnets 40 , 50 holding the smoke detector 30 to the support plate 36 . Thus, in the case of a conventional horizontal ceiling mount, X<(Y−W)<Z, and in the case of a vertical wall mount, X<Y<Z. Of course, if other forces also secure the smoke detector 30 to the support plate 36 (e.g., friction between the electrical contacts 44 , 46 ), those forces may also be taken into account.
[0050] It should be appreciated that the above illustrated embodiment advantageously uses pairs of magnets to provide the magnet connections. As previously mentioned, the polarity of the magnet pairs assists may be used to ensure a desired rotational orientation. Further, the polarity of the magnet pairs on opposite sides of the smoke detector 30 may be used to ensure that the smoke detector 30 is not accidentally installed upside down. That is, the magnets may be installed so that an attempted connection between the pole 34 and the top magnet 50 of the smoke detector 30 would impossibly attempt to connect magnets at their same north or south poles. The same may be used to prevent connection of the bottom of the smoke detector 30 to the support plate 36 . It should also be appreciated, however, that it would still be well within the scope of the invention to provide a single magnet with each connection, with a suitable magnetically attracted (but not itself magnetic) component, such as a steel plate, secured to the other of the components to be secured together.
[0051] It should be appreciated that any suitable selectable spacer, permitting selected different spacing such as provided by the cap 64 in the above described embodiment, may also be used in accordance with the present invention.
[0052] For example, FIGS. 4 and 5 illustrate an alternative embodiment for a tool which may be secured to the end of the pole 34 to create two differing gaps, and hence two different magnetic forces using the same magnet type within the assembly. Specifically, a yoke 70 includes a suitable attachment portion 72 for securing to a selected pole 34 . A housing 74 includes interior supports on opposite ends for supporting magnets 76 , 78 at different spacings relative to the ends 80 , 82 of the housing 74 . Alternatively, to facilitate alignment, the magnets as described above may be designed of the “floating” type, similar to those that may commonly be found on kitchen cabinet doors.
[0053] Therefore, it will be appreciated that substantially identical magnets 76 , 78 may be used at opposite ends 80 , 82 of the housing 74 to provide different selectable connectors at each end having different magnetic attractive forces when the different housing ends are positioned adjacent the smoke detector lower magnet 56 . Further, the housing 74 includes lateral cylindrical projections 84 which may be suitably connected to the yoke 70 , as by a snap-fit, for pivoting between selected positions.
[0054] Detents 86 are provided yoke 70 and are receivable in selected slots in the housing cylindrical projections to allow the housing to be selectively secured in a position relative to the yoke 70 and pole 34 , enabling the user to position the appropriate housing end 80 , 84 (with selected separating force depending on the usage as previously described) in engagement with the smoke detector lower magnet 56 at a convenient position for reaching the support plate 36 . For example, positioning the housing 74 at an angle (e.g., 45 degree angle) relative to the axis of the pole 34 can facilitate the installation of a smoke detector assembly on a non-horizontal, non-vertical surface such as a “cathedral” type ceiling. Of course, still other structures allowing positioning of different magnets/different magnetic forces relative to a selected smoke detector 30 may also be used within the scope of the present invention.
[0055] An alternative embodiment is shown in FIGS. 6 - 11 in which threaded connections are used instead of magnetic connections such as described above.
[0056] In accordance with this embodiment, a support screw plate 100 having right-handed external screw threads 102 may be suitable secured on its upper surface to a support surface (e.g., by adhesives or mechanical fasteners, such as previously described). An upper nut plate 106 is also suitably secured to the top of the smoke detector 30 , such as by adhesives, fasteners, or the like. The support screw plate threads 102 can mate with the internal screw threads 108 of the upper nut plate 106 .
[0057] A lower screw plate 110 with left-handed external screw threads 112 is suitably secured on the lower side of the smoke detector 30 (e.g., by adhesives, fasteners, or the like) and a lower nut plate 114 with left-handed internal screw threads 116 is suitably secured to the end of the pole 34 . The screw threads 112 , 114 of the lower screw plate 110 and the lower nut plate 114 are designed to mate with each other.
[0058] Cooperating snaps 120 , 122 (see FIG. 8) are provided with the lower screw plate 110 and lower nut plate 114 , respectively to provide a two-way snap fit between the lower nut plate 114 and the lower screw plate 112 when the two are sufficiently threaded together, as shown in cross-section in FIG. 11. A similar set of snaps is provided on the support screw plate 100 and the upper nut plate 106 . The snaps may be chosen so that they may be “tuned” by a manufacturer to provide a connection having a fairly precise separating force, or may be more broadly selected with the separating force determined after manufacture by testing.
[0059] As illustrated in FIG. 7, suitable mounting and spacing plates 124 , 126 , 128 may be used to facilitate use of the present invention with smoke detectors 30 , including retrofitting with smoke detectors 30 not specifically adapted for connection of such mounting components. For example, the plates 124 , 126 , 128 may include mounting holes and/or adhesives on both sides for mounting between suitable smoke detectors 30 and mounting components. Moreover, it should be appreciated that the present invention encompasses not only smoke detectors inclusive with the mounting components (including pole 34 ), but also includes kits which may be provided separately from smoke detectors 30 where the kits may then be used with a selected smoke detector 30 for mounting at a desired location. It is conceivable that components of the present invention could also be used to install/remove other items from inaccessible locations, such as video (spy) cameras, banners, curtains, etc.
[0060] In accordance with this embodiment, an installer will first screw the lower screw plate 110 and lower nut plate 114 together until a pronounced “snap” of the cooperating snaps 120 , 122 is heard, at which point the smoke detector 30 will be securely positioned on the pole 34 . The installer then uses the pole 34 to raises the assembly up to position the upper nut plate 106 in the support screw plate 100 secured to the support surface 32 , and then rotates the pole 34 clockwise (when looking up) until the upper nut plate 106 and support screw plate 100 “bottom out” and hence are rotatably locked together. At this point, the installer continues rotating the handle 34 clockwise (when looking up) and the left-handed threads of the lower screw plate 110 and lower nut plate 114 begin to unscrew. The process is complete when the lower screw plate 110 and lower nut plate 114 are completely disengaged, at which point the pole 34 is disconnected from the smoke detector 30 with the smoke detector 30 installed on the support surface 32 .
[0061] Thereafter, when it is desirable to remove the smoke detector 30 , the service person may raise the pole 34 up to mate the lower nut plate 114 (on top of the pole 34 ) with the lower screw plate 110 (on the bottom of the smoke detector 30 ), and then rotates the pole counter-clockwise until the lower screw plate 110 and lower nut plate 114 “bottom out” and hence are rotatably locked together. The counter-clockwise rotation is then continued until the support screw plate 100 and upper nut plate 106 are completely disengaged, at which point the smoke detector 30 will be disconnected from the support surface 32 and securely supported on the pole 34 whereby the service person may lower the pole 34 to gain access to the smoke detector 30 .
[0062] The snaps can be utilized to prevent a user from not tightening the components properly enough by creating an audible indication when the screw threads have attained a specific level of engagement. Further, the snaps can operate to create an additional force holding the threaded components together which is greater than the releasing force (R) of the other threaded components so that, for example, when twisting the pole 34 when mounting the smoke detector 30 the threads between the lower nut plate 114 (on top of the pole 34 ) and the lower screw plate 110 (on the bottom of the smoke detector 30 ) will not begin to unthread until the threaded connection of the smoke detector 30 to the support surface 32 bottoms out.
[0063] FIGS. 12 - 14 illustrate yet another embodiment incorporating the present invention using snap-type connections.
[0064] With this embodiment, a support snap plate 200 is suitably secured to a support surface 32 such as previously described, and a detector snap plate 202 is suitably secured to the top of the smoke detector 30 , as by a mounting and spacing plate 206 which may, for example, have adhesive on both sides. The support snap plate 200 includes a detent-type annular projection 210 which may be snap-fit into an annular groove 212 in the detector snap plate 202 . Similar to the magnetic-attraction embodiment, the snap connection has a separating force of Y. It should be appreciated that a snap connection may be used which may be separated by twisting, in which case the separating force would be required to be sufficient to allow twisting sufficient for such separation without separating the pole 34 from the smoke detector 30 .
[0065] A socket-type receiver 220 is suitably secured to the lower side of the smoke detector 30 , for mating with a selected one of two connectors secured to the pole 34 . Specifically, a connecting member 226 includes two selectable connectors comprising a pair of slotted balls 230 , 232 , where one ball 230 is configured (e.g., by use of larger slots permitting the fingers forming the ball 230 to be more easily bent) so as to have a lower separation force (X) from the socket-type receiver 220 than the separation force (Z) of the other ball 232 . The relationship of X, Y and Z such as previously stated with the magnetic-attraction embodiment may also be provided with this embodiment.
[0066] Further, similarly to the embodiment illustrated in FIGS. 4 and 5, the connecting member 226 is rotatably secured to a yoke 238 secured to the pole 34 , with a suitable detent between the connecting member pivot 240 and the yoke 238 to secure the selected slotted ball 230 , 232 in the desired position for use.
[0067] It should also be recognized that a magnetic coupling (including permanent magnets and electromagnets), screw-type fastener, hook-and loop, removable adhesive may be utilized instead of a snap-fit and vice versa. Any one may be exchanged with any other and still provide a fully functional invention. Moreover, as one example, a magnetic connection between the support surface 32 and smoke detector 30 such as described in connection with the FIGS. 1 - 5 embodiments could be used with the snap connection between the pole 34 and smoke detector 30 as described in connection with the FIGS. 12 - 14 embodiment, where the relative relationship of X, Y and Z is maintained. As yet another of many such examples, a magnetic connection could alternatively be provided between the pole 34 and the smoke detector 30 , with a snap connection provided between the support surface 32 and the smoke detector. At this stage in development, it appears that the snap-type embodiment is the best mode for coupling the topside of the smoke detector 30 to the support surface 32 , and a magnet mounted on the lower side of the detector 30 that can couple to a magnet on the pole 34 would be the best-mode for the lower coupling.
[0068] It should also be appreciated that the use of conical connecting components may be advantageously used in connection with the present application to assist in properly positioning components being secured together. For example, it can be seen in FIGS. 6 - 7 , portions of upper nut plate 106 taper inward to facilitate entry into the annular opening of the support screw plate 100 , portions of the lower screw plate 110 and lower nut plate 114 taper to facilitate entry into each other (see FIGS. 6 - 9 ), and detector snap plate 202 tapers inward to facilitate entry into support snap plate 202 (see FIGS. 12 - 13 ). Particularly for the magnetic connections, this type geometry creates a go-no go situation where there is either a “full” magnetic coupling or there is no coupling.
[0069] It should thus be appreciated that, in use, smoke alarms and mounting kits embodying the present invention can be easily utilized to effect removable coupling of a smoke detector 30 from a distance relative to a support surface 32 within a building structure or the like. The present invention allows an individual to install and selectively decouple the smoke detector 30 from a distance from the support surface 32 so as to effect servicing of the smoke detector 30 and/or silencing of the smoke detector 30 due to a false alarm such as can be caused by cigarette smoke or smoke generated from cooking appliances within the home. Additionally, the present invention will enable the physically disabled and/or elderly to remove and install their smoke detectors with relative ease, and reduce injuries/deaths from the increased use of smoke detectors due to ease of use/install, reduced number of smoke detectors with missing or discharged batteries, and decreased number of falls from ladders.
[0070] Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained. | A mounting kit and smoke detecting apparatus releasably mountable to a distant support surface, including a smoke detector weighing W, a support plate securable to the support surface and releasably securable to the smoke detector by a separating force of Y, and a longitudinal member having a proximate end graspable by a user and a distal end releasably securable to the smoke detector. A selectable first connector on the distal end is releasably securable to the smoke detector for mounting the smoke detector to the support plate and a selectable second connector is securable to the smoke detector for detaching the smoke detector from the support plate. The first connector is secured to the smoke detector by a separating force no greater than X and the second connector is secured to the smoke detector by a separating force no less than Z. At least one of X<(Y−W) and X<Y is true, and at least one of Y<Z and (Y−W)<Z is true. | 6 |
This application refers to and claims benefit of previously filed provisional applications 60/324,367 filed Sep. 24, 2001 and 60/327,946 filed Oct. 10, 2001 and 60/348,246 filed Jan. 15, 2002.
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
A typical toilet tank like that found in most homes has a flush valve located on the inside bottom of the toilet tank. A flapper resting on top of the flush valve stops the flow of water through the flush valve and forms a somewhat watertight seal. When the toilet handle is pushed downwards, the flapper is lifted allowing water to flow through the flush valve, flushing the toilet. The method of sealing the flush valve with a flapper is common. At some point, the underside of the flapper and the top portion of the flush valve that are in contact and forms a somewhat watertight seal degenerates and begins to leak. Leaking begets leaking and after some time a considerable amount of water is being wasted and the flush valve and flapper must be replaced.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to provide a leak proof flush valve that will retrofit existing toilet tanks as well as be able to be installed in new toilet tanks. The Leak Proof Toilet Tank Flush Valve comprises a toilet tank flush entrance that normally rests in a position above the waterline so water can never leak into the flush entrance. Only when the toilet is being flushed does the entrance momentarily fall below the waterline so the water can enter the entrance of the drain and flush the toilet.
An alternative design of the Leak Proof Toilet Tank Flush Valve incorporates the minimum number of components of the Leak Proof Toilet Tank Flush Valve necessary to operate the flush valve.
The invention is thus directed to a flush valve comprising:a flush basket having a drain aperture passing through it, the drain aperture having a peripheral edge; a side wall extending from the flush basket and encircling the peripheral edge of the drain aperture, the sidewall having at least one drain hole passing through it; a guide support connected to the side wall such that the guide support extends within or above drain aperture, the guide support having a guide hole passing through it and wherein the guide hole is disposed in registration with the drain aperture, and further wherein the guide support is a substantially C-shaped member having two arms, wherein the arms of the C-shaped member are connected to opposing points of the side wall; a guide rod having a first end and a second end, wherein one end of the guide rode is disposed within the guide hole of the guide support and is dimensioned and configured to slidingly pass through the guide hole; a flexible tube surrounding the guide rod, the flexible tube having a first end and a second end, wherein the first end of the flexible tubing is fastened about the first end of the guide rod, and the second end of the flexible tube is fastened about the side wall of the flush basket at a point removed from the at least one drain hole; and a flush lever dimensioned and configured to force an edge of the flush basket below the water line within a toilet tank. The invention may further comprise a clip frictionally and releasibly attached to the guide rod at a point proximate to the second end of the guide rod and abutting the guide support, and wherein the clip is dimensioned and configured to prevent the second end of the guide rod from being withdrawn from the guide hole.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is perspective view of the fill valve.
FIG. 2 is perspective view of the flush basket.
FIG. 3 is another perspective view of the partially assembled flush handle mechanism.
FIG. 4 is a perspective view of the flush handle mechanism mounted onto the tank.
FIG. 5 is a perspective view of the flexible tubing.
FIG. 6 is a perspective view of the flush drain.
FIG. 7 is a perspective view of the clip.
FIG. 8 is a perspective view of the assembled parts with the tank filled with water.
FIG. 9 is a perspective view of the assembled parts during the flush cycle.
FIG. 10 is perspective view of the alternative fill valve.
FIG. 11 is perspective view of the alternative flexible tubing.
FIG. 12 is perspective view of the alternative flush handle.
FIG. 13 is perspective view of the alternative flush drain.
FIG. 14 is perspective view of all the alternative assembled parts.
FIG. 15 is perspective view of the alternative assembled parts during the flush cycle.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 . The bottom threaded portion of fill valve 21 extends through a hole in the bottom of tank 2 and is first fastened to the tank 2 with a nut and then connected to a water supply. When the lever 25 is lifted upwards enough, the fill valve 21 is shut off. When the lever is slightly lowered as shown, the fill valve 21 is turned on and water flows into the tank 2 through tank fill holes 23 and into the bowl 4 through the bowl fill outlet 27 via a fill tube 31 (shown in FIG. 8 ).
Referring to FIG. 2 . The flush basket 1 having a drain 7 with side walls that extend both upwards and downwards through the base of flush basket 1 as shown. The top edge of the side walls of drain 7 are of sufficient height so that when the flush basket 1 is placed in a tank of water, the volume of water the flush basket 1 can hold without spilling over the upper edge of the side walls of drain 7 is sufficient in weight to sink the flush basket 1 . Drain holes 9 are positioned around the base of the side walls of drain 7 as shown. A guide hole support 3 extends from the side walls of drain 7 as shown and has a guide hole 5 positioned on the guide hole support 3 as shown. The flush basket 1 is made from a plastic or rubber material or another material that will perform the functions outlined here.
Referring to FIG. 3 and FIG. 4 . The handle 57 has a lever 61 extending from it as shown. A threaded cylinder 59 slips over the lever 61 so one end is flush or nearly flush with the base of the cavity in handle 57 as shown. Two stops 67 extend inwards from the walls of the cavity in handle 57 as shown. A stop edge 69 extends outward from the threaded cylinder 59 and is positioned between the two stops 67 as shown. When the threaded cylinder 59 is held in place, the handle 57 is free to rotate in both directions about the central axis of threaded cylinder 59 with the two stops 67 defining the outer limits of the rotation. A pivot plate 63 has a notch at one end for engaging the threaded cylinder 59 . The flush lever 65 has a hole 70 that extends through flush lever 65 and pivot plate 63 and a pin 71 extending through hole 70 fastens the flush lever 65 and pivot plate 63 together so both can pivot about the central axis of pin 71 . The lever 61 and threaded cylinder 59 extends from the outside of tank 2 through a hole in tank 2 that is designed to accept handles. The notch in pivot plate 63 then engages threaded cylinder 59 and a threaded nut 73 is fastened onto threaded cylinder 59 fastening the handle mechanism to the tank 2 as shown. The handle 57 is free to rotate in both directions about the central axis of threaded cylinder 59 within the defined limits of rotation as previously described. The pivot plate 63 is pinched between the threaded nut 73 and the inside surface of tank 2 and is fixed in place. When handle 57 is rotated in the direction indicated by arrow 75 about the central axis of threaded cylinder 59 , lever 61 rotates in the same direction about the same axis pushing upwards on that portion of flush lever 65 that extends from one end of flush lever 65 as shown, causing flush lever 65 to rotate about pin 71 in the opposite direction as that indicated by arrow 75 .
Referring to FIG. 5 , The skin 18 of flexible tubing 17 is made of a water-resistant material that maintains the physical properties necessary to perform well in water and temperatures and with chemicals that are typically used in this environment. The flexible tubing is designed to stretch to two or more times its relaxed state length.
Referring to FIG. 6 . The bottom threaded portion of the flush drain 11 extends through a hole in the base of the tank 2 and is fastened to the tank 2 with a threaded nut. The guide rod 15 extends upwards. A gasket (not shown) is positioned between the flange 13 and the base of the tank 2 to form a watertight seal when the nut used to fasten the flush drain 11 to the tank 2 is tightened.
Referring to FIG. 7 . The diameter of hole 22 in the central portion of clip 39 is the same or slightly less than the diameter of the guide rod 15 . When the clip 39 is pressed onto guide rod 15 until the central axis of hole 22 is lined up with the central axis of guide rod 15 , the inside edges of clip 39 penetrate or grip the surface of guide rod 15 so the clip is held firmly in place.
Referring to FIG. 8 . Clip 39 is pressed onto guide rod 15 as previously described at a desired height. The buoyancy of flush basket 1 causes the upper edge of the side walls of flush basket 1 to push upwards on lever 25 far enough to turn off fill valve 21 as previously described. Fill tube 31 extends from the bowl fill outlet 27 and down drain 7 and the flexible tubing 17 so when the fill valve 21 is turned on, water will enter the toilet bowl 4 . Guide hole 5 is shown engaging the guide rod 15 , guiding the flush basket 1 on an up and down path. Rubber straps 35 is one of many methods that may be used to fasten one end of the flexible tubing 17 to the upper side walls of flush drain 11 and to fasten the other end of the flexible tubing 17 to the lower side walls of drain 7 as shown. Other methods may include using an adhesive or a strap or having one or more of these pieces molded as a single unit or using different welding or bonding methods or procedures or by using gaskets or seals.
One end of flush lever 65 is bent inwards as shown and is directly above the upper edge of flush basket 1 as shown. When handle 57 is rotated in the direction indicated by arrow 75 flush lever 65 rotates in the opposite direction as previously described, pushing downwards on the upper edge of flush basket 1 and dunking the upper edge of flush basket 1 beneath the water surface 37 so that the flush basket begins to take in water. The drain holes 9 more clearly shown in FIG. 2 are sized so that the water entering the flush basket 1 when it is dunked, enters faster than water can drain through drain holes 9 so that the flush basket 1 eventually fills with water and sinks. Water can then enter drain 7 and flexible tubing 17 and flush drain 11 , flushing the toilet. Lever 25 falls downward turning on fill valve 21 when the flush basket 1 sinks.
Referring to FIG. 9 . The flexible tubing 17 has collapsed as far as it can and the flush basket 1 is resting on top of the flexible tubing 17 . The water has drained until the surface of the water 37 has reached the upper edge of the side walls of the flush basket 1 as shown. The remaining water in the flush basket 1 has drained out through drain holes 9 . Lever 25 is still in a downward position so that water is still filling the tank 2 and bowl 4 as previously described. When the water within flush basket 1 is sufficiently drained, the flush basket 1 will rise with the water surface 37 until the upper edge of flush basket 1 pushes lever 25 upwards far enough to turn off fill valve 21 , ending the flush cycle.
FIG. 10 shows a fill valve 21 . Its bottom threaded portion extends through a hole in the bottom of the toilet tank and is first fastened to the tank with a nut and then connected to a water supply. When the lever 25 is lifted upwards enough as shown, the fill valve 21 is shut off. When the lever is slightly lowered, the fill valve 21 is turned on and water flows into the tank through tank fill holes 23 and into the toilet bowl through the bowl fill outlet 27 via a fill tube 31 (shown in FIGS. 5 and 6 )as will be well understood to those familiar with this art. A float 29 is attached to the end of lever 25 as shown.
FIG. 11 shows flexible tubing 17 . The skin 18 of flexible tubing 17 is made of a water-resistant material that maintains the physical properties necessary to perform well in water and temperatures and with chemicals that are typically used in this environment. Within this skin 18 there may be a flexible support 19 that provides the flexible tubing 17 with the strength necessary to keep the skin 18 from caving in on itself and to perform well under these conditions. A plate 80 is attached to the flexible tubing 17 at one end near it's mouth and has a bend at its other end that has a channel 86 from near one end of the bend to near the other end of the bend as shown. An extension 82 extends inwards from the mouth of the flexible tubing 17 as shown and a guide hole 84 is positioned near the end of extension 82 as shown. The drain entrance 92 is at the mouth of the flexible tubing 17 as shown.
FIG. 12 shows flush handle 41 having an extension 55 . At one end of extension 55 there is a pin 88 extending outwards as shown. A removable cap 90 is place on the end of pin 88 as shown. A counter weight 94 is located on flush handle 41 near one end of extension 55 as shown.
FIG. 13 shows the flush drain 11 . The bottom threaded portion of the flush drain 11 extends through a hole (having a diameter slightly greater than the threaded portion of the flush drain 11 ) in the bottom of the toilet tank and is fastened to the tank with a nut. The guide rod 15 extends upwards from the flush drain 11 . A gasket (not shown) is positioned between the flange 13 and the base of the tank to form a watertight seal when the nut used to fasten the flush drain 11 to the tank is tightened.
FIG. 14 and 6 show the assembled parts comprising the invention. The flush handle 41 is inserted into a hole in the tank designed for that purpose and fastened with a nut from the inside of the tank. The extension 55 of flush handle 41 extends towards plate 80 with the pin 88 inserted into channel 86 and the cap 90 inserted onto pin 88 to fasten pin 88 into channel 86 . The flexible tubing 17 is fastened to the neck of flush drain 11 at one end and has the drain entrance 92 at its other end as shown.
In FIG. 14 the toilet tank is full of water and the water surface 37 forces float 29 upwards holding lever 25 upwards keeping fill valve 21 in an off position as previously described. When the end 45 of handle 41 is pulled upwards extension 55 moves downwards forcing the drain entrance 92 downwards below the water surface 37 allowing water to exit the toilet tank and the toilet flushes as will be well understood to those familiar with this art. The guide rod 15 is engaged with the guide hole 84 guiding the path as the drain entrance moves up and down in a straight path. As the extension 55 moves in a downwards arc, the drain entrance move an a straight downwards path. The pin 88 slides through channel 86 so there is no binding between the pin 88 and channel 86 and the guide hole 84 and guide rod 15 .
In FIG. 15 , all the water that was previously above the drain entrance 92 has drained through drain entrance 92 and out of the toilet tank. The lever 25 has fallen and turned on fill valve 21 as previously described so that water is entering the toilet tank and toilet bowl as previously described. The end 45 of the handle 41 can now be pushed downwards so extension 55 moves upwards raising the drain entrance 92 above the water surface 37 . The toilet tank can now fill with water until the water surface 37 rises sufficiently to force the float 29 and lever 25 upwards far enough to turn off fill valve 21 , ending the cycle. The counter weight 94 holds the end 45 of handle 41 downwards so the drain entrance 92 is held above the water surface 37 in the position shown in FIG. 14 until the next flush. | A flush valve containing a flush drain entrance that while in a rest position is positioned above the water line so that there can be no leakage. When flushed, the entrance falls below the waterline, flushing the toilet bowl and then once again rises to a position above the waterline so that leakage cannot occur. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to rectifiers for electric current.
2. Prior Art
Known rectifiers can be made of material such as galena, selenium, copper oxide and germanium. Although rectifiers containing these materials are useful for many purposes, they are not generally satisfactory in high temperature operation. For example, selenium rectifiers are not satisfactory at temperatures over 125° C., copper oxide is not satisfactory at over 85° to 90° C. Galena is unsatisfactory at over 70° C. and germanium is unsatisfactory over 90° C.
Nevertheless, there are applications where high temperature rectifiers are required. For example, in some automotive applications the temperature in and around the engine exhaust is relatively high and there is a need for rectifying electrical circuit elements. Without the ability to endure such high temperature, the rectification components impose serious constraints on the design and must typically be positioned in the passenger compartment. This, of course, undesirably adds to the cost and complexity of the system.
The prior art also teaches titanium dioxide rectifiers which can perform rectification at temperatures in excess of 200° C. However, the structure and method of manufacture disclosed in U.S. Pat. Nos. 2,699,522 and 2,887,633 have an undesirable complexity. The structure taught in both patents utilizes a titanium dioxide ceramic between dissimilar electrode material thus forming an asymmetrical structure with respect to choice of electrode materials. The cause of rectification can be described in terms of Schottky boundary layers between a semiconductor ceramic and a dissimilar electrode. In U.S. Pat. No. 2,887,633 there is taught coating an inorganic artificial barrier material on a titanium dioxide semiconductor. The coating is obtained by vaporizing silicon monoxide in a vacuum and condensing the vapor on the surface of the semiconducting titanium dioxide. An alternative solution both in structure and method would be desirable for achieving a high temperature rectifier.
SUMMARY OF THE INVENTION
This specification discloses a rectifier having a symmetrical configuration (with respect to choice of electrode materials) with platinum electrodes attached to a titanium dioxide main body. Further, in contrast to rectification caused by Schottky boundary layers, the cause of rectification is a microstructure that results from a combination of circumstances: (1) the presence of platimum, (2) the presence of an electrical ordering field, (3) the presence of a crystallographic shear phenomenon in titanium dioxide, (4) a heat treatment that causes platinum to diffuse into the rutile grains in substantial concentrations and react with titanium to produce microscopic layer defects of PtTi 3 , which may be nucleated along crystallographic shear planes, but grow with epitaxial relation to the titanium dioxide substrate in the [100] direction.
A rectifier in accordance with an embodiment of this invention includes a titanium dioxide main body, a pair of spaced platinum electrodes on the titanium main body, and groupings of PtTi 3 interspersed throughout the titanium dioxide main body thereby forming a structurally symmetric rectifier with different forward and reverse electrical characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of current versus voltage characteristics of a rectifier in accordance with an embodiment of this invention;
FIGS. 2a, 2b, 2c and 2d are schematic representations of the structure of a platinum doped titanium dioxide ceramic during growth of a PtTi 3 microstructure 4 in accordance with an embodiment of this invention; and
FIGS. 3a, 3b, 3c and 3d are perspective representations of various stages of fabrication of a rectifier in accordance with an embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Fabrication of a rectifier in accordance with an embodiment of this invention, includes formation of porous, fine grain, polycrystalline titanium dioxide ceramic pellets, approximately 3 mm in diameter and 1 mm thick, with two fine (200 microns) embedded leads of platinum wire. The ceramic in the pellet is titanium dioxide in the form of rutile, fabricated by a process that produced a ceramic body having a desity of approximately 60% of theoretical and a grain size in the range of 2 to 10 microns. Rutile, a high purity, stoichiometric, single crystal, is a wide band gap semiconductor with a band gap energy in the range of 3 to 4 eV. If exposed to a reducing gas (e.g. carbon monoxide or hydrogen) at high temperatures (e.g. greater than about 400° C.), the rutile material shows, when returend to room temperature, increased conductivity. Referring to the formula TiO x values of conductivity range over many orders of magnitude as x is varied between 2.00 and 1.75.
In view of this behavior, TiO x is considered to be a defect semiconductor. That is, microstructures or defects due to oxygen vacancies within the material are responsible for this behavior. The defects tend to organize into planar defect structures and, in certain temperature ranges, phases with intermediate compositions, Ti n O 2n-1 , may form and be stable. Furthermore, a transformation of defect structures called "crystallographic shear" is known to take place in the TiO x material. The crystallographic shear transformation converts a planar array of oxygen vacancies into a planar array of titanium interstitial ions. Quasi-ferroelectric phenomena have been observed in samples of platinum doped TiO x . These quasi-ferroelectric phenomena are indicators that, at the microscopic level, behavior similar to that observed for polar materials can occur in platinum doped TiO x . It is suggested that the polar behavior is the result of introducing PtTi 3 planar layers into the crystalline structure. That is, the interfacial layer between the TiO 2 rutile and the PtTi 3 is believed to be the seat of the polar behavior.
All the titanium dioxide ceramic pellets have platinum (Pt) present in some form. The form of platinum present in the material is important because the reaction that takes place between Pt and Ti under certain conditions produces a solid, semiconductor ceramic with an asymmetrical direct current conductivity. Platinum in the starting pellet can be present only in the lead wires. Alternatively, platinum can be present at the start both in the lead wires and in the form of fine particles (about 0.1 to 0.5 micron diameter) dispersed throughout the ceramic body.
The particular treatment, in accordance with an embodiment of this invention, that produces titanium dioxide ceramic with electrical rectification characteristics includes the following steps:
(1) Connect the leads of the sample to a source of 1 volt dc and leave the voltage applied during all the subsequent steps described here.
(2) Heat the sample to a temperature between 750° to 850° C.
(3) While the sample is above 750° begin cycling the sample between oxidizing (4% O 2 in N 2 ) and reducing (2% CO in N 2 or 2% H 2 in N 2 ) atmospheres. The total time for a complete oxidation-reduction cycle is about 4 minutes, and the number of cycles is about 100.
(4) Lower the temperature, continuing to cycle the sample, until temperature of approximately 600° C. is reached.
(5) Around 600° C., stop cycling and place the reducing atmosphere over the sample. Allow the sample to cool back down to room temperature in the presence of the reducing atmosphere.
Before this treatment is begun, a pellet of titanium dioxide ceramic normally has a resistance of about 50 megohms or greater and shows no asymmetry in conductivity. After being subjected to the treatment described, the low resistance direction (forward direction) of current flow can be as low as about 5,000 ohms, with a resistance in the direction of reverse current flow up to twenty times larger than the forward direction. Thus, after the treatment just outlined the material has a rectification characteristic and a room temperature conductivity in the forward direction that is about four orders of magnitude larger than that in the untreated material.
As a result of fabrication in accordance with an embodiment of this invention, the rectifier structure has a symmetrical configuration with platinum as both electrodes. The cause of the rectification is ascribed to a defect microstructure that results from a combination of circumstances: (i) the presence of platinum, (ii) the presence of an electrical ordering field, (iii) the presence of the crystallographic shear phenomenon in titanium dioxide, (iv) a heat treatment that causes platinum to diffuse into the rutile grains in substantial concentrations and react with the Ti to produce microscopic layer defects of PtTi 3 , which may be nucleated along crystallographic shear planes, but grown with an epitaxial relation to the titanium dioxide substrate in [100] direction. The current versus voltage characteristic (I-V curve) of a rectifier structure fabricated as described above is shown in FIG. 1.
The formation of the microstructural defects responsible for the asymmetrical conductivity in titanium dioxide depends upon the presence of platinum. Samples showing strong rectification characteristics have had approximately 2% platinum present in the rutile structure. The cyclic oxidation reduction process causes the platinum to react with the titanium dioxide and undergo a reduction in particle size and a dispersion (probably of platinum atoms) into the rutile crystal structure. The platinum reacts with the titanium dioxide to form an intermetallic precipitate, PtTi 3 . This precipitate is first formed as a cloud of fine point defects in the titanium dioxide matrix. With continued cycling, the PtTi 3 particles agglomerate and form planar microstructures, probably under the influence of the crystallographic shear process. The microstructures can be considered to be defects in the rutile structure. The individual PtTi 3 planar defect structures at this point are epitaxial layers, about 30 Angstroms thick and sandwiched between rutile crystal structures. Further treatment results in the formation of multiple layered planar microstructures.
The sequence of microstructures or defects formed by the cyclic oxidation reduction heat treatment described in the preceding paragraph is outlined in the drawings of FIGS. 2a, 2b, 2c and 2d. FIG. 2a shows an overall view of a collection of grains indicating that, probably as a result of varying impurity concentrations, the grains are in various stages of developing the microstructural defects. FIG. 2d indicates that the expitaxial layers are on (100) faces with the normal to these planes corresponding to a [010] direction in both the TiO 2 and PtTi 3 crystal structures.
The defect structures that are most responsible for the rectification effect are probably those in FIG. 2c. These single layered structures will have the greatest surface area to volume ratio. The interface between the PtTi 3 layer and the rutile matrix is probably the seat of the polar phenomena, possibly involving a polar compound of the form PtTiO 3 . The electric field appled during the heat treating process serves to align the polar intermetallic layer for whatever defects are suitably oriented relative to the applied field. Careful examination of the arrangement of the microstructural defects over the extension of the region between the lead wires does not indicate any tendency for the applied field to influence the orientation of the planar defect structures.
In accordance with another embodiment of this invention, fabricating Pt-doped TiO 2-x ceramic rectifiers is based on a tape casting method presently used to fabricate the ceramic material used in TiO 2 exhaust-gas-oxygen sensors. The major processing steps are outlined below and illustrated in FIGS. 3a, 3b, 3c and 3d.
A tape 31 is formed by starting with TiO 2 powder and calcining at 1150° C. for 2 hours. The calcined powder is mixed with water and ball milled for 16 hours. The TiO 2 dried powder is mixed with solvents and binder and again ball milled, deaired, and finally the ceramic slurry is metered onto a cellulose triacetate plastic sheet 32 to form a tape of ceramic about 0.020" thick.
Relatively large area ceramic pieces 33, about 1 inch square, are cut from the plastic tape and fired at 1250° C. Platinum electrodes about 0.00005" thick are sputter deposited on the major faces of the ceramic piece. With the platinum electrodes on the major faces, the material is subjected to the heat treatment procedure given previously.
After heat treatment, the 1 inch square piece 33 is sliced into small square wafers 34 of ceramic (FIG. 3c) lead wires are bonded to the Pt electrodes, and the ceramic wafer is packed in a conventional diode or transistor mounting structure (FIG. 3d).
Various modifications and variations will no doubt occur to those skilled in the art. Useful devices may be achieved in ceramic oxides other than TiO 2 since there is some experimental evidence that Pt and Pd can form polar interfacial layers with oxides of other tetravalent metal atoms. Further, improvement in the performance of the Pt doped TiO 2-x rectifying devices is expected to be obtained by refining the processing in such a way that the ceramic has in its final condition most of its grains with the thin single layer defect structures illustrated in FIG. 2c. These and all other variations which basically rely on the teachings through which this disclosure has advanced the art are properly considered with the scope of this invention as defined by the appended claims. | This specification discloses a titanium dioxide rectifier element. A pair of spaced platinum electrodes are on a titanium dioxide main body. Groupings of PtTi 3 are interspersed throughout the titanium dioxide main body thereby forming a rectifier with electrodes of one material and having a different forward and reverse electrical characteristics. | 7 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The invention herein relates to an improved disposable tray liner for turkey poults or other animals which are contained in trays or cages, said liner comprising one or more layers of an expanded material such as paper which has been permanently affixed to a base sheet. The expanded material provides traction for the standing poults.
2. Description Of The Prior Art
Modern poultry hatcheries and farms utilize trays which are a convenient size for handling and use in, for example, incubators which may require trays sized approximately twenty-six (26) by twenty-eight (28) inches in length and width having walls of approximately four (4) inches in height. Disposable liners are placed on the inside bottoms of such trays to assist in maintenance and cleaning after use since the liners can be easily removed and incinerated. The liners maintain the eggs from rolling, therefore reducing breakage and as hatching occurs, the liners provide traction for the young birds. This is especially advantageous to turkey poults which are awkward and unsteady to a greater degree than young chickens since the poults are processed to include inoculation, debeaking and detoeing prior to being placed in trays for transportation to poultry farms where they are removed and raised to maturity. It is important that young birds and especially turkey poults maintain their footing during shipment so they arrive at the farms in excellent health. Blood and waste products are deposited in the trays during transportation which can cause a slick and unsanitary surface for the feet of the poults. Oftentimes poults that lose their footing and fall are trampled and pecked by other poults and oftentimes have to be destroyed.
Various types of tray liners have been employed in the past including liners made from paper, sponge rubber, excelsior and other materials, all having certain advantages and also which have certain disadvantages. For example, excelsior has often been used but it is more flammable than desired and due to its independent structural components it can be difficult to handle and contain. While removing used excelsior from trays, shards therefrom often stick to the tray bottoms and must be individually loosened and removed requiring additional time and labor. Synthetic foam materials have been affixed to paper underlayers and utilized to a limited degree but have not been satisfactory from a cost standpoint and for other reasons including excessive moisture retention.
Thus, with the known disadvantages of prior art tray liners, the present invention was developed and one of its objectives is to provide a lightweight, disposable tray liner for poultry which will assist the young birds in maintaining their footing as they are transported from hatcheries to farms.
It is also an objective of the invention to provide a tray liner which will trap down from freshly hatched birds in the incubators to prevent the down from becoming airborne upon drying.
It is another objective of the present invention to provide a tray liner which is formed from an inexpensive material such as paper that is easily discarded and which will provide structural qualities necessary for safe and sanitary containment of the poults.
It is yet another objective of the present invention to provide a method for forming a tray liner which is relatively simple and inexpensive to manufacture.
Still another objective of the invention is to provide a high traction tray liner which is formed from two (2) layers of oppositely oriented expanded paper affixed to a flat base sheet.
Various other advantages and features of the invention will become apparent to those skilled in the art as the detailed explanation of the invention is presented below.
SUMMARY OF THE INVENTION
The aforesaid objectives and advantages are realized by forming a disposable tray liner from a plurality of expanded material layers which are affixed to a planar base. The paper used may be of a waste or reprocessed type or other special papers can be used as desired. The liner can be formed by adhering one or more layers of an expanded material laminate to a thin paper base by using a quick-setting, water resistant or hot-melt adhesive. Once the adhesive sets the laminate can be cut into convenient sizes where it is packaged and shipped for use. Two expanded layers and the flat base sheet may form a height of three-eighths (3/8) inch and the openings of the expanded layers allow waste to pass below the top surface to the top of the base which keeps the upper surface of the liner free of waste and allows good foot traction for the young birds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 demonstrates a typical four-section poultry tray in partial cut-away fashion demonstrating and exposing the liner placed therein;
FIG. 2 shows an enlarged end view of the liner as seen in FIG. 1;
FIG. 3 is an enlarged top view of one expanded tier of the liner having a right-to-left orientation;
FIG. 4 demonstrates an end view of the tier as seen in FIG. 3;
FIG. 5 shows a typical laminate processing operation for manufacturing the liner; and
FIG. 6 shows a top view of the expanded paper as slit prior to expansion.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred form of the liner comprises a three-tier laminate having a flat planar base formed from reprocessed paper having a weight of approximately one hundred fifty (150) pounds per thousand (1000) square feet and having two (2) expanded paper layers having a weight each of approximately twenty-six (26) pounds per thousand (1000) square feet prior to expansion. The first expanded layer is adhesively affixed to the planar base and on top of the first expanded layer is affixed in opposite orientation a second expanded paper layer. The openings of the expanded layers are shaped in somewhat of an irregular oval and have an opening width less than the opening length, said opening length being approximately one-half (1/2) inch. The liner thickness consisting of two (2) expanded layers and a planar base is approximately three-eighths (3/8) inch. A waterproof adhesive is used to join the layers and the method of production includes adhering the layers by gluing and then cutting the laminate into convenient sizes for packing and shipping.
DETAILED DESCRIPTION OF THE DRAWINGS AND OPERATION OF THE INVENTION
Turning now to the drawings, FIG. 1 shows a typical four compartment poultry tray 10 having a removable divider 11. Tray 10 and divider 11 may be made from plastics or other suitable materials which are lightweight, durable and sized to accommodate approximately twenty-five (25) poults per section. On the inside bottom of tray 10 is placed a laminated liner 12 consisting of planar base sheet 13 with a first expanded layer 14 and a second expanded layer 15, all of which are permanently bonded together by a waterproof or other suitable adhesive. Liner 12 is formed from paper made of a desired weight and quality and such paper may include waste or reprocessed papers or may include special coated papers. In order to prevent the spread of infection and disease, the paper can be treated with an antiseptic solution such as Neomyicin or mold inhibitors to discourage the spread of disease or sickness. Other coated papers which are waterproof or water-strength papers may be used for additional rigidity and structural integrity of the liner. As shown herein, liners 12 are utilized especially for poultry type purposes although such liners may be used for other animal cages as desired. The adhesive as used herein to adhere the laminate structure may include acrylics, melamines or other waterproof resin-based adhesives which set by solvent evaporation or cross linking or they may include hot-melt adhesives which become rigid as they cool from a high to ambient temperature.
As would be further understood, the particular paper strength and thickness of a particular laminate 12 would depend on the specific bird or animal contained within the tray or cage and the rigidity of the liner can be modified by the amount and type of adhesive and the type of coating application in combination with the particular paper characteristics selected.
In FIG. 2, a three-tier laminate 12 is shown having a thin flat base 13 which is adhered along 16 to first expanded layer 14 by an appropriate waterproof adhesive. As shown in FIG. 2, first expanded layer 14 has a right-to-left orientation and second expanded layer 15 has an opposite orientation, that is, left-to-right, and is adhered at lines 17 to first expanded layer 14. As further illustrated in FIG. 2, the second or top expanded layer 15 includes a series of ridge-like projections 18 having a distance therebetween of approximately one-half (1/2) inch. This configuration provides for good traction for the young birds and as would be understood, liquid and solid waste 19 for the most part passes through expanded layers 14 and 15 and is deposited on planar base 13 as also shown in FIG. 2. As better seen in FIG. 3, expanded layer oval-like openings 20 allow for fluids and other waste to pass therethrough. The lower portion of expanded layer 14 as seen in FIG. 3 is shown in an end view of FIG. 4. and as would be understood, expanded layer 14 has a right-to-left descent or orientation. The oval-like openings 20 are also useful in trapping moist down from birds as they hatch in incubators. Down carries salmonella and other bacteria which can be transmitted when the down dries and becomes airborne. Thus, by being trapped when wet in opening 20, liner 12 improves the sanitary conditions of the environment.
By providing laminate 12 with two (2) expanded layers having opposite orientation as seen in FIG. 2, a relatively thich and inexpensive laminate is provided which is both lightweight, durable and provides a sanitary surface for young birds. The total thickness of laminate 12 as shown in FIG. 2 may be, for example, three-eighths (3/8) inch although thicker or thinner laminates can be manufactured and employed for particular use requirements. As shown in FIG. 6, a portion of a flat paper sheet 23 has been slit along lines 21 which upon expansion form openings 20. Lateral stress has been indicated by arrows 22 and such lateral tension or force causes staggered slits 21 to open in sheet 23 resulting in the irregular top surface as shown in FIG. 1. Flat slitted sheet 23 as shown in FIG. 6 may be expanded to a width of approximately twice its normal size by applying lateral tension as shown by the arrows at 22.
The step forming laminated liners 12 as shown in FIG. 2 is pictured in abbreviated fashion in Fig. 5. A roll 25 of flat base material 13 meets expanded paper layer 14 from roll 26 which has passed over adhesive roller 27 that applies a resin/glue to layer 14, where both are pressed into engagement by pressure roller 28 and proximate support roller 36. Spray or drip adhesive applications may also be employed if desired. Thereafter, as the laminate moves from right to left as shown in FIG. 5, a second expanded paper roll 29 provides top expanded layer 15 to laminate 40 after being coated with an adhesive by second adhesive roller 30. As further explained, first adhesive roller 27 and second adhesive roller 30 may apply a hot-melt or other adhesive depending on the end results desired. Pressure roller 31 then applies desired pressure to the three-tier laminate 40 and drying means 32 which may be a radiant heat source, hot air fan or other device under which laminate 40 passes. Next, laminate 40 moves over support roller 37 and under feed roller 33 which applies a very light pressure to laminate 40. Laminate 40 then travels to hydraulic knife 41 whereby blade 42 which may be activated manually or automatically cuts laminate 40 into desired sheets 43 which are packed and shipped to poultry growers and the like.
The method of assembling laminate 40 as shown in FIG. 5 is but a single schematic of a variety of ways by which laminate 40 can be manufactured. The method of manufacture and liner 12 can be modified by those skilled in the art and the examples and illustrations presented herein are merely for explanatory purposes and not intended to limit the scope of the appended claims. | A disposable laminated tray liner for use by poultry breeders and growers is formed by affixing an expanded paper layer to a planar paper base. The layers are adhered by a waterproof adhesive or the like and the irregular top surface of the expanded paper layer provides traction for turkey poults or chicks while assisting in keeping the birds clean and healthy. | 0 |
This application is a continuation of application Ser. No. 798,585, filed Nov. 15, 1985, now abandoned.
TECHNICAL FIELD
This invention is directed to the working of softenable dielectric materials, particularly the drawing of clad and unclad fibers and fiber bundles from primary and later-stage preforms of glass. The invention particularly relates to processes for drawing glass fibers, bundles, and composite products from the fused or softened end of a preform introduced into a furnace.
BACKGROUND ART
The art of glass drawing is presently the most effective mode of producing either continuous, flexible fibers or of producing relatively short segments for later combining and processing into composite products such as fiberoptic screens, faceplates, and image modifiers of various types. Besides being used for drawing of fibers and multi-fiber bundles, drawing techniques of the type to which the invention relates are applied to late-stage processing of the composite products. Such processing includes cross-sectional reduction, either uniform or graduated, the latter technique used to form image expanders and reducers. Such processing also includes various degrees of twisting and other manipulations to form image re-orienting devices such as partial rotators, inverters, etc.
An important goal in this technical field is uniformity of heating and a high degree of temperature control in the critical softened area of the preform or workpiece. Failure of uniformity in heating the work zone is a major cause of product defect and rejection, resulting in waste of expensive materials and production time. This consideration is particularly critical in the case of a product formed from a preform of highly complex cross-sectional character in which large, sometimes sharp, gradients of optical, physical, and thermodynamic properties are likely to be present. The requirement of uniform heating reaches ultimate criticality when the conventional upper limits of heating and drawing speed and of preform and product cross-sectional dimension are reached and exceeded. It has been the unrealized goal of skilled workers in this art to produce uniform heating in the drawing furnace at the moderate temperatures needed for drawing relatively delicate composite products. Among the main reasons for failure to achieve this goal has been the difficulty of achieving uniform radiation of heat from the radiant heating elements at temperatures of around 1100° F. to 1400° F. (600° to 750° C.) Separate radiant elements produce inherently non-uniform heating. Attempts to produce a radiant source continuously surrounding the fusing area or to embed discrete elements in a diffusing matrix have not produced the desired uniformity. Moreover, most composite products do not absorb radiant energy uniformly even if it is introduced uniformly. This compounds the problem of non-uniform radiant sources, and limits the level of uniformity even for an ideal uniform radiant source.
This problem of absorbtion differential exists in any application where there are different glasses in the same product, the glasses having different infra-red absorbing characteristics (for instance the core relative to the cladding) or any product involving an extremely thick preform or drawn diameter. In the latter case, the rate of heating by absorption at the surface of the working area must be carefully regulated according to the rate of conduction of the heat toward the center of the piece. At locations toward the axis the radiant energy per se fails to penetrate at levels comparable to that at the surface.
A prior method of approximating uniformly radiating elements has been developed which involves turning the preform and the product on their common axis, at a rate sufficient to smooth out the variations in the radiational heating sources. This technique requires complex mechanisms to coordinate the turning of the preform and product, as well as the turning and lateral translation of the take-up reel if the product requires. At best, the technique produces horizontal (stratified) uniformity without producing vertical uniformity and results in hot "rings" instead of hot "spots". Moreover, the technique does not address the problem of non-uniform absorption by a composite product.
The problem of non-uniform absorption is especially acute when the product contains light-absorbing elements such as EMA cladding or fibers which tend to absorb infra-red radiation in disproportion to the remaining materials. Such elements, in a radiant furnace, produce internal anomalies of temperature and viscosity which limit and complicate the choice of drawing speed.
As a secondary consequence to the inability to achieve uniform heating in the drawing process, both the preform size and the reduction ratio in the drawing process are severely limited. The result is that a composite product having very small diameter fiber-optic components must be produced by a many-step process. Typically, the steps include drawing a single fiber, drawing down a multi-fiber bundle, drawing a multi-multi fiber bundle, and fusing a bundle of these latter products into a block. Such many-stage processes consume production time, and each step has its own percentage rejection rate (on the order of 20%).
Thus, the main object of the present invention is to provide a process for acting on the working area of a preform to product highly controlled, uniform heating.
Another object of the invention is to provide a process in which the limits on the size of the preform, the product, and the drawing reduction ratio are greatly extended.
A further object of the invention is to provide a process for drawing glass which allows the elimination of at least one of the successive reduction drawings in certain fiber-optic processes, without loss of quality.
Another object of the invention is to provide a process in which the size of the working zone at which reduction takes place may be chosen and controlled.
In another of its aspects, the invention provides and apparatus particularly adapted to assist in carrying out the uniform heating and control of the working zone of a drawable preform.
Further objects of the invention will become apparent as specific embodiments are described.
DISCLOSURE OF THE INVENTION
The present invention uses a controlled, high-velocity flow of temperature-regulated air or other fluid, preferably produced in a separate heating chamber and introduced into a the drawing chamber. The process takes advantage of the temperature distributing qualities of a mix of forced-and free-convection to uniformly heat the working zone of a preform. The process involves removing heat-depleted fluid, preferably by cycling the cooled fluid back to the separate heating chamber for reheating. The process involves using data from temperature sensors at critical points in the flow cycle to control fluid heating to maintain a desired smooth temperature/time profile.
In another aspect, the process involves temperature regulation of a small part of the preform just outside of the drawing chamber of the furnace in order to insure a consistently temperature-prepared preform entering the working area; this reduces the requirement to regulate ambient temperature and to compensate for different thermal conductivity of different preforms and preform clamping means. In effect, this step forms a thermal insulator which keeps the heat from the furnace from undesirable transfer up the preform.
A further aspect of the process of the invention involves controlled movement of an extendable insulation means in order to regulate the effective distance from the inlet to the outlet of the drawing chamber of the furnace, whereby the size of the working zone is regulated at will.
A still further aspect of the invention is a drawing furnace specifically adapted to carry out the process. The furnace comprises a drawing chamber with a preform inlet and outlet and a preferably separate fluid heating chamber having controllable heating means. The separate fluid heating chamber communicates with the drawing chamber by input passageways or channels, the communication mediated by forced convection means. In accordance with other aspects of the invention, the furnace is provided with a return channel communicating between the drawing chamber and the heating chamber, a pre-entry temperature regulating means at the preform inlet, and a movable insulated sleeve associated with the outlet of the drawing chamber.
In a variation of both the process and the apparatus, the preform inlet is at the bottom of the furnace, and the product is drawn upwardly from an outlet on the top of the furnace drawing chamber. The steps and elements of the variations may be independently employed.
The disclosed process and apparatus solve the technical problem of uniformly heating large-diameter drawable workpieces, possibly having complex shape in all dimensions and which, in addition, may be a composite of materials having different radiant absorbing characteristics. The high-velocity, forced-convection supply of fluid at the work zone allows transfer of heat energy to the work without the extreme differences in temperature encountered in radiant heating. Thus, the avoidance of surface hot spots or internal hot spots does not depend exclusively on the conduction rate into the workpiece or on small amounts of free convection of dead air, but can be controlled by regulation of the velocity and temperature of the forced convection currents. At a given rate of heat energy application, moreover, the technical problem of controlling the size of the work zone (which is related to the shape of the draw and the shape of the diameter reduction profile,) may be readily resolved by extension of an insulating sleeve into the forced convection flow pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
Both the process and the apparatus of the present invention may be best understood by reference to specific embodiments as shown in the drawings, which are illustrative and not limiting.
FIG. 1 shows a flow diagram of an embodiment of the process of the present invention,
FIG. 2 is a sectional view of a furnace embodying the principles of the present invention,
FIG. 3 illustrates a simple embodiment of part of a pre-cooling collar,
FIG. 4 is a top elevational view of a preferred form of the drawing chamber inlet with adjustable diameter means,
FIG. 5 is a sectional view on the line V--V of FIG. 2 showing an embodiment of the heated fluid distribution means,
FIG. 6 illustrates the action of the adjustable insulated sleeve, and
FIG. 7 shows a modified apparatus designed to be capable of carrying out the drawing operation upward instead of downward.
DETAILED DESCRIPTION
There are several modes of carrying out the process of the present invention in which some of the details depend upon the product being made and the raw materials being worked. The following is a detailed description of successful applications, including the best mode contemplated at present. A detailed description of an apparatus specifically designed for carrying out the process is also laid out here.
The process diagram shown in FIG. 1 outlines the basic steps in the general process. Since the process allows very close control of the preform heating, based on calculated and experiential air temperature and flow-rate data, optimal use of the process first requires a certain degree of pre-entry temperature control of the preform. This pre-entry temperature conventionally depends not only on ambient temperature (control of which is inefficient) but also on the conduction rate from prior furnaces through the preform and its feeding mechanisms. The effect of these factors is reduced in the process of the present invention by the step of bringing the temperature of the preform close to a "normalized" temperature just before it enters the furnace. This will most often be a cooling step, although at some stages in the process and for some ambient conditions there may be mild warming. The simplest embodiment of this temperature normalizing step 10 involves bringing more or less constant temperature air from a source and blowing it onto the periphery of the preform at the entry point to the furnace. At the same time, the preform is fed into the furnace drawing chamber in a feeding step 11 using available feeding mechanisms. These include motor driven drive screws. The mechanism may include several of these drive screws if the core and a cladding or a plurality of claddings must be driven at different rates. It is not necessary for these mechanisms to include rotating means. Such means were a complicating expedient to achieve furnace uniformity as mentioned above and have had only qualified success.
The crux of the present invention involves the step of heating air or other heat exchange fluid in a chamber, preferable separate from the chamber in which the fiber drawing will take place. If the chamber is not separate, at least the working zone should be shielded from any radiant elements used therein. The heated air is then introduced or delivered 13 into the drawing chamber using controllable forced convection means: fans, air pumps, etc. The air heating step 12 is preferably controlled (for instance by variable resistance or by introducing a controlled cool gas stream) under the guidance of a temperature measurement step 14. This measurement is preferably carried out as the air is introduced into the drawing chamber. This measurement, which is carried out for example by inserting a thermcouple into the air flow pattern, controls the air heating means by a preselected algorithm, mediated by electrical or electronic processing means. These may involve feedback or feedforward processing with calculated or tabulated parameters, leading to a discrete or continuous heat control setting step 15. This step may also encompass control of variation of the flow rate of the heated air. The goal is the development of a temperature/time profile appropriate for the uniform heating of a given preform in a given working zone. To this end, the heated air is directed to flow past the working zone of the preform, step 16. The preferred mode of flow is rather turbulent, but with a directional trend through the working zone in a distinct direction. It is also preferable that the inflow be distributed around the periphery of the preform inlet end of the drawing chamber.
When the preform is at working temperature, the reduced diameter product is drawn in the usual manner, using combinations of gravity and traction in a drawing step 17. Since the rate of drawing and the degree of reduction in diameter of preform product depend (among other factors) on both temperature profile and the length of the working zone, an additional working zone shaping step 18 may be employed. The working zone shape may be set before the drawing begins or may be adjusted at various stages of the drawing process according to the requirements of the product and/or the character of the preform.
A successful method of shaping the working zone involves varying the effective distance from the inlet of the drawing chamber to the effective outlet. Specifically, this may be accomplished by positioning an insulating sleeve which is capable of variable extension from the outlet of the chamber toward the inlet, concentrically of the axis of the draw.
To facilitate temperature control, the heated air which has been flowed past the working zone may be withdrawn from the chamber in an air return step 19 to be reheated in the heating chamber. If an additional air temperature measurement step 20 is performed on withdrawal of the air, refinement of the heat setting control may be made. Such an adjustment may be made, for example, on the basis of calculation of absorbed heat from the temperature differential.
After drawing of the product, the usual product processing is carried out, indicated generally as step 21. For continuous fiber, a rotating and reciprocating take-up reel may be provided. Additional coatings may be applied. For more discrete product, means may be provided for periodic cutoff of draw segments, either as quasi-finished product or for bundling into multi- and multi/multi-element composites for further processing.
Because this process allows the drawing of very large diameter product from very large diameter preforms due to the extraodinarily uniform heating that the process provides, it has been found to be possible and advantageous to feed the preform up from below the furnace and draw the product up from above. This process variation advantageously modifies the effect of gravity on the working zone shape and on the take-up qualities of the product. The variation is especially applicable in a working zone which is relatively long with a slow taper.
The general process of this invention has been applied without any extraordinary control measures to a composite preform over 4.5 inches (12 cm) in diameter which was drawn down to a diameter of 0.030 inches (0.080 cm) in one stage. The preform was normalized to about 70° F. (21° C.). Air was heated so that it could be delivered to the drawing chamber at about 1380° F. (750° C.). The air was forced at a high velocity past the working zone and withdrawn at about 1375° F. (747° C.). The rate of production and the quality of the product were at least comparable to conventional radiative drawing which would have required multiple stages for this reduction.
In another case the uniformity of heating in this process allowed a one-step production of a one-inch product from a three-inch preform with excellent quality and production rate. The preform was introduced from below the furnace and taken up from above.
No apparent limit has been found to the size of preform to which the process may advantageously be applied. When applied to conventional drawing processes, the production rate approaches 5 to 6 times the usual rate and is presently limited by the capacity of available or readily modified take-up mechanisms.
The ability of this system to deliver heat effectively to large diameter workpieces in the normal drawing operation without distortion in the workpiece allows use of the system in a remarkable manner. Ordinarily, large diameter products formed of large numbers of fine fibers are formed by a very inefficient process involving stacking of the fibers and the fusing of the fibers under heat and very high pressure to remove voids. It has been found that these large diameter products can be formed far more efficiently in the following manner. First, a preform is formed by stacking fibers into a bundle with a diameter slightly larger than the desired product. The bundle is then enclosed in a gas-tight glass envelope which is then evacuated. The resulting preform is then passed through the furnace in the manner of this invention except that the preform is only drawn down a small amount to the desired diameter. The result is a large diameter product formed of uniformly fused, voidless and undistorted fibers. This product is capable of being sliced into gas-tight plates. In practical operation, it may be necessary to continuously evacuate the envelope during the draw. Because of the very low distortion caused by this draw, it is possible to apply a twisting motion to the workpiece in the draw zone. This results in a product in which the fibers have a uniform spiral orientation. The resulting product can be cut to form image rotators or inverters.
APPARATUS
An apparatus specifically designed to carry out the process of the present invention is disclosed in FIGS. 2-7 and is shown most comprehensively in a modified schematic manner in FIG. 2.
Although forced convection ovens have been available in the past, the furnace of the present invention is disclosed in unique combination with other elements and in configuration adapted to utilize the special properties of forced convection in a glass drawing operation. The application of the forced convection heating to the glass drawing art have resulted in extraordinary, unexpected, and surprising increase in the diameter capacity, drawing rate and quality (in terms of product rejection rates) of this art.
The general combination as illustrated in FIG. 2 and indicated generally by the numeral 30, includes a complex of feed mechanisms 31, preferably having a capacity for differential feeding of various components of a composite preform. The feeding complex may include a vacuum pull assembly 32 including the required gas tight seals, and clamping means 33. The workpiece of the apparatus is a heat softenable, drawable preform 34. To carry out the temperature normalization or "pre-cooling" of the preform just before entry into the furnace (indicated generally by 40) this embodiment includes a hollow collar 35 or thermal isolator which is supplied with relatively constant temperature air from a source 36 via a conduit 37 with controllable valve 38. The "pre-cooling" air is directed inwardly toward the preform through a plurality of inwardly facing, radially directed apertures such as 39. It has been successful and convenient to choose, as a standard, a temperature near room temperature of 70° F. (about 21° C.). To achieve a finer degree of control over keeping the preform temperature constant, temperature sensors above and/or below the collar could be provided to control pre-cooling air temperature and/or volume.
The preform 34 is fed into the furnace 40 through a drawing chamber inlet 41. This inlet is preferably supplied with diameter adjusting means 42 such as a fairly refractory "iris" assembly, to insure moderate resistance to heat loss.
The drawing chamber 43 is one of two chambers which this embodiment of the furnace comprehends, the other chamber being the separate air heating chamber 44. The heating chamber is supplied with heating means which may be combustive, inductive, arc-induced, dielectric, etc., but in the preferred embodiment comprised large area resistive coils 45. These are supplied with power from a source 46 and a control mechanism 47 such as variable impedance or a variable transformer.
A forced convection element 50 (a high temperature fan, pump, etc.) draws air through the heating elements and directs a flow through a channel 51 which communicates with the drawing chamber 43. This delivery is preferably mediated by a distribution means 52 such as an internally, radially perforated plenum.
At a point along the path of flow, a temperature sensing transducer means 54 is provided sending its signal to a central control system 60.
The flow of air is actively or passively drawn past the preform/workpiece to create the working zone 55 terminating at or near the effective drawing chamber outlet 56. The flow continues through a return channel 57 which may be provided with a return forced convection element 58 and a return air temperature sensing transducer means 59 also sending to the central control 60.
The effective drawing chamber outlet may be provided with diameter adjusting means 59 similar to the means 42 at the inlet.
The effective drawing chamber outlet 56 is distinguished from the actual outlet 61 by an insulating sleeve 62 which movably engages the actual outlet and extends into the drawing chamber toward the inlet 41. When the product is drawn past the inner end of this sleeve, the product is shielded from the heated flow. This movable point thus defines the end of the working zone 55. The position of the sleeve may be temporarily fixed as by set screws or clamps, or may be under variable central control effected by extension means 63 such as servo-activated rack and gear or friction wheels.
The product is drawn in the usual manner by a drawing mechanism 64 which employs gravity, traction means, etc. The product is then passed on to further processing elements 65: take-up reels, cutters, bundlers, slicers, etc.
An effective pre-cooling collar 35 may be constructed as detailed in FIG. 3. Compressed air of relatively constant temperature is brought via a conduit 37 from a constant temperature air source such as an air compressor into the collar and is directed inward toward the preform through radial apertures 39.
The detailed view in FIG. 4 looking down on the drawing chamber inlet illustrates an embodiment of an adjustable diameter means 42 for causing the effective inlet diameter to approximate that of the preform 34 (shown as a typical single cladding fiber-optic preform.) A similar mechanism can be used for the diameter adjusting mechanism 59 of the effective outlet 56.
FIG. 5 shows a detailed horizontal section on the line V--V of FIG. 2 of a flow distribution means 52 embodied in a toroidal plenum with internal radial perforations 53 shaped to facilitate flow control. In the preferred embodiment, the perforations would be elongated along the axis of the workpiece.
A detail of a dynamic embodiment of the adjustable sleeve 62 is shown in FIG. 6 with an adjustment for a shortening of the working zone in broken lines. Adjustment is made by extending means 63 under central control 60. The extending means are preferably annular.
The process variation which involves feeding the preform from below the furnace and drawing the product from above may be carried out satisfactorily on the apparatus of FIG. 2. Full advantage of this invention may best be taken under the circumstances, however, by the apparatus variation shown in FIG. 7. In this variation, the furnace is so mounted, as by the use of gimbles 70, 71, that it may be rotated at will in a vertical plane. In this case, the feed mechanisms 31 and the drawing mechanism 64 are relocated to their respective appropriate locations as shown in the figure.
As an alternative to the rotatable configuration shown in FIG. 7, the apparatus may be built with a symmetry about a central horizontal plane. Thus, the input channel from the heating chamber to the drawing chamber, as well as the flow distribution means, may be located centrally. The "inlet" and "outlet" areas of the drawing chamber may then be identically supplied with closable return channels, extendable insulated sleeves, pre-cooling collars, and aperture diameter adjusting means. In this way the preform may be fed and the product drawn upward or downward with equal ease. The choice will depend upon the character of preform, product, and production rate.
INDUSTRIAL APPLICABILITY
Some of the modes of industrial applicability of the uniform heating provided by the drawing process of the present invention are readily apparent from the above description of the equipment and its characteristics, while other uses and advantages are totally unexpected.
A typical product rejection rate of about 20% at each step of a multi-step manufacturing process obtains in present radiation furnaces. The process and apparatus of the present invention have significantly reduced this rejection rate.
The drawing rate for moderate diameter products has been greatly limited by the need for a slow enough rate to allow complete and reasonably uniform heating of the preform. The present process heats even large diameter preforms quickly and uniformly to the point that some product can be taken up at rates 5-6 times to that of conventionally configured drawing furnaces, with more than satisfactory quality.
The present process does not generally require special treatment of products which incorporate radiation absorbing claddings and fibers as compared to with the treatment required of such products in radiative furnaces. Such products include most composite image manipulating products: faceplates, image expanders, inverters, etc.
Most significantly, in prior art processes, the normal composite product is produced in several stages. This is due to limitations in the size of the reduction ratio of the product to preform which can be achieved without distortion. There has also been an absolute size limit of the preform that can be heated with threshhold uniformity. The present process can uniformly heat the working zone of a preform, including a composite preform, of at least up to 4.5 inches (12 cm) and possibly much larger. This means:
1. At fairly ordinary product-to-preform ratios, a final product of large diameter may be drawn, possibly eliminating the final pressing, annealing, devoiding, and shaping steps,
2. Advantage can be taken of the vastly larger reduction ratios possible to eliminate one or more stages of the production of multi-multi-type composite products. The elimination of such steps saves time and labor, as well as the cost of materials lost through inevitable waste and rejection.
Clearly, minor changes may be made in the form and construction of this invention and in the embodiments of the process without departing from the material spirit of either. Therefore, it is not desired to confine the invention to the exact forms shown herein and described but it is desired to include all subject matter that properly comes within the scope claimed. | Control of speed and uniformity of the heating of the working zone of the preform in a glass drawing operation in which the softening heat is applied by forced convection (13), using a separate fluid heating zone to introduce temperature and velocity controlled fluid. The size of the working zone is further controlled by changing (18) the configuration of a movable exit sleeve. Uniformity and accuracy of temperature is enhanced by normalization (10) of the temperature of the preform close to a preselected value before the preform enters the furnace.
A glass drawing apparatus embodies the preferred means to carry out the process, providing a two-chamber furnace having an air heating chamber (44) connected by air delivery channels (51) to a drawing chamber (43). The drawing chamber has preform inlet (41) and a drawn product outlet (56). Each of the latter preferably has an adjustable opening diameter. The inlet is provided with a pre-cooling collar (35). The outlet has an insulated, movable sleeve (62) controlling the effective distance from the inlet to the outlet by modifying the temperature gradient. The latter provides means for controlling the length and shape of the working zone (55). | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority from U.S. Provisional Application Serial No. 60/392,388 filed Jun. 29, 2002 which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates in general to water treatment and, in particular, to ballast water treatment for ships. More specifically, but without restriction to the particular embodiments hereinafter described in accordance with the best mode of practice, this invention relates to in-port water treatment systems directed to filtering ballast water and deactivating biological material to prevent translocation of aquatic invasive species.
[0004] 2. General Discussion and Related Art
[0005] Over the past 25 years, the introduction of foreign aquatic invasive species (AIS) into ports and waterways has increased significantly throughout the globe. Ships from around the world pump 40,000 gallons of foreign ballast water into U.S. waterways every minute.
[0006] This discharged ballast water contains countless species of foreign marine life including fish, shellfish, plants, and microorganisms. More than 200 AIS are now established in the San Francisco Bay and Delta areas in California and 150 AIS in the Great Lakes of North America alone.
[0007] Many of these foreign AIS are disrupting the local marine ecosystems. Invading organisms are steadily replacing native species by competition or predation. Viruses and bacteria carried in ships ballast water have the potential to cause the destruction of native species as well as create human health problems.
[0008] The Zebra Mussel, Chinese Mitten Crab, Sea Lamprey, and Purple Loosestrife are just some of the AIS causing serious and costly problems globally by clogging canals and water intake and/or outlet systems. Billions of dollars have been spent on problems arising from these organisms. The primary source comes from the discharge of ships' ballast water, taken in as ballast in one port then discharged into another port.
[0009] Globally, there are seven major marine ecological zones, each having distinct marine species which have evolved in those zones over many millennia. In recent years, however, there has been significant displacement of indigenous species from one zone to other zones around the globe. Today, no country has escaped from the widespread impact of aquatic invasive species arriving from other marine environments. In many instances, these translocated species have prospered in their newly found environment with damaging economic and ecological consequences. According to recent studies conducted by marine scientists, the most significant contributing factor for these undesired re-locations is the discharge of ballast water contained in vessels of commerce. Typically, an ocean going vessel takes sea water into its ballast tanks prior to departing its port of origin to stabilize the vessel during its voyage. This ballast water from the home port may then be discharged at ports of call in other ecological locations. Currently at least 162 non-indigenous aquatic species have colonized the Great Lakes alone. Thus far, the economically most significant aquatic invader to arrive in the Great Lakes system is the zebra mussel. A 1988 import from the Black Sea, the zebra mussel has become an economic and ecological disaster region. In addition to ecologically contaminating the Great Lakes, the zebra mussel is now spreading rapidly to other waters within the United States in spite of massive efforts and methodology deployed to control this invasive species. For all foreign aquatic species invading United States waters, the U.S. Coast Guard estimates the collective domestic economic impact of these undesired AIS arrivals at more than $7.3 billion per year.
[0010] The world's nations and different states of the United States are responding to this threat by promoting treaties and state legislation directed to setting standards for halting the spread of aquatic invasive species. On the international front, the International Maritime Organization (IMO) is developing an IMO Convention relating to ballast water management requirements. This Convention is expected to be signed within a few years then ratified by national legislative bodies and entered into force as domestic law in several of the world's nations. It is currently anticipated that after the year 2008, all international trading vessels using seawater as ships ballast will fall under the IMO Convention. Royal Haskoning Report, Global Market Analysis of Ballast Water Treatment Technology, Oct. 24,2001, Reference No. 42810/001R/HSC/SKO.
[0011] On the U.S. domestic front, the states of Washington and California are leading state legislative development efforts directed to regulating the discharge of ballast water into their respective state ports. These regulations are technical in nature and will provide specific standards relative to the discharge of particulate matter and active biological organisms.
[0012] Prior to current state legislative activities and collective international concern, the shipping industry had shown an acceptable degree of compliance to pre-existing standards. However AIS are still being introduced into the world's ports and waterways. Thus prior standards and technical measures implemented over the past years have proven inadequate. Currently, no known economically viable system has been found to prevent these organisms from entering or leaving ships' ballast water tanks.
[0013] Some of the prior methods and devices that have been employed in an attempt to control the AIS problem include (1) the mid-ocean ballast water exchange method, (2) ozone and nitrogen systems, (3) cyclone systems, (4) heat systems, and (5) use of biocides. These prior methods and systems are briefly described in further detail immediately herein below.
[0014] Mid-ocean Ballast Water Exchange: The U.S. Congress has passed legislation requiring ships carrying ballast water from foreign ports to exchange this point-of-origin ballast water with mid-ocean sea water before entering the Great Lakes. This method has not proven effective in killing freshwater organisms. Very small quantities of survivors, one per several thousand, were found sufficient to start an invasion.
[0015] Ozone and Nitrogen Systems: These gases, when introduced to the ship's ballast water, were found to be effective in controlling bacteria and other small organisms. However, they have proven to be less effective at controlling adult crustaceans and fish. Other disadvantages of these systems include those next enumerated. (1) Problems of uniformity in mixing the gases with the ballast water. Several days are required to kill the organisms. Ballast water exchange sometimes takes place within several hours. (2) Unable to treat the organisms in the sediments which are disturbed during ballasting. (3) Requires modification to the ship and significant space on board for system installation. (4) High cost.
[0016] Cyclone Systems: Water drawn into the system for ballasting is spun to remove organisms. The filtered water is allowed to flow into the ballast tanks and the removed organisms and unfiltered water returned to its source. These types of systems are capable of removing sediments, large particles, and some organisms. The disadvantages of these systems include the following. (1) Centrifugation does not work effectively with organisms that have densities close to that of water. (2) The system is prone to clogging and must be back flushed to clean. (3) An inability to treat or remove organisms that passed through the system. Once in the ballast tanks, these organisms may continue to grow and multiply. (4) Requires modification to the ship and significant space on board for system installation. (5) High cost.
[0017] Heat Systems: Heat energy high enough to kill organisms is added to the ballast water. Disadvantages of these systems are next briefly listed. (1) Huge quantity of energy is required to raise the temperature high enough to kill organisms. The energy required to kill bacteria and viruses make this system impractical for ballast water treatment. (2) Problems of uniformity in mixing the heated water with the ballast water, requiring many hours to kill the organisms. Ballast water exchange may have to take place within several hours. (3) Enough energy to run the system may not be available from the ship's power system. (4) High cost to install and operate.
[0018] Use of Biocides: Biocides such as vitamin K and chlorine are effective at killing AIS when added to the ballast water. Disadvantages of these systems include the following. (1) Problems of uniformity in mixing the biocide with the ballast water, requiring many hours to kill the organisms. Ballast water exchange may have to take place within several hours. (2) Some bacteria and viruses may not be killed by the biocides used. (3) Treated ballast water may be toxic to the environment when discharged.
[0019] In addition to the above technical limitations and cost considerations, none of the known prior art ballast water treatment systems will meet the newly emerging regulatory standards. Therefore it is desired to provide a cost effective, technically efficient ballast water treatment system that is acceptable by the marine shipping industry and that satisfies the emerging more stringent regulatory standards.
SUMMARY OF THE INVENTION
[0020] It is, therefore, an object of the present invention to improve ballast water treatment systems in a cost effective and technically efficient manner that also meets the anticipated future standards of currently developing legislative mandates. These and many other objects and advantages are attained in accordance with the present invention wherein there is provided a portable deck apparatus for treating ballast water discharged from the fire hydrant system of a ship. Different embodiments of the apparatus are provided.
[0021] According to another aspect of the present invention, there is provided a method of distributing portable water treatment devices around the deck of a ship to process ballast water discharged from the fire hydrant system of the ship.
[0022] In accordance with another aspect of this invention, there is also provided a built-in water treatment assembly for processing ballast water discharged from the fire hydrant system of a ship. This assembly is manufactured and installed during the ship building process rather than adapted as a retro-fit device or intended for use on pre-existing ships. There also provided methods related to this built-in water treatment aspects of the present invention.
[0023] According to yet another aspect of the present invention there is further provided a marine service vessel for treating discharged ballast water from a ship. Related methods include a method of treating discharged ballast water from a ship using the in-port marine service vessel and methods of deriving financial revenue for services provided for treating discharged ballast water from a ship using the in-port service vessel of the present invention.
[0024] In accordance with still yet another aspect of this invention, the inventors hereof have also provided a dock-side service vehicle for treating discharged ballast water from a ship in port. Related methods include a method of treating discharged ballast water from a ship using the dock-side service vehicle and methods of deriving financial revenue for services provided for treating discharged ballast water from a ship using the dock-side service vehicle as out-fitted according to the teachings of the present disclosure.
[0025] In addition to the above, the present invention further provides methods for processing, filtering, or treating ballast water discharged from a ship, and related methods directed to using the fire hydrant system of a ship to process, filter, or treat ballast water before directing the ballast water into an open water environment to thereby protect the environment form undesired aquatic invasive species.
[0026] More particularly, the present invention is directed to a portable deck apparatus for treating ballast water discharged from the fire hydrant system of a ship. This apparatus includes (1) a housing having at least one inlet port and one discharge port, the at least one inlet port being adapted to receive ballast water from the fire hydrant system of a ship, (2) a filter positioned within the housing, the filter employed to filter particulate matter from the ballast water received from the fire hydrant system, and (3) a source of electromagnetic radiation maintained within the housing for irradiating the ballast water to thereby deactivate biological organisms contained therein.
[0027] According to another aspect of the present invention there is provided a method of distributing portable water treatment devices around the deck of a ship to process ballast water discharged from the fire hydrant system of the ship, each of the water treatment devices having a known processing rate. This method includes the steps of (1) determining the number and location of fire hydrant outlets on the deck of a ship, (2) ascertaining the flow rate of each of the located fire hydrant outlets, (3) determining an amount of the ship's ballast water requiring treatment, (4) setting a maximum duration of time during which the determined amount of ballast water requiring treatment is to be processed, (5) determining the number of water treatment devices necessary to process the determined amount of ballast water within the maximum duration of time, and (6) distributing the determined number of water treatment devices around the deck of the ship proximate selected fire hydrant outlets to direct ballast water from the fire hydrant outlets into respective water treatment devices for processing.
[0028] In accordance with yet another aspect of the present invention, there is further provided a marine service vessel for treating discharged ballast water from a ship. This vessel includes a water treatment processing area accessible to a respective ship docket in port; a housing tank positioned within the water treatment processing area, the housing tank having at least one inlet port and one discharge port, the at least one inlet port being adapted to receive ballast water from the fire hydrant system of the respective ship by connecting a fire hose between a fire hydrant on the respective ship and the at least one inlet port of the housing tank; a filter positioned within the housing tank, the filter employed to filter particulate matter from the ballast water received from the respective ship's fire hydrant system; and a source of electromagnetic radiation maintained within the housing tank for irradiating the ballast water to thereby deactivate biological organisms contained therein.
[0029] According to certain methods of the present invention associated with the service vessel aspect thereof, there is further provided a method of treating discharged ballast water from a ship using an in-port service vessel. This method includes the steps of (1) providing a ballast water treatment apparatus on board the service vessel, (2) positioning the service vessel adjacent a respective ship requiring ballast water treatment, (3) and directing ballast water from a ballast tank of the respective ship into the ballast water treatment apparatus on board the service vessel to thereby treat the respective ship's ballast water before discharging the ship's ballast water. In this method, the respective ship's ballast water is directed from the ballast tank through the ship's fire hydrant system and into the ballast water treatment apparatus on board the service vessel. The method may include the further step of connecting at least one fire hose between a fire hydrant outlet on a deck of the respective ship and an inlet port provided on the ballast water treatment apparatus on board the service vessel.
[0030] According to the business method aspects of the present invention, there is provided a method of deriving financial revenue for services provided for treating discharged ballast water from a ship using an in-port service vessel. This method includes the steps of positioning the service vessel adjacent a respective ship requiring ballast water treatment; directing ballast water from a ballast tank of a respective ship into a ballast water treatment apparatus maintained on board the service vessel to thereby treat the respective ship's ballast water before discharging the ship's ballast water into the environment; determining an amount of time required to treat the respective ship's ballast water; and calculating a water treatment service fee based on the amount of time required to treat the respective ship's ballast water.
[0031] In accordance with yet another aspect of the present invention, there is further provided another method of deriving financial revenue for services provided for treating discharged ballast water from a ship using an in-port service vessel. This method includes the steps of positioning the service vessel adjacent a respective ship requiring ballast water treatment; directing ballast water from a ballast tank of a respective ship into a ballast water treatment apparatus maintained on board the service vessel to thereby treat the respective ship's ballast water before discharging the ship's ballast water into the environment; determining a total volume of treated ballast water processed from the respective ship's ballast water tanks; and calculating a water treatment service fee based on the total volume of treated ballast water.
[0032] According to still yet another aspect of the present invention, there is also provided a dock-side service vehicle for treating discharged ballast water from a ship in port. This vehicle may advantageously include a water treatment processing platform accessible to a respective ship docket in port; a housing tank positioned within the water treatment processing platform, the housing tank having at least one inlet port and one discharge port, the at least one inlet port being adapted to receive ballast water from the fire hydrant system of the respective ship by connecting a fire hose between a fire hydrant on the respective ship and the at least one inlet port of the housing tank; a filter positioned within the housing tank, the filter employed to filter particulate matter from the ballast water received from the respective ship's fire hydrant system; and a source of electromagnetic radiation maintained within the housing tank for irradiating the ballast water to thereby deactivate biological organisms contained therein.
[0033] A method of treating discharged ballast water from a ship using a dock-side service vehicle is also provided. This method includes the steps of providing a ballast water treatment apparatus on the dock-side service vehicle; positioning the service vehicle adjacent a respective ship requiring ballast water treatment; and directing ballast water from a ballast tank of the respective ship into the ballast water treatment apparatus on the dock-side service vehicle to thereby treat the respective ship's ballast water before discharging the ship's ballast water into an open water environment. In this method, the respective ship's ballast water may be directed from the ballast tank through the ship's fire hydrant system and into the ballast water treatment apparatus on the dock-side service vehicle. The method may further include the further step of connecting at least one fire hose between a fire hydrant outlet on a deck of the respective ship and an inlet port provided on the ballast water treatment apparatus on the dock-side service vehicle.
[0034] There is still also provided a method of deriving financial revenue for services provided for treating discharged ballast water from a ship using a dock-side service vehicle. This method includes the steps of (1) positioning the dock-side service vehicle adjacent a respective ship requiring ballast water treatment, (2) directing ballast water from a ballast tank of a respective ship into a ballast water treatment apparatus maintained on the dockside service vehicle to thereby treat the respective ship's ballast water before discharging the ship's ballast water into an open environment, (3) determining an amount of time required to treat the respective ship's ballast water, and (4) calculating a water treatment service fee based on the amount of time required to treat the respective ship's ballast water.
[0035] There is also provided another method of deriving financial revenue for services provided for treating discharged ballast water from a ship using a dock-side service vehicle. This method includes the steps of (1) positioning the dock-side service vehicle adjacent a respective ship requiring ballast water treatment, (2) directing ballast water from a ballast tank of a respective ship into a ballast water treatment apparatus maintained on the dockside service vehicle to thereby treat the respective ship's ballast water before discharging the ship's ballast water into an open environment, (3) determining a total volume of treated ballast water processed from the respective ship's ballast water tanks, and (4) calculating a water treatment service fee based on the total volume of treated ballast water.
[0036] According to yet a further aspect of this invention, there is also provided a method of processing ballast water discharged from a ship. This method includes the steps of accessing ballast water requiring treatment from a ship's ballast tank through a fire hydrant system of the ship, directing the ballast water from the fire hydrant system through a filter to thereby remove undesired particulate matter from the ballast water, and directing the filtered ballast water into an open water environment. This method may further include the step of directing electromagnetic radiation at the ballast water before directing the filtered ballast water into the open water environment to thereby deactivate biological organisms contained within ballast water.
[0037] There is yet still provided a method of using the fire hydrant system of a ship to treat ballast water. This method includes the steps of accessing ballast water requiring treatment from a ship's ballast tank through a fire hydrant located on a deck of the ship, directing the ballast water from the fire hydrant through a filter to thereby remove undesired particulate matter from the ballast water, and directing the filtered ballast water into an open water environment. This method may include the further step of directing electromagnetic radiation at the ballast water before directing the filtered ballast water into the open water environment to thereby deactivate biological organisms contained within ballast water.
BRIEF DESCRIPTION OF THE DRAWING
[0038] Further objects of the present invention together with additional features contributing thereto and advantages accruing therefrom will be apparent from the following description of preferred embodiments of the invention which are shown in the accompanying drawing with like reference numerals indicating like components throughout, wherein:
[0039] [0039]FIG. 1 is a perspective view of a one embodiment of a ballast water treatment apparatus according to the present invention;
[0040] [0040]FIG. 2 is a view similar to FIG. 1 including a cut-away section to illustrate the interior of a more particular embodiment of the ballast water treatment apparatus according to this invention;
[0041] [0041]FIG. 3 is a top perspective view showing a filter bag assembly as employed in conjunction with different embodiments of the present invention;
[0042] [0042]FIG. 4 is a perspective cut-away view showing a filter frame support structure according to one aspect of this invention and further illustrating removal of the filter bag assembly of FIG. 3;
[0043] [0043]FIG. 5 is an enlarged detailed perspective view of the filter frame support structure and bag assembly illustrated in FIG. 4;
[0044] [0044]FIG. 6 is a perspective cut-away view of another embodiment of the ballast water treatment apparatus according to the present invention;
[0045] [0045]FIG. 7 is an enlarged detailed perspective view of a water treatment tank and related piping as utilized in conjunction with the embodiment of the present invention illustrated in FIG. 6;
[0046] [0046]FIG. 8 is a typified diagrammatic cross-sectional representation of a ship's ballast tank and related mechanical piping as adapted for use with the ballast water treatment apparatus according to the present invention;
[0047] [0047]FIG. 9 is a perspective view of a container ship docked port-side for unloading that is also being serviced by a dock-side service vehicle according to the ballast water treatment aspects of the present invention and alternate methods relating thereto;
[0048] [0048]FIG. 10 is a deck plan of the container ship illustrated in FIG. 9 showing the location of the ship's second deck fire hydrants;
[0049] [0049]FIG. 11 is a cross-sectional view of the container ship illustrated in FIG. 9 showing the ballast tank area relative to cargo space;
[0050] [0050]FIG. 12 is perspective view along the second deck of a typical container ship illustrating the placement of ballast water treatment apparatus according to the present invention;
[0051] [0051]FIG. 13 is a perspective view of a tanker docked port-side for loading or unloading that is also being serviced by an in-port service vessel according to the ballast water treatment aspects of the present invention and additional methods relating thereto;
[0052] [0052]FIG. 14 is a perspective view of a passenger cruse ship docked port-side for loading or unloading;
[0053] [0053]FIG. 15 is a cross-sectional view of the tanker shown in FIG. 13 illustrating the ballast tank area relative to cargo space;
[0054] [0054]FIG. 16 is a cross-sectional view of an intermediate class Great Lakes bulk vessel showing the ballast tank area relative to cargo space;
[0055] [0055]FIG. 17 is a cross-sectional view of a Panamax size oil bulk ore carrier representing the ballast tank area relative to cargo space;
[0056] [0056]FIG. 18 is a perspective view of another embodiment of the present invention illustrating the use thereof as positioned on the side of a typical container ship;
[0057] [0057]FIG. 19 is a perspective view of a half-face housing member that may be employed in combination with the ballast water treatment apparatus illustrated in FIG. 18;
[0058] [0058]FIG. 20 is a perspective view of yet another embodiment of the ballast water treatment apparatus according to the present invention;
[0059] [0059]FIG. 21 is an exploded view of the ballast water treatment apparatus illustrated in
[0060] [0060]FIG. 20 including break-away sections to show interior elements of principal components of the apparatus;
[0061] [0061]FIG. 22 is a detailed partial plan view of the UV lamp assembly utilized in conjunction with the ballast water treatment apparatus shown in FIG. 20 illustrating build-up of UV-irradiated biological material on the lamp assembly;
[0062] [0062]FIG. 23 is a view similar to FIG. 22 showing a tube wiper system and actuator assembly cleaning the build-up of UV-irradiated biological material on the lamp assembly according to another aspect of the present invention;
[0063] [0063]FIG. 24 is a view similar to FIG. 23 showing the lamp assembly in a fully cleaned or wiped condition after full activation of the tube wiper system; and
[0064] [0064]FIG. 25 is a detailed isolated elevation view of a wiper plate employed in the tube wiper system illustrated in FIGS. 22 - 24 .
DETAILED DESCRIPTION OF THE INVENTION
[0065] With reference to FIG. 1, there is shown a ballast water treatment apparatus or device 102 according to the present invention. The ballast water treatment apparatus 102 includes a tank housing 104 as illustrated. The housing 104 includes an inlet port 106 having a gallon metered device as shown. The housing 104 further includes a discharge port 108 . In the embodiment illustrated in FIG. 1, the housing member 104 is further provided with a discharge hose 110 mounted thereon by use of hook brackets 112 . During use of the ballast water treatment apparatus 102 as described in further detail below, the discharge hose 110 is connected to the discharge port 108 . With continuing reference to FIG. 1, there is further shown transport wheels 114 integrally arranged with the housing member 104 to thereby provide mobility during use of the apparatus on a ship's deck. As also shown in FIG. 1, the housing member 104 is provided with a filter apparatus which is discussed in further detail in connection with FIGS. 2 - 5 .
[0066] With reference now to FIG. 2, there is shown the filter apparatus 116 including a filter bag 118 , support rods 120 , and a support frame 122 . The support frame 122 is positioned on a first platform 124 as illustrated. The first platform 124 divides the interior housing 124 into an upper filter chamber 125 and a lower treatment chamber. According to this embodiment of the present invention, there is also provided a second platform 126 positioned below the first platform 124 and above the bottom 128 of the housing 104 . The first platform 124 fluidly isolates the upper filter chamber from the lower chambers. The first platform 124 includes a first flow aperture 130 which allows filtered water to pass from the upper chamber into a first lower flow channel formed between the first platform member 124 and the second platform member 126 . As further illustrated in FIG. 2, the second platform member 126 includes a flow aperture 132 allowing fluid flow from the first treatment channel into the second treatment channel formed between the second platform 126 and the tank bottom 128 . As further indicated by the arrows in FIG. 2 representing the direction of flow of ballast water through the ballast water treatment apparatus 102 , the filtered water exits the housing 104 through a third flow aperture 134 . As illustrated, water flow is through the aperture 134 in the tank bottom 128 and then through the discharge port 108 .
[0067] As discussed above in conjunction with FIG. 1, during use of the device 102 , the discharge hose 110 is connected to the discharge elbow 108 to direct filtered and treated water over the side of the ship as further discussed in detail below. As further illustrated in FIG. 2, each of the lower flow chambers includes at least one ultraviolet (UV) lamp 136 which is secured to either side of the housing 104 by UV lamp sockets 138 . Each of the individual UV lamps 136 is provided with an electrical feedback connection 140 that connects into an electrical control box 132 as illustrated. The electrical control box 132 further includes an electrical power supply 134 that provides power to the UV lamps 136 . Electrical power is provided to the control box 132 by an electrical connection 146 that connects to the ship's power supply. During use of the ballast water treatment apparatus 102 , the control box 142 includes an hour meter to monitor and record UV bulb usage time. FIG. 2 illustrates one UV lamp in each of the lower treatment chambers. It would be readily understood by those of skill in the art, however, that a greater number of UV bulbs may be situated within these treatment chambers to provide additional electromagnetic UV energy into the chamber. Thus during the operation of the ballast water treatment apparatus 102 , after the ballast water has passed through the filter bag 118 , it is directed by gravity flow into the lower UV treatment chambers wherein electrical energy is applied to the UV bulbs and UV energy is directed in all directions into the flowing filtered water.
[0068] The UV energy is selected to be of sufficient power so that any micro-organisms or other biological organisms passing through the filter-bag 118 will be deactivated by the application of the UV energy. As used herein, “deactivation” means rendering any harmful or undesired biological organisms inactive in a manner that either kills the organisms, renders them unable to reproduce, or otherwise prevents them from causing harm to the open water environment into which the ballast water is discharged. The UV lamps utilized in one specific embodiment preferably number 8 in each chamber and are preferably 2000 watts (2KW) with an operating voltage of 1,454 volts AC running at 1.35 amps. Thus in this embodiment of the present invention, UV radiation is principally employed to deactivate any biological organisms contained within the ballast water.
[0069] As further illustrated in FIG. 2, the ballast treatment apparatus 102 may be provided with two inlet ports 106 each having a respective gallon meter. In this alternate embodiment of the present invention, two supply hoses may be utilized from the ship's fire hydrant system to double the input flow into the apparatus 102 thereby decreasing the time required to filter and treat the ship's ballast water according to the various methods of the present invention discussed below in further detail.
[0070] With reference now to FIG. 3, there is shown a perspective top view of the ballast water treatment apparatus 102 according to the present invention. FIG. 3 also shows a top view of the filter apparatus 116 including filter bag 118 and support rods 120 . As further shown in FIG. 3, the filter bag 118 is folded upwardly within the filter bag itself so that the bottom of the filter bag is situated some distance below the top edge of the filter bag 118 . As further shown, the bottom of the filter bag 118 is provided with a change-filter indicator strip 148 . In this manner, during use of the device when particulate matter is filtered from ballast water, the material forming the filter bag 118 will eventually collect an external layer of filtered particulate matter. As this layer of filtered particulate matter increases in thickness, the change-filter indicator strip 148 will eventually become fully covered by such filtered particulate matter. When this occurs, this is an indication that the filter bag 118 should be changed.
[0071] [0071]FIG. 4 illustrates the process for changing the filter bag 118 . As illustrated in FIG. 4, one or two crew members may grasp the support rods 120 and lift the filter bag 116 from the housing member 104 . As further shown in FIG. 4, when filter bag 118 is removed from the housing member 104 , the support frame 122 remains within the housing 104 . The preferred shape of the support frame 122 is the A-frame style indicated in FIG. 4. In this manner, the support frame 122 provides the necessary elevation so that the end of the filtered bag and the change-filter indicator strip 148 , FIG. 3, is situated at a desired height within the housing 104 so that it is substantially always submerged under ballast water during the filtration process to provide an accurate indication of the amount of particulate matter filtered during the filter operation.
[0072] As further illustrated in FIG. 4, the top edge of the housing member 104 is provided with support rod notches 150 that are located to position support rods 120 in a desired parallel fashion as indicated in FIG. 3. The support rod notches 150 also secure the rods during use of the device.
[0073] [0073]FIG. 5 is an enlarged detailed perspective view of the filter frame support structure 122 and filter bag 118 . As illustrated, as the filter bag 118 is loaded into the apparatus, the support frame 122 provides a structure that positions the indicator strip 148 at a desired location above the first platform 124 shown, for example, in FIG. 4. In this manner, not only does the indicator strip 148 result in being positioned in a desired height above the first platform 124 , the surface area of the filter bag is thereby increased thus giving increased flow-through and filtering effect during the filtering operation.
[0074] With reference next to FIGS. 6 and 7, there is shown an alternate embodiment of the ballast water treatment apparatus 102 according to the present invention. In the embodiment illustrated in FIG. 6, the upper chamber is substantially similar to that discussed in connection with FIGS. 1 - 5 . As illustrated, this embodiment of the apparatus 102 includes the filter apparatus 116 , and the housing member 104 having an inlet port 106 and discharge port 108 . This embodiment of the present invention also includes a first platform 124 and a second platform 126 . This embodiment also similarly includes the first flow aperture 130 provided in the first platform 124 and a second flow aperture 132 formed in the second platform 126 . As illustrated, the first flow aperture 130 is rectangular in shape while the second flow aperture 132 in this embodiment is circular to conform to an inlet pipe 152 shown in FIG. 7. As illustrated in FIGS. 6 and 7, this embodiment of the present invention includes a treatment tank 154 . The treatment tank 154 includes the UV lamps 136 . Depending on the application of the energy required, anywhere between one and eight UV lamps extending the entire length of the treatment tank 154 are preferably desired. The tank 154 is further provided with discharge piping 156 . As illustrated in FIG. 6, the discharge piping 156 is fluidly connected to the discharge port 108 . The discharge piping 156 includes a trap portion 158 which is situated above the highest water level attainable within the tank 154 . In this manner during non-use, water will be maintained within a pipe segment 160 to thereby prevent undesired back-flow. The treatment tank 154 is similarly provided with an electrical power supply 144 and an electrical feedback connection 140 . In this specific embodiment of the apparatus as illustrated in FIG. 7, the treatment tank 154 is further provided with heat sensors 162 . The electrical feedback connection 144 and electrical power supply 144 are similarly connected to a control box 142 as illustrated in FIG. 2. In this embodiment, the heat sensors 162 are similarly connected to the control box 142 . The heat sensors detect the temperature of the filtered water as it passes through the treatment tank 154 . In one preferred embodiment, once the UV bulbs 136 reach a desired temperature, they will heat the water and thereby deactivate any biological organisms contained within the ballast water as it passes through the tank 154 . In this embodiment, both UV radiation and heat are employed as indicated to deactivate any biological organisms contained within the ballast water.
[0075] To prevent premature discharge of filtered water from the treatment tank 154 through the discharge port 108 , this embodiment of the present invention is provided with a solenoid-activated valve 164 which is similarly electrically connected to the control box 142 . In this manner, the valve 164 is not opened until the water temperature within the tank 154 reaches a pre-determined processing temperature. In one preferred embodiment, the required bulb temperature for water treatment is 125° F. In this embodiment low pressure UV lamps are employed to achieve the desired temperature. In another preferred embodiment of this aspect of the present invention, high pressure UV lamps are utilized to achieved a water temperature of 400° F. Thus during use of the apparatus illustrated in FIGS. 6 and 7, discharge flow is not permitted until the temperature in tank 154 reaches a predetermined desired temperature set to effectively kill or otherwise deactivate any biological microorganisms contained within the ballast water. As with the embodiment of the ballast water treatment apparatus 102 discussed in connection with FIG. 14, the UV lamps utilized in the embodiment shown in FIGS. 6 and 7 are preferably 2000 watts (2KW) with an operating voltage of 1 , 454 AC running at 1 . 35 amps. In one specific implementation, six UV lamps of this particular rating are preferred.
[0076] Referring now to FIG. 8, there is shown a schematic cross-sectional side view of a typical ship's ballast tank and first main deck. As represented schematically, the main deck includes a fire hydrant outlet 166 as indicated. During the process of loading sea water into the ship for ballast, the sea chest and sea valve 168 are open to allow sea water to enter the ballast tanks 170 . To allow sea water into the ballast tank, ballast tank valve 172 is typically provided to control the flow of sea water into the ballast tank. A strainer is provided to remove any large particulate matter from the sea water as it enters the ballast tank 170 from the sea chest through the sea valve 168 and into the ballast tank 170 through the ballast tank valve 172 . As indicated in FIG. 8, the sea water mechanical system also typically includes a fire hydrant system main valve 174 . During use of the apparatus of the present invention, the sea valve 168 is closed while the ballast tank valve 172 is opened. A pump 176 is activated to pump sea water from the ballast tank 170 up through pump 176 and through the connecting piping 178 to feed the fire hydrant outlets 166 with sufficient pressure. Thus in this manner, the apparatus of the present invention may advantageously utilize the ballast water mechanical systems and the fire hydrant system of a ship to direct ballast water from the ballast tanks of a ship through the fire hydrant system to the fire hydrant outlets 166 on board the ship and then into the apparatus of the present invention.
[0077] With reference now to FIG. 9, there is shown a typical container ship 180 docked in port alongside a dock 182 . According to one aspect of the present invention, the ballast treatment apparatus 102 is mounted on a dock-side service vehicle 184 . In accordance with one method of the present invention, the dock-side service vehicle 184 is positioned adjacent to the docked ship, in this case the container ship 180 . Fire hoses 186 are then connected to the ship's fire hydrant outlets and directed overboard from the ship's deck to be secured to the ballast water treatment apparatus 102 contained on or secured to a suitable work space area provided preferably on the back of the dock-side service vehicle 184 . The fire hoses 186 are then connected to the inlet ports 106 of the apparatus 102 and filtration and treatment of the ship's ballast water proceeds as described above. The dock-side service vehicle 184 contains a discharge pipe 188 which directs the filtered and treated water back into the harbor or port.
[0078] The inventors of the present invention have designed and contemplated many implementations of the ballast water treatment apparatus 102 for use in combination with the dock-side service vehicle 184 . As indicated, the preferred embodiment of the dockside vehicle 184 is a modified, small tank truck that has a filter apparatus contained therein and the UV lamps positioned within the truck-mounted tank or tanks. Thus in this manner, the truck-mounted tanks are completely self-contained and include a suitable number of inlet ports 106 designed to readily quick connect to the ends of fire hoses provided from the ship's fire hydrants.
[0079] With continuing reference to FIG. 9, the inventors hereof have specifically provided a method of treating discharged ballast water from the ship 180 using the dock-side service vehicle 184 . This method includes the steps of providing a ballast water treatment apparatus on the dock-side service vehicle 184 , positioning the service vehicle 184 adjacent the ship 180 , and directing ballast water from a ballast tank of the ship 180 into the ballast water treatment apparatus on the dock-side service vehicle 184 to thereby treat the ship's ballast water before discharging the ship's ballast water into an open water environment. In this method, the respective ship's ballast water may be directed from the ballast tank through the ship's fire hydrant system and into the ballast water treatment apparatus on the dock-side service vehicle 184 . The method may include the further step of connecting at least one fire hose 186 between a fire hydrant outlet on the deck of the ship 180 and an inlet port provided on the ballast water treatment apparatus on the dockside service vehicle 184 .
[0080] The inventors hereof have further provided a method of deriving financial revenue for services provided for treating discharged ballast water from the ship 180 using the dock-side service vehicle 184 . This method includes the steps of (1) positioning the dockside service vehicle 184 adjacent the ship 180 , (2) directing ballast water from a ballast tank of a ship 180 into a ballast water treatment apparatus maintained on the dock-side service vehicle 184 to thereby treat the ship's ballast water before discharging the ship's ballast water into an open environment, (3) determining an amount of time required to treat the ship's ballast water, and (4) calculating a water treatment service fee based on the amount of time required to treat the ship's ballast water.
[0081] There is also provided another method of deriving financial revenue for services provided for treating discharged ballast water from a ship using the dock-side service vehicle 184 . This method includes the steps of (1) positioning the dock-side service vehicle 184 adjacent ship 180 , (2) directing ballast water from a ballast tank of the ship into a ballast water treatment apparatus maintained on the dock-side service vehicle 184 to thereby treat the ship's ballast water before discharging the ship's ballast water into an open environment, (3) determining a total volume of treated ballast water processed from the ship's ballast water tanks, and (4) calculating a water treatment service fee based on the total volume of treated ballast water.
[0082] Referring next to FIG. 10, there is shown the deck plan of the typical container ship 180 and the location of the fire hydrant outlets 166 . FIG. 11 shows the ballast tank areas 170 relative to the cargo areas represented by reference numeral 190 . The typical cargo container ship 180 will carry a known amount of sea water for ballast. Thus if it is desired to completely treat and filter the ballast water in accordance with the methods of the present invention, the number of available fire hydrant outlets 166 may be determined along with flow rates thereof and the known flow rates of the ballast water treatment apparatus 102 to completely filter the entire ship's ballast water within a predetermined maximum amount of time. As represented diagrammatically in FIG. 10, a number of ballast water treatment apparatus 102 are distributed around the ship's main deck or second deck adjacent fire hydrant outlets 166 . The ship's fire hydrant as indicated in FIG. 8 typically includes one outlet. According to one aspect of the present invention, ships with one outlet fire hydrants many be equipped with a Y-adaptor to thereby provide two outlets. Both of these outlets may be employed to direct ballast water into the ballast water treatment apparatus 102 . Alternatively one outlet may be employed with the apparatus 102 while the other is reserved for use in case it is needed in a fire emergency. Thus according to one preferred method of this invention, two hoses may be connected to each of the fire hydrants 166 and directed to adjacent ballast water treatment devices 102 as interconnected by the ship's fire hoses 186 . As represented in FIG. 10, the series connected arrangement of fire hydrants 166 feeding two adjacent ballast water treatment apparatus 102 will utilize the full flow-through rate of the fire hydrant system of the ship to filter and treat the ship's ballast water according to this aspect of the present invention in a minimum amount of time. FIG. 12 next illustrates a perspective pictorial representation of this multi-hydrant and multi-apparatus method.
[0083] Turning now to FIG. 13, there is shown a perspective view of a typical tanker 202 situates dockside in a port-of-call. As indicated in FIG. 13, the main deck of the tanker 202 includes a number of fire hydrant outlets 166 . In accordance with another aspect of the present invention, there is provided an in-port service vessel 204 which is out-fitted with a ballast water treatment apparatus 102 according to the present invention. Thus in accordance with alternate methods of the present invention, the in-port service vessel 204 may be employed to pull alongside a docked ship and provide ballast water filtration and treatment services. For example, as illustrated in FIG. 13, a tanker 202 may be required by local, state, national, or international regulations to have the ship's ballast water treated before its ballast water is discharged into the port or harbor. Thus in accordance with this method of the present invention, the ship's fire hoses 186 are connected to the main deck's fire hydrants 166 and directed to the in-port service vessel 204 as represented in FIG. 13. The in-port service vessel 204 may be a barge type vessel or tug boat type vessel utilized to provide the water filtering and treating service to a ship. According to alternate methods of this embodiment, neither the ship nor the service vessel 204 need necessarily be dockside. The ship may be anchored in port or alternatively, even serviced in this manner in open waters or on the high seas before entering port.
[0084] Thus in continuing reference to FIG. 13, the inventors hereof have provided a method of treating discharged ballast water from a ship using the in-port service vessel 204 . This method includes the steps of (1) providing a ballast water treatment apparatus 102 on board the service vessel, (2) positioning the service vessel adjacent the ship 202 requiring ballast water treatment, (3) and directing ballast water from a ballast tank of the ship 202 into the ballast water treatment apparatus 102 on board the service vessel 204 to thereby treat the respective ship's ballast water before discharging the ship's ballast water. In this method, the ship's ballast water is directed from the ballast tank through the ship's fire hydrant system and into the ballast water treatment apparatus on board the service vessel 204 . The method may include the further step of connecting at least one fire hose 186 between the fire hydrant outlet 166 on the deck of the ship 202 and an inlet port provided on the ballast water treatment apparatus on board the service vessel.
[0085] Accordingly, there is also provided a method of deriving financial revenue for services provided for treating discharged ballast water from a ship using the in-port service vessel 204 . This method includes the steps of positioning the service vessel 204 adjacent the ship 202 requiring ballast water treatment; directing ballast water from a ballast tank of the ship 202 into a ballast water treatment apparatus maintained on board the service vessel 204 to thereby treat the ship's ballast water before discharging the ship's ballast water into the environment; determining an amount of time required to treat the ship's ballast water; and calculating a water treatment service fee based on the amount of time required to treat the ship's ballast water.
[0086] There is further provided another method of deriving financial revenue for services provided for treating discharged ballast water from the ship 202 using the in-port service vessel 204 . This method includes the steps of positioning the service vessel 204 adjacent the ship 202 requiring ballast water treatment; directing ballast water from a ballast tank of the ship 202 into a ballast water treatment apparatus maintained on board the service vessel 204 to thereby treat the respective ship's ballast water before discharging the ship's ballast water into the environment; determining a total volume of treated ballast water processed from the respective ship's ballast water tanks; and calculating a water treatment service fee based on the total volume of treated ballast water.
[0087] Referring next to FIG. 14, there is shown a perspective view of a typical cruise ship 194 in port dockside for loading or unloading passengers, cargo, and supplies. As discussed in connection with FIGS. 9, 10, and 11 , the cruise ship 184 may be similarly serviced by the dock-side service vehicle 184 or alternatively carry on-board a desired number of ballast water treatment apparatus 102 for on-ship deck hands to filter and treat the ship's ballast water according to the methods discussed above. In addition thereto, cruise ship 194 may have its ballast water treated by the in-port service vessel 204 discussed above.
[0088] [0088]FIG. 15 is a cross-sectional view of the tanker illustrated in FIG. 13 illustrating the ballast tank area 170 relative to cargo space 190 . FIG. 16 is a cross-sectional view of an intermediate class Great Lakes bulk vessel showing the ballast tank area 170 relative to cargo space 190 . FIG. 17 is a cross-sectional view of a Panamax size oil bulk ore carrier representing the ballast tank area 170 relative to cargo space 190 . In each of these three different types of ships, typically the weight of the cargo loaded on or off the ship is approximately made equal to the weight of ballast water used to counter-balance the ship in accordance with known methods for loading and unloading ships. In these types of ships, ordinarily, a relatively larger volume of ballast water is discharged during loading as compared to the typical container ship illustrated, for example, in FIG. 9. Nonetheless, the apparatus 102 and methods of the present invention utilizing either the dock-side service vehicle 184 or the in-port service vessel 204 may be readily scaled up to meet the volume of ballast water typically discharged by these types of ships.
[0089] With reference now to FIG. 18, there is shown an alternate embodiment of the ballast water treatment apparatus of the present invention. A ballast water filtration apparatus 210 is shown in FIG. 18. The ballast water filtration device 210 similarly includes a filter bag 118 and support rods 120 . In this embodiment, the support rods 120 are provided with members to hook over the side of the ship as illustrated in FIG. 18. In use, a fire hose 186 is connected to the fire hydrant on the ship's deck and the open end of the fire hose 186 is simply placed in the filter bag 118 as illustrated. Thus in this embodiment of the present invention, there is provided a very simply and economically cost effective filtration apparatus and method.
[0090] [0090]FIG. 19 shows a half-face housing member for the ballast water filter apparatus 210 illustrated in FIG. 18. The half-face housing member 212 illustrated in FIG. 19 may be employed in conjunction with the ballast water filter apparatus 210 shown in FIG. 18 to provide a directed outlet flow as indicated in FIG. 19. The half-faced housing is similarly provided with the discharge port 108 to direct the water downwardly into the harbor. The discharge port 108 may similarly have adapted thereto the discharge hose 110 illustrated in FIG. 1 to thereby further direct the filtered ballast water into the open water environment of the harbor or port.
[0091] With reference next to FIGS. 20 and 21, there is shown a perspective view of yet another embodiment of the ballast water treatment apparatus 102 according to the present invention. FIG. 21 in particular is an exploded view of the ballast water treatment apparatus 102 illustrated in FIG. 20 including break-away sections to show interior elements of principal components of the apparatus 102 . In this embodiment shown in FIGS. 20 and 21, the apparatus 102 includes a filtration unit 214 , a UV containment vessel or compartment 218 , and an electrical compartment 220 . As illustrated, the filtration unit 214 includes a cap member having view ports 216 . When in use, the cap member prevents ballast water from splashing out of the apparatus 102 while the view ports 216 provide viewing access to the interior of the filtration unit 214 during filtration operations. As further illustrated in FIG. 20, the filtration unit 214 includes the inlet port and associated piping 106 which may be implemented with a gallon meter at the T-junction shown. To further increase the intake flow, the filtration unit 214 may be outfitted with two inlet ports and associated piping 106 , one such situated as illustrated and the other similarly installed on the reverse-side or back-side of the unit 214 as shown. The UV compartment 218 includes the UV lamps 136 which in this embodiment are positioned within the UV compartment 218 by use of a pair of UV bulb mounting brackets 222 .
[0092] As shown in FIG. 21, the UV compartment 218 includes UV sensors 221 which are employed to detect the UV output of the bulbs 136 . As shown, the apparatus 102 illustrated in FIGS. 20 and 21 includes the control box 142 that is implemented to similarly control operations of the apparatus as discussed above in connection with the embodiment of the apparatus 102 illustrated in FIGS. 1 - 5 . In the embodiment illustrated in FIGS. 20 and 21, the electrical compartment may include additional components to provide further operations and functions to the apparatus 102 .
[0093] In operation, a fire hose connected to the ship's fire hydrant at one end is connected at its other end to the inlet piping 106 . Ballast water then travels from the lower right area of the filtration unit 214 as illustrated to the upper left thereof to then be directed and discharged into the filter apparatus 116 . The ballast water then drains through the filter 116 to thereby remove particulate matter as small as 1 micron. The filtered ballast water then exits the filtration unit 214 through the first flow aperture 130 and is directed into the UV compartment 218 for UV treatment. As the UV compartment 218 fills with filtered ballast water at one end, filtered water is then directed to the other end thereof toward the discharge port 108 . As the filtered water flows along in the UV compartment 218 toward the discharge port 108 , the UV lamps are activated to treat the filtered water so that any micro-organisms, viruses, or bacteria that may have remained in the ballast water after the filtration step are thereby deactivated by UV treatment. The general direction of flow is indicated by the wide arrows shown in FIG. 21.
[0094] In the embodiment illustrated in FIGS. 20 and 21, the UV lamps 136 are situated substantially perpendicular to the flow of ballast water. In one particular preferred embodiment of the UV compartment 218 , the UV lamps 136 utilized therein are 3000 KW lamps operating at 220VAC and 30 Amps. In one such preferred embodiment, six UV lamps 136 are employed. While in other embodiments, the number of UV lamps 136 may vary depending on the desired flow rate, type of ballast water, and desired deactivation or “kill” effectiveness.
[0095] [0095]FIG. 22 is a detailed partial plan view of a UV lamp assembly utilized in conjunction with the ballast water treatment apparatus shown in FIGS. 20 and 21. FIG. 22 illustrates build-up of UV-irradiated biological material on the lamp assembly. FIG. 23 is a view similar to FIG. 22 showing a tube wiper system and actuator assembly 226 cleaning the build-up of UV-irradiated biological material on the lamp assembly according to another aspect of the present invention. FIG. 24 is a view similar to FIG. 23 showing the lamp assembly in a fully cleaned or wiped condition after full activation of the tube wiper system 226 . FIG. 25 is a detailed isolated elevation view of a wiper or face plate 228 employed in the tube wiper system 226 illustrated in FIGS. 22 - 24 .
[0096] As illustrated in FIGS. 22 - 24 , each UV lamp 136 is enclosed in a transparent sleeve 224 . When the filtered ballast water is treated in the UV compartment, deactivated particulate matter may build up on the transparent sleeves 224 . As this build-up of particulate matter increases in thickness, the effect of the UV lamps will be diminished. Thus the UV sensors 221 are employed to detect the UV output of each associated bulb. Once the UV lamp output decreases below a certain set threshold, the cleaning actuator 226 is activated to wipe clean the transparent lamp sleeves 224 . This wiping effect is achieved by use of a rubber wiper washer 230 , FIG. 25, which snuggly fits around the sleeve 224 as illustrated. After activation, the sleeve is wiped clean and the UV effectiveness is returned to a maximum. The control box 142 and electrical compartment 220 , FIGS. 21 and 22, are implemented with operational features that control sleeve cleaning or wiping in a desired manner.
[0097] While this invention has been described in detail with reference to certain preferred embodiments and aspects thereof, it should be appreciated that the present invention is not limited to those precise embodiments. Rather, in view of the present disclosure which describes the current best mode for practicing the invention, many modifications and variations would present themselves to those of skill in the art without departing from the scope and spirit of this invention. The scope of the invention is, therefore, indicated by the following claims rather than by the foregoing description. All changes, modifications, and variations coming within the meaning and range of equivalency of the claims are to be considered within their scope. | Ballast water treatment apparatus and methods for preventing foreign aquatic invasive species form entering marine ecological zones by translocation in ship's ballast water. The apparatus includes a housing, a filter member, and UV water treatment chambers. Methods include use of a ship's fire hydrant system for moving ballast water from the ship's ballast tanks into the apparatus for filtration and treatment. In-port service vessels and dock-side service vehicles are equipped with the treatment and filtration apparatus to provided in-port or dock-side ballast water treatment services. Related methods are also provided. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a continuation application of U.S. patent application Ser. No. 11/903,614, filed Sep. 24, 2007, which is a continuation application of U.S. patent application Ser. No. 10/764,742, filed Jan. 26, 2004, now U.S. Pat. No. 7,273,375, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/442,671, filed Jan. 24, 2003, the disclosures of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a teaching or instruction aid device or system and to a method of teaching and, especially, to a teaching aid and a method of teaching to assist a visually impaired person in learning mathematics, including, but not limited to, addition, subtraction, multiplication, division, fractions, algebra and calculus.
BACKGROUND OF THE INVENTION
[0003] References set forth herein may facilitate understanding of the present invention or the background of the present invention. Inclusion of a reference herein, however, is not intended to and does not constitute an admission that the reference is available as prior art with respect to the present invention.
[0004] In the past, for various reasons, there has been only limited success in teaching visually impaired people mathematics. Often, without the aid of sight, a visually impaired or blind student of mathematics does not easily obtain the common or established look, feel and lexicon for numbers and simple mathematical operations that sighted students obtain. As well known to instructors of the visually impaired, the Braille System and the Nemeth Braille System are useful instruction tools in mathematics, but have substantial limitations. For example, because of the manner in which numbers and mathematical operators such as division are represented in those systems, the visually impaired quite often have difficulty in both understanding and/or following in a timely manner the spoken instructions provided to sighted students. These difficulties present a significant problem, for example, when a visually impaired student is taught in a classroom with students who are not visually impaired.
[0005] Over the years, a number of teaching aids have been developed for teaching mathematics and other subjects, but none of these teaching aids has adequately addressed the problems of teaching the visually impaired. U.S. Pat. No. 5,865,627, for example, discloses an educational system comprising a set of foam characters including numbers, operational symbols and advanced problem solving activities that include touch sensitive fasteners (hook and loop fasteners) which can be applied to a touch sensitive board. The characters are stored separately from the board and a student can carry out pre-algebraic calculations upon the surface by fastening the characters to the board. No provision is made in the device for the visually impaired to locate, read and/or position the characters. Moreover, application of the characters to the surface is rather cumbersome and slow, making it difficult for a student to apply the characters to the surface in a timely manner, for example, while following a teacher in a typical math class.
[0006] U.S. Pat. No. 4,373,917 also discloses an educational device for teaching arithmetical operations. The device includes a graph- or grid-like base member having a plurality of squares or individual boxes. The device includes packets of numerals for application to the board in a manner set by the grid and an optional rack for holding the numerals for retrieval. The device also includes various nonnumeric cards such as remainder cards, cross-out cards, decimal point cards, arrows, subtraction/addition/multiplication bars, and a long division symbol for application to the base member. The components can be applied to the board through the use of magnets. Like, U.S. Pat. No. 5,865,627, no provision is made for the visually impaired to use the device. Moreover, placing the characters on the grid of the base is likely to be too cumbersome to enable a student to timely use the device while following the instructions of a teacher in a classroom.
[0007] U.S. Pat. No. 5,769,639 discloses a frame with a number line attached to the top of the frame. A math problem is solved by counting the workpieces of the device while sliding them in horizontal grooves on the working surface of the frame. Each row of the frame has ten workpieces (corresponding to, for example, ones, tens, hundreds, thousands etc.) and is designed to allow the student to learn regrouping and place value when performing math problems. Addition and subtraction are done on one side of the work surface, while multiplication and division are done on the other side of the work surface. The workpieces are provided with numeral character and Braille indicia. The device operates in a fashion similar to an abacus and does not replicate the intuitive manner in which math is taught to a sighted student.
[0008] U.S. Pat. No. 4,560,354 discloses a math teaching device including an elongate frame with edge guides. A plurality of counting pieces are slidably mounted in an upper portion of the frame. The counting pieces are independently movable, and are retained in operative relationship with each other and to the frame by the guides. A display is provided behind the counting pieces which can include numerals and Braille indicia. The counting pieces are slid left and right within the frame to perform simple addition and subtraction operations. The device can also be used to teach place value. Like U.S. Pat. No. 5,769,639, the device of U.S. Pat. No. 4,560,354 does not replicate the intuitive manner in which math is traditionally taught to a sighted student.
[0009] U.S. Pat. No. 6,196,847 discloses a device for teaching the fundamentals of numbers and/or mathematics which includes a base having a front surface that includes a plurality of recesses, oriented in columns. Each column represents ones, tens and hundreds. The recesses receive numerical plates which are sized according to specific columns. An operator recess for receiving an operator plate is also provided to enable mathematical processes to be performed by the user. Numerals are provided on the front of plates and representative indicia such a corresponding number of dots. No provision is made to enable the visually impaired to use the device. Moreover, like several other devices discussed above, the device does not replicate the intuitive manner in which math is traditionally taught to a sighted student.
[0010] There is a need for a new system of instructing the visually impaired and other disabled students in mathematics.
SUMMARY OF THE INVENTION
[0011] In one aspect the present invention provides a device for instructing mathematics. The device includes a work surface and a plurality of movable elements. Each of the movable elements includes, on a front surface thereof, at least a portion of a visible mathematical symbol (including numeric and nonnumeric symbols) thereon readable via eyesight. Each of the movable elements further includes an attachment member on a rearward surface to attach the element to the work surface. The attachment member preferably allows the element to be removed from the work surface and to be slidably positionable to any position on the work surface once attached thereto. The device can further include a frame around the work surface. Preferably, the frame defines a boundary for positioning of the movable elements. In one embodiment, magnetic attraction is used to maintain the attachment member in movable connection with the board.
[0012] The visible symbols on the movable elements can, for example, be enlarged so as to be visible by a visually impaired person having some sight. The movable elements can be stored around the perimeter of the work surface to be readily available to a user of the device. Preferably, a plurality of movable elements are provided having the same symbol thereon for at least a portion of the symbols. In one embodiment, each of the plurality of movable elements having a like symbol thereon is stored in a group around the perimeter of the work surface, and each of the groups of movable elements having a like symbol thereon is spaced in position from the other groups. In another embodiment, each of the plurality of movable elements having a like symbol thereon is stored in a stacked group around the perimeter of the work surface, and each of the stacked groups of movable elements having a like symbol thereon is spaced in position from the other groups.
[0013] In still another embodiment, the movable elements are stored in a multicompartment storage container. Each of the movable elements having a different symbol thereon can, for example, be stored in separate compartments of the storage container. In the case that a plurality movable elements are provided having the same symbol thereon for at least a portion of the symbols, each of the plurality of movable elements having a like symbol thereon can be stored/grouped in a separate compartment within the storage container.
[0014] In one embodiment, each of the movable elements further includes indicia on the front surface thereof corresponding to the visible symbol that is readable via the sense of touch to identify the visible symbol (for example, Braille indicia or Nemeth Braille indicia).
[0015] The visible symbols can include, but are not limited to, numerals from 0 to 9, a plus sign, a minus sign, a multiplication sign, a division sign, an equal sign, and at least one type of bar for representing processes. The symbols can, for example, further include a decimal point, a question mark and a remainder symbol. Additional or alternative symbols as known in the mathematical arts can be provided for teaching, for example, algebra, trigonometry, geometry, calculus and/or other subjects.
[0016] In another aspect, the present invention provides a method for instructing mathematics, including the steps:
providing a work surface to a student; and providing a plurality of movable elements for use in connection with the work surface, each of the movable elements comprising on a front surface thereof at least a portion of a visible symbol readable via eyesight, each of the elements further comprising an attachment member on a rearward surface to attach the element to the work surface, the attachment member being adapted to allow the element to be removed from the work surface and to be slidably positionable to any position on the work surface once attached thereto.
[0019] In still a further aspect, the present invention provides a method of teaching mathematics in a class of students including at least one sighted student and at least one visually impaired student, including the steps:
creating mathematical equations on a display for viewing by the sighted student; providing a work surface to a visually impaired student; providing a plurality of movable elements for use in connection with the work surface, each of the movable elements comprising, on a front surface thereof, at least a portion of a visible mathematical symbol thereon readable via eyesight, each of the elements further comprising an attachment member on a rearward surface to attach the element to the work surface, the attachment member being adapted to allow the element to be removed from the work surface and to be slidably positionable to any position on the work surface once attached thereto; and having the visually impaired student construct mathematical equations on the work surface which are displayed upon the display using the symbols of the movable elements by appropriate arrangement of the movable elements, the mathematical equations constructed by the visually impaired student being of substantially the same form as the mathematical equations created upon the display.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 illustrates a front view of an embodiment of a teaching device of the present invention for performing basic mathematical tasks or processes.
[0025] FIG. 2 illustrates a front view of several arithmetic operations utilizing the teaching device of the present invention.
[0026] FIG. 3 illustrates an enlarged front view of an embodiment of one of the movable tiles or elements of the present invention.
[0027] FIG. 4 illustrates a side view of the movable element of FIG. 3 .
[0028] FIG. 5 illustrates a front view of an embodiment of the present invention for performing algebraic tasks or processes.
[0029] FIG. 6 illustrates a front view of an embodiment of the present invention in which movable element having like symbols are stacked in groups in unique positions about the edge of the work surface.
[0030] FIG. 7 illustrates a front view of an embodiment of the present invention in which movable elements having like symbols are grouped in individual compartments of a container for retrieval by a user of the device.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIGS. 1 through 4 illustrate one embodiment of a teaching aid, system and/or method of the present invention that is useful in instructing blind or otherwise visually impaired students in mathematics. As used herein, the term “visually impaired” refers generally to a person having eyesight substantially below average (including the blind), which impairs their ability to, for example, follow instructions or lessons displayed in a classroom (for example, on a blackboard).
[0032] In this embodiment, the teaching aid 10 includes a frame 20 surrounding a work surface or work board 30 on which a visually impaired student can assemble movable character/symbol elements or tiles 40 a - v into mathematical equations, problems or processes much as a sighted student would use a blackboard, a piece of paper or a marker board. In the embodiment of FIGS. 1-4 , movable elements 40 a - v include the following symbols: numerals “1” through “9” and “0” ( 40 a - 40 j, respectively), a plus sign ( 40 k ), a minus sign “−” ( 40 l ), a multiplication sign “×” ( 40 m ), a division sign “÷” ( 40 n ), a symbol used to form a division operator “Γ” ( 40 o ), an equal sign “=” ( 40 p ), a remainder symbol “r” ( 40 q ), a question mark “?” ( 40 r ), a decimal point “.” ( 40 s ) and three different length bars or lines ( 40 t - 40 v ) used in forming or representing mathematical equations or processes. Of course, one skilled in the art, will recognize that many other symbols can be provided including, but not limited to, a dollar symbol “$”, a cent symbol “¢” and a percent symbol “%”.
[0033] Preferably, magnetic attraction is used to maintain movable elements 40 a - 40 v in movable connection with board 30 . In one embodiment, for example, board 30 is magnetically receptive (for example, the board can include a magnetically receptive, ferrous metal) and each of movable elements 40 a - 40 v for assembling the mathematical problems, equations or processes includes a magnetic backing 42 (see FIG. 4 ) so that elements 40 a - v are easily moved around board 30 but remain in place when positioned in a desired area. Of course, board 30 can be magnetic and movable elements 40 a - 40 v can include a magnetically receptive material as a backing. Preferably, elements 40 a - v and board 30 are formed so that elements 40 a - v are readily and quickly slidable on the work surface of board 30 to form mathematical problems, equations or processes at generally any position on board 30 . Moreover, the symbols of elements 40 a - v are such that the mathematical problems, equations or processes substantially or closely resemble or match the form and appearance of mathematical problems, equations or processes used to explain mathematics to sighted students. A location or orientation guide such as an angled or notched upper right corner 46 as illustrated in FIGS. 3 and 4 can be provided to help a visually impaired or blind student properly orient movable elements 40 a - v.
[0034] In one embodiment, frame 20 was formed from wood or plastic and work surface or board 30 was formed from painted steel. Of course, other magnetically receptive materials such as a plastic sheet with ferrous particles therein could be used for board 30 . Preferably, the surface of board 30 is generally smooth to facilitate sliding of movable elements 40 a - v thereon. In one embodiment, movable elements 40 a - v were fabricated with a polymeric (for example, vinyl) front surface having printed thereon a symbol as described above. A clear sheet having corresponding Braille indicia thermoformed thereon was then laminated onto the polymeric material. Magnetic backing 42 is preferably sufficiently strongly magnetic to hold movable elements 40 a - v in place, for example, when board 30 is in a vertical or other orientation and when lightly touched for reading by a visually impaired student, while allowing movable elements 40 a - v to be slid around the surface of board 30 without use of excessive force.
[0035] In the embodiment of FIGS. 1-4 , in addition to the visible mathematical symbol or a portion of a mathematical symbol as described above (which is readable by a sighted person), the front surface of each movable elements 40 a - v also includes indicia of the visible symbol that is “readable” or understandable by a visually impaired person using the sense of touch. For example, the front of each of movable elements 40 a - v can include raised indicia 44 (see FIGS. 3 and 4 ) as commonly used in the Nemeth Braille System.
[0036] Preferably, there are multiple copies of each of movable elements 40 a - v and thus multiple copies of each of the corresponding symbols. For example, as illustrated in FIGS. 1 and 2 , there are multiple copies of each of the number symbol elements 40 a - j as well as multiple copies of each of nonnumeric or operator/character symbol elements 40 k - 40 v. Preferably, like elements are stored in groups at predetermined positions or student chosen positions for easy retrieval. For example, groups of like elements can be stored around the perimeter of the board 30 as illustrated in FIGS. 1 , 5 and 6 . Preferably, in this embodiment board 30 has sufficient surface area to allow storage of movable elements 40 a - v around the perimeter of board 30 while providing ample room in the center of the board for the student to relatively quickly construct one or more mathematical problems, equations and processes. In one embodiment in which movable elements were 0.5 inches by 0.5 inches, for example, work surface or board 30 was approximately 10.5 inches by 13.5 inches. This size of board 30 was found to provide ample room for construction of mathematical problems, equations and processes while allowing easy carrying of teaching aid 30 in, for example, a backpack.
[0037] Positioning of movable elements 40 a - v around the perimeter of board 30 enables, for example, rapid construction of mathematic problems, equations or processes so that a visually impaired student can, for example, follow spoken instructions while in a classroom (which may be a standard classroom with other, sighted students) and replicate on board 30 mathematical equations, problems or processes that may, for example, be drawn or otherwise displayed on a blackboard or other display by an instructor. FIG. 2 , for example, replicates the multiplication problem of 432×15, the division problem of 21÷3, as well as the fraction ⅔ in a manner which corresponds with the manner in which a sighted student would represent those problems and fraction. In the representations of FIG. 2 , bars or line symbols such as bar elements 40 u and 40 v are used as separation lines or as total lines as common with mathematical problems set forth in a vertical arrangement. Likewise bar element 40 u and symbol element 40 o are combined to form a division symbol as commonly used in a vertical arrangement of a division problem. As illustrated in FIG. 1 , equal symbol element 40 p can, for example, be used in problems set forth in a generally horizontal arrangement (for example, “5×7=35”)
[0038] As illustrated in the representative embodiment of FIG. 5 , symbols and operators for performing, for example, algebra, geometry, trigonometry and/or calculus corresponding to symbols and operators used by sighted students in those and other areas can be set forth for a student's use. In FIG. 5 , in addition to many of elements 40 a - v set forth above, additional elements 50 a - v are provided for setting forth algebraic problems, equations and processes. In the embodiment of FIG. 5 , movable elements 50 a - u include, variables “a”, “b”, “c”, “n”, “r”, “s”, “t”, “x”, “y”, “z”, “α”, “Δ”, “π”, and “θ” ( 50 a, 50 b, 50 c, 50 d, 50 e, 50 f, 50 g, 50 h, 50 i, 50 j, 50 o, 50 p, 50 q and 50 r, respectively), right parenthesis “)” ( 50 k ), left parenthesis “(” ( 50 l ), right bracket “]” ( 50 m ), left bracket “[” ( 50 n ), a superscript symbol “ □ ” ( 50 s ), a subscript symbol “ □ ” ( 50 t ), an n th root symbol ( 50 u ), a square root symbol “√{square root over ( )}” ( 50 v ), a plus/minus symbol “±” ( 50 w ), a less than or equal to symbol “≦” ( 50 x ), a greater than or equal to symbol “≧” ( 50 y ), a less than symbol “<” ( 50 z ), a greater than symbol “>” ( 50 aa ) and a termination indicator symbol ( 50 ab ).
[0039] FIG. 6 illustrates another embodiment of the present invention in which movable elements 40 a′ -v′ (having symbols corresponding to movable elements 40 a - v ) are stored in groups of like kind around the perimeter of work surface or board 30 . In this embodiment, movable elements 40 a′ - 40 v′ are generally twice the size of movable elements 40 a - 40 v. Likewise, the visible symbols on movable elements 40 a′ - v′ are generally twice the size as the corresponding symbols on movable elements 40 a - v. Enlarging the symbol portion of the movable elements enables a visually impaired person with partial sight to read the symbols. Use of the teaching aid of FIG. 6 can also be beneficial for disabled or learning disabled students. Movable elements 40 a′ -v′ can also include Braille indicia or Nemeth Braille indicia as described above. In several embodiments of the present invention, movable elements 40 a - v were approximately 0.5 inches by 0.5 inches in size, while movable elements 40 a′ -v′ were approximately 1 inch by 1 inch in size. Of course, one skilled in the art will recognize that the size of the movable elements of the present invention can be varied over a broad range. In several embodiments in which enlarged movable elements/symbols were used for visually impaired or otherwise disabled students, the printed symbols were at least 0.5 inch in height. For example, symbols in the range of approximately 0.5 inches to approximately 0.875 inches are suitable for use in the present invention in the case that the movable elements are approximately 1 inch by 1 inch.
[0040] In the embodiment of FIG. 6 , like elements are grouped by stacking them in space groups around the perimeter of board 30 . FIG. 7 illustrates another embodiment of the present invention in which the movable elements are stored off of the board. In this embodiment, the movable elements are stored in a multicompartment storage container 100 . A single-compartment box, boxes or other holder(s) can also be used. Each group of like elements can, for example, be stored in an individual compartment of storage container 100 (separate from other groups of like elements) to facilitate quick retrieval of a desired element/symbol.
[0041] The teaching aid of the present invention enables a visually impaired student to quickly keep pace with sighted students in a conventional classroom and provides a visually impaired student with the ability to learn mathematics using generally the same lexicon, symbols and problem/process/equation representations that a sighted student uses to learn mathematics. The teaching aid of the present invention also enables a sighted or visually impaired instructor to quickly and readily follow the work of a visually impaired student using the teaching aid of the present invention. The teaching aid of the present invention quickens the math learning process for visually impaired students and better prepares those students to perform mathematical operations as commonly experienced in everyday life.
[0042] The foregoing description and accompanying drawings set forth preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. | A method for instructing mathematics includes providing a work surface to a visually impaired student; providing a plurality of movable elements for use in connection with the work surface, each of the movable elements comprising on a front surface thereof at least a portion of a visible mathematical symbol readable via eyesight, each of the movable elements further comprising Braille indicia on the front surface thereof corresponding to the at least a portion of the visible mathematical symbol, each of the moveable elements being movable to any position on the work surface; and having the student arrange a plurality of the moveable element on the work surface to form a standard mathematical expression wherein the mathematical expression comprises multiple lines set forth in a vertical arrangement. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to microwave transceivers, and more particularly to microwave radar sensors, such as rangefinders and motion detectors.
2. Description of Related Art
Radio and radar transceivers operate at radio frequency (RF) wavelengths that are larger than the active devices used to generate the RF. Active devices, such as vacuum tubes and transistors, are considered to be “beyond cutoff” when subjected to frequencies having a wavelength approaching their physical dimensions or the dimensions of their connection leads. Operation at such short wavelengths is nearly impossible since a quarter-wavelength lead forms a transformer that inverts the impedance from low to high or vice-versa. In contrast, antennas need to be a significant fraction of a wavelength, such as a quarter-wavelength, for efficient radiation into free space.
Small inductors can radiate with limited effectiveness for applications such as automotive remote door-lock transmitters. For example, U.S. Pat. No. 4,307,465 to Geller describes an “inductance or coil” which “functions as the antenna.” However, the coil is much smaller than the radiated wavelength and radiation efficiency is limited.
At microwave and millimeter-wave frequencies, small transmission line elements on a substrate or printed circuit board (PCB) function as quarter-wave radiating elements or as patch antennas. U.S. Pat. No. 6,366,245 to Schmidt and U.S. Pat. No. 6,107,955 to Wagner depict configurations for radiating from patch antennas coupled to dielectric lenses. These antennas are clearly separate from their active devices and their connecting leads.
As a drawback to these radiating devices, additional cost and complexity is incurred by utilizing antennas or coils to serve as the radiating devices. This also increases the size of the device and, due to inefficiencies or losses within such radiating devices or the conductive paths leading to such radiating devices, power consumption may be undesirably high.
SUMMARY OF THE INVENTION
A method and apparatus for radiating high frequency energy is disclosed herein that overcomes the drawbacks of the prior art. In general, a high frequency energy radiator is disclosed that generates a high frequency signal and utilizes interconnects or leads as the radiating elements.
In one embodiment, active devices that exhibit substantial gain at very high frequencies are utilized. Such devices may be limited by package parasitics such as inductance and wavelength effects on the package leads. For example, the data sheet for a pseudomorphic hetero-junction FET type NE3210S01 (or HJ FET herein) by California Eastern Laboratories shows 12 dB gain at 18 GHz. However, no data is provided beyond 18 GHz even though its frequency-gain curve can be extrapolated to 85 GHz at 0 dB gain. Package parasitics seriously limit operation beyond 18 GHz; the device is package-limited rather than transistor-limited. If operation with package-limited devices could be realized beyond 18 GHz, substantial new and cost-competitive applications could be realized in the 24 GHz ISM band, the new 22–29 GHz ultra-wideband (UWB) FCC allocation, and higher bands. The prior art does not teach how to employ package-limited devices in transceiver applications at frequencies beyond cutoff.
At sufficiently high frequencies, the length of transistor package leads become approximately one-quarter wave in length and act as efficient radiators of RF energy into free space, i.e., the package leads become antennas. As used herein, the term RF is defined to mean any frequency greater than 1 gigahertz. In certain embodiments the frequency range of operation is greater than 5 gigahertz while in other embodiments the frequency range of operation is greater than 20 gigahertz. Unfortunately, it is nearly impossible to operate a transistor at such high frequencies that its leads are one-quarter wave long, i.e. at package limited frequencies. Experiments by the applicant show that package lead parasitics limit the upper range of oscillation for a surface-mount packaged HJ FET to about 20 GHz. To overcome this limitation and operate above 20 GHz, a harmonic oscillator may be employed. In an exemplary transceiver, an oscillator is configured to oscillate at a fundamental frequency of 13 GHz with a conduction angle that promotes second harmonic generation at 26 GHz—well beyond the conventional cutoff frequency of the package. The harmonics are generated on the transistor die, which is connected directly to the package leads. At 26 GHz, the package leads approximate a quarter-wavelength and efficiently radiate into free space. “Transistor” is commonly defined as the transistor die and the package in combination. However, depending on the application, it may simply refer to the die or any other signal generation device.
The transistor may be mounted on an industry standard, low-cost 1.6 mm thick glass-epoxy printed circuit board (PCB) substrate, or any other arrangement. If the PCB is metallized on the backside, a quarter-wave reflector is formed to enhance radiation perpendicular to the PCB. An optional feature is a dielectric lens that can be utilized for narrow beamforming. Yet another optional feature is a planar filter that can be located above the PCB to block spurious radiation of a fundamental frequency.
The apparatus may further comprise a receiver function such as a harmonic detector or a sampler to form a transmitter-receiver, or transceiver. While the initial use of the transceiver relates to radar sensors, it may also be used as a radio transceiver or, as a stand-alone transmitter or receiver.
Radar applications for the transceiver include low-cost short-range motion detectors and rangefinders. In one rangefinder mode, a short sinusoidal RF burst is transmitted to a target by an oscillator in the transceiver. Shortly after transmission, the transceiver employs the same RF oscillator to produce a local oscillator pulse (homodyne operation), which gates a sample-hold circuit in the receiver to produce a voltage sample from a target echo. This process is repeated at several megaHertz. With each successive repetition, another sample may be taken and integrated with the previous sample to reduce the noise level. Also, each successive local oscillator pulse is delayed slightly from the previous pulse such that after about 10 milliseconds, the successive delay increments add up to a complete sweep of perhaps 67-nanoseconds, or about 10 meters in range. After each sweep, the local oscillator delay may be reset to a minimum and the next sweep begins. A radar sensor employing this technique is fully described in U.S. Pat. No. 6,414,627 to McEwan.
In one embodiment, a system based on the teachings contained herein may be configured to provide millimeter-wave and near millimeter-wave radar sensors using low-cost packaged transistors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a physical layout for a transceiver of an example embodiment of the present invention.
FIG. 2 is a schematic diagram of an RF transistor and detector for a transceiver of an example embodiment of the present invention.
FIG. 3 a depicts a planar high pass filter of an example embodiment of the present invention.
FIG. 3 b depicts a planar band reject filter of an example embodiment of the present invention.
FIGS. 4 a–c plot the responses of a rangefinder employing a transceiver of an example embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of the present invention is provided below with reference to the figures. While illustrative component values and circuit configurations are given, other embodiments can be constructed with other component values and circuit configurations. All U.S. patents cited herein are herein incorporated by reference.
FIG. 1 is a block diagram of a microwave transceiver 10 of the present invention. Although shown as a transceiver, it is contemplated that the transceiver may comprise a device configured to perform only a transmit function, receive function, or both. A transistor die 12 is enclosed in package 14 and connected to substrate 16 via lead 18 . The embodiments shown herein refer primarily to a transistor or transistor die, however, it is contemplated that in devices, circuits or systems other than a transistor may be utilized. Thus, the claims that follow should not be limited to a transistor or transistor die. Reference to lead 18 generally refers to all leads connected to transistor 12 , and the lengths of all leads to transistor 12 are approximately equal. In the event of asymmetric lead lengths, it is assumed that at least one lead is sufficiently long to efficiently radiate. The length of the leads from the die to the substrate is identified with reference L. In one embodiment the length L of lead 18 is ideally a quarter-wavelength at the frequency to be radiated. Other lead lengths will work for efficient radiation, provided they are a substantial fraction of a wavelength, i.e., greater than 0.1 wavelength long. A length of less than 0.1 wavelength is an inefficient radiator, although in certain applications such a length may be utilized. In some cases, the ideal length of one quarter-wavelength must be altered to account for loading effects at the lead ends. At an exemplary frequency of 26 GHz, the leads for a standard 2 mm diameter surface mount package work well as radiators, although other lengths may be utilized.
In an exemplary embodiment, substrate 16 is fabricated of standard glass-epoxy PCB (printed circuit board) material. Substrate thickness 22 may be a thickness of 1.6 mm, which is one quarter-wave thick at 26 GHz after accounting for the PCB dielectric constant. This thickness is particularly desirable at this frequency because it is quarter-wave reflector. Applicant submits that it is novel to utilize a PCB as a reflector and as such the prior art does not teach use of a printed circuit board as a reflector. This provides the advantage of a low cost, device for use as a reflector which, in the embodiments described herein, is also used as the circuit board. The use of the PCB also provides a large surface area that is not satisfied by the reflective capabilities of a patch antenna, which are small, expensive, and performs inadequately as a reflector. In other embodiments, other thicknesses or configuration of PCB may be utilized to serve as the reflector. Copper metallization 24 , or other reflective substance, on the backside, in combination with the PCB dielectric material (glass-epoxy), may be utilized to form a quarter-wave reflector to further enhance radiation from leads 18 .
RF radiation from leads 18 emanates perpendicular to the PCB in a wide beam. Optional dielectric lens 26 may be added to increase gain and decrease beamwidth. Microwave dielectric lenses are well known in the art and will not be discussed herein.
In an exemplary embodiment, transistor die 12 oscillates at a fundamental frequency of 13 GHz and radiates a second harmonic at 26 GHz, which is in the FCC's newly allocated UWB band. However, some 13 GHz energy radiates from the PCB and it may be desirable to attenuate this spurious component even if it is below FCC limits, either to minimize RF pollution or to reduce spurious sensor responses. Optional planar filter 30 may be added to reject the 13 GHz component.
FIG. 2 is a detailed schematic of an exemplary transceiver circuit 40 of an example embodiment of the present invention. In this example embodiment transistor 12 is configured as a harmonic oscillator and is connected to surrounding circuitry via three leads 18 of length L, as part of package 14 . L is typically one quarter-wavelength long at the radiated frequency, but may assume other lengths. Microstrip 48 is one quarter-wavelength long at 13 GHz for a 26 GHz second harmonic system, but may assume other lengths. It serves to tune the fundamental frequency and to reduce fundamental coupling to diodes 54 .
A transistor drive signal is provided on line 34 to bias on transistor 12 . The drive can be a continuous current for CW Doppler sensing, or short pulses for range gated Doppler sensing, as described in U.S. Pat. No. 5,966,090 to McEwan. For rangefinding, the drive signal may comprise a first, or transmit, pulse followed by a second, or receive, pulse that is swept in delay to serve as a local oscillator pulse in an equivalent time system. This two pulse operation is fully described in the above-cited '627 patent. In other embodiments, other drive signals may be utilized. Microstrips 49 , 50 block RF from coupling back into the drive circuit at the fundamental frequency F and harmonic frequency H. Microstrips 51 , 52 of lengths α, β respectively are fine trims to adjust the conduction angle of oscillator transistor 12 for maximum harmonic output. In some cases they may be omitted. Microstrips 48 – 52 and 56 reside on the surface of PCB 16 , or may be equivalents as known in the art.
Back-to-back diodes 54 form a harmonic sampler. Diodes 54 receive free-space RF that is coupled from the leads of transistor 12 and they may also receive RF directly from their own leads and interconnects. The back-to-back connection of diodes 54 results in conduction on each half cycle of the 13 GHz oscillation provided by oscillator 12 . The net effect is the same as a single diode conducting on every full cycle of a 26 GHz local oscillator. Experiments show that this frequency doubling harmonic sampler has nearly the same sensitivity as a non-harmonic 26 GHz local oscillator and sampler. In addition to harmonic sampling, a key advantage to the back-to-back diode connection is rejection of local oscillator noise, since the back-to-back connection develops zero offset bias (in principle) at its output, and consequently there can be little output noise due to the local oscillator. Of course, a single diode may be used at the expense of oscillator noise rejection. Microstrip 56 provides an RF short at the operating frequency of diodes 54 . Diodes 54 also form a harmonic detector for CW operation. The output from diodes 54 is provided on line 58 as a baseband or video signal, which may be coupled to preamps, bandpass amps, variable gain stages, pulse detectors, digital processors and other receiver and processing functions known in the art.
In an alternative embodiment, the transistor 12 may operate as a fundamental mode oscillator rather than a harmonic oscillator. A fundamental mode oscillator has higher output amplitude but is far more difficult to implement in surface mount technology (SMT) due to lead parasitics. Above 20 GHz, fundamental mode oscillation is possible by violating SMT assembly rules when using transistor packages available at present. Obviously, integrating the transceiver circuitry onto a single chip or hybrid circuit substrate, including an antenna that is separate from the active device, would allow fundamental mode operation and neatly allow all RF functions to reside in one package. However, it is doubtful that the integrated approach will ever be cost competitive to a single discrete RF transistor on an inexpensive glass-epoxy PCB. Thus, the surface mount transceiver of FIG. 1 should remain cost competitive far into the future.
The transistor 12 may be a pseudomorphic hetero-junction FET type NE3210S01 by California Eastern Laboratories, and diodes 54 may be obtained in a single package of type BAT 15014W by Infinion. Of course, these are exemplary devices and the claims that follow are not limited to these devices.
FIG. 3 a shows a planar filter 30 comprised of a metallized grid 70 on PCB 72 . The grid spacing is such that long waves will not fit, i.e. pass through the grid, whereas shorter waves will fit and pass un-attenuated. Thus, the grid serves as a high pass filter that passes 26 GHz harmonics while rejecting 13 GHz spurious fundamental components in an exemplary system.
FIG. 3 b shows an alternative planar filter 30 comprised of a metallized dipole array 74 on PCB 76 . Each dipole is one-half wavelength long at the frequency of maximum rejection. Thus, the grid serves as a rejection filter that passes 26 GHz harmonics while rejecting 13 GHz spurious fundamental components in an exemplary system. Other planar filter designs are known in the art.
FIGS. 4 a–c illustrate plots of hardware bench test data for a 26 GHz UWB rangefinder using transceiver 10 along with timing and receiver circuitry as described in the above-cited '627 patent. The target range is 4 meters. FIG. 4 a plots the target return 80 and room clutter 82 for transceiver 10 without a dielectric lens. FIG. 4 b plots the target return 84 and room clutter 86 for transceiver 10 with a 1 cm diameter dielectric lens. FIG. 4 c plots a very strong, saturated target return 88 and room clutter 90 for transceiver 10 with a 10 cm diameter dielectric lens.
Although the invention has been described with reference to an exemplary 26 GHz system in view of the high interest in this frequency, the principles of the invention can be applied to other frequencies, e.g., 10.5 GHz and 38 GHz. The techniques using harmonic transmit pulses and harmonic sampling can be similarly applied. The transistor 12 may serve other functions besides an RF oscillator, such as an RF amplifier or RF detector. Lead(s) 18 of FIG. 1 may also be wire bonds connected to bare die without package 14 . The package 14 is an exemplary component feature in surface mount embodiments of the transceiver.
Although certain implementations are shown herein, it is contemplated that the method and apparatus disclosed herein may be utilized in numerous environments. For example, applications for the new apparatus are widespread and universal. They include, but are not limited to, non-contact rangefinders for robotics, automotive safety devices, such as backup warning radar, home improvement, such as electronic room measurement devices, tank fill-level sensing, aids-to-the-blind, industrial automation, such as mechanical position control, aircraft altimeters, and boat docking radar. The new apparatus may also be used in 3-D radar imaging for industrial inspection, for through-clothing security screening at airports, for digitizing objects in computer aided design, and for tracking objects in virtual reality applications including computer generated images for Hollywood movie-making. The new apparatus may also be used in innumerable motion sensing applications using its Doppler sensing mode, such as home and automotive security sensors, automatic door openers, police and sports radar speed sensors, vehicle ground speed sensors, wake-up devices in vending machines and toys, and various military applications.
Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims. | Transistor package leads form quarter-wave antenna elements that directly radiate RF energy into free space without the need for a separate antenna. The transistor operates at a fundamental frequency and radiates a harmonic, thereby allowing radiation at frequencies normally considered “beyond cutoff” for a packaged transistor. This technique enables an additional 20 GHz of spectrum for use by surface mount technology. The transistor may be mounted on 1.6 mm thick glass-epoxy circuit board that also forms a quarter-wave reflector at 26 GHz. An optional dielectric lens produces a narrow beam and an optional planar filter rejects spurious fundamental emissions. A 26 GHz ultra-wideband (UWB) pulse-echo radar rangefinder implementation provides a low-cost upgrade to ultrasound. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to phase-locked loop circuits. More particularly, the invention relates to a digital phase-locked loop circuit for locking an output frequency both as to its frequency and its phase to an input frequency signal.
Phase-locked loop circuits have found wide application in the prior art. Control systems, navigation systems, radar, telemetry tracking and communications receivers and bit synchronizers all employ various forms of phase-locked loops to improve performance and enhance capability. Modern electronic technology (e.g. microprocessors and large-scale-integrated-circuits (LSI)) have enabled more exotic embodiments of this basic electronic circuit, including digital approaches. However, digital embodiments of phase-locked loops, such as that disclosed in U.S. Pat. No. 3,736,590, suffer from several disadvantages. Even with the use of LSI circuits, the basic circuit is quite complex, requiring a large number of components to implement the phase-locked loop functions, i.e., loop filter, voltage-to-frequency conversion, phase detection, etc. Accordingly, circuit susceptibility to temperature drifts, circuit reliability, cost to manufacture, and other problems result.
As disclosed in U.S. Pat. No. 3,736,590, the voltage-to-frequency function of the phase locked loop is accomplished through the use of a programmable divider circuit where the desired output frequency is programmed from a microprocessor. The output frequency is then phase shifted to obtain the phase-locked output frequency signal. This phase shift function also must be programmed from the microprocessor. Where a fine resolution in both frequency generation and phase shifting is required, the programmable divider approach simply is not adequate. The resolution of the programmable divider approach is controlled by the time interval of one clock cycle of the clocking signal to the programmable divider. One bit of the programming code being equivalent to one clock cycle time resolution between output pulses of the programmable divider. Applications requiring a higher degree of resolution in the frequency and phase lock of the output frequency signal for the same number of programming bits from the microprocessor require finer control of the voltage-to-frequency function than can be achieved through the use of a programmable divider. Additionally, the phase shift function requires several circuit components which suffer from the aforesaid disadvantages, and adds to the phase locking instability of the loop due to short term phase shift jitter.
Because of the limitations present in the prior art, it would be advantageous to provide a digital phase locked loop circuit which provides a high degree of phase and frequency resolution to accurately phase lock the output to the input. It would also be advantageous to eliminate the need for a discrete component implementation of the phase shift function thereby to remove a large number of components required to implement the phase locked loop circuit and to remove the phase inaccuracies due therefrom.
SUMMARY OF THE INVENTION
In accordance with the present invention, a digital phase-locked loop for controlling an output digital frequency signal to track both the phase and the frequency of an input digital frequency signal is disclosed. The phase locked loop includes a phase detector that responds to both the input and the output frequency signals for detecting the phase difference therebetween. A microprocessor responds to the output of the phase detector to generate a frequency select code that represents the frequency of the output frequency signal. The generation of the frequency select code includes a phase shift correction derived from the phase error and a frequency shift correction also derived from the phase error.
Also included in the phase-locked loop is a binary rate multiplier that responds to the frequency select code from the microprocessor to generate the desired output frequency signal. Included in the binary rate multiplier is a divider circuit for dividing the frequency signal, which is 256 times the resulting output frequency. A crystal controlled oscillator is used as the time base to clock the binary rate multiplier. Both the input and the output of the divider circuit is fed back to the input of the phase detector, the output of the divider being the output frequency of the phase-locked loop and the input being the clocking frequency to the phase detector for use in generating the phase difference. The frequency select code generated by the microprocessor controls the frequency of the output frequency signal to cause the phase difference detected by the phase detector to approach zero. At zero, the output frequency signal is equal in phase and frequency to the input frequency signal.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding 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 block diagram of an analog prior-art phase-locked loop circuit;
FIG. 2 is a block diagram of a digital prior-art phase-locked loop circuit;
FIG. 3 is a block diagram of a digital phase-locked loop according to the present invention;
FIG. 4 is a block diagram of the mathematical equivalent to the analog prior-art phase-locked loop as shown in FIG. 1;
FIG. 5 is a block diagram representation of a mathematical equivalency to the function performed by the microprocessor of the present invention;
FIG. 6 is a circuit diagram of one embodiment of the phase detector illustrated in FIG. 3; and
FIG. 7 is a computer flow diagram of the programming of the microprocessor as shown in FIG. 3.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a prior-art analog phase-locked loop is shown consisting of a phase detector 10, loop filter 12 and voltage controlled oscillator 14. The loop filter can be of any order (first, second, third, etc.) and determines loop tracking response. Most applications are of the second order employing a position (phase) correction and an integration of position error (frequency) correction. This is indicated mathematically in FIG. 4. Factors K1 and K2 are the gain factors which, in terms of classic phase-locked loop theory, describe loop response and define the natural frequency (ω m ) and damping factor ζ(ZETA). The phase error (E) is multiplied by the phase gain factor (K1) to produce an instaneous phase correction (Δθ) which is applied to the oscillator 14. The error (E) is likewise multiplied by the gain factor K2, integrated (indicated by 1/s) and applied as a constant, but variable, frequency correction (f). In the analog phase-locked loop, the loop filter 12 is usually realized as an operational amplifier with discrete resistors and capacitors setting loop gains and frequency responses, and outputs a direct-current voltage to the voltage controlled oscillator 14.
Turning now to FIG. 2, a digital implementation of a phase-locked loop is shown. Microprocessor 12 is capable of accepting the detector error (E), multiplying it as gain values (K1 and K2) and calculating a resulting phase and frequency correction (Δθ and f). The microprocessor 12 outputs a digital code which represents the number of clock cycles of a clocking signal will occur before an output pulse will be produced by the programmable divider 22. Phase shifter 24 then phase shift the output from the divider 22 to produce the output frequency θ OUT . The phase shifter 24 is also under control of the microprocessor 12 as to the amount of phase shift that will be applied.
Referring now to FIG. 3, a block diagram of the present invention is shown. The digital phase-locked loop according to the invention consists of a phase sensitive detector 26, a microprocessor 12, a binary rate multiplier 26 and crystal controlled oscillator 28. Phase detector 26 is shown responding to the input frequency signal θ IN , the output frequency signal θ OUT and a clocking frequency 256f, where f is the frequency of the output signal θ OUT . In other words, the binary rate multiplier is operated at a frequency 256 times the operating frequency of the phase-locked loop. Microprocessor 12 may be any standard microprocessor having sufficient execution speeds to execute a program according to the flow diagram of the programming of the preferred embodiment of the invention as shown in FIG. 7. For the preferred embodiment of the invention, the binary rate multiplier 26 is constructed from individual binary rate multiplier units manufactured by Texas Instruments as their model SN 7497.
A binary rate multiplier is a large scale digital integrated microcircuit designed to produce a quasi-symmetrical pulse train, of varying frequency, from a standard crystal frequency. Cascading of independent rate multiplier stages provides for increasing precision of frequency and may be controlled by a digital input indicative of the frequency desired. Each rate multiplier unit of the preferred embodiment consists of a four-state binary counter with appropriate gates. The maximum number of output pulses for sixteen input pulses is fifteen. This provides the sixteenth interval for cascaded stages to add up to fifteen pulses in this blank time period, and so forth for following stages. The pulses are selected such that reasonable time symmetry exists for each possible combination. Thus, it can be stated, that for a given crystal input frequency any given frequency may be selected up to the precision of the cascaded rate multiplier stages, permitting digital synthesis equivalent to the analog control of a voltage-controlled-oscillator.
Control of the binary rate multiplier is developed within the microprocessor 12 which performs the function of the loop filter in a classic phase-locked loop. The present invention takes advantage of the time-frequency interrelationship between the period of a digital frequency signal and its frequency. This permits a phase error (time) to be converted into a frequency correction (f). This conversion of the phase error (E), derived from the detector 26, to a frequency control function for the rate multiplier 26 relies on the expression: ##EQU1## where: T=Period or 360° phase
ΔT=Change of period or phase error/correction
F=Frequency
ΔF=Frequency error/correction
Mathematically, the equation to derive a frequency correction in terms of period and phase error is:
1=(T+ΔT)(F+ΔF) (2)
1=(FT+FΔT+ΔF(T+ΔT) (3)
Since FT=1: ##EQU2## For small error T+ΔT≈1 and the expression can be simplified to: ##EQU3##
Where ΔT/T is equivalent to phase error, multiplication of phase error by F (operating frequency) is the factor which makes loop operation frequency transparent. Programming microprocessor 12 according to the mathematical model shown in FIG. 5 which is in accordance with equation (7), the loop filter function and the phase shift function can both be accomplished at the same time.
Referring to FIG. 5, the detected phase error (E) is input to the microprocessor 12 which in the description of the detector 26 (see FIG. 6), will be shown to be the equivalent of ΔT/T. This value is multiplied by F (the operating frequency stored in the frequency accumulator) and then multiplexed and multiplied by the gain values, K1 (to obtain Δθ) and K2 (to obtain Δf). The frequency error increment (ΔF) is then added to the frequency accumulator, which functions as an integrator, and the resulting value is the corrected frequency (f). The phase correction (Δθ), converted to an instantaneous frequency correction, is added to this value and results in the interval-by-interval frequency selection for the binary rate multiplier. Each interval constitutes one clock cycle of the input frequency signal θ IN . It should be noted that the phase correction is an interval-by-interval correction and although converted to frequency, the correction is, in fact, an interval phase correction.
One basic application of the universal binary rate multiplier phase locked loop according to the invention is a variable-rate bit synchronizer. This use employs a random information stream of marks and spaces or "1" and "0" for θ IN such that no apriori knowledge of character transitions exists, only the approximate rate of transmission. This then requires detection of transitions and conversion of time displacement error to linear phase error. This detection process is indicated in FIG. 6.
Referring to FIG. 6, the quasi-square wave input θ IN is used as the clock input to a "D" type flip-flop 30. Clocking is either positive or negative transitions and is reset by 256 times the operating frequency (256f). This provides a narrow clock pulse for the counter-enable flip-flop 32, which is clocked "on" at the choosen polarity of transitions in θ IN . Flip-flop 32 enables the linear detector 34, an 8-bit counter. Counter 34 will count until MID-BIT or half-cycle time of the phase-locked loop operating frequency θ OUT . This mid-bit pulse resets the counter enable flip-flop 32 to remove the count enable to counter 34. The state of the counter 34 is then representative of the accuracy of phase lock. When the loop is exactly synchronized to the incoming bit-stream, the mid-bit time will occur at 128 counts or 1000 0000. An error of 1.4° in either direction (360°÷256) will give a count of 1000 0001 or 0111 1111. Thus it can be seen that the most significant bit is the sign of the error and the lesser significant bits are the magnitude. With the least significant bit having a weight of 1.4°, the error (E) can be calculated by the microprocessor based on this weighted binary count.
In order to provide higher weighted outputs, the binary rate multiplier 26 actually operates at a much higher frequency and is divided down to the operating frequency θ OUT . This also has the effect of reducing the phase jitter which is inherent in binary rate multipliers.
The foregoing description of the invention has been directed to a particular preferred embodiment in accordance with the requirements of the Patent Statutes, and for purposes of explanation and illustration. It will be apparent, however, to those skilled in this art that many modifications and changes may be made in the circuit without departing from the scope and spirit of the invention. These, and other modification of the invention will be apparent to those skilled in this art. It is the applicant's intention in the following claims to cover all such equivalent modifications and variations as fall within the true spirit and scope of the invention. | A digital phase-locked loop consisting of a digital phase detector for detecting the phase differences between the output and the input frequency signals, a microprocessor programmed to perform both the functions of the loop filter and the phase shifter, and a binary rate multiplier to perform the function of voltage-to-frequency conversion is disclosed. A more precise frequency resolution is obtained by use of the binary rate multiplier and a further reduction in circuit complexity is achieved by removal of the phase shifter circuit in favor of the microprocessor programming. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation application of application Ser. No. 127,439, filed Dec. 2, 1987, now abandoned which is a continuation-in-part application of application Ser. No. 842,935, filed Mar. 24, 1986, now abandoned, which is a continuation application of application Ser. No. 619,367, filed June 11, 1984, now abandoned, which is a continuation-in-part application of application Ser. No. 570,373, filed Jan. 13, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for use in removing liquid from paper in the press section of a paper making machine.
2. Description of the Prior Art
In the manufacture of paper, after the paper sheet has been formed, it is subjected to mechanical compaction in order to express water therefrom. Water left in the sheet following final mechanical compaction must be removed by evaporative drying. The energy cost associated with the aforementioned evaporative drying is very high, in fact many times higher than is required for mechanical compaction.
The known apparatus for carrying out the aforementioned process in one instance comprises a press-plate adapted to squeeze a stationary formed sheet of paper and, in a further instance, a pair of press rollers arranged to squeeze a moving sheet of paper, i.e., a paper web. In both instances, a combination of felt and vacuum box are used to "receive" the expressed water.
Thus, in known wet pressing operations, as exemplified by the aforementioned static and dynamic systems, there are two essential elements present, i.e., means t apply a mechanical compacting load and means to "receive" water expressed from the wet sheet being compacted.
Either of the aforementioned systems, examined when the maximum compacting pressure has been applied to the wet sheet, will reveal the following picture.
The wet sheet has been compacted (reduced in thickness) so that, first, water has displaced air in all remaining spaces thus eliminating the air, and, second, the pore volume is reduced and thus only water remains in such pores. Under these conditions, the water content of the sheet will be that which is required to saturate (fill all available pores) the compressed sheet of paper; and this quantity of water will depend on the compacting pressure, the extent to which the paper sheet can be compressed (its wet compressibility properties), and in the dynamic case, the extent to which water has had the time to be forced out of the sheet.
Independent of all these details, however, it is possible to assign for any wet pressing operation the minimum residual water content the operation is capable of producing. It is the water content required to saturate the sheet when it has been compacted to the extent imposed by the wet pressing system.
This minimum theoretical water content is never achieved in current practice because in the process of removing the applied pressure, the paper sheet or web tends to suck water back from the felt or other reservoir as it expands. This phenomenon is well recognized, and steps have been taken to minimize this "rewetting". To the extent that these steps are successful, the wet pressing operation approaches the above indicated theoretical limit.
It is, therefore, an important aim of the present invention to provide an improved, more efficient apparatus to those presently available, being ones which will overcome the aforementioned disadvantages. Accordingly, it is a further important aim of the present invention to provide an apparatus which will enhance the water removal capability of a wet pressing operation.
SUMMARY OF THE INVENTION
The invention may be summarized as follows.
If under the conditions described above, where the maximum compression load has been applied and the compacted sheet being sandwiched between a pair of rolls is saturated with water, air is forced through the sheet, water will not only be expressed from the pores in the sheet, but water in the felt adjacent to the paper will also be expelled into the receiving chamber. The net result is that (a) at maximum compaction the water content of the sheet is less than the theoretical limitation which applies to all current wet pressing operations, and (b) by expelling water from felt adjacent to the paper sheet, the "rewetting" phenomenon is greatly reduced. The consequence is to significantly increase the amount of water removed from the sheet by the wet pressing operation and thus reduce the energy requirements of the subsequent evaporative drying process.
In a further aspect of the present invention, there is provided a method of removing liquid from compressible porous materials, including, for example, non-wovens and paper, comprising the steps of: extending a pair of felts or the like absorbent material to sandwich a web of the porous material containing the liquid; compressing the felts and the material containing the liquid at a nip; and passing a flow of gas at the nip of the rolls and the compressed porous material and felts and passing the same therethrough to remove liquid therefrom.
In a further aspect of the present invention, there is provided an apparatus for use in removing liquid from a compressible porous material comprising in combination: a first abutment, the abutment including a working surface having apertures therethrough; a second abutment including a working surface having apertures therethrough, the first and second abutments cooperatively arranged one to another whereby to receive therebetween the material and to compress the material, and means for introducing compressed gas to the apertures in either the first or second abutments for passage through the apertures in the first and second abutments when such are compressing the material.
In a further aspect of the present invention, there is provided an apparatus for use in removing liquid from a compressible porous material comprising a first roll including a working surface having apertures therethrough. A second roll includes a working surface having apertures therethrough. The first and second rolls are cooperatively arranged one to another to receive therebetween the material and to compress the material. Means are provided for introducing compressed gas to the apertures in either the first or second rolls for passage through the apertures in the first and second rolls at the nip when such are compressing the material. The apertures in at least one of the rolls comprise grooves which open toward the working surface thereof. The grooves extend circumferentially around the roller.
In a more specific embodiment in accordance with the present invention, the grooved rolls are provided with a sleeve having a plurality of apertures thereon communicating with the grooves. One of the rolls has a plurality of grooves which are parallel to the axis of the roll, and thus compressed air can be fed through the grooves from the ends of the rolls. The other roll, that is, the receiving roll, may be provided with circumferentially extending grooves covered by the perforated sleeve.
The phenomenon which occurs, particularly with the rolls described in the present specification, is explained as follows.
In the manufacture of paper, a pulp slurry consisting of approximately 1 lb. of pulp fiber per 100 lbs. or more of water is transformed into a sheet in which 1 lb. of fiber includes only .05 lb. of water. Almost 99 lbs. of the original 100 lbs. of water are removed by mechanical action including free drainage, vacuum drainage, air displacement drainage, and high pressure squeezing. The last pound or so of water must be removed by evaporation. Presently, it costs as much to remove this last pound of water as it does to remove the previous 99 lbs. Thus, there is a tremendous economic importance in delivering a wet paper web to the dryer section of a paper machine with the lowest possible water content.
The last mechanical operation currently employed by a modern paper machine in order to induce maximum water removal is to compress and thus squeeze water out of the sheet by carrying it through a loaded nip created by two press rolls. Presently, improvements have been directed to the felts to carry the paper web through the nip, and the design of the rolls has been improved in order to increase the efficiency of water removal. The result has been a beneficial improvement in general levels of dryness of the sheet delivered to the dryers, from earlier levels of 35 to 40% solids to current levels of 40 to 45% solids (i.e., 60 to 65% moisture content, to 55 to 60% moisture content). When a wet sheet of paper supported on a felt is passed through a press nip, it is compressed, at the nip, and the total load is the sum of the two rolls acting at the nip. Compression of the sandwich of the felt and paper will continue until air has been displaced and the water contained in the sandwich starts to "see" the load. When this happens, the water which is essentially incompressible, develops an internal pressure. This internal pressure causes water to flow out of the sandwich and thus relieves the pressure. For this reason, the pressure in the water contained in the sandwich decreases in some manner as the applied load is taken up more and more by the compressed structure and less and less by the water in the structure. When the compressed structure has been compressed to the extent that it absorbs the total load, then the water which remains in the compressed structure will carry no load and, therefore, contain no pressure and, therefore, cannot be removed. This, then, represents the ultimate, theoretical dewatering limit of the mechanical loading of paper.
The amount of water that will remain in the sheet is the water which saturates the fully compressed paper/felt sandwich under the maximum loading conditions that can be economically applied by the press.
According to the present invention, if air can be applied under suitable pressure in the nip during highly compressed conditions, the air will tend to push additional water out of a fully compressed sandwich. It is current practice to pass air through a web of paper. This is done in every paper machine, at the flat boxes, and at the suction couch roll. When air passes through the sheet under these conditions, it displaces more water. However, under these conditions, the amount of water that can be removed is very limited. What happens is that the water in large pores is displaced, and the air then leaks through these passages. Water in all the small pores remains unaffected. Passing air through a sheet does not, for this reason, achieve substantial dewatering.
It is essential for a high degree of mechanical loading to be applied to the paper web prior to applying air pressure. Under such conditions, the large pores in the paper are squeezed down so that the paper exhibits a much more uniform pore structure than when uncompressed. The applied air pressure will then empty sufficiently the more uniformly sized pores before it leaks through the emptied channels, so that significant dewatering will be achieved.
In other words, passing air through a sheet of paper has been demonstrated to have little dewatering effect. In the present invention, the novelty is to recognize that by highly compressing the paper web at the nip and then passing air therethrough changes the passage of air from an ineffective dewatering tool to a highly effective dewatering tool.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by way of example in the accompanying drawings wherein:
FIG. 1, appearing on the same sheet as FIG. 4, is a sectioned, elevational view of one embodiment in accordance with the present invention with parts thereof displaced prior to compressing material, shown therebetween;
FIG. 2 is a sectioned, elevational view showing a further embodiment in accordance with the present invention;
FIG. 2a is a sectioned, elevational view, similar to part of that shown in FIG. 2;
FIG. 2b is a fragmentary view of an alternative component to one shown in FIG. 2;
FIG. 2c is a sectioned view of the alternative component shown in FIG. 2b;
FIG. 3 is a further view of the embodiment shown in FIG. 2 with parts thereof displaced prior to compressing material, shown therebetween;
FIG. 4 is a sectioned elevational view showing a further embodiment in accordance with the present invention;
FIG. 5 is a perspective view of a further embodiment in accordance with the present invention;
FIG. 5a is a part sectional view of FIG. 5;
FIG. 6 is a perspective view, partly broken away, similar to FIG. 5, showing a still further embodiment of the present invention; and
FIG. 7 is an end elevation of the embodiment shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 shows an apparatus 100 for use in removing liquid, including, for example, water, from a compressible porous material, including, for example, paper, designated 10, such being positioned intermediate a first jaw-abutment 20 and a second jaw-abutment 30. Jaw-abutment 20 and 30 include respectively working faces 21 and 31 and apertures 22 and 32 therethrough, clearly seen in FIG. 1. In this embodiment, jaw-abutment 20 is positioned vertically above jaw-abutment 30, jaw-abutment 20 being adapted to move toward and away from jaw-abutment 30 by means (not shown) and which, for example, may comprise a power cylinder. Alternatively, jaw-abutment 30 could be adapted to move toward and away from jaw-abutment 20 or for both jaw-abutments to move toward and away from one another.
Felt or the like absorbent material 11 extends on opposite sides of material 10, covering respectively the outer opposite surfaces of material 10, and as is evident, contactable with working surfaces 21 and 22 when jaw-abutments 20 and 30 are brought into a closing position.
In this embodiment, apertures 22 and 32 are completely aligned with each other. Thus, when working surfaces of jaw-abutments 20 and 30 are compressing materials 10 and 11 together, a plurality of passages are provided, each passage comprising aperture 22 and an aperture 32 interrupted by materials 10 and 11. Adjacent one common end of the passages, i.e., apertures 22, there is provided a chamber 23 communicating with a compressed air supply passage 24 which is in turn connected to a compressed air supply (not shown). It is visualized that a gas other than air might be used for present purposes, such being selected from those having improved drying qualities and deemed well known to those skilled in the art to which the present invention is directed. Further, gaseous fluids might be applied.
Jaw-abutment 30 includes a drainage chamber 33 for use in draining fluid expressed from materials 10 and 11, as better understood from the description hereinafter.
Regarding operation of apparatus 100, jaw-abutments 20 and 30 are moved apart as seen in FIG. 1, and materials 10 and 11 arranged in the afore-mentioned manner are statically deposited there-between. Jaw-abutment 20 is then moved toward jaw-abutment 30 to compress materials 10 and 11. With compression of materials 10 and 11 taking place, compressed air is introduced to apertures 22 via passage 24 and chamber 23. The compressed air thence passes downwardly of apertures 22 through materials 10 and 11 and downwardly of apertures 32 to exhaust into chamber 33. As will be realized, liquid moisture in materials 10 and 11 will be carried into chamber 33 and expelled therefrom via outlet 34. As will be further realized, the degree of compression, the length of time compression is maintained, and the pressure of the compressed air, may be varied as may be the size and density of the apertures in the working surfaces 21 and 31. All will, of course, be determined by the requirements to be achieved, taking into account the type of materials to be processed.
As may be still further realized, should it be particularly necessary, jaw-abutments 20 and 30 may be arranged whereby the central axis 35 lies in, for example, a horizontal plane rather than a vertical plane, seen in FIG. 1. Such arrangement would thus accommodate materials 10 and 11 suspended in a vertical plane. In such instance, outlet 34 would, of course, be arranged to lie vertically below the central axis 35 to ensure proper drainage of the expressed fluid.
As may be further realized from the afore-mentioned operation, liquid in the material is "pushed" rather than "pulled" from the material to be treated, as in the case of the operation of the prior art devices. This accordingly results in a much more efficient operation, apart from avoiding the afore-mentioned high energy costs associated with evaporative drying.
Turning now to the further embodiment of the invention disclosed, i.e., shown in FIGS. 2 and 3 and depicted as apparatus 150, as seen, the cooperatively arranged pair of abutments in this case comprise a pair of rotatably mounted rollers 40 and 50, and as further seen in FIG. 2, positioned one to another to provide a nip therebetween through which material 10 and 11 is propelled by rollers 40 and 50, the latter being powered by suitable known means (not shown). Although roller 40 is disposed vertically above roller 50, it is contemplated, as in the case of apparatus 100, that materials 10 and 11 comprising webs may extend to travel in a vertical direction, in which case rollers 40 and 50 would be mounted about a substantially horizontal axis, and in such instance, the drainage chamber outlet would be modified to suit, providing efficient drainage.
In the FIG. 2 embodiment, a statically arranged chamber 42 is provided within roller 40 and extends adjacent one aperture 41. Chamber 42 is, in effect, an elongated chamber extending adjacent a plurality of apertures 41, extending lengthwise of roller 40 (not shown). Chamber 42 is interconnected to a compressed air supply (not shown). As noted from FIG. 2, the housing of chamber 42, designated 43, includes a convex face 44 mating with inner concave face 45 of roller 40 in sliding engagement therewith. Thus, when roller 40 is rotatably positioned as shown in FIG. 2, chamber 42 connects fully with an aperture 41 (and the others not shown), and as roller 40 is rotated in either a clockwise or counterclockwise direction, chamber 42 will fully communicate with further apertures 41 in turn. Chamber 42, as seen in FIG. 2, is thus remote from working surface 46 of roller 40.
A statically arranged drainage chamber 52, mentioned above, is provided within roller 50 and extends adjacent a plurality of apertures 51. As in the case of chamber 42 mentioned above, chamber 52 is an elongated chamber extending lengthwise of roller 40. Chamber 52 is interconnected to a drain line (not shown) for removing liquid expressed from materials 10 and 11 during compression by rollers 40 and 50. Chamber 52 is substantially U-shaped and includes a pair of outer ends 53 which are convex to slidably and matingly engage the concave inner surface 54 of roller 50. Chamber 52 could also be connected to a vacuum source in order to increase the pressure differential.
As indicated, rollers 40 and 50 may be mounted for movement toward and away from one another so as to provide the two positions shown respectively in FIGS. 2 and 3. Any well-known arrangement may be utilized for this, being ones deemed well known to those skilled in the art to which the present invention is directed.
Regarding operation of apparatus 150, the paper web 10 and felts 11 are passed between rollers 40 and 50 and thereafter propelled therebetween by powered rotation of either or both of rollers 40 and 50 (FIG. 2). With the compression of web 10 and felts 11 at the nip by the rollers 40 and 50, compressed air is introduced to apertures 41 via chamber 42. The compressed air then passes downwardly through apertures 51 to exhaust into chamber 52, having passed through web 10 and felts 11. Liquid moisture in web 10 and felts 11 is thus carried into chamber 52 and is thereafter expelled therefrom via a drainage outlet (not shown). Thus, apparatus 150 operates much like apparatus 100 to remove water from paper web 10 and felts 11. Again, as in the case of the FIG. 1 embodiment, this embodiment utilizes felt 11 on opposite sides of web 10.
As will be seen in FIG. 4, an apparatus 200 is disclosed somewhat similar to that of FIGS. 2 and 3 in that it includes the pair of rollers 40 and 50 having respectively chambers 42 and 52 therein, and the web passing intermediate the rollers. The main differences from that of the FIGS. 2 and 3 embodiment, of course, include that the plane passing through the axes of rollers 40 and 50 lies at an angle respective the vertical plane. As will be appreciated, this is not important but is convenient since it provides a compact and tidy design.
Conveyor means 60 comprises an annular material support surface 61 having a plurality of apertures 62 therein to permit the compressed air to pass from roller 40 to roller 50 through the material to be dried in similar manner as aforedescribed. As will be noted, annular conveyor means 60 is rotatably supported upon roller 50 and a second roller 50a. Rotation is effected through the known ratchet arrangement 63 operated through a power cylinder 64 secured to a base 65, which serves to support rollers 50 and 50a.
Movement of roller 40 toward and away from roller 50 is controlled by power cylinder 66 secured to base 65 operating through link arm 67 pivotally mounted to base 65 via support 68. Thus, cylinder 66 controls the degree of the compression of the material intermediate rollers 40 and 50, i.e., at the nip thereof.
Apparatus 200 further includes a material infeed arrangement 70 and a material outfeed arrangement 80, comprising screw conveyors. A material guide plate 90 extends intermediate roller 40 and outfeed arrangement 80 for use in guiding the dried material to outfeed arrangement 80.
Material to be dried is fed to annular support surface 61 via infeed arrangement 70. Operation of ratchet arrangement 63 via cylinder 64 rotates the annular support surface 61, introducing the material to the nip of rollers 40 and 50, which is adjusted through operation of cylinder 66 to provide the desired compression of the material. During the compression, compressed air is introduced to the material via chamber 42 of roller 40 and thereafter subsequently received by chamber 52 of roller 50, in similar manner aforedescribed. Following passage through rollers 40 and 50, the material is advanced via guide 90 to outfeed arrangement 80.
Although apparatus 200 discloses the use of an annular conveyor, it will be readily appreciated that such may be modified to accommodate in place thereof, a linear type conveyor, the material supporting surface of which corresponds to that of apparatus 200, for use in advancing the material to be treated through the nip of rollers 40 and 50. In the case of such modification, rollers 50 and 50a may be utilized to support the linear conveyor which would, in effect, comprise a perforated belt. Such modification may also include disposing rollers 40 and 50 one above the other, as per that of apparatus 150. In such modified embodiment, power cylinder 64 and ratchet arrangement 63 would be dispensed with and material infeed arrangement 70 and material outfeed arrangement 80 could be repositioned adjacent respective ends of the linear conveyor. Again, as in the case of apparatus 150, rollers 40 and 50 may be arranged for registered or non-registered movement, one to another.
From the foregoing, it will be seen that during operation, the materials are compressed, preferably using a maximum compressive force in keeping with permitted conditions. Further, the compacted material, in the case of the embodiments disclosed, is a formed sheet of paper which is saturated with water, that a felt web is used on opposite sides of the formed paper and that the compressed fluid used is air which is forced through the formed sheet. It is to be noted that, during such operation, additional water will not only be expressed from the pores in the paper sheet, but water in the felt adjacent the paper sheet will also be expelled into the receiving chambers of the apparatus. The net result of this is that, at maximum compaction, the water content of the sheet is less than the theoretical limitation which applies to current wet pressing operations and that by expelling water from the felt adjacent the paper sheet, the "rewetting" phenomenon is greatly reduced.
Apparatuses 100, 150, 200 and, of course, others not shown but in accordance with the present invention, may, if desired, be modified, particularly in terms of the drainage abutment. Reference is made to FIG. 2b showing vented nip type roller 50b. Roller 50b may be used in place of roller 50 with its accompanying chamber 52. In such case, the grooves 50c serve the same function as that provided by apertures 51 and chamber 52 To explain, the compressed air, following passage through the material and felt, enters groove or grooves 50c adjacent the working surface of roller 50b, carrying the expressed fluid therewith; thereafter such is exhausted in lengthwise direction of the grooves 50c, as best seen in FIG. 2c indicated by the arrows. The expressed fluid may be subsequently collected in suitable means (not shown).
Reference is made to FIG. 5 showing further apparatus 250, according to the invention. Apparatus 250 includes roller 50b and accordingly grooves 50c and also includes an abutment roller 40' having elongated grooves 50c' similar to those of roller 50b but extending in axial direction thereof As seen, rollers 50b and 40' provide a nip similar to that of the other aforedescribed embodiments. Additionally, apparatus 250 includes a chamber 42' which is connected to a compressed air supply (not shown), chamber 42' thus being for use in supplying compressed air or gas in a direction along grooves 50c', which air or gas is exhausted after passing through paper 10 via grooves 50c, lengthwise thereof.
As in the case of the other roller embodiments described, rollers 50b and 40' are positioned or are positionable to provide a nip through which the material to be compressed passes when propelled therethrough. Chamber 42' includes nozzle means (not shown) for directing the compressed air or gas along one or more of grooves 50c', at a given time. If desired, a second chamber 42' may be situated at the opposite end of roller 40' to thus introduce compressed air or gas from both ends of the roller 40' and thus increase the amount of compressed gas or air passing along grooves 50c' and passing through material 10.
In further reference to operation of the FIG. 5 embodiment, reference is made to FIG. 5a showing the passage of the compressed gas or air passing along an axially extending groove 50c' of roller 40' to exit through material 10 and thereafter along the circumferentially extending groove 50c of roller 50b.
As indicated previously, the compressed gas or air may be discharged along one or more of the longitudinally extending grooves 50c' of roller 40', i.e., at the formed nip.
The pair of rollers 350, shown in FIG. 6, include a core roller 340 provided with axial grooves 342 similar to those grooves illustrated in FIG. 5. Surrounding the roller 340 is a sleeve 344 having a plurality of apertures 346. Thus, as shown in FIG. 7, the axial groove 342 covered by the sleeve 344 provides separate elongated plenums or chambers with nozzles in the form of apertures 346. In FIGS. 6 and 7, the web of paper is identified by the numeral 10 as are the felts 11 sandwiching the web 10. A roll 360 is located in vertical alignment and parallel relationship with the roll 340. The roll 360 has circumferential grooves 362 similar to grooves 50b in FIG. 5. Roll 360 is also covered by a sleeve 364. Sleeve 364, which is similar to sleeve 344, is provided with innumerable apertures.
When the two rolls are pressed against each other and compressed air is fed from unit 366 endwise through the chambers formed by the grooves 342, the compressed air passes through the so-formed nozzles 346 through the felts 11 and paper web 10 to be discharged with the displaced water into the grooves 362 within the sleeve 364. The plurality of apertures 346 allow the water being displaced to enter within the discharge grooves 362. The water is then drained from the roll 360 by centrifugal force. | A paper machine includes a press section in which the paper web is carried along between a pair of paper machine felts. A dewatering apparatus is included in the press section which consists of a pair of opposed press rollers, one on either side of the felts, with the rollers forming a nip. The rolls are pressed toward each other to compress the felts and the paper web to the maximum mechanical compression. Compressed air is passed through one roller at the nip to the other roller which includes an exhaust device for draining the water blown through by the compressed air. The air is passed under pressure at the nip to evacuate water from the pores of the compressed felts and web. When the paper advances from the nip into an environment at atmospheric pressure, the paper web is substantially free of water. | 3 |
PRIORITY
[0001] The present application is a continuation of U.S. patent application Ser. No. 13/442,271, filed Apr. 9, 2012, which is a continuation of U.S. Patent Application No. 10/610,045, filed Jun. 30, 2003, now U.S. Pat. No. 8,155,974, issued Apr. 10, 2012, the contents of which are incorporated herewith by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention is related to information gathering with automated systems. More particularly, the present invention is related to obtaining profile information from individuals with automation where the profile information is applied for subsequent uses.
BACKGROUND
[0003] Various automated services may be provided for individuals that are specialized for the particular preferences and situation of each individual. For example, an automated system may assist in making purchases for an individual such as automatically purchasing flowers each year on a birthday through an electronic transaction. As another example, an automated system may assist in setting up a dinner reservation for an individual through an electronic transaction. For these transactions, individual specific information must be known, such as the date and type of flowers to purchase or the time and place to schedule the reservation as well as the smoking preference.
[0004] Profile information for individuals may specify the preferences and factual scenarios such as birthdays of interest for an individual. This profile information may be accessed by automated systems when assisting with purchases, scheduling, etc. so that the individual is not required to provide this information for each task being performed. However, this profile information must be acquired from the individual before it can be put to use by the automated systems.
[0005] Acquiring such profile information can be a tedious task. An individual could be asked to complete a questionnaire. However, the information that is relevant to services to be provided for a particular individual at any given time may be difficult to anticipate such that a script of questions intended to elicit that information cannot be prepared in advance. Furthermore, the amount of information may be lengthy such that the individual is required to remain focused on answering numerous questions for an uncomfortable period. As a result the individual may become agitated and may provide hasty answers that are not useful to building the profile for the individual.
SUMMARY
[0006] Embodiments of the present invention address these issues and others by providing methods and systems that obtain information from individuals using automation. These embodiments present questions and analyze the answers that are received. The analysis of answers provides the basis for the selection of the next questions to be asked so that the questioning of the individual can effectively proceed.
[0007] One embodiment is a method of obtaining profile information from individuals using automation. The method involves providing a first question to an individual over a communication network from a network-based computer-implemented application. A first answer to the first question is received from the individual over the communication network at the network-based computer-implemented application. The first answer is analyzed with the network-based computer-implemented application, and based on the analysis of the first answer, a second question is selected and provided to the individual over the communication network from the network-based computer-implemented application.
[0008] Another embodiment is a system for obtaining profile information from individuals using automation. The system includes a profile database storing profile information for an individual. A network-based computer-implemented application is linked to the individual by a communication network. The network-based computer-implemented application is configured to provide a first question to the individual over the communication network and also receive a first answer from the individual over the communication network. The network-based computer-implemented application analyzes the first answer to select a second question and provides the second question to the individual over the communications network. A second answer to the second question is received over the communications network and profile information is determined from the first and second answers. The profile information is stored in the profile database.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows one illustrative embodiment of a system for obtaining profile information from individuals.
[0010] FIG. 2 illustrates one set of logical operations that may be performed within the system of FIG. 1 to obtain the profile information.
DETAILED DESCRIPTION
[0011] Embodiments of the present invention provide an individual with a network-based service that obtains profile information from the individual so that the other network-based services may utilize the profile information when performing automated tasks for the individual. The individual is thereby relieved from manually filling out tedious questionnaires with fixed sets of questions. Also, the questions are presented to the individual while accounting for the manner in which the individual is responding so that the questions can be tailored to minimize the aggravation to the individual.
[0012] FIG. 1 illustrates one example of an encompassing communications network 100 interconnecting communications devices of the individual with the network-based system that automates the profile building process. The individual may access the system through several different channels of communication including both data communication and verbal communication. As discussed below, the individual communicates verbally with a voice services node that may be present in various locations for different embodiments.
[0013] As one example, the individual may place a conventional voiced telephone call from a telephone 112 through a network 110 for carrying conventional telephone calls such as a public switched telephone network (“PSTN”) or adapted cable television network. The call terminates at a terminating voice services node 102 of the PSTN/cable network 110 according to the number dialed by the individual. This voice services node 102 is a common terminating point within an advanced intelligent network (“AIN”) of modern PSTNs or adapted cable networks and can be implemented as a soft switch and media server combination.
[0014] Another example of accessing the system is by the individual placing a voiced call from a wireless phone 116 . The wireless phone 116 maintains a wireless connection to a wireless network 114 that includes base stations and switching centers as well as a gateway to the PSTN 110 . The PSTN 110 then directs the call from the wireless phone 116 to the voice services node 102 according to the number dialed by the individual on the wireless phone 116 . Furthermore, the wireless phone 116 may function as a thin client device relative to the verbal functions of the automated profile building system such that the wireless phone 116 implements a distributed speech recognition (“DSR”) platform to minimize the information transmitted through the wireless connection. The DSR platform takes the verbal communication received from the individual at the wireless device 116 and generates parameterization data from the verbal communication. The DSR platform then transmits the parameterization data as the verbal communication to the voice service node 102 or 136 rather than all the data representing the verbal communications. The voice services node 102 or 136 then utilizes a DSR exchange function 142 to translate the DSR parameterization data into representative text which the voice services node 102 or 136 can deliver to an application server 128 .
[0015] Another example of accessing the system is by the individual placing a voiced call from a voice-over-IP (“VoIP”) based device such as a personal computer 122 or where telephone 112 is a VoIP phone. This VoIP call from the individual may be to a local VoIP exchange 134 which converts the VoIP communications from the individual's device into conventional telephone signals that are passed to the PSTN 110 and on to the voice services node 102 . The VoIP exchange 134 converts the conventional telephone signals from the PSTN 110 to VoIP packet data that is then distributed to the telephone 112 or computer 122 where it becomes verbal information to the individual. Furthermore, the wireless phone 116 may be VoIP capable such that VoIP communications occur with the wireless network 114 which are converted to speech prior to delivery to the voice node 102 .
[0016] The VoIP call from the individual may alternatively be through an Internet gateway 120 of the individual, such as a broadband connection or wireless data network 114 , to an Internet Service Provider (“ISP”) 118 . The ISP 118 interconnects the gateway 120 of the individual or wireless data network to the Internet 108 which then directs the VoIP call according to the number dialed, which signifies an Internet address of a voice services node 136 of an intranet 130 from which the automated service is provided. The voice services node 136 has the same capabilities as voice services node 102 like advanced speech recognition and text-to-speech, but is accessed over a VoIP network such as the Internet 108 . As shown, the voice services node is included within an intranet 130 that is protected from the Internet 108 by a firewall 132 . The voice service node 136 includes a VoIP interface and is typically implemented as a media server which performs the VoIP-voice conversion such as that performed by the VoIP exchange 134 . However, as discussed above, the voice services node 136 also performs text-to-speech and speech recognition such as that performed by the voice services node 102 and discussed below. Accordingly, the discussion of the functions of the voice services node 102 also applies to the functions of the voice service node 136 .
[0017] As yet another example, the wireless device 116 may be a wireless data device such as a personal digital assistant. The wireless device 116 and/or personal computer 122 may have a wi-fi wireless data connection such as IEEE 802.11 to the gateway 120 or directly to the wireless network 114 such that the verbal communication received from the individual is encoded in data communications between the wi-fi device of the individual and the gateway 120 or wireless network 114 .
[0018] Another example of accessing a voice services node 102 or 136 is through verbal interaction with an interactive home appliance 123 . Such interactive home appliances may maintain connections to a local network of the individual as provided through a gateway 120 and may have access to outbound networks, including the PSTN/cable network 110 and/or the Internet 108 . Thus, the verbal communication may be received at the home appliance 123 and then channel via VoIP through the Internet 108 to the voice services node 136 or may be channeled via the PSTN/cable network 110 to the voice services node 102 .
[0019] Yet another example provides for the voice services node to be implemented in the gateway 120 or other local device of the individual so that the voice call with the individual is directly with the voice services node within the individual's local network rather than passing through the Internet 108 or PSTN/cable network 110 . The data created by the voice services node from the verbal communication from the individual is then passed through the communications network 100 , such as via a broadband connection through the PSTN/cable 110 and to the ISP 118 and Internet 108 and then on to the application server 128 . Likewise, the data representing the verbal communication to be provided to the individual is provided over the communications network 100 back to the voice services node within the individual's local network where it is then converted into verbal communication provided to the individual.
[0020] The voice services node 102 provides text-to-speech conversions to provide verbal communication to the individual over the voiced call and performs speech recognition to receive verbal communication from the individual. Accordingly, the individual may carry on a natural language conversation with the voice services node 102 . To perform these conversations, the voice services node 102 implements a service control logic written in a language such as or similar to the well-known voice extensible markup language (“VoiceXML”) context which utilizes a VoiceXML interpreter function 104 of the voice services node 102 in conjunction with VoiceXML documents. An alternative language for the control logic is the speech application language tags (“SALT”) platform. The interpreter function 104 operates upon the VoiceXML or SALT documents to produce verbal communication of a conversation. The VoiceXML or SALT document provides the content to be spoken from the voice services node 102 . The VoiceXML or SALT document is received by the VoiceXML or SALT interpreter function 104 through a data network connection of the communications network 100 in response to a voiced call being established with the individual at the voice services node 102 . This data network connection as shown in the illustrative system of FIG. 1 includes a link through a firewall 106 to the Internet 108 and on through the firewall 132 to the intranet 130 .
[0021] The verbal communication from the individual is received at the voice services node 102 and is converted into data representing each of the spoken words through a conventional speech recognition and natural language understanding function of the voice services node 102 . The VoiceXML or SALT document that the VoiceXML or SALT interpreter function 104 is operating upon sets forth a timing of when verbal information that has been received and converted to data is packaged in a particular request back to the VoiceXML or SALT document application server over the data network. This timing provided by the VoiceXML or SALT document allows the verbal responses of the individual to be matched with the verbal questions and responses of the VoiceXML or SALT document. Matching the communication of the individual to the communication from the voice services node enables an application server 128 of the intranet 130 to properly act upon the verbal communication from the individual. As shown, the application server 128 may interact with a voice services node through an intranet 130 , through the Internet 108 , or through a more direct network data connection as indicated by the dashed line.
[0022] The voice services node 102 may also employ a voice analysis application 126 . The voice analysis application 126 allows various qualities of the individual's speech to be analyzed such as the energy, frequency, and various other speech parameters. For example, the tonal qualities of the speech can be analyzed to determine the gender of the individual as well as the individual's current mood. This information is delivered back to the application server 128 as data along with the data representative of the words that are spoken. The application server 128 may then analyze the qualities of the individual's speech along with the spoken content to determine which question(s) to subsequently present to the individual and when they should be presented. For example, the voice analysis application 126 may provide data to the application server 128 indicating that the individual is frustrated, such as because the individual's voice pitch has substantially increased. The application server 128 follows up by terminating the current session or asking a general question requiring a simple answer now while waiting until a subsequent session to ask a question for a current subject matter that requires a detailed answer.
[0023] The application server 128 is a conventional computer server that implements an application program to control the automated profile building service for the individual. Where verbal communication is utilized to communicate with the automated profile building service, the application server 128 provides the VoiceXML or SALT documents to the voice services node 102 to bring about the conversation with the individual over the voiced call through the PSTN/cable network 110 and/or to the voice services node 136 to bring about the conversation with the individual over the VoIP Internet call. The application server 128 may additionally or alternatively provide files of pre-recorded verbal prompts to the voice services node where the file is implemented to produce verbal communication. The application server 128 may store the various pre-recorded prompts, grammars, and VoiceXML or SALT documents in a database 129 . The application server 128 also interacts with a customer profile database 124 that stores the profile information for each individual that is acquired through the profile building process.
[0024] In addition to providing VoiceXML or SALT to the one or more voice services nodes of the communications network 100 , the application server 128 may also serve hyper-text markup language (“HTML”), wireless application protocol (“WAP”), or other distributed document formats depending upon the manner in which the application server 128 has been accessed so as to provide for non-verbal communication with the individual. For example, an individual may choose to communicate with the application server to build the profile information by accessing a web page provided by the application server to the personal computer 122 through HTML or to the wireless device 116 through WAP via a data connection between the wireless network 114 and the ISP 118 . Such HTML or WAP pages may provide a template for entering information where the template asks a question and provides an entry field for the individual to enter the answer that will be stored in the profile database 124 and/or will be used to determine the next question to provide on the template to seek further information from the individual.
[0025] The profile database 124 contains the preference information that has been provided by the individual through the profile building process. The profile database 124 may contain many categories of information for an individual. For example, the profile database 124 may contain payment preferences of the individual such as various credit accounts to be used. The profile database 124 may contain item preferences such as the permissible brands of products and services to be purchased and the permissible vendors that the purchase may be made from. As a specific example, the profile database 124 may specify the type of flowers to be automatically purchased each year on Valentine's Day and/or on a birthday. Additionally, the customer profile may specify the range of acceptable prices for the goods and services to be purchased.
[0026] As shown in FIG. 1 , the profile database 124 may reside on the intranet 130 for the network-based profile building service. However, the profile database 124 likely contains information that the individual considers to be sensitive, such as the credit account information. Accordingly, an alternative is to provide customer profile database storage at the individual's residence or place of business so that the individual feels that the profile data is more secure and is within the control of the individual. In this case, the application server 128 maintains an address of the customer profile database storage maintained by the individual rather than maintaining an address of the customer profile database 124 of the intranet 130 so that it can access the profile data as necessary.
[0027] FIG. 2 illustrates one example of logical operations that may be performed within the communications network 100 of FIG. 1 to bring about the automated profile building process for the individual. This set of logical operations is provided for purposes of illustration and is not intended to be limiting. For example, these logical operations discuss the application of VoiceXML within the communications network 100 where verbal communication occurs between the profile building system and the individual. However, it will be appreciated that alternative platforms for distributed text-to-speech and speech recognition may be used in place of VoiceXML, such as SALT as discussed above, or a proprietary less open method.
[0028] The logical operations of FIG. 2 may begin at question operation 202 where the application server distributes a question to the individual via email, other data messaging, or via a web template. Upon the first iteration where the first message has been sent to the individual or the individual has first visited the web page, then instructions may be provided to the individual to guide the individual in completing answers to the questions, such as by stating that the individual may answer in as general or detailed terms as desired and may terminate the question and answer session whenever the individual chooses. An example of an initial question may be to state the services that the individual will be using for which the customer profile information will be applicable. Another example of an initial question may be for the individual to identify himself or herself When the logical operations begin at question operation 202 , then operational flow proceeds to answer operation 214 .
[0029] At answer operation 214 , the individual enters an answer to the question that has been presented when convenient for the individual. The answer is provided in a reply email or other data message or by entering text within the template of the web page. The individual may answer in general or detailed terms. For example, when asked which services the customer profile information will be applicable to, the individual may respond in general terms by entering only the basic name of each of the desired services. The individual may choose to respond in more detailed terms by elaborating on the services by also specifying key preferences for each of the services that should be contained within the profile database. As another example, when asked to identify himself or herself, the individual may simply enter the individual's name or may choose to elaborate by specifying name, age, and gender. After the individual provides the answer, operational flow transitions to analysis operation 216 .
[0030] The logical operations may alternatively begin at transfer operation 204 where the application server provides questions in the form of VoiceXML documents to a voice services node that has established a voiced call with the individual. The voiced call may be established at the initiative of the individual by dialing a number for the profile building service which results in a connection to the voice services node. Alternatively, the voiced call may be established at the initiative of the application server by instructing the voice services node to place a call to a known number for the individual.
[0031] Where the individual places the voiced call to the voice services node such as by dialing the number for the profile building service for the voice services node on the communications network or by selecting an icon on the personal computer where the voiced call is placed through the computer. The voice services node accesses the appropriate application server according to the voice call (i.e., according to the number dialed, icon selected, or other indicator provided by the individual). Utilizing the dialed number or other indicator of the voice call to distinguish one application server from another allows a single voice services node to accommodate multiple verbal communication services simultaneously. The voice services node may provide identification data to the application server for the individual based on the received caller ID information for the individual which allows the application server to create or access an existing profile for the individual.
[0032] Alternatively, the voice services node may implement a standard VoiceXML introduction page to inform the individual that he has dialed into the service and ask that the individual say his formal name or other form of identification, such as a user name and password. This identification can then be captured as data and provided back to the application server where it is utilized to create or access an existing profile for the individual.
[0033] Once the voice services node receives the VoiceXML document from the application server, it is interpreted at speech operation 206 to convert the VoiceXML text to speech that is then verbally provided to the individual over the voiced call. This verbal information may provide further introduction and guidance to the individual about using the system. This guidance may inform the individual that he can barge in at any time with a question or with an instruction. The guidance may also specifically ask that the individual provide a verbal answer to each question and that the verbal answer may be in as general or detailed terms as the individual chooses. The initial question is then provided verbally to the user. The speech from the voice services node may begin in a neutral tone and pace that may later be altered for subsequent questions depending upon analysis of the verbal answers received from the individual.
[0034] Eventually, the voice services node receives a verbal answer from the individual at answer operation 208 . The content of the verbal answer may be in general terms or may be detailed. For example, the verbal answer may be a one word, yes or no type of answer or the verbal answer may be several sentences that elaborate. Furthermore, the speech will have various characteristics such as pace and tonal qualities. The verbal answer is interpreted through speech recognition at the voice services node to produce answer data that represents the words spoken by the individual at recognition operation 210 . This data is representative of the words spoken by the individual that are obtained within a window of time provided by the VoiceXML document for receiving verbal answers so that the application server can determine from keywords of the answer data what the individual wants the service to do.
[0035] The voice services node also analyzes the voice characteristics of the verbal answer to quantify the characteristics such as pace and tonal quality to produce additional answer data. For example, the verbal answer may be slow and relatively low pitched indicating that the individual is in a calm mood and may be willing to participate for a while or may be fast and high pitched indicating that the individual is in an agitated mood and likely wants to be done with the session or the current line of questioning as soon as possible. Furthermore, the frequency content of the voice allows the gender to be estimated so that the gender specific questioning can be selected without specifically asking about gender and/or without receiving a specific answer about gender.
[0036] The answer data including the content of the verbal answer as well as the voice characteristics is transferred from the voice services node over the data network to the application server at exchange operation 212 . Operational flow then transitions to analysis operation 216 where the application server analyzes the answer data for the content and characteristics. Based on this analysis, the application server can then select the appropriate follow-up question with the individual from a hierarchy of question content, temperament, and timing. Such selection is discussed below with reference to selection operation 218 . In addition to analyzing the answer data so that the next question can be determined, the application server also analyzes the answer data to determine whether the content of the answer is appropriate for storage within the profile database for use by automated services performing tasks for the individual. For example, certain answers may be too vague or general to be useful and are not stored while other answers may directly address a category of information of the profile database. The answers adequately addressing a category of information of the profile database are stored for the appropriate category and for the individual.
[0037] Where the communication with the individual is text-based rather than verbal, then the characteristics of the text-based answer are analyzed for the length of the answer and the particular vocabulary used for the answer. For example, if the answers consist of only a few short words, then the application server may detect that the individual is in an agitated mood or that the individual does not type effectively. Where the communication with the individual is verbal, then the characteristics of the verbal answer are analyzed including the length of the answer as well as the voice characteristics discussed above that have been identified by the voice analysis at the voice services node. For example, the application server may recognize from the answer data that the verbal answer was lengthy, high-pitched, and fast paced which may indicate that the individual is not agitated with the questioning but that the individual has a personality that involves speaking quickly in a relatively high voice.
[0038] From the analysis, the application server then chooses the next content, temperament, and timing of the next question from the hierarchy of question options at selection operation 218 . For example, where the analysis has indicated that the individual is agitated, such as due to a verbal answer that had a higher pitch, faster pace, and less content than normal for this individual, then the application server may select a verbal question that requires only a yes or no answer, that is provided in a very soft-spoken voice presentation with a moderate pace from the voice services node, and is provided immediately. For example, the application server can provide a yes or no question immediately which can mean taking place a very short time following the previous question and taking place before any other questions or user interaction, while within the same session. The application server may also select a question that requires a more elaborate answer from the individual, that is provided in a neutral voice presentation in a quickened pace from the voice services node, and is set to be provided upon the next session that occurs between the automated profile building system and this individual.
[0039] The selection of questions may be based on statistical modeling that allows correlations of characteristics to be established. For example, the tonal qualities of speech may be correlated with mood and/or gender, while length of response may be correlated with mood and/or personality. From the correlations resulting from statistical modeling, the hierarchy of question content, temperament, and timing may be created and stored for application within the automated system.
[0040] Upon selecting the appropriate content of a question, as well as selecting the temperament including tone and pace and selecting timing for presentation to the individual, operational flow returns to question operation 202 or transfer operation 204 as appropriate for the current mode of communication with the individual. If the application server has selected that a question be present during the current session, then operational flow immediately continues at question operation 202 or transfer operation 204 . Otherwise, operational flow stops until the next session is initiated, and operational flow then re-starts at question operation 202 or transfer operation 204 .
[0041] The automated profile building system allows the individual to communicate with the system at the convenience of the individual and allows the individual to answer in a style that the individual chooses. The automated profile building system adapts to the current style of the individual to choose follow-up questions based on the analysis of the individual's answer. Accordingly, the follow-up questions may be provided with content, temperament, and timing such that the question and answer exchanges proceed in an effective manner as opposed to forcing the individual to answer a fixed set of questions that are not sensitive to the individual's personality, current mood, or other characteristic.
[0042] Although the present invention has been described in connection with various illustrative embodiments, those of ordinary skill in the art will understand that many modifications can be made thereto within the scope of the claims that follow. Accordingly, it is not intended that the scope of the invention in any way be limited by the above description, but instead be determined entirely by reference to the claims that follow. | Methods and systems obtain profile information from individuals using automation to select and provide the questions that are given to the individual. The answers the individuals provide to the questions can then be used to generate the profile information. Subsequent questions are selected and presented according to analysis of the previous answers. The exchange of the questions and answers occurs over a communications network and may take the form of emails, web page interfaces, wireless data messages, or verbal communication over a voiced call. The answers are analyzed to determine certain characteristics, such as the personality type, mood, and gender of the individual. The subsequent questions are selected based on the characteristics that are found from the answers to facilitate the information exchange between the automated system and the individual. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is related to U.S. patent application Ser. No. ______ (Attorney Docket No. (AUS9-2000-0617-US1) which is hereby incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates in general to Very Large Scale Integration (VLSI) Schematic design program scheduling method that allows a designer to submit and execute multiple VLSI Schematic design program jobs in an automated fashion.
BACKGROUND INFORMATION
[0003] Schematic generation in VLSI design is that part of the design process where the Logic and Logic interconnections are designed to implement a particular system function. The Schematic describes the logic blocks and how their inputs and outputs are connected to make various functions and ultimately an entire VLSI chip What kind of and how many devices (e.g., transistors) are required to make a given function (e.g., AND gate) may not be important to the Logic of the function relative to the Schematic.
[0004] In this phase of the VLSI design process, noise, power, actual wiring structure, delay, and etc. are not necessarily considered. There are various details in this phase of the design that affect the Logic functionality (realizing the desired function) and there are other details (e.g., device sizes, transistor types, labels, etc.) that are important but do not affect the Logic functionality of the design. Logic functionality may be represented simply by “Logic” throughout this disclosure.
[0005] Typically there are several VLSI Schematic design programs (jobs) that are run to complete and verify a VLSI design. A designer may submit the jobs in sequence or in parallel. When the designer submits the design jobs in sequence, typically errors encountered in running the first design job (program) are corrected and that job is rerun until it is error free. Outputs from the first design job are then applied to the next applicable design job. This process is continued until the VLSI Schematic design is complete. If the jobs are run in parallel, then several design jobs are launched simultaneously. In the parallel mode, the designer may have to determine whether to abort other jobs still running when a design job fails. Aborting incomplete jobs may be appropriate when it is known the failing job also indicates probable errors in the incomplete job. In other instances, a job may fail for reasons that do not adversely affect incomplete jobs and therefore these jobs may be allowed to run until completion. Regardless, the designer would have to continually take action and may have to restart several jobs to keep the VLSI design process going until all jobs complete successfully.
[0006] It is useful to review the present VLSI design job environment. In a part of the VLSI design a Schematic, which represents a desired system Logic, is generated and verified by various Schematic design and checking programs. The following describes programs which may be used to explain embodiments of the present invention:
[0007] Gatemaker—generates models and verifications of the test view
[0008] VIM—generates circuit features, inputs/outputs, transistor models, etc.
[0009] VHDL—is a high level description language view of the design
[0010] Schematic—is the circuitry diagram
[0011] Cosmetic Error Programs—programs that keep unchanged the results of schematic based programs (the data defining the Schematic itself) while updating other descriptive data.
[0012] To describe the Schematic design process, assume that the VHDL of the Schematic macro has been completed. After the Schematic is checked and saved, the VIM of the macro is generated from data in the Schematic database. At this time, the designer may run a VHDL versus Schematic checking program. On the other hand, the Gatemaker program may also be run. Gatemaker in this example comprises two steps:
[0013] 1. generate the test view (Gatemaker Model) of the Schematic.
[0014] 2. Validation of models
[0015] a) generate the test patterns and apply that to the test view to generate the response,
[0016] b) apply the same test patterns to Schematic view to generate the response,
[0017] c) compare those two responses to see if they are the same.
[0018] After the generation of Gatemaker Model, the VHDL versus Gatemaker Model has enough inputs to do the verification. Normally, the designer discretely and manually submits these jobs in series. Submitting the VLSI Schematic design jobs may be very sequential, step-by-step, and done manually. The whole process depends on the actions of an individual designer. The designer has to keep track of multiple jobs and know which jobs to re-submit and which jobs have valid results. This takes up valuable time the designer may use for other design tasks.
[0019] Because of this there is a need for a VLSI Schematic design job scheduler that would relieve the designer of any tasks except correcting errors and re-starting the design process wherein a design job scheduler decides which programs need to be re-run and what results may be used for executing subsequent jobs.
SUMMARY OF THE INVENTION
[0020] A Schematic is generated by creating functional Logic by interconnecting library logic blocks or interconnection library macro logic blocks until it is believed that the desired function has been implemented successfully. Within a Schematic various logic blocks may require the resizing of transistors within a logic block depending on fan out requirements, speed or other requirements. While these considerations are important they may not be pertinent to the Logic represented by the Schematic. Data defining a Schematic is generated, checked and saved as the starting database. A scheduler program launches several Schematic design programs in parallel. One of the programs is a checking program that extracts and separates data from the Schematic entry that is related to the Logic of the Schematic and data that is not related to the Logic. Since initially the data has not been changed, the checking program awaits results of the first pass of Schematic program execution. The first pass will generate a Schematic which may or may not have errors. When the Schematic data is updated the Schematic design programs are re-launched. If the changes are not related to the Logic then a previously generated result data regarding the Logic may not have to be re-run and the uncompleted “Logic related” programs may be stopped. However, if the changes are related to Logic then the programs are allowed to run to completion and the resulting errors noted and corrected by the designer. As the design process nears completion, when the changes are most likely cosmetic, then long running Logic programs are not re-run and their results remain as release data.
[0021] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0023] [0023]FIG. 1 is a state diagram indicating decision used in design job launch using a design job scheduler according to embodiments of the present invention;
[0024] [0024]FIG. 2 is a flow diagram of steps in an embodiment of the present invention;
[0025] [0025]FIG. 3 is a flow diagram of execution of one of the programs in an embodiment of the present invention;
[0026] [0026]FIG. 4 is a diagram that illustrates the interconnection of program states and the program scheduler, designer controls and schematic database; and
[0027] [0027]FIG. 5 is a block diagram of a data processing system may employ method steps according to embodiments of the present invention.
DETAILED DESCRIPTION
[0028] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits have been shown in block diagram form in order not to obscure the present invention in unnecessary detail. For the most part, details concerning timing considerations and the like may have been omitted in as much as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art.
[0029] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0030] Embodiments of the present invention disclosure a method of submitting Schematic-related VLSI design jobs in “clicking one button” manner. All the jobs that are submitted on different load leveler machines are automatically being kept track of and canceled by the software program if necessary.
[0031] In embodiments of the present invention different modes are used during the VLSI Schematic design process, for example, the Audit Mode and the Non-Audit Mode. The purpose of Audit Mode is to guarantee the consistency, validity, and coherence of the database. The designer wants to make sure that the decision to “tape out” (release to manufacturing) of the Schematic is based on absolutely correct data. The design programs must all have been run without errors at the time of tape out.
[0032] One of the important criteria of microprocessor design is the computer performance index (CPI) of the design at the time of release to manufacturing. Microprocessor performance is estimated by running the microprocessor logic against the industry benchmark using the VHDL. The microprocessor logic is reflected in different views: VHDL view, Schematic view, test view, etc. If at some point in the design process all the layout design programs have run error free, then the Schematic database would have an error free tag. However, if for some reason a small change is made, then an Audit Program within the Audit Mode will detect an inconsistency between the “official” data and the changed data. This inconsistency would cause the Audit Program to assign the entire Schematic database as being in error thus rendering the entire Schematic database invalid including the CPI information.
[0033] In another example, after the design process has run, all the Schematic design programs error free the Schematic is opened in an Edit Mode. In the Audit Mode an Audit Program may determine that even a change that did not affect the Schematic (e.g., the date when programs where run and the date the Schematic was opened in the Edit mode are different) and require all the Schematic programs to be rerun.
[0034] Near the “tape out” (release to manufacturing) phase, all the runs are done in Audit Mode to check the validity of the database. At this stage, every check should have been run successfully at least once. Therefore all the inputs, correct or not correct, are already generated. However, past experience shows that all the jobs have to be rerun many times until the tape out date (ready to complete VLSI layout) due to small changes in Schematic, cell libraries or checking decks. The designer wants to have a quick turn-around time in rerunning those checks on the database. This kind of environment is suitable for the proposed method. Since all the checks are to be rerun, most of them are likely to pass.
[0035] There are other changes, which when made to the Schematic, do not affect the Logic of the VLSI function represented by the Schematic. For example, device size, transistor type (normal voltage threshold, low voltage threshold), wiring, instance name, wire label, or explanation comments on the Schematic do not change the Logic. There are cases wherein changes are “cosmetic” and the circuit build-up structure does not change. In these cases, it may be possible to determine if the logic stays the same by simply comparing the circuit topology of each cell without considering device size/type, wiring, etc. and by checking if the cell connections between cells, flat or hierarchically, remain the same. Using a program scheduler, according to embodiments of the present invention, will speed up the Audit Mode when the VLSI design is near completion since it is more likely that changes do not affect the logic of a VLSI Schematic.
[0036] [0036]FIG. 4 illustrates how the program scheduler 401 interconnects all the program states ( 102 through 109 ), Schematic database 101 and Designer Controls 110 .
[0037] Designer Controls 110 are used by a Designer to direct operation of the program scheduler 401 by passing commands and data 402 (e.g., mode control, start, Designer action data, etc.). Program data 403 for the individual program states is accessed by the programs scheduler 401 from the Schematic database 101 . The Designer simply starts the Schematic design process and the program scheduler 401 schedules the programs and runs, stops and reruns the program states in response to program logic outputs and the mode controls and then tags program output data and updates the Schematic database 101 .
[0038] [0038]FIG. 1 is a design program state diagram illustrating the possible paths of a Schematic design program execution during the VLSI Schematic design process according to embodiments of the present invention. Paths between various program states are illustrated in FIG. 1 by including a number in each path. The following is a legend explaining the conditions and associated numbers governing transition paths used in following embodiments of the present invention:
[0039] (1)—unconditional launch of the program state
[0040] (2)—if the source program state failed, continue incomplete running programs
[0041] (3)—if the source program state fails, signal stop incomplete running programs
[0042] (4)—launch Cosmetic error correction programs only
[0043] After the Schematic is checked and saved in state 101 , the Schematic view is generated by launching the program GenVim 104 . When GenVim 104 completes, it launches (path 1) a Checking program 102 . The Checking program 102 determines whether or not any changes to the Schematic database are related to the Logic (e.g., device size, transistor type, labels, instance names and etc.). The program GenVim 104 also launches a program VHDL versus Schematic 103 which compares the VHDL description with the Schematic and Generate Gatemaker 105 (paths 1) which generates a test view model (Gatemaker). A test view creates models used to describes what outputs are expected with input patterns to check the validity of the Logic of the Schematic.
[0044] The Checking program 102 determines if the any changes made to the Schematic cause the Logic, described by the Schematic, to remain unchanged (conserves the Logic). If the changes conserve the Logic, the Checking program 102 may stop or interrupt (paths 3) programs incomplete and still running. The Checking program 102 may stop, VHDL versus Schematic 103 , Gatemaker 105 , VHDL versus Schematic 107 , and Validation of Gatemaker Model 106 . At the same time, the Checking program may keep (determined by the scheduler program and the mode) the results (grades) of the previous run. If the results of previous run are bad (errors affected the Logic), the bad results may still be in the release area (runs completed have not run error free). If the results of previous run are good, the good results are also still in the release area. If the Checking program 102 determines that the changes does conserve the Logic, it signals (path 2) Interrupt Logic Programs 108 to stop (paths 3) Logic programs that are running. In the case that the Logic is conserved then there is no need to rerun the Logic programs. If the Checking program 102 determines that the changes are not related to the Logic (e.g. “cosmetic errors”) then Cosmetic error programs (path 4) update the Schematic database data that is not related to the Logic of the Schematic.
[0045] The VHDL versus Schematic 104 verifies that the VHDL and Schematic view are equivalent. If VHDL versus Schematic 104 executes successfully, then no additional action is taken. However, if VHDL versus Schematic 104 fails (VHDL and Schematic view are not equivalent), VHDL versus Schematic signals a stop (paths 3 ) to Generate Gatemaker 105 and/or the Checking program 102 .
[0046] When Generating Gatemaker 105 sends a signal (paths 1) it simultaneously launches Validation of Gatemaker Model 106 and VHDL versus Gatemaker Model (test view) 107 . A failure of Generating Gatemaker 105 results in Validation of Gatemaker Model 106 and VHDL versus Gatemaker Model 107 not being launched. VHDL versus Gatemaker Model 107 determines if VHDL and Gatemaker Model are equivalent. The program, VHDL versus Gatemaker Model 107 , is launched after Generating Gatemaker Model 105 is complete. The Designer would receive Designer action data to correct errors and update the Schematic data and restart the program scheduler. Restarting the programs scheduler 401 would repeat the Schematic design process according to embodiments of the present invention.
[0047] The run time for the sequence Schematic related design programs, according to embodiments of the present invention, may be determined. The best case run time occurs when the Checking program in 102 completes first and there are no Logic changes. A normal case may be as follows in equation form:
running time=GenVim(time)+worst case of [(VHDL versus Schematic(time) OR Generating Gatemaker Model(time))AND(VHDL versus Gatemaker Model(time)OR Generating Gatemaker Model(time))AND Validation of Gatemaker Model(time).]
[0048] There are effectively two branches in the diagram of FIG. 1. The branch on the left (Checking program 102 and Continue 108 ) is not needed in a normal manual program submission process. Its purpose is just to speed up the process of running the Schematic design programs. The result of the Checking program 102 , may stop or keep the results of design programs (jobs) of the branch on the right (e.g., states 104 , 105 , 106 , and 107 ). The success of Checking program 102 may keep the results (grades) of a previous run of Schematic related design jobs. The branch on the right, GenVIM 104 , VHDL versus Schematic 103 , Generate Gatemaker 105 , VHDL versus Gatemaker Model 107 , and Validate Gatemaker Model 106 comprise the checking and modeling programs that are related to the Logic and rerunning these programs may not be needed for changes not related to the Logic. Stopping Schematic design programs related to the Logic (paths 3) from Interrupt Logic Program 108 when changes are only cosmetic errors allows rerunning (path 4) only Cosmetic errors programs 110 . The Cosmetic errors program 110 correct those errors which are known to not affect the Logic.
[0049] Embodiments of the present invention free the designer from keeping track of the various Schematic design jobs. If the whole process needs to be rerun due to cosmetic changes in Schematic, the designer just needs to “click one button” the expectation is that Schematic design pass will complete run error free. Embodiments of the present invention also speed up the Schematic design process because of the Checking program 102 which determines if changes made in error correction still conserve the Logic eliminating unnecessary re-runs.
[0050] [0050]FIG. 2 illustrates a flow diagram of steps in embodiments of the present invention. In step 201 both the Logic related programs (e.g., Gen Vim 104 , Checking 102 , VHDL versus Schematic 103 and Generate Gatemaker 105 ) are launched simultaneously. In step 202 , a test is run to determine if any changes are related to Logic. If the result of the test in step 201 is NO, then incomplete Logic programs are stopped in step 203 . Since Logic programs are launched in response to outputs from other programs, multiple programs may be running at this time. A test is done in step 204 to determine if any changes to the Schematic data are “cosmetic” (do not change the Logic). If the result of the test in step 204 is NO, then any launched Cosmetic programs 110 are stopped in step 212 . Then a test is done in step 206 to determine if all Logic related programs have completed successfully. If the result in step 206 is NO, then a branch to step 201 is executed in step 207 . If the result in step 206 is YES, then the Schematic design is complete in 211 . If the result of the test in step 204 is YES then Cosmetic data update programs are run in step 205 and then step 206 is executed as explained above. If the result of the test in step 202 is YES, the changes may contain both cosmetic and Logic changes. Therefore both steps 204 and 208 are executed. The branch to step 204 has been explained above. In step 208 , Logic related programs are launched. A test is done in step 209 to determine if there are any Logic program errors. If the result of the test in step 209 is YES, then step 210 the Logic program errors are corrected and step 206 is executed as explained above. If the result of the test in step 209 is NO, then the Logic related programs have run successfully and then step 206 is executed as explained above.
[0051] [0051]FIG. 3 is a flow diagram of another embodiment of the present invention. In step 301 both the Logic related programs (e.g., Gen Vim 104 ) are launched simultaneously. In step 302 , a test is run to determine if any changes are related to Logic. If the result of the test in step 302 is NO, then incomplete Logic programs are stopped in step 303 . Since Logic programs are launched in response to outputs from other programs, multiple programs may be running at this time. A test is done in step 304 to determine if any changes to the Schematic data are cosmetic. If the result of the test in step 304 is NO, then any launched cosmetic programs are stopped in step 312 . Then a test is done in step 306 to determine if all Logic related programs have completed unconditionally. If the result in step 306 is NO, then in step 307 the errors are corrected and a branch is executed to step 301 . If the result in step 306 is YES, then the Schematic design is complete in step 311 . If the result of the test in step 304 is YES then Cosmetic data update programs 110 are run in step 305 and then step 306 is executed as explained above. If the result of the test in step 302 is YES, the changes may contain both cosmetic and Logic changes. Therefore both steps 304 and 308 are executed. The branch to step 304 has been explained above. In step 308 , Logic related programs are launched. A test is done in step 309 to determine if there area any Logic program errors. If the result of the test in step 309 is YES, then in step 310 the Logic programs are completed and results are flagged as conditional and step 306 is executed as explained above. If the result of the test in step 309 is NO then the Logic related programs have run successfully and then step 306 is executed as explained above.
[0052] Referring to FIG. 5, an example is shown of a data processing system 500 which may use embodiments of the present invention. The system has a central processing unit (CPU) 510 , which is coupled to various other components by system bus 512 . Read-Only Memory (“ROM”) 516 is coupled to the system bus 512 and includes a basic input/output system (“BIOS”) that controls certain basic functions of the data processing system 500 . Random Access Memory (“RAM”) 514 , I/O adapter 518 , and communications adapter 534 are also coupled to the system bus 512 . I/O adapter 518 may be a small computer system interface (“SCSI”) adapter that communicates with a disk storage device 520 and/or a tape storage device 540 . A communications adapter 534 may also interconnect bus 512 with an outside network 541 enabling the data processing system 500 to communicate with other such systems. Input/Output devices are also connected to system bus 512 via user interface adapter 522 and display adapter 536 . Keyboard 524 , trackball 532 , mouse 526 , and speaker 528 are all interconnected to bus 512 via user interface adapter 522 . Display 538 is connected to system bus 512 and display adapter 536 . In this manner, a user is capable of inputting to the data processing system 500 through the keyboard 524 , trackball 532 , or mouse 526 , and receiving output from the system via speaker 528 , and display 538 . Data processing system 500 may employ software which uses methods according to embodiments of the present invention.
[0053] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. | A Schematic database defining a Schematic is checked and saved. Multiple programs affected by the Logic of the VLSI Schematic are launched along with a Checking program that extracts data related to the Logic of the VLSI Schematic design and other data that may be necessary but is not related to the Logic of the VLSI Schematic design. The Schematic design programs operate as executable program states with each program state having program data inputs and outputs and program logic inputs and outputs. Once the method is started, a designer simply corrects errors that occur and then restarts the Schematic design process If changes in the Schematic database do not affect the Logic then Logic related programs states are stopped and programs for correcting non Logic related changes are run. Program output data may be conditional with errors or unconditional without errors depending on operational modes. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of machining and more particularly to modifications allowing to ensure the tool exchange of a machining machine-tool under the best conditions.
2. Discussion of the Background
Machine-tools which today ensure very high speed machining, reduce the amount of time spent both in machining and part transfer and thus the time the tool is in use. Very high speed machining thus defines new criteria or at least more restrictive criteria in the time allowed to exchange tools, loading or unloading on the spindle(s), as well as loading and unloading in the tool magazine.
In fact, the tool exchange device of a very high speed machining machine-tool must be able to ensure under the best conditions, the following functions:
unloading from the spindle of the tool just being used,
its storage in a storage device,
the engagement of the tool in a storage device,
the loading of the tool on the spindle.
Another criterion to be added to that of speed is the quantity of tools offered by the said storage device. It is classical to use a rotary storage device so as to present the device ensuring the engagement of the tool as fast as possible with a free housing to house the tool having just been used, and after, by rotation of the device, to present the tool to use in the next machining stage.
Even though such a device, called with turret, answers perfectly to the needs of a machine-tool using a limited number of tools, it is not adapted to the case when the machining stage of the piece to be machined by the machine-tool, requires the use of a large number of tools.
It is nevertheless possible to make a larger number of tools accessible by doubling the number of turret devices which requires two tool exchange devices or at least doubles the space needed.
Amongst the turret devices, the rotary storage device described in the French patent No 2 748 225 which comprises a multiplicity of tools arranged on its periphery is known in the prior art. During tool exchange, the turret enters by rotation in the machining zone, a ram carrying a mobile electric spindle on three axes puts the tool having been used in the previous machining stage in an empty housing of the turret and takes, after a suitable rotation of the turret, the tool which is needed in the next machining stage.
The limitations of a turret device are as follows:
the number of tools is very limited,
the rotary movements of a turret carrying a large number of tools should be ensured by an oversized motorisation,
the turret should be of a very large diameter,
the doubling of turrets is not enough to supply enough tools for some applications,
the loading and unloading of tools during the function of machining is not possible,
the ram waits for the rotation of the turret before it can take the tool needed to be used in the following machining stage.
In the prior art there also exists a device in which the tool housings are integral with one another as well as with a driving means, thus constituting a chain moving to present, at the level of the exchange zone between the storage device and the machining station, either the empty housing to retrieve a tool having been used, or a housing containing the tool to be used in the next machining stage. It is obvious that the number of tools can be very large for such a storage device. Nevertheless, this same number of tools also determines the speed to go from one tool housing to another. Consequently, the more tools there are, the slower the speed to ensure storage of the tool having been used and to bring to hand the tool to be used.
SUMMARY OF THE INVENTION
The research of the applicant have therefore been oriented towards a high capacity tool storage and tool exchange device respecting the speed criteria defined by very high speed machining.
The inconvenience of increasing the number of tools, in relation to a classical device of a classical tool exchange, is that it increases the amount of time needed to unload the tool as well as to bring it towards the exchange zone between the tool storage and tool exchange device and the ram, due to the fact of increasing the travelling distance. The applicant has thus carried out research to also reduce the time of the functions mentioned above, research which has led to the original conception of a particularly new and inventive high capacity tool storage and tool exchange device obviating the inconveniences mentioned above and offering optimised tool storage and tool exchange functions.
According to the main characteristic, the tool storage and tool exchange device of a high speed machining machine-tool comprising a horizontal ram receiving a tool on its end, is remarkable in that it is made of the following parts:
a tool storage module comprising, inside a sealed chamber, a multiplicity of aligned housings receiving the tools so that the axes of those tools are parallel with the axis of the ram and form part of a same vertical storage plane,
a handling module which, moving in a vertical plane parallel with the tool storage vertical plane, ensures loading or unloading of at least one housed tool and its transport in the aforesaid chamber, along a direction parallel with the axis of the ram, from its housing towards an exchange zone with a third module and vice-versa, and
a transfer module ensuring transport of the tool present in the ram from an exchange zone with the ram towards the exchange zone with the handling module to transmit the tool to it, and vice-versa.
This characteristic is particularly advantageous in that it adds an intermediary module in the movement of the tool from its storage zone to its zone of use. In fact, it is not the transfer module which ensures the loading or unloading of the tool in the storage module, but the handling module. Inversely, it is not the handling module which ensures passage of the tool from the storage zone to the ram, but the transfer module.
So, by adding an intermediary element, it is parfectly possible to realise most classical functions of a tool storage and tool exchange device at the same time.
So, for example, the transfer module of the tools ensures the removal of the tool carried by the ram and its replacement by another tool while the handling module places another tool in the storage magazine. Alternatively, while the transfer module is ensuring the replacement of a tool, the handling module can get a new tool from the magazine.
The addition of an intermediary module therefore allows to carry on and not stop the machining when the handling module unloads a tool having been used and/or finds another tool. Consequently, the size, volume or capacity in tools of the tool storage module conceived by the applicant, does not affect the speed of tool exchange of the device of the invention, as the route to unload, load and transport from the exchange zone, between the transfer module and the handling module, towards the tool storage module and vice-versa, is taken on by a module independant of the one which ensures transfer.
This disposition demarcates itself from the prior art devices which, as in the case of a turret, oblige machining to stop when the tool storage device is rotating to present a housing to take the tool which has just been used and another housing containing the tool to be used in the new machining stage.
Contrary to the storage devices of the prior art which had a tendency to group together all the functions in the one and same device, this new tool storage and tool exchange device concept is particularly inventive in that it separates the principal functions of such devices in three modules so that these modules can each function independently.
In addition, the arrangement in which the axes of tools arranged parallel to the axes of the ram, (the tools being oriented in the direction of the machining) garantees a minimum of additional movement during the transport and the tool exchange. This arrangement is particularly advantageous in that the change of direction of a tool for transport means can require some significant speed increases. Consequently, the change of direction of the tool, as for example, in going from a position perpendicular to the axis of the tool carrier ram to a parallel position, can lead to a change in the efforts necessary for gripping and thus require means to grip and to move oversized tools.
The disposition of the tools according to which their axes are all parallel and included in a same vertical plane parallel to axis of the ram, has for advantage, apart from the fact that it avoids additional movements while moving, that it minimizes the width requirement of the combined machine-tool—tool magazine.
To complete the addition of an intermediary in the transport and tool exchange line of the machine-tool, from the ram to the tool magazine and vice-versa, the applicant has judiciously conceived the said handling module comprises two arms which are each fitted at their ends with a tool gripping mechanism, and which are arranged one on top of the other in a same vertical plane perpendicular to the aforesaid vertical plane of the tool storage. These arms take two positions, i.e.:
a first extended position of loading and unloading tools when the gripping mechanism becomes in line with the axis of the cradle,
a second folded position of tool transport when the gripping mechanism moves away from the vertical plane of storage.
This disposition enables to move two tools at the same time or at least to keep one gripping mechanism free from the engagement of a tool presented by the transfer module.
In combination with the doubling of gripping mechanisms of the handling module, the applicant has conceived a transfer module with two gripping means. This disposition where the transfer module has two gripping means has not only the advantage of being able to ensure the gripping of the tool having just been used and to present by way of a second gripping means the tool to be used in the next machining stage in the same movement of the transfer module coming in its exchange zone towards the ram, but also to allow limiting the duration of tool exchanges between the two transfer and handling modules.
Limiting the duration of the exchange between the different modules reduces the number of operations despite adding an intermediary element. Thus, the storage device of the invention comprising the following three modules,
a storage module,
a handling module and,
a tool transfer module,
the said handling and transfer modules being each fitted with two gripping means is remarkable in that it satisfies both the criteria for the capacity relating to the number of tools and also to the speed of loading and unloading the tools.
This device which provides optimal satisfaction in relation to the new criteria created by high speed machining, leads to, in view of its new and inventive conception, a particularly new and inventive operating process of which the different stages will be defined in the following description.
Although, the fundamental concepts of the invention have just been detailed hereinabove in their most elementary form, more details and characteristics of the invention will come out more clearly when reading the description hereinafter using, as a non limitative example and having regard to the attached drawings, an embodiment of a tool storage and tool exchange device according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general schematic view of a tool storage and tool exchange device, in accordance with the invention, placed on its right side against the frame of a high speed machine-tool.
FIGS. 2 a , 2 b , 2 c , 2 d , 2 e , 2 f , 2 g are schematic front views of the combined machining machine-tool—storage device with the storage device placed on its left side against the frame of a machining machine-tool; these figures illustrate the movements and functions of tool exchanges and tool transfers between the different modules of the device in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated on the drawing of FIG. 1, the tool storage and tool exchange device of the invention referred to as D as a whole for a high speed machining machine-tool M comprising a horizontal ram C receiving a tool O at its end, is made up of the following parts:
a tool storage module 100 comprising, inside a sealed chamber 110 (shown in broken lines), a multiplicity of aligned housings 120 receiving tools O so that the axes of the tools are parallel with the axis of the ram C and are part of a same vertical storage plane,
a handling module 200 which, moving in a vertical plane which is parallel with the vertical plane of the storage of tools O, ensures loading or unloading of at least one tool O in a housing 120 and its transport in the aforesaid chamber 110 , along a direction parallel with the axis of ram C, from its housing 120 towards an exchange zone with a third module 300 and vice-versa, and
a transfer module 300 which ensures the transport of the tool O present in the ram C towards the exchange zone with the handling module 200 to transmit the tool to it, and vice-versa.
According to the invention, the said housings 120 of the aforesaid storage module 100 are each constituted by a cradle which, accessible on one side, holds tool O by gravity. The use of gravity to ensure the holding of the tools enables avoiding having any gripping means in the storage module 100 .
Also, according to a preferred but non limitative illustrated embodiment, the said cradles 120 are arranged on the vertical plane on which they are fixed according to the same distance between two axes in height and the same separation along the length. This particular disposition has for advantage to offer a storage module 100 which is one hundred per cent dedicated to tools 0 of a certain diameter, while still allowing the storage of bigger tools in freeing the adjacent cradles 120 .
As illustrated, when the machining machine-tool M comprises a frame B of mainly parallelepiped shape, the said cradles 120 are fixed advantageously by means of their closed side to a lateral side of the frame B of the aforesaid machining machine-tool M. This characterisitic combined with the disposition in a same vertical plane and parallel with the axis of the ram of the tools axes are such that the presence of a high capacity storage module 100 does not increase by much the width of the combination.
According to a particularly advantageous characteristic of the invention, the said cradles 120 are open on their top and take the shape of an arc of a circle of which the bisecting line of the angle formed by both ends of the arc and the center of the cradle 120 is tilted along an angle α in relation to the horizontal axis of the said cradle 120 . The object of this tilting is to ease by gravity the holding of the tools present in the said storage module. According to a preferred but non limitative embodiment and such as illustrated, angle α is equal to 15° in absolute value.
According to the illustrated embodiment, storage module 100 is constituted by four vertical uprights 130 on which are fixed the closed sides of the cradles 120 thus forming some vertical ramps, for storing the tools, integral with a side of the frame of machine-tool M. Each ramp being independent, it is easy to imagine that such ramps can be added, removed, brought nearer or further so as to offer a very evolutionary storage module 100 .
The applicant has also conceived, for the storage device D of the invention, an interface with the outside, i.e this interface allows to add, remove or exchange the tools in the storage module 100 . In order to fulfill this function which is not illustrated, a first solution involves one part of the cradles 120 of the said storage module 100 being mounted moveable and integral with an opening device so that, when set in motion the said moveable cradles can be accessible from the outside of the chamber 110 of the said storage module 100 and can allow either loading, unloading or the exchange of the tools 0 from outside by the operator or an automatic device. Thus, when a tool must be replaced, handling module 200 removes it from the housing in which it is stored and takes it towards a detachable housing so that this tool is removed from the sealed chamber 110 of the storage module and is replaced or not by a new tool. According to a preferred embodiment, these cradles are mounted on slide blocks guiding them in a translatory movement towards the outside like the movement of a drawer. It is of course the independence of each module which allows the changing or replacement of tools during the machining process.
According to a second solution, a part of the cradles is detachable in that the said cradles are integral with a removable case which can move back and forth in the chamber 110 of the said storage module 100 so as to allow either loading, unloading or exchange of tools from the outside. This solution is particularly suited for changing or replacing tools O by means of an automated arm or at least by an automated device but can easily be put into place by an operator.
According to a particularly judicious technical disposition, the base of the chamber 110 of the storage module is constituted by a swarfs collecting device.
According to the invention, the said handling module 200 comprises two arms 210 and 220 which, each fitted at its end with a gripping mechanism 230 and 240 of the tools O, are arranged one on top of the other in a same vertical plane perpendicular with the aforesaid vertical tool storage plane, the said arms 210 and 220 taking up two positions i.e.:
a first extended position of loading and unloading tools O when the gripping mechanism 230 or 240 comes in line with the axis of the cradle 120 ,
a second folded position of transporting tools O when the gripping mechanism 230 or 240 moves away from the vertical storage plane.
According to the preferred embodiment illustrated with more details on the FIG. 2, the two arms 210 and 220 are moved simultaneously by a one and same actuator. The simultaneous movement of both arms from a folded or a transport position, during which the gripping mechanisms 230 and 240 are separated from the vertical storage plane, to an extended position in which the gripping means are positioned, in order to be in line with the cradles 120 and vice-versa, by a one and same actuator has for advantage to reduce the number of components as well as to simplify the working of such a handling module 200 .
In addition, in order to adapt to the particular disposition of the opening of the cradles 120 , the simultaneous travel of both arms 210 and 220 of the aforesaid handling module 200 is achieved along an angle (−α) in relation to the horizontal so that it can at its best come to take and to drop the tools O in the cradles 120 .
Both gripping mechanisms 230 and 240 placed respectively at the end of arms 210 and 220 have the advantage of being controlled separately.
Therefore, even though the setting in motion of the arms 210 and 220 is simultaneous, the engaging or freeing of the tools by the gripping mechanisms 230 and 240 is controlled independently from one gripping mechanism to another.
In refering to the drawing on FIG. 1, it will be noticed that the said handling module 200 comprises a subset of setting in motion ensuring movements in a straight line in a vertical plane parallel with the tool storage plane, by means of a vertical logical structure 250 comprising vertical guide rails 251 and 252 and horizontal rails 253 and 254 on which the handling module 200 moves.
In the eventuality that the specifications of a tool storage and tool exchange device in accordance with the invention would require extremely fast movements for the handling module 200 , the applicant has conceived that the said handling module 200 can be driven by linear motors.
A particularly advantageous, but not illustrated, characteristic of the handling device 200 is that the aforesaid gripping mechanisms are in two parts:
an actual clamping part constituted by a clamping device coming to clamp the tool O,
and an indexing part ensuring the straightening of the angular positioning of the tool O in relation to its rotation axis.
In this aim, the said clamping device of the aforesaid gripping mechanisms 230 and 240 is made up of
on one hand, a fixed tool positioning and resting fork which receives the tool O between both its branches and,
on the other hand, a means of keeping it in a mobile position which in order, to close the said clamping device, comes to rest axially on the tool O so as to keep this one in position on the fixed tool positioning and resting fork. Consequently, differing from classical gripping devices, the gripping mechanisms 230 and 240 of the invention, do clamp to ensure via a means of axially resting on the said tools O, to keep the said tools O in position on a fixed fork for resting on of which the branches receive the tool O but do not move to ensure clamping.
The non illustrated indexing part, comprises a plate which, coming into position at the rear end of the tool O engaged in the clamping device of the gripping mechanism 230 or 240 , comprises lugs on springs retracting on a filled part of the rear of the tool O engaged in the said clamping device and rising on its hollow part.
According to a particularly judicious choice of conception, the plate of the indexing part is integral with the means to keep in mobile position and ensures the straightening of the angular position of the tool O during the closing movement of the said clamping device.
The angular indexing of the tools O is particularly important. In fact, classically the electric spindle or at least the driving means of the tool O cannot auto-index the angular position of the tool O which it will drive, but can nevertheless always stop in the same position. So, in order to engage tool O, it is necessary that the tools O be presented to ram C along the same angle.
From the moment that the cradles 120 hold the tools O by gravity, it was then particularly important that the handling module 200 angularly index the position of the tool O during its engagement and transport as well as during its unloading. The advantage of the retractability of the angular indexing lugs is that they do not interfere with the clamping of the tool O when the said tool does not have a hollow part at its rear end.
In addition, due to the fact that the fork of the gripping mechanisms 230 and 240 stays fixed, the centering of the tool O in relation to the axis of the cradle made up by this fork can be judiciously executed by means of a centering cone integral with the aforesaid means to keep in position coming to rest on the rear of the tool O during the closing of the clamping device.
As the handling module 200 always takes, transports and presents the tools O along the same angle, the transfer module 300 must respect this criterion by moving the tools O from its exchange zone with the handling module 200 to its exchange zone with the ram C.
According to the invention, the said transfer module 300 comprises two gripping means 310 and 320 which, coming to face the gripping mechanisms 230 and 240 of the aforesaid handling module 200 , in the exchange zone of the latter, to receive the tool O to be used and give back the tool O having just been used, take up in the exchange zone with the ram C and in the plane perpendicular with the rotation axis of the tools O, at least one position so as to receive the tool O having just been used and present the tool O to be used in a same angular position in the exchange zone with the ram C and in a perpendicular plane with the rotation axis of the tool O.
As illustrated, a first gripping means 310 of the aforesaid transfer module 300 adopts a rotation path about a first fixed point A integral with the frame B and a second gripping means 320 takes up a movement which, controlled by the revolving movement of the first gripping means 310 ensures a change of angular positioning of the said second gripping means 320 in relation to the first one 310 .
In fact, to save space in the machining zone, the tool carrier ram C of the machining machine-tool M stays fixed in the movements plane perpendicular with the axis of rotation of the tools O during tool exchange. The fixed position of the ram C during the tool exchange stages thus requires that both gripping means 310 and 320 of the transfer device 300 come into position exactly in the same way one after the other in the exchange zone with the ram C.
Furthermore, as illustrated on the drawing of FIG. 2 b , the rotation movement of the said transfer module 300 is combined with a translatory movement of a protection hood 400 separating the exchange zone between the handling module 200 and the transfer module 300 of the machining zone.
As illustrated on the drawing of FIG. 2 a , the said second gripping means 320 of the transfer module 300 is integral with a plate 321 pivotally mounted in relation to the first gripping means 310 , the said plate 321 being slidingly connected with a slide bar 322 pivotally mounted about a second fixed point E of the frame B, the separation between the aforesaid pivoting first fixed point A and the aforesaid pivoting second fixed point E being such that the gripping means 310 and 320 are angularly oriented one in relation to the other so that both gripping means 310 and 320 always keep the same angular orientation on a common point in their path.
The device conceived by the applicant and having been described above adopts an operating process of which the different stages follow the cycle illustrated by the whole of FIGS. 2 .
As illustrated on the drawing of FIG. 2 a , the handling module 200 is in its transport position and comprises a first free gripping mechanism 230 and a second gripping mechanism 240 with a first tool O 1 , a machining function is taking place by means of a second tool O 2 , the transfer module 300 is facing the handling module 200 with a first gripping means 310 holding a third tool O 3 facing the first free gripping mechanism 230 of the handling module 200 and with a second free gripping means 320 facing the said second gripping mechanism 240 holding the first tool O 1 .
The drawing on FIG. 2 b illustrates an intermediary position when the handling module 200 moves away from the exchange zone with the transfer module 300 so as to put in the cradle the first tool O 1 . With this aim, the two arms 210 and 220 ensure a tilting movement translatory towards the storage module 100 ; the first gripping mechanism 230 staying in open position, the second gripping mechanism 240 holding the tool O 1 opening so as to free the said tool, the protection hood 400 synchronised with the pendulum movement of the transfer module 300 is retracted, the machining is stopped and the ram C moves towards its fixed position for tool exchange at the level of which the free gripping means 320 of the transfer module 300 has taken position.
The drawing of FIG. 2 c illustrates an intermediary position, during which the two arms 210 and 220 of the handling module 200 are in transport position with their respective gripping mechanisms 230 and 240 free, the handling module 200 being on standby while the ram C has taken its fixed transfer position so that the second tool 02 is engaged with the free gripping means 320 of the transfer module 300 and with the ram C reversing, the said ram C breaks away from the said second tool O 2 . The transfer module 300 is in the same position as the one illustrated in FIG. 2 b , the axis of the ram C being aligned with the axis of the cradle defined by the free gripping means 320 so that the two branches 323 and 324 close themselves on the tool O 2 on a surface destined for the gripping of the tools O.
FIG. 2 d illustrates an intermediary position in which the handling module 200 moves and opens its arms 210 and 220 while controlling its first gripping mechanism 230 to make it engage with a fourth tool O 4 , the second gripping mechanism 240 staying free, while the transfer module 300 tilts to present the third tool O 3 in fixed tool exchange position so that with the ram C moving forward it comes integral with the third tool O 3 . The gripping means 310 places the third tool O 3 in line with the axis of the ram C and in the same angular position as the second tool O 2 when it stops.
FIG. 2 e illustrates an intermediary position in which, the arms 210 and 220 of the handling module 200 come back in transport position so that the said handling module 200 brings the fourth tool O 4 of the storage module 100 towards the exchange zone of the handling module 200 with the transfer module 300 while the ram C frees the third tool by moving along a plane perpendicular to the rotation axis of the tools O.
FIG. 2 f illustrates a position in which, the handling module 200 is in transport position in its exchange zone with the transfer module 300 with the fourth tool O 4 in its first gripping mechanism 230 , while the transfer module 300 tilts from its exchange zone with the ram C towards its exchange zone with the handling module 200 with the second tool O 2 in its second gripping means 320 and so that the first 310 and the second 320 gripping means of the transfer module 300 face respectively the first 230 and the second 240 gripping mechanisms of the handling module 200 , the tilting causing the protection hood 400 to fit back in place, a machining function starting with the third tool O 3 .
FIG. 2 g illustrates an intermediary situation in which, the handling module opens its arms 210 and 220 so that the fourth tool O 4 present in the first gripping mechanism 230 comes engaged with the first gripping means 310 of the transfer module 300 and that the second tool O 2 engaged in the second gripping means 320 enters in the second gripping mechanism 240 of the handling module 200 , the latter then controlling the opening of the first gripping mechanism 230 and the closing of the second gripping mechanism 240 so that when the handling module 200 goes back in its transport position, the second tool O 2 is present in the second gripping mechanism 240 and the fourth tool O 4 is engaged with the first gripping means 310 of the transfer module 300 , while a machining function is taking place with the third tool O 3 reproducing the initial situation illustrated by the drawing on FIG. 2 a.
It is understood that the description and illustration just given hereinabove of the tool storage and tool exchange device of a machining machine tool and operating process of such a device are given for the purpose of disclosure and not limitation. It is obvious that various arrangements of, as well as modifications and improvements to, the example here above will be possible without departing from the scope of the invention taken in its broadest aspects and spirit. | A tool storage and tool exchange device of a high speed machining machine-tool having a horizontal ram that receives a tool. The exchange device includes a tool storage module that has a multiplicity of housings receiving the tools, a handling module that loads or unloads at least one tool from a housing and transports the tool from the housing toward an exchange zone with a transfer module, and a transfer module that transports a tool present in the ram from an exchange zone with the ram toward the exchange zone with the handling nodule and vice-versa. The multiple modules allow simultaneous execution of different operations by a tool storage and tool exchange device. | 1 |
TECHNICAL FIELD
The present invention concerns a method and apparatus for producing fibre yarn by first extruding a fibre suspension through a nozzle, removing excess water, and finally, by drying the yarn.
Especially an embodiment of the invention concerns a method and apparatus for dewatering the yarn and for twisting the yarn from extruded suspension to dried yarn.
BACKGROUND
Many different types of yarns made of natural fibers are known in the art. One well known example is paper yarn, which is traditionally manufactured from paper sheets. The first and only industrial method was developed in the late 19th century in Germany. It has been refined over time but the basic principle has remained the same and it is still in use today. Typically, paper manufactured from chemical, mechanical or chemi-mechanical pulp is slit to strips (width typically from 5 to 40 mm), which are twisted to thread. Said thread may be subjected to dyeing and finishing. The product (paper yarn) has limited applications because of deficiencies in its properties, such as limited strength, unsuitable thickness, layered or folded structure, and further, the manufacturing method is inefficient.
Cotton is very widely used as raw material in the manufacture of yarns and ropes. However, the cultivation of cotton requires significant water resources and it is widely carried out in regions where there is shortage of water and food. When available water is used for the irrigation of cotton fields, the situation with regard to food supply becomes worse. Thus the use of cotton does not support sustainable development, and there is a need for alternative sources of fiber, suitable for replacing cotton at least partly.
Cotton farming covers 5% of the world's farming area but it uses 11% of all agrochemicals. Intensive farming of cotton has caused pollution to the waters, wear of the soil and it has changed the animal population. In the future highly pollutant cotton can be replaced by cellulose based materials. There are already alternatives to cotton. Rayon is a material produced from cellulose fibers but it still requires heavy chemical treatments.
Methods for producing fibre yarn and other products from cellulosic materials are described in documents JP 4004501 B, JP 10018123, JP 2004339650, JP 4839973, EP 1493859, CN 102912622, CN 101724931, WO 2009028919 and DE 19544097. The methods described usually include chemical treatment of cellulose before or during manufacture of the product.
SUMMARY OF INVENTION
Production of yarn directly from fibres, such as pulp fibres, without a dissolution process or disintegration of the fibres to nanofibres would increase the efficiency and ecofriendliness of the yarn manufacturing process. It would also decrease the raw material cost significantly. Currently there is no industrial scale fibre yarn manufacturing process available for producing fibre yarn from said fibres. Fibre yarn products are produced of cotton yarn, different viscose process yarns etc. Currently there are many attempts to produce yarn from NFC.
For the above reasons, it would be beneficial to provide a method and apparatus for producing yarn directly from cellulose fibres in a manner that is commercially exploitable in industrial scale.
In a first aspect, the invention relates to a method/apparatus for taking advantage of new material by forming it mechanically into a yarn and enabling of producing environmentally friendly material which can substitute cotton and rayon.
Generally speaking the object of the invention is achieved by a novel method and apparatus as defined by the claims.
One embodiment of the invention provides a device and method that can produce cellulose based yarn continuously.
According to other aspects and embodiments of the present invention, the invention provides a yarn product that is cheaper than comparative product made of cotton.
According to one further aspect of the invention, the invention provides new use of wood and other vegetable fibres.
An embodiment of the invention is based on feeding pulp fibre suspension, such as pulp fibre suspension, from a nozzle on a first wire sieve, transporting the suspension on the first sieve to a nip formed by the first and a second sieve having a machine travel direction different from that of the first sieve for twisting and rotating the yarn to be formed between the wire sieves.
According to one embodiment, the relative machine travel directions of the at least two sieves is adjustable.
According to one embodiment, the gap between the at least two wire sieves narrows in the machine travel direction.
According to one embodiment of the invention, the gap between the at least two wires is adjustable.
According to one embodiment of the invention, at least one vacuum suction box is arranged on opposite side of at least one of the wires in relation of the wire gap.
According to one embodiment of the invention, the apparatus is equipped with at least one heating element for drying and treating the yarn to be manufactured.
The various embodiments of the invention provide essential benefits.
New method described herein for producing cellulose based yarn is cleaner to the environment compared to, for example, use of cotton and it can use harvesting surplus of wood and other cellulosic plant material. Finland's harvesting surplus of cellulosic material alone could replace 20% of the world's cotton demand. This device enables industrial scale fibre yarn production using technologies currently available in pulp and paper industry. The invention provides a possibility to create new field of industry and open totally new uses to northern wood fibres.
By the method and apparatus of the invention a fibre yarn can be made of pulp mass that need not be excessively chemically or mechanically processed. The fibre yarn can be used to replace yarn made of other materials. Further, the yarn can be used in new applications utilizing characteristic properties of the fibre yarn such as twistability. The fibre yarns can be recycled several times just like paper or board. The fibre material of the fibre yarn can be sourced from several sources. Wood fibre is suitable but also fibre materials used for manufacture of paper or board can be used as raw materials. The twisting to the yarn inherent for the inventive method increases the strength and elasticity of the yarn as it increases contacts between the fibres in the yarn, i.e. cross linking.
Other objects and features of the invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are intended solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic side view of one embodiment of the invention.
FIG. 2 is a schematic cross section of a nozzle that can be utilized for realizing the invention.
FIG. 3 is a schematic perspective view of one embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
Definitions:
Machine travel direction is the direction the sieve wires over their operating zone. Return travel direction is the direction on which the sieve wire loop runs on return side.
Operating zone of the wire sieve is the part of the sieve wire loop on which the yarn to be manufactured travels when it is processed.
Centerline of the wire is the centerline of that part of the wire loop on which the yarn to be manufactured travels when it is processed.
Pulp is considered to be mechanical, chemi-mechanical or chemical pulp mass wherein fibres have not been dissolved or disintegrated to nanofibres.
Starting point for this invention is a new method for the manufacture of fibrous yarn for connecting cellulose fibers to solid material. The method is disclosed in WO 2013/034814, which is included herein as reference. The main application for the material was the producing of the yarn by connecting fibers continuously together.
Main functions of this device are dewatering and forming of the cellulose yarn. Based on experiences from manual laboratory scale manufacturing moisture and excess water should be compressed out of the yarn while the yarn is simultaneously twisted to achieve the final form and to maintain the round cross section of the yarn during pressing.
According to the invention the pulp fibre suspension, such as pulp fibre suspension, is extruded between two angled wire sieves and the compression of wire sieves dewater the yarn and angular force element rotates and twists the yarn and the yarn will achieve its final form. The final result would resemble ordinary cotton yarn.
The proper parameters for producing the yarn such as speed, pressure and rotating angle affect to the quality and properties of the yarn. Other significant parameters include the angle of the nozzle, the speed difference between the respective speeds of the sieve and the fiber suspension 13 , which speed difference results in the stretching of the yarn, as well as speed difference between the respective speeds of formation part and drying part.
The embodiment in FIG. 1 comprises a first, lower sieve wire 1 arranged to run in a loop over guide rolls 2 . On the loop is formed a straight part between first guide roll 3 and second guide roll 4 . A second wire sieve 5 is arranged to run on a loop against the straight part of the first wire sieve 1 so that a gap 6 is formed between the wire sieves 1 , 5 . The gap between the two wire sieves 1 , 5 is arranged to narrow in the machine travel direction by guiding the second wire sieve 5 by third and fourth guide roll. This provides a narrowing pressurized gap for removing water from the pulp fibre suspension. The wire sieves 1 , 5 form a narrowing nip that is positioned to begin, in the machine travel direction, after the first guide roll 3 of the first wire sieve 1 . The first guide roll 7 of the second wire sieve 5 is positioned downstream of the first guide roll 3 of the first wire sieve 1 so that that an open space is formed on the first wire sieve 1 on the distance between the first guide roll 3 of the first wire sieve 1 and the first guide roll 7 of the second wire sieve 5 . The operation zone of the formed between the first and second guide rolls 3 , 4 of the second wire sieve 1 .
A nozzle 9 is positioned at the beginning of the operation zone of the apparatus over the open space of the first wire sieve 1 for feeding a pulp fibre suspension 13 on the first wire sieve 1 . On the opposite end of the operation zone is winder roll 11 or corresponding winding apparatus for collecting the manufactured yarn. The second guide roll 8 of the second wire sieve 5 and the second guide roll 4 of the first wire sieve 1 are spaced apart so that open space is formed on the first wire sieve 1 between these guide rolls 4 , 8 . Over this space optional heaters 12 can be placed. Suitable heaters are infrared heaters, hot air dryers or other known dryers or heaters used for example in paper, pulp and board industry. A suction box 14 for removing water and moisture from the yarn through the wire sieve can be placed on opposite side of each wire sieve 1 , 5 in relation to the yarn to be formed. In this example one suction box 14 is placed under the first wire sieve. The wire sieves 1 , 5 and winder roll are rotated by driven guide rolls, for example by means of electric motors or corresponding actuatiors.
Yarn is manufactured by the above described apparatus by feeding pulp fibre suspension over the first wire sieve 1 so that the running wire sieve 1 transfers the suspension to the nip of first and second wire sieve 1 , 5 . In the gap the yarn to be formed is twisted and rotated and pressed against the surfaces of the wire sieves 1 , 5 . This action removes water effectively and forms a good quality yarn.
One embodiment of a nozzle suitable for implementing the invention is shown in FIG. 2 , depicting a cross-section picture of a nozzle 9 . In this embodiment a circular nozzle is shown. The fiber suspension 13 is fed through the inner die or orifice 17 and if salt or other chemicals 15 are used for crosslinking, they may be fed through outer die or orifice 16 . Other cross-section geometries besides circular may as well be used, such as elliptical or rectangular. When the fibre suspension is pushed through the nozzle it has a velocity and narrow to a circular thin line 18 of fibre suspension. The diameter of the suspension line is defined by exit speed of the suspension 13 and speed of the first wire sieve 1 on which the suspension is fed.
Moist yarn obtained from the nozzle 9 initially contains water typically from 30 to 99.5% w/w. In the dewatering step the solid content of the yarn may be adjusted to desired level until all free water is removed.
The nozzle 9 forms a jet causing the gel formation. The nozzle is designed so that the flow accelerates and orients the fibres inside the nozzle. The crosslinking fluid merges with the fibre suspension outside the nozzle and the gel is formed. To maintain the round shape of the yarn in the wire section the yarn has to be twisted and rotated during the dewatering. This is done by tilting one of the wire sieves so that there is an angle difference in the wire machine direction alignment. Dewatering speed is adjusted by changing the wire gap 6 in machine direction and by vacuums. Jet to wire speed difference changes the tension and stretches the yarn. Wire tension and wire gap causes also pressing of the preformed yarn to the wires.
FIG. 3 shows one embodiment of the apparatus according to the invention. It must be noted that parts and designs not shown in FIG. 1 but shown in FIG. 3 should be considered to be present in both embodiments when functionally needed as some of the part s are shown only in one figure for clarity. In here, the first wire sieve 1 is guided by three guide rolls. These rolls are mounted on a fixed (lower) frame part 19 . Second wire sieve 5 is mounted through its guide rolls to a movable (upper) frame part 20 that is movably mounted on the fixed frame part. An actuator 21 is used for adjusting the relative position of the movable frame part 20 and the fixed frame part 19 . This allows for adjusting the relative positions of the wire sieves 1 , 5 .
The method and apparatus is most suitable for producing yarns using the teachings of WO 2013/034814 that discloses a method for producing cellulose based yarn. The results from earlier experiments show that material properties of this new type of cellulose yarn are promising and good quality yarn has already been made. Previous experiments are made in laboratory scale and produced yarns have not been long enough for making e.g. fabric out of them. This problem can be solved by means of the invention.
Initial shape of the yarn is achieved through fast suspension crosslinking right after the nozzle 9 before the suspension hits the wire. In the nozzle rheology modifiers prevent clogging and the fibres are oriented with the flow. Different compounds are pumped through the nozzle with synchronized speeds and as they get mixed, the crosslinking prevents further mixing and initial dewatering with gravity.
Wet gel yarn 18 is extruded directly to the first wire sieve 1 , which conveys the material between first and second wire sieves 1 , 5 . When the preformed yarn encounters the second, in here upper, wire sieve 5 , water begins to be pressed out of it. The diameter of yarn decreases when it moves along between the wire sieves 1 , 5 . Wire sieves 1 , 5 are aligned so that the gap 6 between them decreases when approaching the output point and an angle difference in machine travel direction (X-Y) direction between the centerlines of the wire sieves 1 , 5 rotates the yarn while pressing.
All free water is removed by pressing and twisting the yarn between the wire sieves 1 , 5 . At this point the strength of the yarn is sufficient for reeling and the final dewatering takes place there. Also further drying of the yarn may be included to this device as described in narration of FIG. 1 .
Angular adjusting of the wires is implemented by two-pieced frame 19 , 20 . Fixed (lower) frame part 19 is solid and movable (upper) frame part 20 can be rotated as depicted by an arrow in FIG. 3 . Movable frame part 20 rotates along two conductors and it is lockable. Conductors permit slight movements also in horizontal plane. It is clear that a person skilled in the art can design various options for implementing this relative movement.
Frame of the device is designed to be easy to adjust and maintain.
The frame of the device is required to have high stiffness because rolls are attached only from one end and they must stay well aligned to get the yarn to uniform quality. Adding features and modifying the placement of the rolls for possible upcoming needs should be easy. It is clear that construction of the frame is not limited to the example shown.
The speeds of the wire sieves 1 , 5 are preferably accurately adjustable to get the operating speed synchronized with the pump that is feeding the material through the nozzle 9 . The operation of wire sieves can be accomplished individually with two PC controlled AC servo motors. The velocities can be automatically synchronized to each other by giving the amount of deviation in angularity of wires.
A fully functional and highly adjustable device for dewatering and forming cellulose yarn can be designed and manufactured according to the invention.
Main production parameters that effect each parameter on the form of yarn are wire sieve speed, rotating angle (angle between the wire sieves) and space between the upper (second) and the lower (first) wire. By changing the wire sieve angle in X-Y plane the force rotating the yarn at horizontal plane is changed. Gap between the wire sieves affect the compression pressure and it can also change the yarn rotation by changing friction force.
In a fully operating manufacturing facility it would be foreseeable to arrange a plurality of parallel nozzles to produce yarn on several production lines simultaneously. After the production stage described above with reference to FIGS. 1 to 3 the simultaneously produced plurality of yarns may be wound together to form one or several thick yarn(s). Such a thick yarn consisting of said individual yarn may then be wound to a roll with or without a supplementary treatment stage of applying suitable chemicals for a particular desired effect.
Rough adjusting for these parameters can be based on results of visual inspection of the yarn. The main goal of the invention is to produce yarn continuously. The specific properties of yarn (constant diameter, tensile strength) can be adjusted by changing operating parameters. The results of the preliminary tests run on the invention were promising and established solid basis for future research.
The purpose of the invention is to provide a device to continuously produce yarn directly from a fibre suspension, preferably pulp fibre suspension. The way of turning fibre suspension into a yarn is completely new.
The device can be easily adjusted to manufacturing needs. The apparatus according to the invention can produce cellulose yarn continuously at very high speeds. Even higher speeds than 10 m/s are possible but then at least motors and drive pulleys needs to be dimensioned and chosen accordingly.
It can be contemplated that the angle and distance of the wires could be accurately adjustable by a computer while the process is ongoing for producing even longer and better shaped yarn. Further, the speed of the wire sieves may be same or different in relation to each other. Speed differences may be utilized for affecting the surface structure and twisting of the yarn, for example.
The invention utilizes preferably liquid penetrable wires, felts or belts as transfer and pressing elements. However, rubber or plastic bands or similar non-penetrable bands might also be used if water removal from the gap between the transfer and pressing elements is arranged, for example by suction. One alternative is use penetrable/non-penetrable pair of transfer and pressing elements.
With similar treatments as used with cotton yarn, cellulose yarn can reach comparable properties to cotton and can be utilized in fabrics. Raw cellulose material costs less than cotton which makes it also economically interesting. In addition, cellulose yarn is environmentally friendly. Raw material for cellulose can be gathered for example from harvesting surplus.
Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the method and device may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same results are within the scope of the invention. Substitutions of the elements from one described embodiment to another are also fully intended and contemplated. It is also to be understood that the drawings are not necessarily drawn to scale but they are merely conceptual in nature. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended. | A method and apparatus for producing fiber yarn is provided. The novel apparatus includes a first transportation and pressing element ( 1 ) and a second transportation and pressing element ( 5 ) arranged adjacent to the first transportation and pressing element ( 1 ) as well as elements for driving the transportation and pressing elements ( 1, 5 ). The first and second transportation and pressing elements ( 1, 5 ) are arranged to form a nip therebetween. The apparatus also includes a nozzle ( 9 ) for feeding fiber suspension ( 6 ), such as pulp fiber suspension, to the nip between the first and second transportation and pressing elements ( 1, 5 ). | 3 |
This is a continuation of application Ser. No. 350,549, filed Apr. 12, 1973, now abandoned.
BACKGROUND OF THE INVENTION
The object of the present invention is to provide an apparatus for orienting patterns carried by masks, intended especially, but not exclusively, for the production by serigraphy of connector circuits of thick multiple layers, called multilayer circuits, and a device for performing the process.
The development of printed circuits is known to have resulted in the study of connection means for these circuits. Practically, such connection means have to consist of a large number of conductors, distributed over a very small surface with, certain conductors being, for example, 100 microns in width. One method of designing these connections consists of the application of multilayer circuits, in which the conductors are distributed over laminae, insulated one from the other, except at certain fixed points. The problem that is resolved by the present invention is that of the exact positioning of the conductors, one in relation to the other distributed over the various layers.
The manufacture of printed circuits of the multilayer type having thick layers is generally as follows: Each configuration desired is achieved by application, through a mask or screen, of a layer substance, which is either conductive or insulating, on an insulating substrate, which may be, for example, alumina. After each application of a layer, the substrate is removed from serigraphy apparatus and placed into a furnace at an elevated temperature (for example, on the order of 1,000°) which depends, of course, on the type of substrate and layer. During this operation, the pasty layer solidifies, due to the removal of the solvents, and only a layer of metallic or insulating characteristics remains, strongly adhering to the substrate or to the preceding layer. The complete multilayer circuit is obtained by a series of such operations. It is absolutely essential that the position of the configurations, one in relation to the other, be very exact or else the connections between the layers would not be achieved.
By a known technique, the screens are stretched over a frame and coated with a photosensitive resin which is subjected to a partial insulation such that the resin is removed in certain places, thus forming a pattern for printing. The mask obtained in this manner is mounted on a serigraphy machine and the substrate, placed underneath the screen, receives the paste only through the transparent configuration of the screen. In a known device, the frame is inserted on two prongs which provide for its exact positioning in relation to the machine. Still, the photography does not permit one to accomplish a sufficiently exact positioning of the cliche (transparent configuration) in relation to the borders of the screen in the application, which is intended here, such that the adjustment, preceding the fabrication of the multilayer circuits, requires a good deal of time.
The superposition of different layers, therefore, involves a certain number of risks, which are intolerable in industrial production. It is the object of the present invention to remedy these shortcomings.
SUMMARY OF THE INVENTION
According to the invention, the apparatus for orienting patterns supported by masks that are equipped with openings intended to cooperate with the prongs of the machine, is characterized in that an identical set of markings outside the pattern is formed on each mask, the latter being mounted freely on a support. Said support is then immobilized by two prongs on the apparatus supporting a set of reference patterns, the mask being then shifted in relation to the support in such a way that said markings fall in coincidence with said reference patterns, and is solidly attached to the support such that the position of the support then determines the position of the pattern.
Since it is difficult to attain a sufficiently accurate positioning of the transparent pattern in relation to the frame of the screen, the advantage of the apparatus according to the invention consists in the very precise positioning of the configuration in relation to an additional support in such a fashion that the position of each configuration in relation to the support, and more accurately, in relation to two bore holes of the latter, is exactly defined, (with the precision on the order of about 10 microns). In view of the fact that the position of the different supports on the serigraphy machine can be perfectly well defined, the various layers applied by means of the screens mounted on the support, containing varied patterns, are in exact superposition. The apparatus of the invention includes a plate bearing means for the maintenance and the positioning of the above cited support, means for the shifting of the mask in relation to said support, and a set of reference patterns.
It is thus possible to accomplish an exact positioning of the different patterns, in a very short time.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will evolve in the course of the following description, of a special type of design, with respect to the illustrations in which:
FIG. 1 is a top plan view partially is section of the positioning device;
FIG. 2 is an elevational view of the same device;
FIG. 3 is another elevational view;
FIG. 4 is a top plan view of the screen, its frame, and the support;
FIG. 5 is an elevational view of the assembly illustrated in FIG. 4; and
FIG. 6 is a perspective view of the positioning device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The positioning apparatus, shown in FIG. 1, includes a plate 1 equipped with positioning prongs 3 and a pivoting ring 4. A second ring 2 is capable of turning more than several degrees around the plate axis. The interior of the plate 1 is hollow for the entering of two light sources 5, covered by a diffusor screen. The luminous sources are placed roughly opposite the optical axes of microscopes which appear on the following illustrations. They may be, for example, two small electric bulbs.
The screen 10, its frame 11 and the support 12, in which the assembly of frame and screen will be mounted, (represented in FIG. 4), are installed on the plate at the beginning of the operation by means of the two prongs 3, which cooperate with corresponding bore holes 26 provided in the support 12. In this manner the support 12 is firmly attached to the plate 1 during the entire duration of the operation.
The screen 10 and the frame 11, by contrast, may be displaced in the interior of the support 12 so that the pattern takes on a set position in relation to the axes of the prongs 3. The displacement of the frame 11 is effected by action of 4 push buttons with the reference markings 6, 7, 8, and 9, 7, and 8, being more accurately counter-pushbuttons.
The push button 6, controlled by a fine gauge screw with knurled head 13 permits the shifting of the screen in the horizontal direction, as shown in the illustration, or more generally, in accordance with a direction, termed X. The push button 9, controlled by the screw with knurled head 14. permits the displacement of the screen in a direction perpendicular to the just defined direction, or direction Y. The combination of these two translation movements makes it possible to attain all positions of the screen 10 in relation to the support 12 within a certain range of displacements, defined by the path of the push buttons. It must be clearly understood that the pattern 30 carried by the screen 10 (FIG. 4); is as accurately centered as the photography permits it to be, in relation to the rims of the frame 11, and that the device allows for correction of the shifting on the order of a few millimeters.
It may be equally necessary, however, to produce a rotation of the configuration with respect to the support 12 so that the markings 31 and 32 (FIG. 4), one of which is, for example, a cross and the other a horizontal stroke, (to define an origin and a direction) come to coincidence with the reference patterns which consist of cross hairs placed in the eye piece of the microscopes. Such a rotational movement, whose extent is a maximum of 5°, for example, may be accomplished by the action of the screw with the knurled head 15 which acts laterally on the push button 7 so as to cause the moveable ring 2 to turn in the guides 16.
The counter-push-buttons 7 and 8 which are not controlled by screws have springs which press the heads 7a, and 8a against the edges of the frame 11.
To enable the screen mounted on the support to engage in the apparatus, the push buttons must be able to take on an unlocked position. The necessary withdrawal movement is effected by action of the axes, in solid connection with the heads 7a, and 8a of the counter-push buttons, against two cams 17 which bring about the withdrawal of the heads 7a and 8a when the moveable plate is shifted through a substantial angle. This movement is controlled by a handle 18. It must be clearly understood that the precision of the positioning of the configuration attained on the screen in relation to the bore holes 26 of the support depends on the precision achieved in the position of the support in relation to the reference patterns, that is, the precision of the mounting of the support on the positioning apparatus. As mentioned above, the positioning of the support is effected by insertion of the latter on the two prongs 3.
The manufacturing tolerances for the openings cooperating with the prongs are of the order of a few microns. The result is a very accurate mounting on the prongs and the impossibility of lifting the support out by hand.
For this purpose, an automatic ejection mechanism for the support has been provided, which consists of 4 removeable studs 19 protruding under the action of the handle 18, simultaneously with the movement of withdrawal of the heads of the counter-push-buttons 7 and 8. The movement of protrusion is accomplished by the reach of the lower end of the studs 19 to the helicoidal slopes 20, formed on the plate 4. There are 4 studs to effect a good distribution of the extraction effort.
The withdrawal movement of the heads of the counter-push-buttons and the protrusion movement of the studs are simultaneous such that during the entering of the assembly 10, 11, and 12 into the apparatus, the support rests on the studs 19 and then inserts itself on the two prongs due to the action of the handle 18. At the same time, the heads of the push buttons 6, 7, and 9 come into contact with the edges of the screen. At this moment, the displacement of the frame in relation to the support occurs by the operator acting on the knurled buttons 13, 14 and 15 which aligns the exterior markings 31 and 32 of the pattern with the reference patterns.
When this alignment is completed, the frame is immobilized on the support, as will be described hereafter, then the device is unlocked by the handle 18 which causes the ejection of the frame from the prongs.
FIG. 2 represents the positioning apparatus, viewed from the side, in a section. The reference characters of FIG. 1 have been maintained for identical elements. Two microscopes 21 are resting on two consoles 22. Cross hairs having an identical shape as that of the markings on the mask are installed in the eye pieces, said cross hairs being then located in the focus of the eye pieces and thus aligned with the optical axes of the microscopes. It is essential that the positioning of the microscopes in relation to the prongs 3 which affects the eventual positionings must be adjusted with utmost precision and, in particular, must have the ability to be repeated after having been disassembled for reasons of maintenance, so that all patterns placed on the machine must be capable of being superimposed. For this purpose, the position of the microscopes in relation to the prongs is preferably determined with the aid of an adjustment gauge which is applied after disassembling of the apparatus. The setting of each microscope is effected by means of the knurled button 23. In this figure, the studs 19 may be seen which, in the rest position, are within the centering base. FIG. 3 exhibits another lateral view of the apparatus, showing more particularly the form of a console 22.
FIGS. 4 and 5 illustrate the assembly mask or screen 10, frame 11, and support 12. In FIG. 1 the means are described that come into play to shift the screen in relation to the support 12. It goes without saying that once the exact position has been achieved, it is important to have the screen fixed in a good position in relation to the support. This is done in the following manner.
The frame 11 is firmly attached to the support 12 by 4 flat-headed screws 24 which are milled. These screws rest with the lower part of their head on the upper face of the support and penetrate a bore hole 25 of a diameter greatly exceeding the diameter of their body, before they screw into the frame 11. During the entering of the support into the apparatus, the screws have the function of maintaining the frame and the screen, but are not locked so as to provide the necessary air space between the frame and the support. When the correct position of the screen has been accomplished by the action of the means, described above, the screws are locked and the frame is in solid connection with the support, for the further serigraphy operations. The free space of the screw body 24 across the bore holes 25, makes possible the displacement of the edges of the frame 11 in relation to the borders of the support 12.
Since these prongs are delicate and would run the risk of deformation, the position of the frame on the machine is, on the other hand, secured and reinforced by two screws 27 which are screwed onto the machine, during the serigraphy operations. Since it is not feasible to provide an ejection device on the serigraphy machine similar to that of the positioning device, two screws 29 have been provided of which only the thread is represented in FIG. 4. These screws resting on the border of the serigraphy machine (not shown), permit one to lift out the support by turning the screws, also the frame and the screen from the prongs of the machine, without damaging them. The transparent pattern 30 takes up roughly the screen center 10 and is surrounded by two markings, of which one 31 constitutes a cross and the other 32 a dash. It is self-understood that other markings may be used. The application of two different markings is justified to avoid the risk of the reversal of direction.
FIG. 6 is a perspective view of the positioning device, on a reduced scale. The extraction screws 29 cooperate with threads bearing the same reference numerals (see FIG. 4). Screws 29 are use to lift the support 12 and the screen 10 out of the machine so that the support and screen may be employed, for example, in the production, by serigraphy, of multi-layer connector circuits. The L form or shape of the microscope supports is intended to facilitate the entering and extracting of the support on the device, and to facilitate the locking of the screws 24.
Obviously, the example of application of the process according to the invention to the superimposition of patterns, obtained by serigraphy, is not limitative, and the process and device similar to that which was just described may be utilized in each case where very accurate positioning of a pattern, each one in relation to the other, is involved. It is self-understood that other methods of positioning, of fixation and of marking the pattern and the screen on the support may be employed without thereby departing from the framework of the invention.
OPERATION
At the beginning of the operation, the handle 18 of the positioning apparatus is manually operated to cause a withdrawal movement of the heads 7a and 8a and, simultaneously, a protrusion movement of the studs 19. Moreover, the frame 11 which carries the screen 10 is mounted on the support 12 by means of the four screws 24, but the latter are not locked in order to permit the frame to be displaced in relation to the support. Then, this support 12 is installed on the studs 19 of the apparatus in such a manner that the bore holes 26 are just above the positioning prongs 3 of the plate 1. Afterwards, the handle 18 is operated in reverse direction to cause a withdrawal movement of the studs 19. In the course of this movement, the prongs 3 fit into the bore holes 26, and thus a precise positioning of the support 12 in relation to said prongs is obtained. Simultaneously, the heads of the push buttons 6, 7, 8 and 9 come into contact with the frame 11. Thereafter, the operator, while looking through the microscopes 21, acts on the knurled buttons 13, 14 and 15, in order to shift the frame 11 in relation to the support until the markings 31 and 32 of the screen come to coincide with the reference patterns which are installed in the eye pieces of the microscopes. The screws 24 are then locked so that the frame is in solid connection with the support. Finally, the handle 18 is again operated to cause, on one hand, the withdrawal movement of the heads 7a and 8a, and, on the other hand, the protrusion movement of the studs 19 which then lift the support 12 so that the latter is set free from the prongs 3. | An apparatus for orienting patterns supported by a silk screen which is advantageously employed in producing multi-layer printed circuits.
The screen and the screen carrying frame are mounted into a support and displaced with respect to it so that markers outside of the patterns come to coincide with reference patterns. | 6 |
RELATED APPLICATIONS
This is a continuation-in-part of co-pending application Ser. No. 08/696,140 filed Aug. 13, 1996, which is a continuation of Ser. No. 08/261,727 filed Jun. 17, 1994, now abandoned, which is a continuation of Ser. No. 08/142,620 filed Oct. 25, 1993, now U.S. Pat. No. 5,330,405.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of exercise equipment, and particularly to an exercise machine in which at least a substantial portion of the exercise resistance is provided by the body weight of the operator.
2. Background Art
A wide variety of exercise machines have been developed for exercising various muscle groups of the body. Most such machines employ weights to provide resistance to the operator's exercise movements. Most commonly, a stack of individual weight plates is provided in an arrangement such that a selected number of the weight plates may be coupled to the exercise station by a cable, lever mechanism or other device. Exercise machines of this type typically have a weight stack with a total weight of 200 to 300 pounds. Such weights represent a significant fraction of the cost of an exercise machine, especially when transportation costs are considered. Moreover, conventional weight plates are noisy when the exercise machine is in use.
The use of a person's own body weight as a source of exercise resistance is, of course, well known. For example, many calisthenic exercises, such as push-ups, sit-ups and the like, employ body weight as a source of exercise resistance. Several types of exercise apparatus that use body weight resistance have been commercially introduced. For example, the HealthRider® is a device for simultaneously exercising muscle groups of the upper and lower body in which the operator is alternately raised and lowered on a seat by operation of the apparatus. The Total Gym®, marketed by EFI/Total Gym, employs an inclined sled to support the operator. Various exercises available with this machine cause the sled to be pulled up the incline as the operator exercises. The Body Force™, marketed by Maximus, provides a selectable amount of assistance to an operator while performing body weight exercises such as dips and chin-ups. The Gravity Edge™ has a pivoted platform on which the operator is supported in either a sitting or standing position. The platform is coupled by linkage to an exercise arm such that operation of the exercise arm causes the platform to be lifted.
Other variations of body weight exercise machines are shown in U.S. Pat. Nos. 4,632,390 and 4,949,958, both issued to Richey. These patents disclose devices in which an operator is supported on a generally horizontal bench which is lifted by various exercises. A roller and lever arm arrangement provides adjustment for the amount of body weight that is communicated as exercise resistance.
The various body weight resistance machines mentioned above provide a relatively limited selection of exercises compared to more conventional multi-station exercise machines that employ weight stacks. The latter class of machines has found wide acceptance among exercisers in both the home and health club markets. There is a perceived need for an exercise machine that combines the exercise flexibility of a conventional multi-station exercise machine with the advantages of a machine that derives exercise resistance from the operator's own body weight.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a multi-station exercise machine that has a plurality of exercise members similar in nature to those that are afforded on conventional multi-station exercise machines which utilize a weight stack for providing exercise resistance. Various operable members for performing exercises are coupled to a movable subframe, which also supports a seat for the operator. The subframe is pivotally attached to a stationary frame. In a preferred embodiment of the invention, a lever arm is also pivotally attached to the stationary frame. A carriage movably located on the lever arm acts against a pivot arm that suspends the subframe from the stationary frame. A cable and pulley system couples the lever arm to the various operable members of the apparatus so that a selectable ratio of the weight of the subframe, including the operator, is communicated as exercise resistance. The amount of weight that is coupled to the operable members is selected by positioning the carriage on the lever arm. This adjustment also varies the height to which the subframe is lifted by the exercise stroke and hence the effort that must be exerted by the operator.
In effect, the subframe is a complete multi-station exercise machine, except only for the weights used in conventional exercise machines. The weight of the subframe together with that of the operator is generally more than adequate for providing any desired level of exercise resistance. Thus, the use of a weight stack as has heretofore been conventional with exercise machines of this class is not required. Apart from the advantage of dispensing with conventional weights, the present invention provides a new and exciting exercise sensation as the operator feels the lifting movement while exercising.
In one embodiment of the invention, the subframe comprises a generally L-shaped member having a seat and back rest for the operator. The subframe is pivotally coupled to the stationary frame with a four-bar linkage. A press arm is pivotally attached to an extension of the subframe at a pivot location generally above the operator's head. This embodiment of the invention employs two interconnected cables. A first cable is threaded through sets of pulleys on both the subframe member and the press arm and is coupled at one end thereof to a lat bar. The other end of the first cable is made available as an intermediate pulling point generally behind the operator's head. The subframe also carries a leg extension arm pivotally suspended forward of the operator's seat and coupled to a second cable. The end of the second cable is made available as a low pulling point. The cables are interconnected by a floating pulley assembly such that operation of any of the operable members or cable pulling points is communicated through the entire cable and pulley system to tension both of the cables. The second cable is threaded through pulleys mounted on the lever arm so that any of the exercise movements will exert a pulling force on the lever arm, thereby lifting the subframe from its rest position to a height that is determined by the selected position of the carriage.
The main L-shaped member of the subframe is preferably constructed so that it is separable at a location between the seat and backrest. Separating the subframe member at this location allows the upper portion of the subframe to be folded down to place the apparatus in a more compact configuration for shipping or storage.
In an alternative embodiment of the invention, the subframe is coupled to the stationary frame at a single pivot and only a single cable is employed. This embodiment foregoes an intermediate pulling point so that a single cable can be used. An operator of the machine is nevertheless able to perform lat pull/row, press, leg extension and low pull exercises.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exercise machine according to the present invention.
FIG. 2 is a side elevation view of the exercise machine of FIG. 1 showing it in its rest position.
FIG. 3 is a side elevation view of the exercise machine of FIG. 1 showing it in an elevated position.
FIG. 4 is a detailed top plan view of the lever arm of the exercise machine of FIG. 1.
FIG. 5 is a front elevation view of an alternative press arm for use with the exercise machine of FIG. 1.
FIG. 6 is a side elevation view of the press arm of FIG. 5.
FIG. 7 is a partial cross-sectional view taken through line 7--7 of FIG. 6.
FIG. 8 is a side elevation view of the exercise machine of FIG. 1 in a folded configuration for shipping or storage.
FIG. 9 is a side elevation view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for purposes of explanation and not limitation, specific details are set forth 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 exercise methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
FIGS. 1-3 illustrate an apparatus 10 constructed in accordance with the present invention. The apparatus is supported by a fixed frame 12 which comprises a main longitudinal member 14. Frame member 14 abuts forward transverse support member 16 and rests on rear transverse support member 18. Upright frame member 20 is secured to rear end 15 of frame member 14.
Fixed frame 12 supports a movable subframe 22 comprising a generally L-shaped member 24. Member 24 consists of an upper portion 24a, and a lower portion 24b joined together by bolts 25. The subframe includes a seat 26 and a back rest 28 to support a user while performing exercises with apparatus 10. It should be observed that, since both seat 26 and back rest 28 are secured to subframe member 24, the relative positions of the support cushions remain fixed while performing exercises, unlike certain prior art devices such as the Gravity Edge™ referred to above.
Seat 26 is secured to subframe member 24 so that it can be adjusted vertically to accommodate users of varying sizes. To provide adjustability, seat frame 30 includes a downwardly extending member 32 which telescopes within tube member 34 secured to subframe member 24. The seat is secured at a desired elevation with a pop pin (not shown) as is common practice for exercise equipment. Seat frame 30 supports seat cushion 36 and knee cushion 38. The latter is provided mainly for support when performing a leg extension or leg curl exercise as more fully described below. When performing other exercises, the user's knees will generally straddle knee cushion 38 as shown in FIG. 1.
Subframe 22 includes a foot support platform 40 suspended from member 24 by members 42 and 44. Cross members 46 provide lateral support for platform 40. Stops 47 on the underside of forward cross member 46 rest against transverse frame member 16 when subframe 22 is in its rest position (illustrated in FIG. 2). Stops 47 are adjustable in height so that the rest position of subframe 22 may be adjusted vertically. The utility of this adjustment will be explained below.
Subframe 22 is coupled to fixed frame 12 by upper pivot arms 50a, 50b and lower pivot arms 52a, 52b. Upper pivot arms 50a, 50b are coupled to upright frame member 20 at pivot 53 and to subframe member 22 at pivot 54. In like fashion, lower pivot arms 52a, 52b are coupled to upright member 20 at pivot 55 and to subframe member 42 at pivot 56. Subframe 22 is thus coupled to fixed frame 12 by a four-bar linkage so that it remains relatively level as it is lifted from the rest position. The seating position actually reclines somewhat as the subframe is elevated owing to the fact that upper pivot arms 50a, 50b are shorter than lower pivot arms 52a, 52b.
Other linkage arrangements may be used to couple the subframe to the fixed frame. For example, the subframe could be configured to slide or roll along a generally upright member of the fixed frame. Still other generally equivalent linkage arrangements will be apparent to persons of ordinary skill in the art of exercise equipment.
Lever arm 60, which is shown in greater detail in FIG. 4, is pivotally coupled to fixed frame 12 at pivot 62, the latter being supported by bracket 64. Carriage 66 is slidably disposed on lever arm 60 and carries rollers 68a, 68b. These rollers bear against the underside of lower pivot arms 52a, 52b, respectively. The position of carriage 66 along the length of lever arm 60 is selectable by the user with pop pin 70. This pin, which is spring biased in a downward direction, engages a selected one of a plurality of holes 69 in the upper surface of lever arm 60. As will be better appreciated from the discussion that follows, the position of carriage 66 along the length of lever arm 60 determines the amount of exercise resistance experienced by the user when performing the exercises that are available with apparatus 10 and also varies the height to which subframe 22 is lifted by the exercise stroke. As mentioned above, stops 47 allow the rest position of subframe 22 to be adjusted vertically. This permits pivot arms 52a, 52b to be aligned parallel with lever arm 60. In turn, this permits carriage 66 to be smoothly positioned anywhere along the lever arm. Although lever arm 60 is a preferred means for transmitting the load of subframe 22 to the cable and pulley system of the apparatus, it should be noted that the load could be transferred directly to one or more of the pivot arms. For example, a cable attachment could be made to a sleeve or carriage that is slidably positionable on the pivot arms.
The principal structural members of apparatus 10 are preferably constructed of square and rectangular section steel tubing as is common practice for exercise equipment. The individual members are joined by welding or by mechanical fasteners as appropriate in each case.
Apparatus 10 incorporates a plurality of operable members coupled to subframe 22 for performing exercises. One such operable member is press arm 72 which is pivotally coupled to subframe member 74 at pivot 76. Press arm 72 is provided with both horizontal grips 78 and vertical grips 80. When not in use, press arm 72 rests against stop member 71 which projects from subframe member 24. A second operable member is lat bar 82 which is suspended on cable 84 at a lat pull down station above the user's head. When not in use, lat bar 82 is retained on brackets 86a and 86b which extend forwardly from subframe member 74. A third operable member is leg extension arm 88, which is pivotally suspended from subframe member 44 at pivot 90. It is important to note that all of these operable members are mounted on the moving subframe structure and thus remain in a fixed relationship to seat 26 and back rest 28. This is in contrast to most prior art body weight resistance machines that have their operable members mounted on a stationary frame.
Each of the above-mentioned operable members is coupled through the cable and pulley system of apparatus 10 so that as the user exercises, subframe 22 is lifted, thereby providing exercise resistance. To illustrate this, consider first a leg extension exercise using exercise arm 88. As the user applies forward pressure against ankle cushion 92, lower cable 94, which is coupled to arm 88, is placed in tension. Cable 94 passes under pulley 96, which is rotatably mounted on subframe member 44, and then under pulley 98 which is rotatably mounted on lever arm 60. Cable 94 then passes over lower pulley 102 of floating pulley assembly 100 and downwardly under pulley 104 mounted on lever arm 60 adjacent to pulley 98. Cable 94 continues upwardly and is secured between upper pivot arms 50a, 50b at location 106. As exercise arm 88 is moved forwardly, lever arm 60 is drawn upwardly by the action of cable 94 on pulleys 98 and 104. This, in turn, causes lower pivot arms 52a, 52b to be lifted by rollers 68a, 68b, respectively. The lifting force is thus communicated to subframe 22 causing it to be elevated in a nearly linear vertical path as shown by the dashed arrow in FIG. 2.
In a similar fashion, operation of press arm 72 causes subframe 22 to be lifted from its rest position. Upper cable 84, one end of which is coupled to lat bar 82, is routed over pulley 108 on bracket member 86 and then around pulleys 110, 112, 114 and 116 which are alternately mounted on press arm 72 and subframe member 24. Cable 84 then passes around pulley 101 of floating pulley assembly 100 and upwardly over pulley 118 on subframe member 24. Cable 84 terminates with cable stop 120 which is retained against subframe member 24 when cable 84 is in tension. As the user moves press arm 72 forwardly to the position shown in FIG. 3, floating pulley assembly 100 is drawn upwardly causing lever arm 60 to be pulled upwardly by cable 94. Subframe 22 is thus lifted in the same manner described above in connection with operation of the leg extension exercise. It will be observed that use of lat bar 82 pulls downwardly on cable 84 and causes the same result, but without the force multiplying effect experienced with press arm 72 as a result of the serpentine path of cable 84 through pulleys 110-116.
As already mentioned, lower cable 94 is attached between upper pivot arms 50a, 50b at location 106. This attachment is preferably adjustable to accommodate variations in the lengths of cables 84 and 94 and also to periodically compensate for cable stretch. With this adjustment, which need not have a great range of travel, the cables can be placed in a taut condition while subframe 22 is in its rest position. This removes any slop in the operation of the various operable members. It will be recognized that adjustment of the cable length at attachment 106 will influence the position of lever arm 60, and thus further adjustment of stops 47 may be necessary to maintain a parallel relationship between lever arm 60 and lower pivot arms 52a, 52b.
As mentioned above, cable 84 terminates with cable stop 120 at pulley 118, which is slightly above and behind the user's head. A loop 122 is secured to this end of cable 84 to permit the attachment of an auxiliary exercise bar or strap (not shown). Additional exercises, such as an abdominal crunch or overhead triceps, can thus be performed from this exercise station. Cable 94 also terminates with a cable stop 124 at pulley 126 on leg extension arm 88. Loop 128 is provided at the end of cable 94 to provide a low pulling point for additional exercises. For example, arm curls and upright row exercises may be performed while standing on platform 40 with an auxiliary exercise bar coupled to an extension chain or cable attached to loop 128. It should be noted that a number of exercises may also be performed using this low pulling point while standing on the floor adjacent to apparatus 10. In this regard, the weight of subframe 22 alone is more than adequate for performing a number of exercises, such as side leg raises.
While the combined weight of subframe 22 and the user seated thereon is generally adequate for providing the maximum desired exercise resistance, additional resistance may be desired by certain users. In this situation, auxiliary weights may be added to subframe 22 on support bars 130. Such auxiliary weights may comprise disc-shaped weight plates of the type that are widely used for barbells and dumbbells.
In an alternative embodiment of the present invention, press arm 72 may be replaced with press arm 172 as shown in FIGS. 5-7. Press arm 172 is configured to be used as a conventional press arm, but may also be used to perform a pectoral fly exercise. Upper press arm members 178 and 180 are pivotally coupled to frame member 200 at pivot 173. For use as a conventional press arm, individual arm members 174 and 176 are locked with respect to cross member 181 by pins 182 and 184, respectively. To perform the pectoral fly exercise, pins 182 and 184 are retracted so that arms 174 and 176 are free to rotate about pivots 186 and 188, respectively. In addition, pin 210 is inserted through press arm stop member 212 and into bar 214, which is attached to cross member 181. This locks the upper press arm assembly in position so that it cannot rotate about pivot 173. A plurality of holes for pin 210 are preferably provided in bar 214 so that arms 174, 176 may be optimally positioned with respect to the seat for performing the pectoral fly exercise.
Opposite ends of cable 190 are secured to sectors 192 and 194, which are attached to arms 174 and 176, respectively. Cable 190 is reeled around pulleys 196 and 198 mounted on subframe arm 202 and around floating pulley 204. Pulley 204 is the upper member of floating pulley assembly 206 which communicates with the remainder of the apparatus in the same manner as discussed above.
In yet a different configuration, the press arm may combine the features of both press arms 72 and 172. In this regard, a press arm with pulleys 110 and 114 and the cable rigging as shown in FIGS. 1-3 may be provided with folding pec fly arms similar to arms 174 and 176 of FIGS. 5-7. In this arrangement, lower cable 94 of apparatus 10 may be conveniently extended from attachment point 106 (this fitting being omitted) to a pulley or "Y" fitting at which it would be coupled to cable 190. The exercise resistance for press exercises would thus be communicated through upper cable 84 with the force multiplying effect of pulleys 110-116, whereas exercise resistance for the pec fly exercise would be communicated through lower cable 94 and cable 190. This arrangement obviates the need for pin 210 since operation of the pec fly arms against the relatively lower amount of resistance communicated by cables 94 and 190 would not tend to displace the press arm assembly about the press action pivot (76 in FIGS. 1-3 or 173 in FIGS. 5-7).
With reference again to the embodiment illustrated in FIGS. 1-4, and with particular reference to FIGS. 2 and 3, an important aspect of the present invention involves the separability of subframe member 24 into upper portion 24a and lower portion 24b. With bolts 25 removed, upper portion 24a can be folded forwardly and downwardly on pivots 53 and 54 to a substantially horizontal position as illustrated in FIG. 8. This results in a much more compact configuration so that apparatus 10 can be conveniently shipped and/or stored. Press arm 72 is preferably removed from the apparatus at pivot 76 since it would otherwise strike fixed frame members 90 before the upper portion of the subframe is fully lowered. Pulleys 110 and 114 are removed from the press arm so that cable 84 may be left in place with the subframe lowered. However, even leaving press arm 72 in place would allow the upper portion of the subframe to be lowered substantially, thereby reducing the total volume occupied by apparatus 10. Moreover, the configuration of press arm 72 may be suitably altered to fit around fixed frame members 90 so that the upper portion of the subframe may be fully collapsed without removing the press arm. Furthermore, using the press arm configuration shown in FIGS. 5-7, the individual arm members can be folded in to allow the subframe to be collapsed without removing the press arm.
Referring now to FIG. 9, a further alternative embodiment of the present invention is illustrated. In this embodiment, apparatus 300 employs a single pivot arrangement in contrast to the four-bar linkage employed in the previously described embodiment. Subframe 304 of apparatus 300 pivots with respect to stationary frame 302 only at pivot point 306. Subframe 304 is otherwise generally similar to subframe 22 of the previously described embodiment, but is generally more compact.
Subframe 304 carries seat cushion 308 and back cushion 310. Press arm 312 is pivotally coupled to subframe 304 at pivot 314 which is located below the operator's seat. This is in contrast to the previously described embodiment, wherein the press arm is suspended from a pivot above the operator's seat. Leg extension arm 316 is also pivotally coupled to subframe 304 at pivot 318.
Lever arm 320 is pivotally coupled to the stationary frame at pivot 322. Subframe 304 is supported on roller 324, which is rotatably mounted on carriage 326. As in the previously described embodiment, carriage 326 is selectably positionable along lever arm 320 for the purpose of adjusting the amount of exercise resistance communicated to the various exercise stations.
The cable and pulley system of this embodiment is somewhat simpler than that of the previously described embodiment. Beginning at leg extension arm 316, a single cable 330 is guided under pulley 332. The end of cable 330 is fitted with ball stop 334 and a loop 336 allowing the cable end to be used for low pull exercises. Cable 330 extends rearwardly and loops over pulley 338, which is rotatably mounted on subframe 304. Cable 330 then loops around pulley 340 which is rotatably mounted on press arm 312. Cable 330 continues rearwardly and loops around pulley 342 which is rotatably mounted at the rear of lever arm 320. Cable 330 then loops around pulley 344 rotatably mounted on subframe 304 and returns back around pulley 346 on lever arm 320. Cable 330 proceeds upwardly and forwardly over pulley 348 on subframe 304 and terminates at pulley 350, also on subframe 304. This end of cable 330 is also fitted with a ball stop 334 and a loop 336. This loop is used to perform lat pull exercises.
When cable 330 is displaced by pulling on either of loops 336, or by pushing forward on either the press arm or the leg extension arm, the cable acts on pulleys 342 and 346 to pull lever arm 320 upwardly about pivot 322. This, in turn, causes subframe 304 to be lifted by roller 324. Thus, as in the previously described embodiment, the combined weight of the operator and the subframe 304 is communicated as exercise resistance through the cable and pulley system. The ratio of the exercise resistance to the combined weight of the operator and subframe 304 is determined by the position of carriage 326 along lever arm 320. Moving carriage 326 closer to pivot 322 reduces the exercise resistance since there is less upward travel of the subframe for a given amount of cable displacement.
It will be recognized that the above described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims. | A multi-station exercise machine has a movable subframe on which a user sits while performing various exercises. The subframe is movably coupled to a stationary frame and is supported by a lever arm that is pivotally attached to the stationary frame. A cable and pulley system couples the lever arm to the various operable members of the apparatus so that a selectable ratio of the weight of the subframe, including the user, is communicated as exercise resistance. The main structural member of the subframe may be disconnected so that the upper portion of the subframe may be folded down for convenient shipping and/or storage of the apparatus. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to structural reinforcement in general and in particular to reinforcing adjacent wood product structural members to each other.
2. Description of Related Art
In the field of construction, it is often desirable to make a structure as strong as possible. The strength of a building is desirable for the purposes of load bearing ability as well as resistance to outside loads such as earthquakes, wind and other environmental loading.
Building construction typically includes a plurality of elongate members connected each other to form walls, ceilings, floor and the like. In the case of walls, such elongate wall members are often referred to as studs while in ceilings and roofs, they may be referred to as joist.
One difficulty that exists is the tendency of relatively long structural members to loose strength and rigidity as their length increases. This is often required for floor and ceiling joists so as to provide larger rooms unobstructed by supporting walls and columns. Such long joists may commonly be subject to torsional buckling failure. Another difficulty that exists with floor joists is when they are exposed to dynamic environmental loads such as earthquakes, strong winds and the like. Under such loads, the floor joists may rotate axially along their length so as to lay flat instead of upright. The resulting horizontal and vertical deflection of the entire load above such a floor may contribute to an entire building failing or collapsing.
Conventional methods of reinforcing structural members has not been adequate to resolve the above difficulties. Previous attempts have tried to locate bridges or blocks between adjacent joists to distribute point loads located near a single joist to adjacent joists so as to distribute the load between more than one joist. Bridging involves locating a pair of crossed diagonal wooden members between adjacent joist whereas blocking typically includes locating a shortened length of the joist member transversely between the joists. Such attempts have not adequately solved the above difficulties. In particular, blocking or bridging is only able to act as a compressive member between the joists and will have a very limited ability to prevent the joists from moving away from each other.
When the joist members are subjected to torsional loading, the blocking members on one side of the joist are subjected to opposite loads. For example, when a torsional load is applied to the joist along the longitudinal axis of the structural member, the blocking member abutting one side of the top chord of the joist is subjected to a primarily compressive load, and the blocking member abutting opposite side of the top chord is subject to a tensile load. Similarly, for the same torsional load, the bottom chord on the same side of that joist will also be subjected to a tensile load. The compressive load may be conveyed efficiently to the blocking member abutting the top chord through the contacting surfaces of the blocking and the joist chord. However the tensile load on both blocking member on the opposite side of the top chord and on the bottom blocking member is born entirely by the fastening device used. Therefore unless such fasteners are specifically designed to bear tensile loads under repeated loading cycles, this is likely to lead to cause premature failure of the structure when such fasteners, such as a nail or a screw pulls out. Due to the inability of bridging and blocking to effectively handle loads in tension, such reinforcing will not significantly assist in the reinforcing of a structure under cyclical environmental loads such as earthquakes, winds and the like.
SUMMARY OF THE INVENTION
According to a first embodiment of the present invention there is disclosed an apparatus for reinforcing adjacent parallel spaced apart wooden structural members wherein each of the structural members has opposed first and second edges. The apparatus comprises a rigid member having first and second ends and being sized to extend between the first edge of a first structural member and the second edge of an adjacent second structural member. The apparatus further comprising a first socket connected to the first end of the rigid member and a second socket connected to the second end of the rigid member. The first socket is sized to receive the first edge of the first structural member therein and the second socket is sized to receive the second edge of the second structural member therein.
The first and second sockets may comprise channels. The channels may comprise c-shaped channels. The c-shaped channels may extend perpendicularly to a longitudinal axis of the rigid member. The c-shaped channels may have vertically oriented openings. The openings of the c-shaped channels may be in opposite directions to each other. The openings of the c-shaped channels may be angularly oriented relative to the rigid member.
The c-shaped channel may be formed of a pair of opposed flanges and a web portion therebetween. One of the pair of opposed flanges may be secured to the rigid member. The other of the pair of opposed flanges may be selectably deformable so as to open the c-shaped channel. The c-shaped channels may include at least one fastener bore, sized to pass a fastener therethrough so as to secure the c-shaped channel to the structural member.
The first and second sockets may be rigidly affixed to the rigid member. The first and second sockets may be integrally formed with the rigid member. The rigid member and the first and second caps may be formed of metal. The rigid member may comprise an elongate beam. The beam may be selected from the group consisting of a tube, a box section, an I-beam, a c-shaped channel, an L-shaped channel and a triangular cross section beam.
The apparatus may further comprise a pair of intersecting rigid member each sized to extend between top and bottom edges of opposed parallel structural members. Each of the rigid members may have a first socket sized to receive a top edge of one of the pair structural members therein and a second socket sized to receive a bottom edge of the other of the pair of structural members therein. The pair of intersecting rigid members may be pivotally connected to each other. The pair of intersecting rigid members may be pivotally connected to each other by a bolt.
According to a further embodiment of the present invention there is disclosed a method for reinforcing adjacent parallel spaced apart wooden structural members wherein each of the structural members having opposed first and second edges. The method comprises locating a first structural member in a desired position and engaging the first socket of a reinforcing device around the first edge of the first structural member. The method further comprises locating a second structural member in a desired position with the second edge of the second structural member within a second socket of the reinforcing device wherein the reinforcing member has a rigid member extending between the first and second sockets.
According to a further embodiment of the present invention there is disclosed a method for reinforcing adjacent parallel spaced apart wooden structural members wherein each of the structural members have opposed first and second edges. The method comprises locating a first structural member in a desired position, and locating a second structural member in a desired position. The method further comprises rotating a reinforcing device between the first and second structural members until a first socket at a first end of the reinforcing device is engaged around a second edge of the first structural member and a second socket at a second end of the reinforcing device is engaged around a first edge of the second structural member. The reinforcing device has a rigid ember extending between the first and second sockets.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,
FIG. 1 is a perspective view of a plurality of apparatus' according to a first embodiment of the present invention applied between a plurality of adjacent joists.
FIG. 2 is a perspective view of the apparatus of FIG. 1 .
FIG. 3 is a perspective view of one arm of the apparatus of FIG. 2 .
FIG. 4 is a plan view of a cut-sheet to be utilized to form one arm of the apparatus of FIG. 2 .
FIG. 5 is a perspective view of one arm of the apparatus of FIG. 2 according to a further embodiment of the present invention.
FIG. 6 is a cross-sectional view of a floor construction utilizing a reinforcing member of FIG. 3 being applied to a first joist and subsequently a second joist being secured to the reinforcing member.
FIG. 7 is a cross-sectional view of a floor construction applying a second reinforcing member between adjacent joists.
FIG. 8 is a cross-sectional view of an apparatus according to a further embodiment of the present invention being applied between adjacent wall studs.
FIG. 9 is a top plan view of the reinforcing member of FIG. 3 having angularly oriented top and bottom caps according to a further embodiment of the present invention.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , an apparatus for stabilizing adjacent structural members 6 according to a first embodiment of the invention is shown generally at 20 . The apparatus 20 comprises a pair of intersecting rigid members 22 each spanning between a top edge 8 of one structural member and a bottom edge 10 of an adjacent structural member. Each rigid member includes a first or top socket 24 sized to receive the top edge 8 of the structural member and a second or bottom socket 26 sized to receive the bottom edge 10 of the structural member. Each set of a rigid member 22 , top socket 24 and bottom socket 26 comprises a single structural reinforcing device 28 . As illustrated in FIG. 1 , the top socket 24 of one rigid member 22 and the bottom socket 26 of its corresponding pair cooperate together to retain the structural member therebetween. The apparatus 20 may optionally include a tensile member 88 spanning corresponding top and bottom sockets 24 and 26 so as to retain the sockets at a minimum distance from each other.
It will be appreciated that such a tensile member 88 will serve to retain the top and bottom sockets 24 and 26 in engagement on the structural member. The tensile member 88 may be formed of a rigid or resilient flexible members such as, metal straps, bars, chain and the like, by way of non-limiting example.
Turning now to FIG. 3 , a single reinforcing device 28 is illustrated according to a first embodiment of the present invention. The rigid member 22 of the reinforcing device 28 illustrated in FIG. 3 may be formed of sheet metal bent into a c-shaped channel having a pair of sides 30 and 32 and a central web portion 34 therebetween. The sides 30 and 32 may be bent to the same or opposite sides of the web portion 34 however it will be appreciated that where two reinforcing devices 28 are desired to be utilized together as illustrated in FIGS. 1 and 2 , it will be preferable to bend both sides 30 and 32 to the same side of the web portion 34 . It will also be appreciated that although the rigid member 22 illustrated in FIG. 3 may be formed of bent sheet metal, it may also be formed by other means such as an extruded, cast or welded structure. It will also be appreciated that one or both of the sides 30 or 32 may be omitted depending on the strength requirements of the application. The central web portion 34 includes a bore 37 therethrough so as to permit a pair of reinforcing devices 28 to be pivotally secured to each other by a bolt 35 or the like.
The top socket 24 may comprise an open c-shaped channel formed of first and second top side flanges 40 and 42 , respectively and a top web portion 44 forming a channel opening 46 . The top channel opening 46 is sized and shaped to correspond to the top edge 8 of the structural member. The bottom socket 26 may comprise an open c-shaped channel formed of first and second bottom side flanges 50 and 52 , respectively and a bottom web portion 54 forming a channel opening 56 . The bottom channel opening 56 is sized and shaped to correspond to the bottom edge 10 of the structural member. In many applications, the structural member 6 will comprise a floor joist, such as by way of non-limiting example dimensioned lumber or I-joists. Dimensioned lumber is commonly of a 1.5 inch width and therefore for such applications the top and bottom channel openings 46 and 56 will be sized to have a similar width opening. It will be appreciated that other thicknesses of structural members in general and joist sin particular may also be utilized. In some applications, the top and bottom channel openings 46 and 56 may be sized slightly larger than the width of the joist so as to facilitate installation. In particular, the top and bottom channel openings 46 and 56 may be up to 3.2 mm (⅛ of an inch) larger than the joist for which they are designed. The sizing of the top and bottom channel openings 46 and 56 for I-joists may be similarly selected to correspond to the I-joist to be used.
The top and bottom sockets 24 and 26 may include one or more fastener bores 48 located in any one or more of the flanges or webs forming the socket. The fastener bores 48 are sized to permit nails, screws or other suitable fasteners to be passed therethrough so as to secure the top or bottom socket 24 or 26 to the structural member 6 . Optionally, the top and bottom sockets 24 and 26 may include barbs, spikes or other suitable projections from an interior surface thereof so as to engage the joist when the reinforcing device 28 is secured thereto. Adhesives may also be applied between the top and bottom edges 8 and 10 of the structural member and the top and bottom sockets 24 and 26 . The top and bottom sockets 24 and 26 may also include an optional connecting tab 58 for fastening adjacent top and bottom sockets to each other with fasteners and the like.
As discussed above, the rigid member 22 is sized to extend between a top edge 8 of one structural member 6 and a bottom edge 10 of an adjacent structural member. In practice, the length of the rigid member 22 will depend upon both the height of the structural members and the spacing distance between them. As illustrated in FIG. 2 , the height of the structural members 6 will correspond to the distance between the top web portion 44 and the bottom web portion 54 generally indicated at 36 . Correspondingly, the distance between the structural members, which is commonly expressed in centre to centre distance will correspond to the distance to the centres of the two top or bottom web portions 44 and 54 generally indicated at 38 . It will also be appreciated that the distance between a first top side flanges 40 the second top side flange 42 of a paired reinforcing device 28 . Similar spacing distances will apply for the other side flanges of the sets of reinforcing devices 28 so as to maintain the centre to centre spacing of the adjacent structural members 6 . By way of example, for a floor constructed of 302 mm (11⅞ inches) high joists spaced 406 mm (16 inches) apart, the width 38 of the apparatus 20 would similarly be 406 mm (16 inches) and the height 36 of the apparatus 20 would be 302 mm (11⅞ inches). It will be appreciated that other heights and widths will apply for joists of differing heights and spacing.
As illustrated in FIG. 3 , the top web portion 44 of the top socket 24 may be angularly aligned relative to the rigid member about a horizontal axis by an angle generally indicated at 49 . It will be appreciated that the angle 49 will permit the top web portion 44 to be angularly aligned with the top edge 8 of the structural member 6 while permitting the rigid member 22 to be angularly aligned thereto. The bottom web portion 54 of the bottom socket 26 will have a similar corresponding angle. The top and bottom sockets 24 may also be angularly oriented relative to the rigid member about a vertical axis as illustrated in FIG. 9 . It will be appreciated that such arrangement will permit the rigid member to span adjacent joists at a non-perpendicular angel so as to permit the rigid member to avoid obstructions and the like as well as to permit a series of rigid members to extend diagonally across a floor.
Turning to FIG. 4 , a cut sheet is illustrated for forming the reinforcing device 28 of FIG. 3 . As illustrated the reinforcing device may be cut from a single sheet of metal, such as, by way of non-limiting example, steel, stainless steel, aluminium or galvanized steel. The sheet metal may be cut into a blank 60 . The blank may thereafter be bent along rigid member bend lines 62 to form the rigid member 22 and socket bend lines 64 so as to form the top and bottom sockets 24 and 26 according to known methods. Any thickness of metal as required to provide the necessary strength may be utilized such as between 12 and 22 gauge. In particular, it has been found that sheet metal of between 16 and 20 gauge has been useful. It will also be appreciated that the reinforcing device 28 may also be formed of non-metal materials, such as, by way of non-limiting example, carbon fibre, fibreglass, plastics, ceramics and composite materials.
Turning to FIG. 5 , an alternative embodiment of the present invention is illustrated having a central beam 70 spanning between the first and second sockets 24 and 26 . The first and second sockets 24 and 26 may be as described above and may be secured to the beam by welding, bolting or by being integrally formed with the beam 70 by casting or any other suitable means. The beam 70 may comprise any suitable structural member such as, by way of non-limiting example, bar, tube, box section, I-beam, c-shaped channel, L-shaped channel, a triangular cross section beam, or any other suitable member. It will also be appreciated that although elongate, substantially straight members are shown, non-straight members may also be utilized, such as, by way of non-limiting example, arcuate, space frame, plates or any other shape as long as the top and bottom sockets 24 and 26 are rigidly translationally fixed relative to each other so as to securely locate a top edge 8 of one structural member relative to a bottom edge 10 of an adjacent structural member.
The beam 70 may include a central portion 72 having a flat surface 74 therein having a bore 37 . The flat surface is vertically oriented such that a corresponding flat surface 74 of a matching reinforcing device 28 may be mated therewith so as to align matching bores 37 for connection with a bolt 35 or the like. Although a bolt is described as being utilized to rotationally secure the pair of reinforcement devices to each other, it will be appreciated that other pivotal means may also be utilized, such as hinges, clamps, rivets and bearings. The flat surface 74 may be formed in the beam 70 by casting or welding of a flat section into the beam or by clamping the central portion 72 of the beam 70 in a machine press or the like. It will also be appreciated that some beam types will already include an adequate flat surface and will not require additional processing.
In operation, a first structural member 6 a may be located at a desired location. Thereafter a reinforcing device 28 may be located on the first structural member 6 a by moving the reinforcing device 28 in a downward direction as indicated generally at 80 such that the top edge 8 of the first structural member is retained within the top socket 24 of the reinforcing device. A second structural member 6 b may then be located such that its bottom edge 10 is retained within the bottom socket 26 by moving the second structural member 6 b in a downward direction generally indicated at 82 . Thereafter, subsequent reinforcing devices 28 and structural members 6 may be placed in succession to provide a single row of reinforcing devices. Fasteners may also be passed through the fastener bores 48 so as to secure the reinforcing devices 28 thereto.
Turning to FIG. 7 , a second reinforcing device 28 b may be located between the first and second structural members 6 a and 6 b by pivotally located the second reinforcing device 28 b to the first reinforcing device 28 . Thereafter the second reinforcing member 28 b may be rotated such that the top socket 24 engages with the top edge 8 of the second structural member 6 b and the bottom socket 26 engages with the bottom edge 10 of the first structural member 6 a . As illustrated, the second top side flange 42 of the top socket and the second bottom side flange 52 of the bottom socket 26 may be bent outwards to facilitate the rotation of the first and second sockets 24 and 26 into engagement with the top and bottom edges of the structural members. Thereafter, these side flanges may be bent back into position to engage their respective edge of the structural member.
Although the description above is in reference to floor joists, it will be appreciated that the apparatus 20 may also be applicable to other structural members as well. Turning to FIG. 8 , a further embodiment of the present invention is illustrated as applied to adjacent wall studs 90 . It will be appreciated that for use in such applications it will be necessary to increase the length of the rigid member 22 and increase the angel 49 . Thicker materials may also be required depending upon the strength requirements of the application.
While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims. | Disclosed is an apparatus and method for reinforcing adjacent parallel spaced apart wooden structural members wherein each of the structural members has opposed first and second edges. The apparatus comprises a rigid member being sized to extend between the first edge of a first structural member and the second edge of an adjacent second structural member. The apparatus further comprising first and second sockets connected to first and second ends of the rigid member each sized to receive and edge of one of the structural members therein. The method comprises engaging the first socket around the first edge of the first structural member and locating a second structural member with the second edge of the second structural member within a second socket. The method may also comprise rotating the rigid member between the first and second structural members until the first and second sockets are engaged around diagonally opposed edges the structural members. | 4 |
RELATED APPLICATIONS
[0001] This is an US National Phase Patent Application Under 35 USC §371 of International Patent Application No. PCT/IL2009/001108, filed on Nov. 25, 2009, which claims priority of Israeli Patent Application No. 196406, filed on Jan. 8, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of signaling/messaging in broadband access networks being wire-line (non-cellular) networks. More specifically, the invention relates to a technology for evaluation of quality of service (Quality of Experience or QOE) in the mentioned access networks utilizing multicast services.
BACKGROUND OF THE INVENTION
[0003] Multicasting of telecommunication services to access subscribers is a common modern solution for providing, to groups of the access subscribers, such broadcast services as TV services, video on demand and the like from a sender located beyond the access network.
[0004] In order to provide multicast services to a number of access subscribers, the required broadband service is sent as a single stream by a source/sender to an access node, and then the access node multicasts the received stream to the subscribers that ordered it.
[0005] Modern standard streaming protocols allow not only for streaming the required services, but also for evaluation of Quality of Experience (QOE), by collecting the QOE data from receivers of the services and by forwarding the collected QOE data to the source of the stream (at application layer).
[0006] However, in modern access networks, the above-mentioned method of QOE evaluation fails due to several reasons, and mainly due to the fact that the number of subscribers is very high so the sender of the multicast services cannot be aware of all the subscribers (receivers).
[0007] To be more specific, the presently known actual streaming applications utilize the following types of standard protocols:
Data forwarding protocols (e.g. RTP—Real time Transport Protocol) for the actual forwarding of the streamed data packets. The data forwarding protocols may include UDP (User Datagram Protocol) or TCP (Transport Control Protocol) for packet transport, and IP (Internet Protocol) for packet forwarding. The IP protocol allows both the unicast and the multicast forwarding of the frames. Streaming control protocols (e.g. RTSP—Real Time Streaming Protocol) for controlling the streaming of the packets. The streaming control commands may include start, stop, fast forward rewind and other streaming commands.
[0010] Streaming service control protocol (e.g. RTCP—RTP Control Protocol) for conveying control messages between the sender and the receiver(s). These messages allow the sender to indicate to the receiver how many packets were sent, and allow the receiver to respond how many packets were received, how many are missing, or are received with errors, etc. These protocols should allow the sender to modify the nature of streaming according to the reports received from the receivers.
[0011] For unicast conditions (one sender to one receiver), the above-described functions of the standard streaming protocols are performed properly. In cases where multicasting is required, the streaming protocol relies on the IP multicast data forwarding protocol to produce multiple streams to the users. However, the standard streaming control protocols cannot be used since, when one of the receivers commands to affect its specific stream, it affects all the remaining multicast streams and receivers. Such a situation is non-acceptable; as a result, the multicast streaming is not controlled today.
[0012] As to the streaming service control protocols, they theoretically can be used for multicast cases; however, the problem of numerous feedback responses sent by numerous receivers/subscribers to one and the same source makes these protocols problematic, at least due to the necessity to process all the responses.
[0013] IETF RFC 3550[1], Tree Structure for Source-Specific Multicast with Feedback Aggregation [2] and US published application US2006/0069799 AA [3], describe several methods that allow multicast forwarding of control packets from sender to multiple receivers and further aggregation of receivers' feedback packets, sent from the receivers to the sender/source, at an intermediate node. These methods suppose that there is an ability of the streaming application in the sender to analyze and adapt the downstream service based on the aggregated feedback QOE control packets from the receivers.
[0014] However,
The sender's application is typically unaware of the specific receivers. This is a result of the multicast method in access nodes that multicast the streamed data based on previously learned data (usually via IGMP protocols). Even if the sender application were aware of the receivers it could not do anything in response to the obtained streaming service control data (QOE), since for the sender application, any loss or error in a packet for a specific receiver must not degrade the user experience of the many other receivers that receive the same stream but, say, without errors.
[0017] Even if the burden on the sender applications is alleviated by aggregating the data on the path from the many receivers to the sender (as it was suggested in [1] and [2]), functionally there is nothing meaningful the sender application can do with the aggregated data for the same reasons: 1) the receivers are unknown and 2) that the streaming must continue to all receivers even in case when one of them has degraded.
[0018] To the best of the Applicant's knowledge, none of the presently known streaming applications and none of the streaming service control protocols discuss how to handle QOE data collected from multiple receivers which are often unknown to the sender, none of them proposes an idea how to use this type of data, and none of them discusses or uses specific features of wire line access networks for handling that data.
OBJECT AND SUMMARY OF THE INVENTION
[0019] In view of the above-mentioned problems, the Inventors have recognized the following:
1. An access node of the access network can be utilized so as to undertake more responsibility and make the multicast streaming more effective. 2. The streaming service control messages SSCP, which are not used for multicast services at the present stage, contain important information. It is the information on the so-called Quality of Experience (QoE) or Quality of Service (QoS) of the streaming service as perceived by numerous receivers of the access network. This information is presently thrown away, while it could serve some important needs of the access network.
[0022] In the frame of the present application, the QOE data comprised in the SSCP messages should be understood as an informative portion reflecting one or more parameters of the streamed data, for example the number of lost frames, the Bit Error Rate (BER) value, the Packet Error Rate (PER) value, the noise ratio, etc.
[0023] The Inventors therefore see some important functions which are new for a modern access node that handles multicast traffic for numerous access network receivers.
[0024] For example, the first of them is as follows:
The access node itself, or the access node in cooperation with some hardware/software entity (say, a processing and monitoring entity) may be enabled to analyze the QOE data in the SSCP report messages, to identify specific receivers which encounter “bad” QOE and to indicate problems to the provider of the network. Once such condition is identified, it allows performing some activities to remedy the problem.
[0026] Therefore, to make multicasting in access networks more effective and utilize SSCP messages (streaming service control protocol messages), the Inventors propose a Method, a System, an Access Node and a Monitoring Entity which, separately and together, implement the proposed new technology.
[0027] First of all, there is proposed a method for handling SSCP messages received at an access node that serves an access network, the method comprises:
multicasting, by the access node, a traffic stream generated by a source, to two or more access network receivers, wherein a Streaming Service Control Protocol SSCP is utilized for said traffic stream and wherein each of said receivers is served via a transmission path in the access network, processing SSCP report messages received at the access node from said two or more receivers, comprising analysis of Quality of Experience (QOE) data retrieved from said SSCP report messages; based on the analyzed QOE data, providing status information, wherein the status information comprises indication of problems, if any, per access network section wherein the access network section includes a receiver out of said two or more receivers and a transmission path associated with said receiver in the access network; using the status information in monitoring the access network.
[0031] The above method may also be called a method of forming an inventory data base for an access network. The method may then comprise registering the status information, and/or may comprise managing the network based on that information.
[0032] The step of providing the status information may comprise generating a QOE evaluating message per multicast session, forwarding the message to a monitoring entity and registering the status information in said entity. The method may further comprise: accumulating and updating the status information about said receivers and their associated transmission paths; forming indications of persistent problems in the transmission paths and generating alerts about the persistent problems.
[0033] Preliminarily, the processing may comprise steps of handling an SSCP sender message received by the access node with said traffic stream transmitted from the source, and further comparing said sender SSCP message with the report SSCP messages received at the access node from the two or more receivers.
[0034] The comparing may comprise checking of at least one of the following parameters of the QOE data: a number of lost frames, BER value, PER value, noise ratio at a specific receiver in comparison with a threshold value set for the respective parameter and in comparison with the respective parameter in the sender SSCP message. The analyzing of the QOE data may comprise filtering floods of said SSCP report messages indicating similar errors.
[0035] The method may further initiate maintenance and/or repair operations based on the indication of problems in the access network.
[0036] To implement the above method, there is also provided a system for handling SSCP messages, comprising at least one access node AN, at least one processing unit PU and at least one monitoring entity ME, wherein
AN out of said at least one AN is supporting a Streaming Service Control Protocol SSCP and serving two or more access network receivers of an access network via two or more respective transmission paths; the access node being capable of multicasting a traffic stream, generated by a source, to said two or more access network receivers and to receive report SSCP messages from said two or more receivers; said at least one processing unit PU being adapted to process the report SSCP messages, form status information and supply it to said at least one monitoring entity ME, wherein the processing comprising analysis of Experience data (QOE data) retrieved from said SSCP report messages, the status information being formed based on the analyzed QOE data and comprises indications of problems, if any, per access network section, wherein said section includes a receiver out of said two or more receivers and a transmission path associated with said receiver in the access network; said at least one monitoring entity ME being capable of at least monitoring the access network using said status information.
[0042] Arrangement of the above-mentioned units in the system can be selected in accordance with a specific preferred configuration. For example, AN may incorporate both PU and ME; AN may incorporate PU while ME remains a separate unit; AN may be a separate unit while ME may be merged with PU.
[0043] From the point of view of location of the above units in the networks, various options may exist as well. For example, more than one PU and more than one ME may serve more than one AN of the access network, PU and ME may either reside in one location, or be distributed between two or more of the following locations: a Network Management and/or Service system NM/SS, a Central Office serving the access network, a Network and/or Service provider, at least one access node, at least one network node in the access network, at least one network node beyond the access network, etc.
[0044] The monitoring entity of the system may be further capable of generating alerts for performing repair and maintenance operations in the access network, based on said indications.
[0045] The system may be further adapted to perform one or more of the following functions:
filtering the status information to distinguish problematic receivers and their associated transmission paths versus non-problematic ones; identifying persistent problems related to specific problematic receivers and their associated transmission paths, identifying problems of peak-time consumption of multicast services, generating alerts; initiating corrective actions if needed.
[0051] In view of the above-mentioned various options of arrangement and allocation of the system components, the present invention also provides independent protection to an Access Node AN enhanced to possess the novel functions, and to a Monitoring Entity ME which allows providing the novel functions in cooperation even with a conventional Access Node(s).
[0052] The inventive Access Node AN should be suitable for handling multicast traffic to and from multiple subscribers, e.g. Digital Subscriber Line (xDSL)/Passive Optical Network (xPON), Point to Point Ethernet traffic, etc. The inventive access node AN can be designed on the basis of such modern access equipment as a DSLAM (Digital Signal Line Access Multiplexer), an MSAN (Multiservice Access Node), or the like.
[0053] The Access Node may be operative to provide the status information by generating a QOE evaluating message per multicast session. The Access Node may be further adapted to process an SSCP sender message, received at it with said traffic stream sent from the source, and to compare said SSCP sender message with said SSCP report messages. The Access Node may be further capable of filtering floods of said SSCP report messages indicating similar errors.
[0054] In the above definitions, the transmission path should be understood as comprising a fixed section in the access network, terminated with and including the receiver's equipment. In contrast with wireless networks, status information about such fixed sections in the access networks of interest can be collected gradually, since their characteristics do not change quickly. The status information can be registered and accumulated to indicate (by means of a responsible entity such as ME) some persistent problems in specific transmission paths. The status information with indications of problems, and/or the registered persistent problems' indications can be then used for producing alerts/alarms, monitoring the access network and finally for management, e.g., for handling the problems off line.
[0055] The access network may constitute a wire-line access network such as any Digital Subscriber Line (XDSL), any Passive Optical Network (XPON), Point to Point Ethernet (PtP Ethernet), etc.
[0056] The source of the traffic stream should be understood as a node which, in a general preferred case, is located beyond the access node. However, in some specific cases, the access node may serve as the source that performs multicasting, for example, for diagnostic purposes, for building the complete data base comprising status information about all receivers in the access network, etc.
[0057] In the general and more practical case, the traffic stream is transmitted from the source, located beyond the access network and the access node, towards multiple receivers belonging to the access network, but the transmission is performed via the access node. The access node should be adapted to process SSCP sender messages received with said traffic stream sent from the source.
[0058] This preliminary processing will further allow evaluation of the report SSCP messages obtained at the access node from the two or more multicast receivers of the multicast traffic stream.
[0059] The step of providing the processed QOE information to the Monitoring Entity (directly from the Access Node, or via the Processing unit) preferably comprises generating a so-called QOE evaluating message per multicast session, forwarding the message to the entity and registering the status information in a suitable data base.
[0060] In some cases, an SSCP message sent by the AN to the source as the AN report message can be used for forming the QOE evaluating message.
[0061] The system and, more specifically,—the monitoring entity ME is preferably responsible for management and/or service of the access network. ME is preferably adapted to accumulate and update the status information in the status data base, to form indications of persistent problems in the transmission paths and in particular in their fixed portions per multicast receiver, to generate alerts/alarms in response to the status information and/or to the persistent problems and to initiate management and/or service operations for eliminating the problems in specified transmission paths/receivers. For example, the network/service provider, using the information and/or the alerts provided by the ME, will be able to send a technician to the premises of a specific “problematic” receiver. The proposed management would allow performing effective and focused repair and maintenance operations in the access network.
[0062] In the monitoring entity, the QOE information may be received from AN out of said at least one AN in the form of a QOE evaluating message.
[0063] The QOE information may be received in the ME from AN out of said at least one AN in the form of a copy of an SSCP message sent by the AN to the source as a report message.
[0064] The data base which stores and updates the status information about all receivers and their associated links in the access network can be called an QOE inventory data base of the access network and used accordingly.
[0065] It should be noted that alternative techniques to produce such data about status of receivers and links in the access network are much more complicated and include dedicated hardware for the purpose of QOE analysis.
[0066] The second function which is believed to be important and novel is the following. The access node can be enabled to process (aggregate, filter, analyze, etc.) floods of “error messages” (i.e., messages with error indications in the QOE) of the streaming service control protocol (SSCP). This relates both to SSCP sender messages arriving to the access node with the incoming traffic stream and to SSCP report messages arriving from the multicast receivers to the access node. For example, in case one packet is missing at the input to the access node, it is not retransmitted, so all receiver applications will mark it as an error (the reports will comprise the similar error indications). The access node can detect/identify that such a case has occurred, by comparing the SSCP reports obtained from different receivers; the access node may treat the reports differently in this case, e.g. such an error messages flood may be ignored because the problem is located in another part of the network.
[0067] Still further, the technology may comprise representing the status information as a QOE map of the access network and possibly storing it in the data base. The representation can be performed in the form of a map allocating specific problems in the receivers and/or the transmission paths (links) associated with the receivers.
[0068] Yet another embodiment of the proposed technology may comprise optionally storing, in said data base, status information concerning QOE of the access node as a receiver of at least one said traffic stream transmitted by the source. Such access node status information comprises at least QOE data obtained from an SSCP message being a report of the access node to the source upon receiving the mentioned traffic stream.
[0069] As has been mentioned, the processing of said reports preferably includes preliminary processing/handling of a sender SSCP message received at the access node with said traffic stream; results of the preliminary processing of the sender's message may be further compared with said reports.
[0070] To perform the preliminary processing of the SSCP messages, the access node may act, for example, as a “snooping node” or as a “proxy node”.
[0071] In the first case, the preliminary processing may comprise a so-called “snooping” of the sender's SSCP message, which includes looking into the sender's message at the access node, registering its data, and sending the sender's message as is to the multicast receivers. The processing then comprises obtaining SSCP receivers' messages (the receivers' reports) at the access node, comparing them with the sender's message, analyzing, aggregating the reports at the access node and issuing towards the source node an aggregated SSCP message.
[0072] In the second case, the preliminary processing may comprise storing the sender's SSCP message, converting it at the access node (which serves as a proxy), and issuing the converted SSCP access node (AN) message to the multicast receivers. The processing comprises receiving at the access node SSCP receivers' messages (reports of the multicast receivers), comparing the reports with the sender's SSCP message, analyzing and forming not just an aggregated message, but an SSCP access node (AN) receiver message which is sent from the access node towards the source node.
[0073] The proxy access node may be preferable since it is capable of sending its own additional messages, for example in case of detecting a problem in one or more transmission paths, it may send verifying messages to check whether the problem indeed persists.
[0074] The comparison and analysis of the QOE data in the reports may comprise analyzing the number of lost frames/the BER value/PER value/the noise ratio etc. at a specific receiver in comparison with a threshold value set for the respective parameter and with the value of the respective parameter in the sender message.
[0075] Status information formed about links/receivers in the data base, when accessed by the network and/or service provider, serves a tool for determining problematic links, receivers, for detecting congestion-affected regions in the access network, etc.
[0076] Examples of problems and suitable analysis that can be performed in this way are:
Excess Packet Error Rate (PER) can be understood from the Receivers SSCP messages. Once identified, a Trouble Ticket can be created to analyze the causes of the malfunction. This can be done by the ME in the Service Provider even before the user complains. Tracking of time of day related aspects of the QOE may reveal congestion problems related to peak time usage of the access links.
[0079] The proposed technique may further comprise performing one or more of the following functions by the system (or more specifically, by the monitoring entity ME):
Filtering the status information in the data base to distinguish problematic receivers and their associated links versus non-problematic ones; Identifying persistent problems related to a specific receiver and initiation of corrective actions as needed; Identifying persistent problems in links between the source and the receivers and initiation of corrective actions if needed; Identifying problems of peak-time consumption of multicast services; Generating alerts and initiating maintenance and/or repair/corrective operations if needed, based on the status information received/accumulated at the monitoring entity.
[0085] The QOE information in the ME may be received from AN out of said at least one AN in the form of a QOE evaluating message. The QOE information may be received from AN out of said at least one AN in the form of a copy of an SSCP message sent by the AN to the source as a report message.
[0086] According to yet another aspect of the invention, there is further provided a software product comprising computer implementable instructions and data stored on a non-transitory computer readable medium; the software product being capable of implementing operations of the described method, when being installed and run in a computer system. Such a computer system may, for example, be a system distributed between a number of locations in the network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0087] The invention will be further described in detail with reference to the following non-limiting drawings in which:
[0088] FIG. 1 (prior art) schematically illustrates a route of a traffic stream transmitted from a source node to an access node, and there-from to multiple receivers, as a multicast traffic stream.
[0089] FIG. 2 (prior art) shows a chart schematically illustrating how SSCP messages are presently handled in access networks utilizing multicast traffic streams.
[0090] FIG. 3 is one example of the proposed technology for handling SSCP messages in access networks.
[0091] FIG. 4 is another example of the proposed technology for handling SSCP messages in an access network.
[0092] FIG. 5 schematically shows an exemplary block diagram for analyzing SSCP messages of multicast receivers for building inventory information of the access network.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0093] FIG. 1 shows a general widely accepted scheme of providing a stream of data packets from a Sender 10 to multiple Receivers marked 22 , 24 . . . 26 located in an access network 20 , being performed via a transport network (called here core or aggregation network) 16 and an access node 18 . The Sender 10 is provided with a Sender Streaming Application 12 and a Sender Streaming Platform 14 which together allow utilizing the protocols necessary for streaming data downwards and upwards (i.e., a data forwarding protocol, a streaming control protocol and a streaming service control protocol). The receivers 22 - 26 , each utilizing a suitable receiver streaming application, are expected to return their control messages responses that indicate service status, to the Sender 10 via the access node 18 and the transport network 16 . The data stream transmitted by the Sender 10 can be multicast at the core/aggregation network 16 so as to reach not only the access node 18 but also other access nodes (not shown) which, in turn, return to the Sender their responses and reports. In that specific example, the Sender 10 can be a videoserver providing a video stream over RTP/RTSP/RTCP Streaming Application 12 , the network 16 can be any packet transport network that is suitable for handling various multicast traffic technologies, for example over IP and/or over MPLS and/or over Ethernet.” The access node (AN) 18 can be any type of equipment suitable for handling multicast traffic to and from multiple subscribers, e.g. the XDSL/XPON or Point to Point Ethernet traffic. The receivers 22 - 26 are any type of receivers located in a home network, like a Set top box and TV, a PC with its display, etc. The inventive solution which will be explained below is applicable, for example, to the basic configuration illustrated and described with reference to FIG. 1 .
[0094] FIG. 2 (prior art) presents a schematic chart which illustrates how data and messages of streaming service control protocol (SSCP messages) travel between the Sender 10 and receivers 22 - 24 of FIG. 1 in presently known network systems which utilize multicasting at access node 18 .
[0095] The Sender's Application 12 , by using its data forwarding protocol, causes streaming of data packets ( 30 ) from the sender 10 up to the access node 18 . At the access node 18 , the data stream is copied and forwarded to multiple users (receivers) in the access network 20 by multicasting ( 32 ). The copied data streams ( 34 ) arrive to receivers 22 , 24 , 26 .
[0096] Inter alia, the Sender's Application 12 also provides a sender's Streaming Service Control message (SSCP message) 31 which reaches the access node 18 and is transparently forwarded to the multicast receivers as a number of SSCP messages 33 .
[0097] The Receivers' Streaming Applications ensure that the receivers 22 , 24 , 26 return to the Sender SSCP receiver messages (reports) 35 , 37 , 39 where each of them should report to the sender about Quality of Experience of receiving the streams 34 of data packets. Theoretically, the sender (i.e., the sender's streaming application) should be capable of adjusting its operation based on SSCP reports obtained from receivers of the streamed data packets.
[0098] As has been mentioned in the Background section of the invention, the sender application 12 is usually non-aware on the quantity and identity of the multiple receivers to which the data stream is transmitted by multicasting. Therefore, effectiveness of the reports 35 , 37 , 39 received at the sender's application 12 , is almost zero.
[0099] FIG. 3 . The present invention proposes that the access node, or a system comprising the access node, be provided with a new intermediary (additional, supplementary) function taking place between the sender application and a receiver application for the purpose of collecting, aggregating, analyzing and reporting data sent by the receivers via the streaming services control protocol SSCP (for example such as formal RTCP [1]). This intermediary function, while being new as is, seems ideal for creating a data base of access network receivers (and their associated transmission paths) from the point of view of QOE. We keep in mind that the QOE data is reflected in the SSCP reports of the receivers.
[0100] Conventional functions of the access node are illustrated and marked in FIG. 3 similarly to the way it has been made in FIG. 2 .
[0101] One method for implementing the newly proposed intermediary function is a so-called snooping method, schematically presented in the chart of FIG. 3 as follows. In FIG. 3 , the modified access node is marked 118 . While the conventional functions/blocks are marked with the same reference numerals as in FIG. 2 , new functions/blocks are indicated with differing reference numerals.
[0102] The Access node 118 “snoops” sender SSCP messages such as 31 and forwards them untouched to all multicast receivers (for our example, to 22 , 24 , 26 ). That operation is performed in a snooping block 36 , which can be considered part of a newly proposed Processing Unit PU 41 , and refers to a method to learn the message contents without affecting its forwarding (as any other packet). The contents of the sender message is registered and will serve for future decisions made by the access node after the feedback receiver messages (report SSCP messages) are handled by it.
[0103] The Access Node 118 , using a new analyzing block 38 which forms another portion of the inventive Processing Unit PU 41 , snoops the receivers' report SSCP messages, compares them to the data registered from the Sender SSCP messages. Suppose that the results of the analysis performed in block 38 will yield a receiver with a problematic link (transmission path). The behavior of the link can be further tracked with the aid of block 38 , to see if the problems are persistent. Indication of the problem can be sent to a monitoring entity ME 44 comprising a data base and schematically shown by a box 44 . The monitoring entity may, for example, belong to a network operator or a service operator. Details of how the network/service operator can be informed will be explained below. The Access node 118 can further aggregate the receivers' SSCP messages (the aggregation is optionally comprised in block 38 ). Such aggregation is not a collection of all messages into one single SSCP header but a functional collection in which the access node analyzes the root cause of the problem and produces only the SSCP data related to it. For example, if the same data packet was not received by all receivers, then only one indication of this packet loss will be sent to the Sender in the frame of the SSCP Aggregated message 40 , instead of the many loss indications from all the receivers.
[0104] The Access Node 118 , in addition to its novel snooping and analyzing functions, issues a QOE evaluation message 42 to a newly provided monitoring entity ME 44 . The QOE evaluation message reflects QOE data of the multicast receivers 22 , 24 , 26 . In the specific preferred case, the message 42 comprises information about QOE problems, if any, in one or more of the specific receivers (and their associated transmission paths/links). As an option, a copy of the SSCP aggregated message 40 can be used for informing the ME 44 ; such a message will be further processed in the ME to obtain status information on problems, if any, of specific receivers/paths.
[0105] It should be added that the ME 44 can be organized in any entity intended for management and service of the access network, and even be distributed there-between. It can be a Central Office (CO) of the access network, a management unit in the access node such as DSLAM or MSAN, a Network or Service management system which is in charge of the access network 20 , a Network Provider, etc.
[0106] Similarly, the processing unit PU (at least its analyzing block 38 ) may be located beyond the access node, for example be merged with the monitoring entity ME. In this case, the access node remains almost conventional and should just provide the PU & ME with information about the report SSCP messages or even with copies of these messages (see 35 , 37 , 39 of the access node 18 in FIG. 2 ).
[0107] FIG. 4 illustrates a functional chart of another example of a modified access node 180 . The chart comprises a number of functions similar to those in FIGS. 2 and 3 . However, FIG. 4 illustrates a new intermediary functionality of the modified Access Node (AN) 180 , being a so-called “proxy” functionality. The access node 180 , similarly to the access node 118 of FIG. 3 , provides information about status of access network to a monitoring entity ME 44 . In this example, it is executed in the form of a QOE evaluation message 42 .
[0108] The Access Node 180 serves as an SSCP Proxy. As a proxy, the Access Node 180 will play a role of a receiver application towards the sender application 12 (on the section from sender to access node). The Access Node 180 will also serve as a sender application towards the final receiver applications 22 , 24 , . . . 26 (on the section from the access node to the multiple receivers). In this role, the Access Node 180 , by means of a proxy block 46 , creates from the SSCP Sender message 31 a number of individual SSCP messages—SSCP AN messages 43 , 45 , 47 . These messages may be different, or be sent with different frequency, etc.
[0109] In such a proxy mode, when receiving the report messages 35 , 37 , 39 from the receivers, the Access Node 180 , with the aid of an analyzing unit 48 , will be able to compare these messages with the sender message, analyze the results and create its own receiver message (SSCP AN receiver message 50 ) which will accumulate both the QOE information concerning the receivers 22 , 24 , 26 , and the QOE information concerning the AN 180 as a receiver of the data stream 30 . The Access Node 180 will therefore be able to provide to the sender application 12 a QOE picture between the sender 10 and Access Node, and a QOE picture between the Access Node and each of the receivers of the multicast stream. By combining the two pictures, a general QOE picture can be established end to end (from sender to receivers).
[0110] To emphasize and further utilize the possibility of obtaining the QOE pictures of the combined network, from the sender up to the access network receivers, the Access Node 180 (say, its analyzing block 48 ) is adapted to generate an QOE evaluating message 52 which is issued to the Monitoring Entity 44 .
[0111] FIG. 4 illustrates the system where the monitoring entity ME 44 is located beyond the access node AN 180 which incorporates the Processing unit PU 51 (blocks 46 & 48 ). Modern access nodes such as DSLAM (Digital Signal Line Access Multiplexer) or MSAN (Multiservice Access Node) can be modified to incorporate the proposed PU and even ME. However, various arrangements are possible, as has been mentioned before with reference to FIG. 3 .
[0112] With respect to possible configurations of the system, it should be kept in mind that an access network can be served by more than one access nodes AN, and that more than one processing units PU and monitoring entities ME may be utilized and may cooperate with one another in various combinations for monitoring the mentioned access network.
[0113] FIG. 5 presents a block diagram being a schematic example that lists some operations performed in the novel analyzing block 38 (see FIG. 3 ). Block 38 is the main block of the Processing Unit PU 41 ; it is responsible of processing the SSCP report messages with QOE data, received from multicast receivers 22 , 24 , 26 at the Access Node 118 . The example indicates some parameters which were checked at the multicast receivers to detect specific problems, for further reflecting them in QOE data of the report messages. Such problems to be checked, for example, are excessive PER (Packet Error Rate), excessive BER (Bit Error Rate), missing frames, noise ratio, etc.
[0114] The analyzing block 38 comprises an SSCP receipt block 60 which receives report messages 35 , 37 , 39 and distributes them to processing blocks 62 , 64 , 66 (per receiver). The processing block 62 related to receiver 22 is shown in more detail, with its accompanying group of supplementary operation blocks. The processing blocks 64 and 66 of the receivers 24 and 26 are similar to the group of block 62 , and should be understood as performing analogous functions with respect to reports of receivers 24 and 26 .
[0115] Block 62 analyzes QOE data in the report SSCP message 35 in comparison with the QOE data in the SSCP message 33 which was stored in the Access Node 118 and is now fed to block 62 . The result of analysis may be, for example, that no problem is identified by receiver 22 (block 68 ), that receiver 22 has detected a pattern of excessive Bit Error Rate BER or Packet Error Rate PER (block 70 ), that a block of data packets is missing at the receiver 22 (block 72 ), or any other problem, say, excessive noise level, is detected at the transmission path (Block 74 ). All these or other problems are monitored to analyze their time related behavior (block 76 ), for example to detect whether the problem is persistent or random, whether there is a congestion problem perceived by the specific receiver/link, etc.
[0116] Based on results of the analysis performed by block 76 , the Access Node 118 prepares a problems report concerning receiver 22 . Similarly, the Access Node 118 prepares (in the blocks 64 , 66 ) reports concerning the remaining multicast receivers 24 , 26 . These partial reports are then fed a) to block 80 , to form the SSCP Aggregated message 40 for the Sender, and b) to block 82 , in order to form the combined QOE evaluation message 42 which is further used for creating status information of any problems in receivers/transmission paths of the access network 20 .
[0117] The responsible monitoring entity ME 44 receives the message 42 (which, in principle, can be formed upon each multicast session performed to those or different receivers of the access network) and thus updates the status information in its data base.
[0118] The monitoring entity ME 44 , in cooperation with the Processing unit 51 , allows producing alerts and performing the following actions:
Filter the reports to look for patterns. Based on the application sensitivity to Bit errors and Frame errors, the ME at the Network provider or the Network service/management system creates presentations that emphasize problematic links vs. good links or sections; Identify persistent problems related to a specific receiver and initiation of corrective actions as needed. Identify persistent problems in Sender—access node links/sections. Such persistent problems may indicate congested links that cause repetitive loss of frames. The ME then initiates corrective actions to remedy the problem. Identify problems that arise during peak-time consumption of multicast services. In many cases the noise level rises when many subscribers use the links extensively for streaming. In view of that, the multicasting at the access node can be regulated accordingly.
[0123] The benefits of the invention are numerous:
By a simple method (snooping or proxy of the SSCP protocol messages) in the access node, valuable QOE data can be collected, analyzed and stored in a specified Data Base of a Monitoring entity Alternative methods to produce such data are much more complicated and include specifically dedicated hardware for the purpose of QOE analysis; The Sender application can receive processed data with valuable QOE information that may affect its streaming behavior; The Monitoring Entity, for example residing at a Network and/or Service provider, using the created specified Data Base, can collect and evaluate valuable QOE data about their streaming services, find problematic links and take care of congestion cases.
[0127] It should be appreciated that other modifications of the proposed technique can be suggested in addition to those described and illustrated as specific examples, and such modifications should be considered part of the invention as far as being covered by the claims which follow.
REFERENCES
[0000]
[1] IETF RFC 3550 RTP: A Transport Protocol for Real-Time Applications
[2] Dan Komosny, Vit Novotny, Tree Structure for Source-Specific Multicast with Feedback Aggregation;
[3] US Patent US2006/0069799 AA—Wager Stefan et al, Reporting for Multi-User services in a wireless network | A technique enabling an access node to undertake more responsibility and render multicast streaming more effective by utilizing streaming service control messages SSCP which contain important information such as Quality of Experience or Quality of Service. The access node itself or in cooperation with a processing/monitoring entity may be enabled to analyze QOE data in SSCP report messages from different access network receivers, to identify specific receivers which encounter problems and to indicate the problems to the provider of the network. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of patent application Ser. No. 08/974,536 filed on Nov. 19, 1997, now U.S. Pat. No. 5,924,899.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrical connectors. Specifically, it relates to electrical connectors constructed of a plurality of circuit substrate modules, to which mating terminals and other components may be attached.
2. Brief Description of Prior Developments
Connectors formed of printed circuit boards arranged in side by side relationship have been disclosed. One such system is shown in U.S. Pat. No. 4,521,014. However, the construction shown in this patent would be expensive to produce and difficult to miniaturize.
Published European Patent Application Serial No. 0 752 739 (commonly owned by the assignee of the present invention and incorporated herein by reference) discloses a modular connector system using side by side stacked circuit substrates to form miniaturized, high speed connectors capable of being manufactured at lower cost.
U.S. application Ser. No. 08/784,743 filed Jan. 16, 1997 illustrates modular connectors of a similar type used to form high speed cable interconnections. U.S. patent application Ser. No. 08/784,744 filed Jan. 16, 1997 illustrates arrangements for surface mounting such high speed connectors. Both of these applications are commonly owned by the assignee of the present application and are incorporated herein by reference. However, a need exists to increase the high frequency performance of these systems and reduce the manufacturing costs. Regarding performance, current widely commercial backplane connector systems having a 2 mm grid pitch run at levels of 10% cross talk at 500 picosecond rise times (0.7 GHz). Electrically enhanced versions of these systems approach a performance level of 6% cross talk at 500 picosecond rise times. However, for data transmission especially performance levels of 1% cross talk at signal rise times of 60to 100 picoseconds (3.5 to 6 GHz) are desirable for systems meant to carry digital signals at a 2.5 Gigabits/second rate.
SUMMARY OF THE INVENTION
This invention relates to electrical connectors and interconnection systems formed in a modular fashion from stacked assemblies of circuit substrate elements. Contact terminals, especially receptacle terminals are provided with shielding in the mating region of the terminal. High cross talk performance is achieved by shielding that can be carried through the interconnection, with also the possibility of incorporating signal conditioning elements in the connector.
Manufacturing costs are improved by providing terminal carriers for holding a plurality of terminals in position to be mounted on the circuit substrate simultaneously. The carriers can be designed to function as a means for retaining modules in a housing and/or transmitting insertion force to press fit terminals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a,1a', 1a", 1b, 1c and 1d are isometric views of the various components of a right angle receptacle connector made in accordance with the invention;
FIGS. 2a and 2b are isometric views of components of a right angle header module;
FIGS. 2c and 2d are isometric views of terminal blocks or carriers used in the module shown in FIG. 2b;
FIGS. 3a and 3b are isometric views of a right angle header using the module shown in FIG. 2b;
FIGS. 4a, 4b and 4c are isometric views of a module or parts thereof used for forming cable connectors;
FIGS. 5a, 5b and 5c are isometric views of a receptacle cable connector using modules of the type shown in FIG. 4b;
FIGS. 6a and 6b show another embodiment of cable connector module similar to that shown in FIG. 4a;
FIGS. 7a and 7b are isometric views of a right angle receptacle connector arranged for differential signal pairs;
FIG. 8a is an isometric exploded view of a right angle receptacle connector having shielded receptacle contacts;
FIGS. 8b and 8c are isometric views of a receptacle carrier having first make, last break functionality;
FIG. 9a, 9b, 9c an 9d shown several variants of terminal carriers for forming connections to printed circuit boards;
FIG. 10 is a front elevational view of the terminal carrier shown in FIG. 9a;
FIG. 11a is a top elevation of a shielded receptacle carrier and
FIG. 11b is a side elevational view of that carrier;
FIG. 12 is a cross-sectional view taken generally along line A--A of FIG. 13.
FIG. 13 is a side elevational view of the right angle connector shown in FIG. 8a, mated with a header connector;
FIGS. 14a and 14b are top and side views respectively of a shielded pin carrier for surface mounting on a circuit module, and
FIG. 15 is an isometric view of an interconnection system made up of several of the connectors illustrated in the proceeding figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a shows an exploded view of a right angle receptacle connector embodying features of the invention. The connector 20 includes a plurality of circuit modules 22. Each module 22 includes a circuit substrate 24 that can be formed of a substantially planar piece of printed circuit board material, such as that sold under the commercial designation FR4, or other suitable materials. Also, the substrate 24 can be formed of a molded or cast piece of a suitable insulative material, especially one receptive to or easily treated to be receptive to the formation of conductive traces on its surface. The substrate 24 carries a plurality of conductive traces (see FIG. 2a) extending from the region of one edge, such as edge 24a to the region of a second edge, such as edge 24b. Preferably, ground tracks are interlaced with the terminal traces for shielding of these traces. In addition, the side of the substrate 24 opposite the side carrying the circuit traces (the side disposed upwardly in FIG. 1a) is covered with a continuous shielding or ground layer. Such constructions are disclosed in above-noted published European patent application.
Each module has one or more sets of terminals secured on its track receiving side. In the embodiment illustrated in FIG. 1a, one terminal set comprises a receptacle terminal assembly 26. As shown in exploded view in FIG. 1a", the terminal carrier 26 comprises a housing 28 of insulative material having a plurality of aligned openings 30. A receptacle terminal, such as a tuning fork terminal 32, is received in each of the openings 30 and is retained therein by retentive barbs 33 on side edges of the terminals. The tines 34 of the terminals extend through an offset region 35 to a base section 36 having a surface 38 adapted to be surface mounted on a conductive trace of the substrate 24. Preferably, the surfaces 38 are arranged to be substantially coplanar with the top surface 28c of the housing 28. Suitable location and retention structure, such as locating/mounting pegs (not shown) may be formed on the housing 28 to aid in location and retention of the terminal carrier on the circuit substrate 24. Similarly, a press fit terminal carrier 40 having a plurality of press fit terminals 42 may be mounted along edge 24b. The press fit terminal carrier 40 may also include an extension 44 that comprises structure for transmitting press fit insertion force to the terminals. 14. Terminal carriers 26 and 40 are described in greater detail below.
The connector 20 also includes an insulative housing 46. The housing 46 includes a top wall 48 and a front wall 50 having a plurality of a lead-in apertures 52 position to be aligned with the receptacle terminals 32. A plurality of interior walls 53 extend between the top wall 48 and the bottom wall 54 to form a plurality of parallel stacked compartments, each of which receives one of the circuit modules 22. The housing can include a plurality of ground springs 56 for establishing a ground connection between the circuit modules 22 and a mating connector. Alternatively, as described later, the ground springs 56 can be carried by terminal carrier 26.
As shown in FIG. 1b, a plurality of circuit modules 22 are inserted into the housing 46 to form a completed right angle connector. Preferably, the modules are retained in the housing by means of an interference fit between the housing and portions of the modules. Such an interference fit may be created by sizing terminal carrier 26 and/or the press fit carrier 40 in their thickness or width dimensions, or both, so that there is a suitable interference fit with the slots between the dividing walls 53. The modules 22 are supported so that there are spaces 62 between each of the modules. Such spacing allows for other components to be mounted on the module 24, as will be later explained. The connector 20 may also include an additional ground spring 58, that is adapted to ground the connector to the printed circuit board on which it is mounted. The ground spring 58 is retained by a mounting structure 60 that is received on the locating post 63. Grounding can be carried from modules 22 through contact springs (not shown) similar to ground springs 56, that contact ground spring 58.
As previously described, the press fit terminal carrier 40 may include a force transmitting extension 44 that is adopted to bear against the bottom surface of the housing top 48. Thus, when a press fit insertion force is applied to the top 48, that force is applied directly, through extension 44, to the carrier housing 40 to push the press fit terminals 42 into the circuit board. This avoids applying shear stress directly to the solder interface between the terminals 42 and the circuit substrate 24. Alternately, an insertion force may be applied directly to housing 40 by appropriate tooling.
FIG. 1c is an isometric view of the connector shown in 1b taken from the front of the connector, showing the front face 50 with lead-in apertures 52. FIG. 1d is an isometric view showing the top view of the connector 20, with grounding springs 56 extending through slots in the top 48 of the housing and positioned to engage shielding contacts of a mating header.
Referring to FIGS. 2a and 2b, there is illustrated a module 22 that is similar to the receptacle module illustrated in FIG. 1a, with the primary difference being that, in place of the receptacle carrier 26, a pin carrier 64 comprising an insulation body 66 and a plurality of contact pins 68, is mounted on circuit substrate 24. As shown in FIG. 2a, the circuit substrate 24 has a plurality of circuit traces 70 formed thereon. The press fit terminal carrier 40 is secured on one edge of the board with the press fit terminals 42 attached to contact pads 72. The pin carrier 64 is applied to another edge of the circuit substrate. In one variant, the pin header 64 may have one or more contact pins 74 that extend beyond the lower surface of body 66 as shown in FIG. 2c. The pins 74 are adapted to be received in plated through-holes 76 in the circuit substrate. Alternately, the contacts 74 can be substantially flush with the bottom surface of the carrier body 66 (as shown in FIG. 14b), thereby providing for surface mounting of the pin carrier 64 onto the circuit substrate 24.
As shown in FIG. 2d, the circuit substrate 24 may be populated with appropriate passive or active electronic elements 78 for purposes of signal. conditioning or modifying signals carried by conductive traces 70.
As shown in FIG. 2d, the press fit carrier 40 includes press fit terminals 42 that have surface mounting pads 80 substantially coplanar with the bottom surface of the carrier 40. The pads 80 may be integrally formed with the press fit pins 42, for example by bending an integral tab in a U-shape to form the pad 80.
As shown in the exploded view of FIG. 3a and assembled view of FIG. 3b, a suitable header connector may be formed from the modules 22 in essentially the same manner as described with respect to the receptacle connector 20. In this form of a connector, a body 82 of insulative material is formed in a similar manner to the housing 46 of FIG. 1a, with the exception that the front wall 84 of the housing 82 includes an array of integrally formed insulating ferrules 86. A shroud 88 is mounted onto the insulative housing 82, with the ferrules 86 received in openings 90 in the base of the shroud. The shroud in this embodiment is formed of a conductive material, such as a die cast zinc, for shielding purposes. A. latch structure 92 may be secured onto the shroud 88 for purposes of latching a cable connector onto the shroud. FIGS. 4a, 4b and 4c illustrate a module 22" for forming a cable connector. In this version, the circuit substrate 24" includes a receptacle carrier 26 generally of the same type as illustrated in FIG. 1a having a plurality of tuning fork contacts 32. At the end of the substrate 24" opposite the terminal carrier 26, is an insulation displacement contact (IDC) carrier 94 that includes a plurality of insulation displacement contacts 96 received in an insulative cover 98. The bottom surfaces 100 of the IDC terminals are adapted to be surface mounted onto the circuit substrate 24". As is conventional, the terminals 96 are assembled to the cover 98, with the cover positioned to allow insertion of conductors 102 into channels 104 in the cover. To attach the conductors, the cover is pushed toward the terminals 96, causing the conductors 102 to be driven into the IDC contacts 96 and thereby causing the upstanding portions of the terminals to slice through insulation surrounding the conductors 102, as is conventional in such type connectors. Drain wires 105, if present may also be placed in one of the IDC contacts 96. For additional securing of the cables, metal strain relief ferrules 104 may be applied to the cable 106. The strain relief ferrules 104 may be secured to the substrate 24" by means of pegs or by soldering through vias 108 in the substrate 24". A cable connector module 22" is formed as shown in FIG. 4b by applying the receptacle carrier 26 and the IDC terminal carrier 94 to the substrate 24". FIG. 4c illustrates a receptacle carrier 26 of essentially the same type as shown in FIG. 1a. It should be noted that the opposed cantilever sections of each tuning fork terminal formed by the tines 34 and offset portions 35, are joined together at the base 36. The plane of base 36 is offset from the plane of portions 34 by the offset defined by the portions 35. The amount of the offset is sufficient for a signal pin to be received between forks 34 and to pass next to base 36, as shown in FIG. 13. As shown in FIGS. 5a, 5b and 5c, a cable connector may be formed by inserting a plurality of cable connector modules 22" into a cable connector housing 110 formed of an insulative material and having a plurality of parallel slots 111 for receiving the modules 22". As shown in FIG. 5b, a plurality of modules 22" are fit into the housing 110. A shielded connector is formed by securing metal shields 112, with a suitable strain relief structure about the unit formed by the housing 110 and the modules 22". The assembled, fully shielded cable connector is shown in FIG. 5c.
FIGS. 6a and 6b illustrate another form of cable connector module 22" similar to that shown in FIG. 5a except that, instead of the insulation displacement carrier 94, the conductors 102 are stripped and soldered directly onto appropriate contact pads on the circuit substrate.
FIGS. 7a and 7b illustrate a receptacle printed circuit board connector essentially as shown in FIG. 1 with the exception that the modules are placed in alternating orientation to provide for a differential pair arrangement. FIG. 8a is an exploded view of an alternative embodiment to the right angle receptacle connector shown in FIG. 1a. In this embodiment, the receptacle contact carrier 26' includes a surrounding metal shield having contact springs 112 integrally formed with a shield, as will be later described. Contact springs 112 extend through slots 114 in the housing 46. FIG. 8b illustrates a modified form of receptacle terminal carrier useful with the FIG. 8a receptacle embodiment, as well as with other receptacle embodiments. The carrier 26' has a body 28 having a plurality of terminal receiving openings 30. One of the openings, 30', is relieved along the top edge. The relief allows the center tuning fork terminal 32' to be positioned forwardly of the other terminals 32 by a distance FMLB. This provides the receptacle assembly with the capability of a "first make, last break" function with the mating terminal pins, whereby the center pin of an equal length set of pins will engage terminal 32' before the remaining pins engage terminals 32 during mating and will remain in contact with terminal 32' after the remaining pins separate from terminals 32 during unmating. This functionality is provided on the receptacle side of the connector and avoid the need for using unequal pin lengths in the mating header.
FIG. 9a is a cross sectional view of a press fit terminal carrier, such as carrier 40 previously described. In this arrangement, the body 118 of insulative material has a plurality of slots 120 (FIG. 10) in each of which is received a press fit pin 42. Each pin 42 includes a retention section 122 having barbs for retaining the terminal. Each terminal further includes a tab 124 that is bent into a U-shape to form a surface mounting pad 80 that is soldered onto a contact pad on the circuit substrate 24. The press fit section 128 may be formed in a suitable shape, such as an eye of the needle shape, to be retained in a through-hole 130, by being pressed therein, as is conventional.
In another form of mounting illustrated in FIG. 9b, an insulative body 132 includes a plurality of channels 134 formed along a bottom edge thereof. A plurality of surface mount terminal members 136 are wrapped about a core section 138 to form surface mount surfaces 140 and 142 that are adapted to be surface mounted respectively to a contact pad 144 on the printed circuit board or a contact pad on a trace of the circuit substrate 24. The terminal members 136 can float somewhat and are maintained on body 132 by the bent portions 145 and 147.
In another variant shown in FIG. 9c, insulative body 146 has a metallic terminal 148 mounted therein. The terminal 148 includes a surface mount portion 150 adapted to be soldered onto the circuit substrate 24. An opposite end 154 of the terminal extends into a well 156 and has a fusible element, such as a solder ball 158, secured thereto. The solder ball 158 is adapted, upon reflow, to effect a solder connection with contact pad 160 on the printed circuit board.
Another embodiment of printed circuit board mounting is shown in FIG. 9d. The insulative housing 162 has a metallic solder terminal 164 secured therein. The terminal 164 has a surface mount portion 166 adapted to be surface mounted onto the circuit substrate 24. A tail portion 168 is adapted to extend into a plated through-hole 170. Using intrusive reflow techniques, solder paste received in the through-hole 170 fuses the tail section 168 into electrical communication with the plated through-hole 170.
Referring to FIGS. 11a and 11b, a shielded receptacle carrier is shown therein. In this embodiment, the insulative housing 28 carries a plurality of tuning fork type receptacle contacts 32, as previously described. In addition, a surrounding shield 170 provides electrical shielding of the individual tuning fork contacts 32. Each end of the shield 170 is turned underneath the insulative housing 28 to form hold-down sections 172 (FIG. 12) that are soldered onto the circuit substrate 24. In order to shield individual terminals, tabs 174 (FIG. 12) are punched out of the shield 170 and are bent to extend in slots formed in housing 28 between adjacent terminals 32. The tabs 174 may be soldered onto suitable grounding contact pads formed on the circuit substrate 24. In this manner, effective shielding about individual terminals or groups of terminals may be effected, as shown in FIG. 12.
FIG. 13 is a side sectional view of a right angle receptacle connector received in a mating header connector. As shown, in this arrangement, the contact springs 112 from the shield of the receptacle carrier 26 are positioned to engage the shroud 116 of the header, directly along one edge (at the top) and directly through the ground spring 58 at the bottom. Contact pins 113 are received by the tuning fork contacts 32 and the tips thereof pass by the base section 36 by reason of the offset in the tines 34.
FIGS. 14a and 14b show a shielding arrangement similar to that illustrated in FIG. 11a, 11b and 12, except that the shield 180 is applied to a header carrier as previously illustrated in connection with FIG. 2a. In this arrangement, the shield 180 may have tabs 182 that are punched from the shield and folded, to substantially surround individual or groups of contact pins 68. In addition, contact springs 184 may be integrally formed in the shield 180.
FIG. 15 shows a cable interconnection arrangement utilizing several of the previously described connectors. If the system is single ended, a cable connector 200 of the type generally illustrated in FIGS. 5a, 5b and 5c is used. For improved high speed capabilities, a shielded receptacle carrier as shown in FIGS. 12a, 12b and 13 is used in cable connector 200. Cable connector 200 mates with a right angle header connector 202 as generally illustrated in FIG. 3b. Again, if improved high speed performance is desired, a shielded pin carrier as shown in FIGS. 14a and 14b is used on the modules forming header 202. Right angle header connector 200 is mounted on one end of a circuit board 204. A right angle receptacle connector 206 of the type illustrated generally in FIG. 1a or, for higher speeds, using a shielded receptacle contact carrier, as shown in FIG. 8a, is used. Receptacle connector 206 is mated with a shielded pin header that extends through a back plane 210 to a mirror image arrangement partially represented by the connectors 208', 206'and circuit board 204'.
Manufacturing costs are improved by the use of terminal carrier assemblies that locate and accurately place multiple terminals simultaneously. Housings for the carriers are formed with flat surfaces that allow placement by pick and place equipment. By the use of the shielding arrangements shown, high speed interconnections with low cost cross talk have be achieved.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | Modular connectors employ terminal carriers for gang mounting of terminals onto circuit substrates. The carriers may be shielded for providing shielding through the connector. Substrate mounting systems include press fit, floating surface mount, solder ball and intrusive reflow arrangements. | 7 |
This application is a division of U.S. patent application Ser. No. 08/689,461, filed Aug. 8, 1996, now U.S. Pat. No. 5,723,632.
BACKGROUND OF THE INVENTION
Natural products from plants and microorganisms have proven to be a major source of active anticancer agents and lead compounds for cancer chemotherapy. Mushrooms of the class Basidiomycetes are an exception. Although they occur widely and some are well known to contain a variety of highly poisonous substances, only Omphalotus illudens (jack o'lantern mushroom) is known to produce promising anticancer compounds. These are the sesquiterpenes illudin S and illudin M. The illudins are extremely cytotoxic compounds but have a low therapeutic index particularly in solid tumor systems. However, modification of their structures has yielded several analogs, which possess a greatly improved therapeutic index. Remarkable efficacy has been observed in tests on mouse xenografts of leukemias and various solid tumors.
First and second generation analogs, for example, dehydroilludin M and acylfulvene, have been described (WO 91/04754). A promising compound is a third generation analog hydroxymethylacylfulvene (HMAF). In tests with MV 522 metastatic lung carcinoma xenografts in nude mice, complete tumor regression was observed in all animals. HMAF also exhibited outstanding activity against breast (MX-1), colon (HT-29) and skin cancers.
The structures of illudin S and illudin M were first published in 1963 (McMorris et al., J Am. Chem. Soc. 85:831 (1963)). Until recently only one total synthesis of these compounds had been reported (Matsumoto et al., Tetrahedron Lett. 1171 (1970)). This synthesis involved Michael addition of a cycylopropane intermediate to an appropriately substituted cyclopentenone. The resulting product was then transformed into an intermediate which could undergo aldol condensation to form illudin's six-membered ring. A number of further reactions were required to complete the synthesis.
Padwa et al., (J. Am. Chem. Soc. 116: 2667 (1994)), have published a synthetic approach to the illudin skeleton using a dipolar cycloaddition reaction of a cyclic carbonyl ylide dipole with cyclopentenone to construct the six-membered ring. Kinder and Bair (J. Org. Chem. 59:6955 (1994)), have also employed the Padwa methodology to synthesize illudin M. However, these syntheses are long and not well suited for making acylfulvenes on a large scale.
Thus, a continuing need exists for improved methods for synthesizing acylfulvenes.
SUMMARY OF THE INVENTION
The present invention provides a method of synthesizing compounds of formula (I): ##STR2## wherein R and R' are independently (C 1 -C 4 )alkyl, preferably methyl. According to the invention, a method is provided of synthesizing a compound of formula (V), a preferred intermediate in the synthesis of compounds of formula (I),: ##STR3## comprising the steps of coupling a cyclopentanone of formula (II): ##STR4## wherein R 4 is --O--C(R 9 ) 2 O(R 9 ), wherein R 9 is (C 1 -C 4 )alkyl, preferably methyl;
with a cyclic carbonyl ylide dipole of formula (III): ##STR5## to form a compound of formula (IV): ##STR6## and treating compound (IV) with base to form a ketone of formula (V).
The present method further may further comprise the steps of dihydroxylating the ketone to yield a compound of formula (VI): ##STR7## and treating the compound of formula (VI) with a removable 1,2-diol protecting reagent to yield an intermediate of formula (VII): ##STR8## wherein X is a removable 1,2-diol protecting group. Protecting groups may be introduced by forming a cyclic acetal by treatment with an aldehyde or ketone such as acetone, formaldehyde, acetaldehyde or benzaldehyde. For example, an isopropylidene derivative (acetonide) may be introduced by reaction with acetone. Preferably, the isopropylidene group is introduced by acid-catalyzed exchange with 2,2-dimethoxypropane.
The method further comprises the steps of treating compound (VII) with RMgCl, where R is (C 1 -C 4 )alkyl, to yield a Grignard product of formula VIII: ##STR9## and cleaving the oxybridge to yield a diol of formula (IX): ##STR10##
The method further comprises the step of removing the diol protecting group to yield a tetraol of formula (X): ##STR11## The tetraol is then converted to an orthoester of formula (XI): ##STR12## wherein R" is (C 1 -C 3 )alkyl; and the cis hydroxyls are eliminated to yield a dienone of formula (XII): ##STR13##
The method further comprises the steps of reducing the compound of formula (XII) to convert the ketone to an alcohol, under conditions which dehydrate the resulting alcohol to yield a fulvene of formula (XIII): ##STR14##
The fulvene of formula (XIII) is then oxidized to yield a compound of formula (I): ##STR15##
The present invention also provides a method of synthesizing a compound of formula (XVII): ##STR16## wherein R 1 is OH, R 2 is H, and R' is (C 1 -C 4 )alkyl, preferably methyl.
According to the present invention, a method is provided of synthesizing a diketone of formula (XIII), a preferred intermediate in the synthesis of compounds of formula (XVII),: ##STR17## comprising the steps of (a) cleaving the oxybridge in the compound of formula (XIV): ##STR18## to yield a diketone of formula (XIII).
The method further comprises the steps of
(b) protecting the hydroxyl group in the compound of formula (XIII) with a removable hydroxyl protecting group X; and
(c) introducing a double bond in the five-membered ring to yield a compound of the formula (XV): ##STR19## wherein R' 1 , and R' 2 together are keto; and
X is a removable hydroxyl protecting group. Removable hydroxyl protecting groups may be introduced by reaction with a suitable reagent, such as a reagent of the formula ((C 1 -C 4 )alkyl) 3 SiCl, including triethylsilyl (TES) chloride, trmethylsilyl (TMS) chloride, t-butyldimethylsilyl (TBDMS) chloride, dimethyl (1,2,2-trimethylpropyl)silyl chloride, or tris(isopropyl)silyl; and methoxymethyl chloride, β-methoxyethoxymethyl chloride, and isobutylene.
The method further comprises the steps of
(d) reducing both keto groups to yield hydroxy groups under conditions that yield a compound of formula (XVI): ##STR20## (e) eliminating the cyclopentenol hydroxyl group; and (f) oxidizing the cyclohexanol hydroxyl group and removing hydroxyl protecting group X to yield a compound of formula (XVII): ##STR21## wherein R 1 is OH and R 2 is H.
The method additionally comprises the step of
(g) following step (d), treating the alcohol with mesyl chloride in the presence of a base to produce a mesylate of the formula (XVIII): ##STR22## wherein R" 1 is --OX, R" 2 is absent and R is H.
The present invention further provides a method of synthesizing compounds of the formula (XXIII): ##STR23## wherein R' 1 and R' 2 together are ethylenedioxy, and R' is (C 1 -C 4 )alkyl, preferably methyl.
According to the present method, the carbonyl group of the compound of formula (XIII) is converted to an acetal group to yield a compound of formula (XIX): ##STR24##
The method further comprises the steps of
(b) protecting the hydroxyl group in the compound of formula with a removable hydroxyl protecting group X; and
(c) introducing a double bond in the five-membered ring to yield a compound of the formula (XX): ##STR25## wherein X is a removable hydroxyl protecting group.
The method further comprises the steps of
(d) reducing the keto group to yield a hydroxy group under conditions that yield a compound of formula (XXI): ##STR26## (e) eliminating the cyclopentenol hydroxyl group; (f) removing hydroxyl protecting group X to yield a compound of formula (XXII): ##STR27## and (g) oxidizing the cyclohexanol hydroxyl group to yield a compound of formula (XXIII): ##STR28##
The method further comprises the step of
(h) following step (d), treating the alcohol with mesyl chloride to produce a mesylate of the formula (XXIV): ##STR29##
With respect to both mesylates of formulas (XVIII) and (XXIV), the mesylates are relatively unstable and convert to fulvenes upon standing. Removal of the protecting group X and oxidation yield compounds of formulas (XVII) and (XXIII), respectively.
The invention also provides novel compounds of formula I-XXIV, all of which are useful as intermediates in the synthesis of 6-substituted acylfulvene analogs (6-substituted acylfulvenes) as disclosed, for example, in Kelner et al., U.S. Pat. N. 5,523,490, or which have antitumor or cytotoxic activity per se.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the synthesis of a compound of Formula (I), specifically compound 26.
FIG. 2 is a schematic representation of the synthesis of compound of Formula (XV), specifically compound 35.
FIG. 3 is a schematic representation of the synthesis of compound of Formula (XV), specifically compound 42.
DETAILED DESCRIPTION OF THE INVENTION
An illudin analog of formula (I), where R and R' are methyl (compound 26), can be synthesized by utilizing FIG. 1. The numbers following the named compounds refer to the numbered compounds of Schemes I, II and III. The starting compound (14) is readily prepared from furfural and methylmagnesium chloride followed by acid catalyzed rearrangement (Piancatelli et al., Tetrahedron Lett. 3555 (1976)). Protection of the hydroxyl in 14 by forming the acetal derivative 15, for example, followed by reaction with ylide 5 gives the adduct 16 (84% yield). Mild base treatment (KOH-MeOH, room temp., 1 h) of 16 affords the unsaturated ketone 17 (95%). Dihydroxylation of 17 with OsO 4 , NMO in THF (room temp., 24 h) gives the cis-dihydroxy product 18 which is converted to the acetonide 19 with dimethoxy propane and p-TsOH (87% for the two steps). Regioselective reaction of 19 with methylmagnesium chloride (in THF, -78° C.) affords the Grignard product 20. Treatment of 20 with 10% KOH-MeOH at 80° C. for 2 h cleaves the oxybridge giving the diol 21 (75% for the two steps). The structure (21) has been confirmed by X-ray crystallographic analysis which indicates trans relationship of the two hydroxyls.
Hydrolysis of the acetonide with Dowex resin (H + form) in MeOH at room temperature for 12 h affords the tetraol 22 in 95% yield. Conversion of 22 to the orthoester 23 by treatment with trimethylorthoformate and p-TsOH at room temperature followed by heating 23 at 190° C. under reduced pressure results in elimination of the cis hydroxyls yielding the dienone. The yields in this reaction are rather low but can be improved by adding acetic anhydride. A good yield of the monoacetate and diacetate (24a, b) is obtained. Reduction of the ketone with NaBH 4 --CeCl 3 gives the corresponding alcohol which is unstable and is converted to the fulvene on standing. The acetate groups are removed by treatment with lithium aluminum hydride and the resulting fulvene 25 is oxidized with the Dess-Martin reagent to±acylfulvene 26. The overall yield for the last four steps is approximately 30%.
An acylfulvene analog of formula (XV) where R' 1 and R' 2 together are ethylenedioxy (compound 35), may be synthesized as shown in FIG. 2. The oxybridge in the intermediate 7 is cleaved with K 2 CO 3 in isopropanol at room temperature giving the diketone 27 (82%). Regioselective acetal formation (ethylene glycol, p-TsOH, C 6 H 6 , room temperature) gives in quantitative yield the monoacetal 28. Protection of the hydroxyl as the triethyl silyl ether (triethylsilylchloride, pyridine, 60° C.) is quantitative. A double bond is introduced into compound 29, by treatment with benzene seleninic anhydride in chlorobenzene at 95° C., yielding cross conjugated ketone 30 (78%). Reduction of 30 (NaBH 4 , CeCl 3 . 7 H 2 O in MeOH) gives alcohol 31. This compound on treatment with methane sulfonyl chloride and triethylamine gives the fulvene 33 (via the unstable mesylate 32). Removal of the silyl protecting group (p-TsOH, acetone-water 1:1) gives the alcohol 34, which upon oxidation with pyridinium dichromate in dichloromethane affords the acylfulvene 35 (60% yield for four steps).
Another analog of formula (XVII) where R 1 is OH and R 2 is H (compound 42) can be made from intermediate 27. As shown in FIG. 3, compound 27 is converted to the triethylsilyl (TES) ether 36. A double bond is then introduced in the five membered ring by reaction with phenylseleninic anhydride giving 37 in good yield. Reduction of the diketone with sodium borohydride-ceric chloride gives the corresponding alcohols accompanied by rearrangement of the TES group, resulting in compound 38. Treatment of the latter with triethylamine and mesylchloride gives the unstable mesylate 39 which directly yields the fulvene 40. Oxidation of 40 with Dess-Martin reagent and removal of the silyl protecting group gives±acylfulvene analog 42.
The compounds of formulas (I), (XVII) and ((XXIII) and intermdiates thereof are useful as antineoplastic agents, i.e., to inhibit tumor cell growth in vitro or in vivo, in mammalian hosts, such as humans or domestic animals, and are particularly effective against solid tumors and multi-drug resistant tumors. These compounds may be particularly useful for the treatment of solid tumors for which relatively few treatments are available. Such tumors include epidermoid and myeloid tumors, acute (AML) or chronic (CML), as well as lung, ovarian, breast and colon carcinoma. The compounds can also be used against endometrial tumors, bladder cancer, pancreatic cancer, lymphoma, Hodgkin's disease, prostate cancer, sarcomas and testicular cancer as well as against tumors of the central nervous system, such as brain tumors, neuroblastomas and hematopoietic cell cancers such as B-cell leukemia/lymphomas, myelomas, T-cell leukemia/lymphomas, and small cell leukemia/lymphomas. These leukemia/lymphomas could be either acute (ALL) or chronic (CLL).
The compounds may also be incorporated in a pharmaceutical composition, such as pharmaceutical unit dosage form, comprising an effective anti-neoplastic amount of one or more of the illudin analogs in combination with a pharmaceutically acceptable carrier.
The methods of the present invention may also be adapted to make pharmaceutically acceptable salts of compounds of formula (I), (XVII) or (XXIII). Pharmaceutically acceptable salts include, where applicable, salts such as amine acid addition salts and the mono-, di- and triphosphates of free hydroxyl groups. Amine salts include salts of inorganic and organic acids, including hydrochlorides, sulfates, phosphates, citrates, tartarates, malates, maleates, bicarbonates, and the like. Alkali metal amine or ammonium salts can be formed by reacting hydroxyaryl groups with metal hydroxides, amines or ammonium.
The compounds can be formulated as pharmaceutical compositions and administered to a mammalian host, such as a human cancer patient, in a variety of forms adapted to the chosen route of administration, i.e., orally or parenterally, by intravenous, intraperitoneal, intramuscular or subcutaneous routes.
The subject can be any mammal having a susceptible cancer, i.e., a malignant cell population or tumor. The analogs are effective on human tumors in vivo as well as on human tumor cell lines in vitro.
Thus, the compounds may be orally administered, for example, in combination with a pharmaceutically acceptable vehicle such as an inert diluent or an assimilable edible carrier. They may be enclosed in hard or soft shell gelatin capsules, may be compressed into tablets, or may be incorporated directly with the food of the patient's diet. For oral therapeutic administration, the active compound may be combined with one or more excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between 2 to about 60% of the weight of a given unit dosage form. The amount of active compound in such therapeutically useful compositions is such that an effective dosage level will be obtained.
The tablets, troches, pills, capsules and the like may also contain the following: A binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose, or saccharin or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring may be added. When the unit dosage form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier, such as a vegetable oil or a polyethylene glycol. Various other materials may be present as coatings or to otherwise modify the physical form of the solid unit dosage form. For instance, tablets, pills, or capsules may be coated with gelatin, wax, shellac or sugar and the like. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any unit dosage form should be pharmaceutically acceptable and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and devices.
The active compound may also be administered intravenously or intraperitoneally by infusion or injection. Solutions of the active compound can be prepared in water, optionally imixed with a nontoxic surfactant. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, triacetin, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical dosage forms suitable for injection or infusion use can include sterile aqueous solutions or dispersions or sterile powders comprising the active ingredient which are adapted for the extemporaneous preparation of sterile injectable of infusible solutions or dispersions. In all cases, the ultimate dosage form must be sterile, fluid and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (for example, glycerol, propylene glycol, liquid polyethylene glycols, and the like), vegetable oils, nontoxic glyceryl esters, and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the formation of liposomes, by the maintenance of the required particle size in the case of dispersion or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, or example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and gelatin. Sterile injectable solutions are prepared by incorporating the active compound in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filter sterilization. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and the freeze drying techniques, which yield a powder of the active ingredient plus any additional desired ingredient present in the previously sterile-filtered solutions.
Useful dosages of compounds made according to the present methods can be determined by correlating the compounds' in vitro activity, and in vivo activity in animal models, such as murine or dog models as taught for illudin analogs such as those of U.S. Pat. Nos. 5,439,936 and 5,523,490, to activity in higher mammals, such as children and adult humans as taught, e.g., in Borch et al. (U.S. Patent No. 4,938,949).
The therapeutically effective amount of analog necessarily varies with the subject and the tumor to be treated. However, it has been found that relatively high doses of the analogs can be administered due to the decreased toxicity compared to illudin S and M. A therapeutic amount between 30 to 112,000 μg per kg of body weight is especially effective for intravenous administration while 300 to 112,000 μg per kg of body weight is effective if administered intraperitoneally. As one skilled in the art would recognize, the amount can be varied depending on the method of administration.
The invention will be further described by reference to the following detailed examples.
EXAMPLES
Example I
Synthesis of Compound 36
General. Solvents were dried and distilled prior to use. THF and diethyl ether were distilled from sodium-benzophenone, CH 2 Cl 2 and triethylamine from CaH 2 , Melting points are uncorrected. 1H- and 13C-NMR spectra were measured at 300 MHz and 75 MHz, respectively. High resolution mass spectra were determined at 70 ev (EI) by the Mass Spectrometry Service Laboratory at the University of Minnesota. Column chromatography was performed on silica gel (Davisil 230-425 mesh, Fisher Scientific ). In some cases, a small amount of triethylamine was used to neutralize the silica gel.
Compound 15. To a solution of 14 (0.448 g, 4 mmol) in 2-methoxypropene (1.55 ml, 16.2 mmol), a drop of POCl 3 was added under Ar. The solution was stirred at 25° C. for 12 hours and quenched by 3 drops of Et 3 N. The volatile components were removed in-vacuo and the product 15 was obtained as a brown liquid which crystallized below 0° C.(0.69 g, 94.3%). 1 H NMR (CDCl 3 ): δ 7.43(dd, 1H), 6.17(d, 1H), 4.58(br s, 1H), 3.26(s, 3H), 2.26(m, 1H), 1.41(s, 3H), 1.40(s, 3H), 1.22(d, 3H).
Compound 16. To a mixture of 15 (5.02 g, 27.3 mmol), rhodium acetate (145 mg, 0.33 mmol), DMF(500 uL) in CH 2 Cl 2 (50 mL), a solution of 4 (6.0 g, 39.5 mmol) in CH 2 Cl 2 (50 mL) was added dropwise within 10 minutes at 40° C. The orange-red solution was refluxed at 40° C. for 1.5 hours and the solvent was removed in vacuo. Chromatography (Hexane/EtOAc, 10:2) gave product 16 as white crystals (7.10 g, 84.5%). m.p.:142°-144° C.; 1 H NMR (CDCl 3 ): δ 4.98(s, 1H), 4.13(dd, 1H), 3.28(s, 3H), 2.82(t, 1H), 2.63(d, 1H), 2.54(m, 1H), 1.43(s,3H), 1.42(s,3H), 1.18(s, 3H), 1.08(d, 3H), 1.29(m, 1H), 1.03-1.16(m, 2H), 0.72(m, 1H); 13 C NMR (CDCl 3 ): δ 213.3, 212.1, 101.2, 87.4, 81.8, 73.8, 59.4, 50.4, 49.7, 45.8, 39.0, 26.0, 25.1, 14.1, 13.7, 12.4, 11.4. IR (film, cm -1 ): 2985, 1738, 1389, 1339, 1173, 1080, 1052, 991, 859, 827; HRMS calcd. for C 17 H 24 O 5 : 308.1624, found: 308.1625
Compound 17. The solution of 16 (594.3 mg, 1.93 mmol) in 5% KOH-MeOH (35 ml) was stirred at room temperature for 1 hour. The generated red solution was then neutralized and extracted with EtOAc. The combined organic phase was washed with sat. brine (20 ml×2) and dried over Na 2 SO 4 . Chromatography (Hexanes/EtOAc, 10:3)gave the product 17 as white crystals (390.9 mg, 93%).m.p.: 108.5°-109.4° C.; 1 H NMR (CDCl 3 ): δ 7.15(d, 1H), 4.24(s, 1H), 3.21(br s, 1H), 2.55(d, 1H), 1.75(s, 3H), 1.23(s, 3H), 1.25(m, 1H), 1.10(m, 1H), 0.97(m, 1H), 0.74(m, 1H); 13 C NMR (CDCl 3 ): δ 211.77, 205.86, 154.23, 145.86, 86.05, 80.93, 54.68, 45.82, 37.56, 14.05, 13.22, 11.58, 10.22; IR (film, cm -1 ): 1754, 1703, 1639, 1389, 1339, 997; HRMS calcd. for C 13 H 14 O 3 : 218.0943, found: 218.0941
Compound 19. To a solution of 17 (349.4 mg, 1.60 mmol), NMO (355 mg) in THF (17.7 ml) and H 2 O (0.5 ml), was added OsO 4 -THF solution (2.5 wt %, 3.5 ml). After stirred at 25° C. for 21 hrs, the reaction was quenched by aqueous Na 2 SO 3 solution. The reaction mixture was extracted with EtOAc. The organic phase was washed with sat. NaCl solution, dried over Na 2 SO 4 and concentrated. The crude diol product 18 was used for next step without further purification. A small amount of 18 was purified by chromatography. 1 H NMR (CDCl 3 ): δ 4.60(s,1H), 3.95(t, 1H), 3.01(d, 1H), 2.94(d, 1H), 2.88(s, 1H),2.81(dd, 1H), 1.36(s, 3H), 1.28(s, 3H), 1.33(m, 1H), 1.18(m, 1H), 1.06(m, 1H), 0.75(m, 1H)
The crude diol 18 was reacted with 2,2-dimethoxypropane (0.8 ml, 4 eq.) in CH 3 CN (8.0 ml) in the presence of a trace of pTsOH. After being stirred at 25° C. for 10 hrs, the mixture was diluted with CH 2 Cl 2 and washed with sat. NaHCO 3 solution and brine. Chromatography (Hexanes/EtOAc, 10:2) gave the product 19 as white crystals (308.5 mg, 87.3%). m.p.:178.5°-179.5° C.; 1H NMR (CDCl 3 ): δ 4.58(s, 1H), 4.36(s, 1H), 2.89(q, 2H), 1.42(s, 3H), 1.34(s, 3H), 1.31(s, 3H), 1.20(s, 3H), 1.28(m, 1H), 1.16(m, 1H), 1.05(m, 1H), 0.69-0.76(m, 1H); 13 C NMR (CDCl 3 ): δ 215.53, 210.05, 110.66, 87.96, 86.44, 85.03, 83.34, 57.36, 45.37, 38.49, 27.17, 25.96, 16.92, 14. 19, 13.57, 12.32; IR (film, cm -1 ): 2986, 1746, 1372, 1338,1247, 1216, 1158, 1082; HRMS calcd. for C 16 H 20 O 5 : 292.1311, found: 292.1315
Compound 21. To the solution of 19 (289.5 mg, 0.99 mmol) in THF (25 ml) at -78° C., was added MeMgCl-THF solution (3.0M, 830 μl, 2.5 eq) slowly. After 2.5 hrs, the solution was warmed to 0° C. and quenched with sat. NH 4 Cl solution. The solution was extracted with EtOAc and the organic phase was washed with brine solution. Concentration of dried organic solution gave the crude compound 20. 1 H NMR (CDCl 3 ): δ 4.29(s, 1H), 4.23(s, 1H), 3.45(d, 1H), 2.78(d, 1H), 1.39(s, 3H), 1.35(s, 3H), 1.33(s, 3H), 1.24(s, 3H), 1.01(s, 3H), 0.77(m, 1H), 0.67(m, 1H), 0.52(m, 1H), 0.20(m, 1H); IR (film, cm -1 ): 3492, 2984, 2934, 1743, 1454, 1373, 1257, 1210, 1159, 1082; HRMS calcd. for C 17 H 24 O 5 : 308.1624, found: 308.1629.
The crude compound 20 was dissolved in 10% KOH-MeOH solution. The red mixture was heated at 80° C. for 2 hrs then partitioned between H 2 O and CH 2 Cl 2 . The organic layer was washed with brine then dried over Na 2 SO 4 . Chromatography (Hexanes/EtOAc, 10:15) gave the product 21 as white crystals (228.0 mg, 75%) (inseparable mixture of isomers shown by 1 H NMR).m.p.:162.0°-164.0 ° C.; 1 HNMR(CDCl 3 ): δ 4.52(d, 1H), 3.88(dd, 1H), 3.38(m, 1H), 2.33(d, 1H), 2.18(s, 1H), 1.81(d, 3H), 1.42(s, 3H), 1.38(s, 3H), 1.07(s, 3H), 0.97-1.18(m, 4H); 13 C NMR (CDCl 3 ): δ 201.52, 152.89, 126.44, 112.96, 85.95, 81.34, 73.14, 72.31, 44.44, 29.41, 28.71, 28.22, 22.82, 21.07, 14.11, 12.58, 7.58; IR (film, cm -1 ): 3455, 2987, 2935, 1694, 1599, 1445, 1373, 1240, 1212, 1092, 1048; HRMS calcd. for C 17 H 24 O 5 : 308.1624, found: 308.1624
Compound 22. The compound 21 (60.9 mg, 0.20 mmol) was stirred with Dowex 50w-x16 resin (2.96 g) in MeOH (5.0 ml) at r.t. for 22 hrs. The resin was filtered away and the filtrate was washed with sat. NaHCO 3 , sat. NaCl and dried over Na 2 SO 4 . Chromatography (CH 2 Cl 2 /MeOH, 10:1) gave the product as white crystals (49.5 mg, 93%). m.p.:149.0°-151.0° C.; 1 HNMR (CD 3 OD): δ 3.83(d, 1H), 3.81(s, 1H), 3.25(m, 1H), 1.90(d, 3H), 1.25(s, 3H), 1.07(s, 3H), 0.99-1.11(m, 4H); 13 C NMR (CD 3 OD): δ 202.95, 156.24, 127.16, 76.44, 74.38, 74.12, 71.69, 44.52, 30.07, 23.14, 20.03, 14.56, 13.30, 8.20; HRMS calcd. for C 14 H 20 O 5 : 268.1311, found: 268.1312.
Compound 24a and 24b. To the solution of 22 (40.2 mg, 0.15 mmol) and pTsOH (3.0 mg) in THF (3.0 ml), was added HC(OCH 3 ) 3 (130 μl, 8 eq.) at 25° C. After 2 hrs, sat. NaHCO 3 solution was added and the mixture was extracted with EtOAc. The combined organic phase was washed with brine and dried over Na 2 SO 4 . Concentration of the filtrate gave the ortho ester 23 (46.3 mg, 100%) as the intermediate for next reaction.
The ortho ester 23 (35.7 mg, 0.12 mmol) in Ac 2 O (2.0 ml) was heated at 150° C. for 1 hr. To the cooled reaction solution was added sat. NaHCO 3 solution and extracted with EtOAc. The organic phase was washed with brine and dried over Na 2 SO 4 . Chromatography (Hexanes/EtOAc, 10:3to 10:7) gave the products 24a and 24b as white crystals in 57.3% (18.2 mg) and 9.8% (3.6 mg) respectively.
Product 24a: m.p.: 119°-121° C.; 1 H NMR (CDCl 3 ): δ 6.98(s, 1H), 5.25(d, 1H), 3.92(br s, 1H), 1.95(s, 3H), 1.92(s, 3H), 1.80(t, 3H), 0.94-1.42(m,4H); 13 C NMR (CDCl 3 ): δ 195.59, 170.87, 147.53, 145.85, 145.25, 128.16, 74.16, 72.64, 41.02, 30.30, 22.93, 20.89, 13.48, 11.19, 11.00, 7.70; IR (film, cm -1 ): 3431, 2982,2914, 1735, 1671, 1613, 1437, 1374, 1237, 1222, 1086, 1027; HRMS calcd. for C 16 H 20 O 4 : 276.1362, found: 276.1363.
Product 24b: m.p.: 189.3°-191.2° C.; 1 H NMR (CDCl 3 ): δ 6.95(s, 1H), 6.12(d, 1H), 3.49(br s, 1H), 2.00(s, 3H), 1.97(s, 3H), 1.92(s, 3H), 1.79(s, 3H), 1.30(s, 3H), 0.92-1.27(m, 4H); 13 C NMR (CDCl 3 ): δ 195.35, 170.17, 170.35, 146.76, 146.00, 145.47, 127.95, 83.75, 70.53, 41.12, 29.27, 22.38, 20.78, 17.23, 12.35, 11.39, 10.95, 9.11.
Compound 26 Acylfulvene from 24a. To the clear solution of 24a (2.3 mg, 8.8 umol), CeCl 3 .7H 2 O (24.9 mg, 8.0 eq) in Methanol (78 ul) and THF (155 ul) at 0° C., excess of NaBH 4 was added in one portion. After 15 minutes at 0° C., the suspension was stirred at 25° C. for 30 minutes. At 0° C., the mixture was quenched with 5% HCl solution and Sat.NH4Cl solution and extracted with CH 2 Cl 2 . The organic phase was washed with H 2 O and dried over MgSO 4 . Concentration and chromatography (Hexanes/EtOAc, 10:5) gave the product as yellow solid (1.8 mg, 84%). 1 H NMR (CDCl3): δ 6.06(s, 1H), 6.01(s, 1H), 5.84(s, 1H), 2.21(s, 3H), 2.04(s, 3H), 1.81(s, 3H), 1.15(s, 3H), 0.62-1.44(m, 4H);
The yellow compound was then dissolved in absolute ethanol (100 ul) and a trace of KCN was added. The solution was stirred overnight at 25° C. and TLC showed the compound 25 was the exclusive product. The solution was diluted with ether and washed with sat.brine and dried over Na 2 SO 4 .
After concentration, the crude diol 25 was oxidized by Dess-Martin reagent (11.8 mg) in CH 2 Cl 2 solution (1.2 ml). After being stirred at 25° C. for 1 hour, the reaction solution was diluted with ether and quenched with the mixture of aqueous sodium bicarbonate and sodium bisulfite. The organic phase was washed with sat. NaHCO 3 and sat. NaCl solution and dried over NaSO 4 . Concentration and chromatography (Hexanes/EtOAc, 10:1) gave product 26 Acylfulvene as a yellow gum (1.1 mg, 47% from 24a). 1 H NMR (CDCl 3 ): δ 7.16(s, 1H), 6.43(t, 1H), 2.15(s, 3H), 2.00(s, 3H), 1.38(s, 3H), 0.70-1.55(m, 4H); IR (film, cm -1 ): 3464, 2922, 2851, 1723, 1664, 1610, 1487, 1441, 1355, 1327, 1264, 1095, 1031; HRMS calcd. for C 14 H 16 O 2 : 217.1229(M+H + ), found: 217.1224(M+H + ).
Compound 26 Acylfulvene from 24b. To the clear solution of 24b (4.1 mg, 0.013 mmol), CeCl 3 .7H 2 O (39.5 mg, 0.11 mmol) in Methanol (100 ul) and THF(200 ul) at 0° C., excess of NaBH 4 was added in one portion. After 1 hour at 0° C., the suspension was stirred at 25° C. for 15 minutes. At 0° C., the mixture was quenched with 5% HCl solution and Sat.NH4Cl solution and extracted with CH 2 Cl 2 . The organic phase was washed with H 2 O and dried over MgSO 4 . Concentration and chromatography (Hexanes/EtOAc, 10:3) gave the product as yellow solid (3.9 mg, 100%). 1 H NMR (CDCl 3 ): δ 6.24(s, 1H), 6.18(s, 1H), 6.02(d, 1H), 2.06(s, 3H), 2.03(s, 3H), 1.89(s, 3H), 1.82(s, 3H), 1.50(s, 3H), 1.39(m, 1H), 0.99-1.07(m, 3H);
The yellow solid (3.0 mg, 0.01 mmol) was redissolved in ether (0.6 ml) and added to the reaction vial with LiAlH 4 (12 mg, 0.31 mmol) in ether (0.4 ml) at 0° C. The suspension was stirred at 0° C. for 30 minutes and warmed up to 25° C. for 20 minutes. The reaction was quenched with acetone then 5% HCl solution and sat. NH 4 Cl solution were added. The mixture was extracted with ether. The combined ether phase was washed with sat. NaCl solution and dried over NaSO 4 . Remove of solvent gave the crude diol 25.
The crude diol 25 was oxidized by Dess-Martin reagent (70 mg) in CH 2 Cl 2 solution (1.5 ml). After being stirred at 25° C. for 1 hour, the reaction solution was diluted with ether and quenched with the mixture of aqueous sodium bicarbonate and sodium bisulfite. The organic phase was washed with sat. NaCO 3 and sat. NaCl solution and dried over NaSO 4 . Concentration and chromatography (Hexanes/EtOAc, 10:1) gave product 26 Acylfulvene as a yellow gum (0.7 mg, 33% from 24b). 1 H NMR (CDCl 3 ): δ 7.16(s, 1H), 6.43(t, 1H), 2.15(s, 3H), 2.00(s, 3H), 1.38(s, 3H), 0.70-1.55(m, 4H); IR (film, cm -1 ): 3464, 2922, 2851, 1723, 1664, 1610, 1487, 1441, 1355, 1327, 1264, 1095, 1031; HRMS caled. for C 14 H 16 O 2 : 217.1229 (M+H + ), found: 217.1224 (M+H + ).
Example II
Synthesis of Compound 35
General. Melting points are uncorrected. 1 H and 13 C NMR spectra were measured at 300 and 75 MHz. High resolution mass spectra were determined at the University of Minnesota Mass Spectrometry Service Laboratory. All chromatography used silica gel (Davisil 230-425 mesh, Fisher Scientific) and solvent was ethyl acetate and hexanes. Analytical TLC was carried out on Whatman 4420 222 silica gel plates. Reactions were routinely monitored by TLC. Yield was calculated after recycling starting materials.
Compound 7. Compound 7 was made following literature as a white solid: mp 134°-6° C.; IR (KBr) 2993, 2952, 1757, 1743, 1454 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.74 (m, 1H), 1.03 (m, 1H), 1.13 (m, 1H), 1.25 (s, 3H), 1.32 (m, 1), 2.08 (m, 2H), 2.27 (m, 2H), 2.54 (d, J=7.5 Hz, 1H), 2.92(m, 1H), 4.45 (s, 1H); 13 C NMR (CDCl 3 ) δ 216.6, 211.4, 87.7, 87.4,57.6,41.3,39.2, 38.3, 25.1, 14.1, 13.4, 11.9; MS m/z 206 (M + ), 177, 149, 124; HRMS for C 12 H 14 O 3 calcd 206.0943, found 206.0941.
Compound 27. To a stirred solution of 7 (2.83 g, 13.7 mmol) and 2-propanol (500 ml) was added K 2 CO 3 (8 g, 58.0 mmol) at 25° C. The mixture was stirred for 7 days, then partitioned between EtOAc and water. The organic extract was washed with saturated NH 4 Cl and dried over MgSO 4 . Then the crude product was concentrated and chromatographed to give 1.88 g of 7 and 0.78 g of 27 (82.1%). 27 is a white solid: mp 183°-5° C.;IR (KBr) 3369, 2995, 1696, 1616, 1407, 1367, 1226 cm 1 ; 1 H NMR (CDCl 3 ) δ 1.24 (m, 1H), 1.38 (m, 1H), 1.68 (m, 1H), 1.88 (m, 1H), 2.00 (s, 3H), 2.16 (m, 2H), 2.46 (m, 2H), 3.21 (m, 1H), 4.06 (d, J=2.7 Hz, 1H); 13 C NMR (CDCl 3 ) δ 206.1,204.8, 147.5, 128.0, 72.0, 42.2, 39.5, 32.1,21.7, 19.4, 18.6, 11.7; MS m/z 206 (M + ), 177, 150, 147; HRMS for C 12 H 14 O 3 calcd 206.0943, found 206.0944.
Compound 28. p-Tolunesulfonic acid (12 mg, 0.063 mmol) was added to a stirred solution of 27 (107 mg, 0.519 mmol) and ethylene glycol (3.04 g, 49 mmol) in benzene (10 ml) at 25° C. which was then stirred for 24 h. The mixture was partitioned between EtOAc and saturated NaHCO 3 . The combined organic layers were washed with saline, dried over MgSO 4 and concentrated to an oil which was chromatographed to give 5 mg of 27 and 118 mg of 28 (95.3%) as colorless oil: IR (KBr) 3469, 2952, 2892, 1757, 1690, 1616, 1374, 1159, 1085 cm -1 ; 1H NMR (CDCl 3 ) δ 1.00 (m, 3H), 1.36 (m, 1H), 1.88 (d, J=2.7 Hz, 3H), 1.96 (m, 2H), 2.36 (m, 2H), 3.19 (t, J=3.9 Hz, 1H), 3.78 (t, J=3.9 Hz, 1H), 4.00 (m, 4H); 13 C NMR (CDCl 3 ) δ 205.4, 148.3, 128.3, 108.9, 67.9, 65.6, 64.5, 41.9, 39.3, 26.8, 20. 8, 12.8, 11.5, 6.22; MS m/z 250 (M + ), 221, 193, 177; HRMS for C 14 H 18 O 4 calcd 250.1205, found 250.1201.
Compound 29. To a stirred solution of 28 (8.0 mg, 0.032 mmol) and pyridine (0.5 ml) was added TESCl (0.1 ml, 0.25 mmol) under N 2 . The reaction mixture was stirred at 60° C. for 30 min and then concentrated to an oil. The crude product was purified by chromatography to give 13 mg of 29 (quantitative) as a colorless oil: IR (KBr) 2959, 2885, 1710, 1610, 1454, 1414, 1381, 1219 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.62 (q, J=7.8 Hz, 6H), 0.94 (m, 11H), 1.28 (m, 1H), 1.83 (m, 1H), 1.87 (d, J=2.4 Hz, 3H), 2.35 (m, 2H), 3.13 (m, 2H), 3.75 (d, J=3.3 Hz, 1H), 4.01 (m, 4H); 13 C (CDCl 3 ) δ 205.6, 148.8, 128.8, 109.5, 69.1, 65.3, 64.7, 43.3, 39.5, 27.4, 21.5, 12.9, 11.6, 6.8, 6.5, 4.8; MS m/z 364 (M + ), 336, 291, 219, 161; HRMS for C 20 H 32 O 4 Si calcd 364.2070, found 364.2070.
Compound 30. A solution of 29 (13 mg, 0.0357 mmol) and phenylseleninic anhydride (13 mg, 0.0361 mmol) in chlorobenzene (0.5 ml) was stirred at 95° C. for 0.5 h under N 2 . The solution was then concentrated and chromatographed to give 4.9 mg of 29 and 7.0 mg of 30 (78.2%) as colorless oil: IR (KBr) 2959, 2878, 1716, 1683, 1622, 1454, 1381, 1213 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.54 (q, J=6.3 Hz, 6H), 0.89 (m, 10H), 1.27 (m, 2H), 1.57 (m, 1H), 1.93 (m, 3H), 3.79 (s, 1H), 4.00 (m, 4H), 6.30 (dd, J=2.4, 6 Hz, 1H), 7.28 (dd, J=2.1, 6 Hz, 1H); 13 C NMR (CDCl 3 ) δ 195.9, 154.7, 146.9, 137.7, 127.5, 109.5, 69.2, 65.5, 64.6, 47.4, 28.0, 12.8, 11.1, 7.1, 6.7, 5.0; MS m/z 362 (M + ), 333, 289, 187, 159, 87; HRMS for C 20 H 30 O 4 Si calcd 362.1913, found 362.1919.
Compound 34. To the solution of 30 (20 mg, 0.055 mmol) and CeCl 3 .7H 2 O (35 mg, 0.094 mmol) in MeOH (1 ml) was added NaBH 4 (excess). The mixture was stirred for 15 min at 25 ° C. and then more NaBH 4 was added. After 15 min of stirring the mixture was partitioned between Et 2 O and saturated NH 4 Cl. The ether extract was dried over MgSO 4 and concentrated to give crude product 31 as pale yellow oil.
To the solution of the above crude product 31 in CH 2 Cl 2 (1 ml) was added Et 3 N (20 ml, 0.143 mmol) and MsCl (20 ml, 0.258 mmol) respectively at 25° C. It was stirred for 5 min. Then the mixture was partitioned between Et 2 O and saturated NaHCO 3 . The ether extract was washed by saline and dried over MgSO 4 . After concentration, it was chromatographed to give 33 and 34 as yellow gum.
To the solution of the above compound 33 in acetone (2 ml) and water (1 ml) was added some p-TsOH at room temperature. The mixture was set aside for 5 min and partitioned between Et 2 O and saturated NaHCO 3 . Then the ether extract was washed by saline and dried by MgSO 4 . After concentration and chromatography, it was mixed with the above product 34 to give 10.5 mg of 34 as yellow gum: IR (KBr) 3456, 2912, 2885, 1730, 1636, 1441, 1367 cm -1 ; 1 HNMR (CDCl 3 ) δ 0.75 (m, 1H), 1.10 (m, 2H), 1.24 (m, 1H), 1.88 (s, 3H), 2.34 (d, J=6.9 Hz, 1H), 3.95 (m, 2H), 4.06 (m, 2H), 4.68 (d, J=5.7 Hz, 1H), 6.34 (m, 1H), 6.42 (m, 2H); 13 C NMR (CDCl 3 ) d 152.0, 139.8, 134.6, 130.5, 125.3, 117.9, 111.9, 71.3, 67.0, 66.1, 31.5, 16.4, 9.5, 6.6; MS m/z 232 (M + ), 215, 189, 160, 145; HRMS for C 14 H 16 O 3 calcd 232.1099, found 232.1093.
Compound 35. A solution of 34 (7.3 mg, 31 mmol) and pyridinium dichromate (26 mg, 69 mmol) in CH 2 Cl 2 (1 ml) was stirred for 1 h at 25° C. The mixture was diluted by Et 2 O and then filtered. The concentrated crude product was chromatographed to give 5.2 mg of 35 (71.9%) as yellow crystal: mp 138°-140° C.; IR (KBr) 2959, 2892, 1683, 1616, 1549, 1441, 1360 cm -1 ; 1H NMR (CDCl 3 ) δ 1.14 (m, 2H), 1.35 (m, 2H), 2.06 (s, 3H), 4.02 (m, 2H), 4.16 (m, 2H), 6.63 (dd, J=2.4, 4.8 Hz, 1H), 6.76 (d, J=4.8 Hz, 1H), 7.39 (s, 1H); 13 C NMR (CDCl 3 ) δ 187.6, 159.6, 140.3, 135.4, 131.0, 127.9, 124.8, 106.2, 66.0, 33.4, 16.9, 12.9; MS m/z 230 (M + ), 202, 158; HRMS for C 14 H 14 O 3 calcd 230.0942, found 230.0948; UV γ max (methanol) 230 nm (e 6543), 330 (e 3484).
Example II
Synthesis of Compound 42
Compound 36. To a solution of 27 (Example II) (37 mg, 0.18 mmol) in pyridine (3 ml) was added TESCl (0.25 ml, 0.624 mmol). The mixture was stirred at 60° C. for 0.5 h under N 2 . After concentration and chromatography, it gave 50 mg of 36 (87%) as colorless oil: IR (KBr) 2952, 2872, 1703, 1622, 1461, 1414, 1226 cm -1 ; 1 HNMR(CDCl 3 ) δ 0.58 (q, J=7.8 Hz, 6H), 0.97 (m, 10H), 1.25 (m, 2H), 1.58 (m, 1H), 1.85 (m, 2H), 1.98 (s, 3H), 2.42 (m, 2H), 3.09 (b, 1H), 4.01 (d, J=3 Hz, 1H); 13 C NMR (CDCl 3 ) δ 206.0,205.0, 147.0, 128.6, 72.6, 43.0, 39.6, 32.1, 21.4, 19.6, 18.0, 11.5, 6.5, 4.5; MS ml/z 320 (M + ), 291, 259, HRMS for C 18 H 28 O 3 Si calcd 320.1808, found 320.1803.
Compound 37. The solution of 36 (278 mg, 0.869 mmol) and phenylseleninic anhydride (320 mg, 0.889 mmol) in chlorobenzene (2.5 ml) was stirred at 95° C. for 0.5 h under N 2 . The mixture was then concentrated and chromatographed to give 58.7 mg of 36 and 131.2 mg of 37 (60.2%) as colorless gum: IR (KBr) 2952, 2878, 1730, 1690, 1636, 1454, 1240 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.52 (q, J=7.8 Hz, 6H), 0.85 (t, J=7.8 Hz, 9H), 1.20 (m, 1H), 1.36 (m, 1H), 1.69 (m, 1H), 1.82 (m, 1H), 2.06 (s, 3H), 3.58 (s, 1H), 4.26 (d, J=2.4 Hz, 1H), 6.45 (dd, J=2.1, 6 Hz, 1H), 7.33 (dd, J=2.1, 6 Hz, 1H); 13 C NMR (CDCl 3 ) δ 205.9, 195.3, 153.2, 144.3, 139.4, 127.7, 72.1, 47.3, 32.4, 20.1, 19.7, 11.4, 6.4, 4.4; MS m/z 318 (M + ), 289, 261; HRMS for C 18 H 26 O 3 Si calcd 318.1651, found 318.1658.
Compound 40. To a solution of 37 (9.5 mg, 0.0299 mmol), CeCl 3 .7H 2 O (58.5 mg, 0.157 mmol) in MeOH (0.3 ml) was added NaBH 4 (excess) at 25° C. It was stirred for 30 min. Then the mixture was partitioned between Et 2 O and saturated NH 4 Cl. The ether extract was dried by MgSO 4 and concentrated to give crude product 38 as pale yellow oil.
To the solution of above 38 in CH 2 Cl 2 (0.2 ml) was added Et 3 N (5 ml, 0.036 mmol) and MsCl (5 ml, 0.965 mmol) at 25° C. The mixture was stirred for 5 min and then separated between Et 2 O and saturated NaHCO 3 . Then the ether extract was washed by saline and dried by MgSO 4 . After concentration, it was chromatographed to give 8.2 mg of 40 (90.3%) as yellow gum: IR (KBr) 3557, 3449, 2946, 2878, 1716, 1643, 1461, 1112 cm -1 ; 1 H NMR(CDCl 3 ) δ 0.66 (q, J=7.8 Hz, 6H), 0.87 (m, 2H), 0.98 (t, J=7.8 Hz, 9H), 1.26 (m, 2H), 1.86 (s, 3H), 2.55 (d, J=3.9 Hz, 1H), 3.24 (s, 1H), 4.94 (d, J=2.1 Hz, 1H), 6.35 (m, 2H), 6.46 (m, 1H); 13 C NMR (CDCl 3 ) δ 148.9, 140.0, 130.4, 117.8, 117.5, 77.0, 68.6, 61.9, 16.1,11.6, 7.8, 6.8, 5.0; MS m/z 304 (M + ), 287, 275; HRMS for C 18 H 28 O 2 Si calcd 304.1859, found 304.1860.
Compound 41. A solution of 40 (1.2 mg, 3.95 mmol) and Dess-Martin reagent (2.2 mg, 5.19 mmol) in CH 2 Cl 2 (0.2 ml) was stirred for 30 min at 25° C. The mixture was separated between Et 2 O and 10% Na 2 SO 3 . Then the ether extract was washed by saline and dried by MgSO 4 . After concentration, it was chromatographed to give 1.1 mg of 41 (92.3%) as yellow gum: IR (KBr) 2952, 2872, 1690, 1610, 1549, 1354, 1132 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.71 (q, J=7.8 Hz, 6H), 0.85 (m, 1H), 0.97 (t, J=7.8 Hz, 9H), 1.21 (m, 2H), 1.45 (m, 1H), 2.08 (s, 3H), 4.50 (s, 1H), 6.66 (dd, J=2.4, 4.8 Hz, 1H), 6.72 (d, J=5.1 Hz, 1H), 7.25 (s, 1H); 13 C NMR (CDCl 3 ) δ 193.3, 161.2, 140.7, 131. 8, 131.2, 128.3, 122.8, 32.9, 17.1, 12.5, 10.3, 6.9, 5.2; MS m/z 302 (M + ), 273,245; HRMS for C 18 H 26 O 2 Si calcd 302.1702, found 302.1710; UV γ max 227 nm (e 15612), 323 nm (e 10720).
Compound 42. To a solution of 41 (9.0 mg, 0.0298 mmol) in acetone (0.8 ml) and H 2 O (0.4 ml) was added some p-TsOH. The mixture was stirred for 30 min. Then it was partitioned between Et 2 O and saturated NaHCO 3 . The ether extract was washed by saline and dried by MgSO 4 After concentration, it was chromatographed to give quantitative 42 as yellow gum: IR (KBr) 3449, 3013, 2925, 1663, 1609, 1441, 1367, 1260 cm -1 ; 1 H NMR(CDCl 3 ) δ 0.81 (m, 1H), 1.25 (m, 1H), 1.36 (m, 1H), 1.44 (m, 1H), 2.12 (s, 3H), 3.82 (d, J=2.4 Hz, 1H), 4.55 (d, J=2.1 Hz, 1H), 6.70 (dd, J=2.7, 5.1 Hz, 1H), 6.81 (t, 1H), 7.32 (s, 1H); 13 C NMR (CDCl 3 ) δ 194.2, 162.2, 140.9, 132.7, 131.4, 126.5, 124.1, 74.6, 32.8, 17.0, 12.7, 10.3; MS m/z 188 (M + ), 160, 145; HRMS for C 12 H 12 O 2 calcd 188.0837, found 188.0840; UV γ max (methanol) 227 nm (e 13626), 323 nm (e 7474).
All publications, patents and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The present invention provides a method of synthesizing compounds of formula (I): ##STR1## wherein R and R' are independently (C 1 -C 4 )alkyl. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/EP01/09759, filed Aug. 23, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a moving blade for a turbomachine. The invention relates, furthermore, to a turbomachine with a moving blade.
Moving blades for turbomachines, for example moving blades for high-pressure, medium-pressure or low-pressure part turbines of a steam turbine or gas turbine moving blades for compressors or turbines, are conventionally produced from homogeneous metallic alloys. In this case, in addition to milling methods, casting and forging techniques are also used. The metallic raw material is in this case melted and subsequently rolled as bar stock or forged as a blade blank.
A turbomachine of this type contains an individual rotor or a number of rotors that are disposed one behind the other in the axial direction and around the moving blades of which a gaseous or vaporous flow medium flows during operation. The flow medium in this case exerts on the moving blades a force which gives rise to a torque over the rotor or blade wheel and consequently to the working power output. For this purpose, the moving blades are conventionally disposed on a rotatable shaft of the turbomachine, of which the guide vanes disposed on corresponding guide wheels are disposed on the stationary casing, the casing of the turbomachine, the casing surrounding the shaft so as to form a flow duct.
Whereas, in a compressor, mechanical energy is supplied to the flow medium, in a turbine functioning as a turbomachine mechanical energy is extracted from the flow medium flowing through. In a conventional turbomachine with a shaft rotating during operation and with a stationary casing, the centrifugal force in each moving blade fastened to the shaft generates a tensile load on which is superposed a bending load caused by the flow forces of the flow medium. This results in a critical load at those points in the blade foot and in the shaft at which the bending tensile stress and the tensile stress as a result of centrifugal forces are superposed on one another. Owing to the critical load, there is a limit to the blade height in its radial dimension and consequently to the efficiency of the turbomachine.
In particular, the moving blades of steam turbine low-pressure parts (LP moving blades) are predominantly loaded by centrifugal forces as a result of the rotation of the shaft. The load is therefore directly proportional to the density of the blade material used. Since the densities of the materials used are very similar to that of iron, the load in the case of long LP blades is such that a specific blade length cannot be exceeded. This is important particularly for the higher stages of the LP blading, the radial dimensions of which are limited by the limits of the centrifugal force load. Due to the limited blade length, only a specific outlet cross section can be achieved for the flow medium, so that the flow medium, for example the exhaust steam of a low-pressure part turbine, leaves the turbomachine at a high velocity and consequently with high losses.
Previous solutions to the problem for LP moving blades provide for the use of materials consisting of titanium alloys in the case of very high blade lengths. As compared with alloys based on iron, cobalt or nickel, titanium alloys have a lower density, and therefore, with dimensions otherwise being the same, moving blades consisting of this material are subject to lower stresses than moving blades consisting of the metallic materials customary hitherto. The disadvantage of this solution to the problem is, however, that titanium alloys are very costly and the problem of the centrifugal force load persists, as before, albeit to a somewhat lesser extent.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a moving blade for a turbomachine and a turbomachine which overcomes the above-mentioned disadvantages of the prior art devices of this general type, which specifies a blade configuration that, under the given loads in the turbomachine, does not exceed the permissible stresses and nevertheless allows high efficiency. A further object of the invention is to specify a turbomachine for high stresses, along with high efficiency.
With the foregoing and other objects in view there is provided, in accordance with the invention, a moving blade for a turbomachine. The moving blade has a moving blade body containing, at least in regions, a cellular material and an outer surface. The cellular material has cells forming the outer surface with a structure being closed with respect to the cells.
According to the invention, the object directed at the moving blade is achieved by the moving blade for the turbomachine, the moving blade containing, at least in regions, a cellular material.
As compared with the conventional configurations of moving blades for turbomachines, for example gas or steam turbines, the invention takes a completely new path. Although homogeneous metallic materials have been used hitherto for the moving blades, the concept of the invention is based on the structural configuration of the moving blade and of the materials forming it. By cellular materials being used for the moving blade, a considerable reduction in the average density for the moving blade is achieved. The cellular structure ensures a substantially lower density than homogeneous materials customary hitherto. Since the cellular material is disposed in regions in a specific way, moving blades according to the invention therefore give rise to substantially lower stresses as a result of centrifugal forces. Consequently, when cellular materials are used, moving blades with a markedly higher blade length can be produced, so that a larger flow cross section with lower losses when the moving blade is used in a turbomachine can be implemented.
Moreover, cellular materials have higher internal damping than homogeneous materials, so that they advantageously damp possible vibrations particularly efficiently. Furthermore, cellular materials exhibit good rigidity properties, so that, owing to the high specific strength, they have approximately the permissible load of comparable homogeneous materials. This is particularly advantageous in application in a turbomachine, where considerable thermomechanical loads are to be noted. By virtue of the specific selection of regions of the moving blade where the cellular material is provided, a load-adapted blade configuration can be specified for the moving blade. Depending on the application, therefore, different regions of the moving blade may have the cellular material.
The moving blade preferably has a blade leaf region with the cellular material. It is precisely the blade leaf region of a moving blade which, when the moving blade is used in a turbomachine, is exposed to particularly high blade stresses as result of the action of centrifugal force, since, as compared with other regions of the moving blade, the blade leaf region is at a greater radial distance from the axis of rotation. As a result of the markedly lower density, a blade leaf region having the cellular material undergoes a correspondingly lower centrifugal load.
Preferably, the moving blade has a fastening region, in particular a blade foot, the cellular material being provided in the fastening region. The fastening of a moving blade takes place normally on a rotatable shaft, a fastening region of the moving blade being connected to a corresponding reception region of the shaft. Various blade fastening concepts are known, for example pine tree slot connections or hammer head connections, to which the novel moving blade concept can be applied. By the cellular material being provided in the fastening region of the moving blade, the blade stresses in the fastening region, too, can be reduced correspondingly. By the combination of various regions of the moving blade in which the cellular material is provided, specific adaptation to the respective loads becomes possible. For example, the cellular material may be provided both in the blade leaf region and in the fastening region.
The moving blade may also be formed of as a whole of the cellular material, as a result of which, because of the reduction in density in relation to a comparable solid material, a lightweight form of construction of the moving blade is achieved overall. In terms of the physical properties, such as weight, hardness and flexibility, the cellular construction of the moving blade is far superior to the use of solid light metals, for example titanium alloys.
In a preferred embodiment, the moving blade has an inner region and a casing region surrounding the inner region, the cellular material being provided in the casing region and/or in the inner region.
Also preferably, the cellular material forms an outer surface with a structure that is closed with respect to the cells. This is particularly advantageous, insofar as the outer surface is a part surface of the blade leaf region of the moving blade, the blade leaf region being acted upon by a flow medium during operation. By the outer surface being produced with a closed structure, a surface, for example a surface in the blade leaf region, with correspondingly low roughness is provided. Insofar as the outer surface of the cellular structure is exposed to a flow medium, the flow resistances and consequently the flow losses are correspondingly low. Advantageously, due to the cellular structure of the material, an outer surface is provided which also has a highly damping action with respect to secondary losses as a result of transverse flows. For this purpose, for a possible transverse flow, the surface has barriers that may be formed along mutually contiguous cells of the cellular structure.
In a particularly preferred embodiment, the cellular material is a metal foam. Metal foams, above all, are lightweight construction materials with high potential and with a widespread field of use. Metal foams may be obtained by various production methods, for example by fusion and powder-metallurgic precipitation and sputtering techniques. In a powder-metallurgic method, by a metal powder being mixed with an expanding agent, for example metal hydride, an exchange material is produced, which, after subsequent axial hot pressing or extrusion, is compacted into a prefabricated semi-finished product which, by appropriate forming, can be adapted in a dimensionally accurate manner to a respective final product and, by corresponding heating, is properly foamed to just above the fusion temperature of the metal. The expanding agent which is contained in the semi-finished product, and for which titanium hydride is typically used, decomposes during heating and splits off hydrogen gas. The hydrogen occurring in gaseous form leads as a propellant to forming a corresponding pore formation in the metal melt. The metal foam porosity formed by the pores can in this case be set specifically for the duration of the foaming operation.
Preferably, the density of the metal foam is between about 5% and 50%, in particular between about 8% and 20%, of the density of the solid material.
Preferably, the metal foam consists of a material resistant to high temperature, in particular a nickel-based or cobalt-based alloy. The selection of a material resistant to high temperature is particularly advantageous especially for use in a gas turbine having turbine inlet temperatures of up to 1200° C. Use in a steam turbine with high steam states with a steam temperature of more than 600° C. is also made possible by the selection of material for the metal foam.
Preferably, the moving blade is configured as a gas turbine moving blade, a steam turbine moving blade, in particular a low-pressure steam turbine moving blade, or a compressor moving blade. In particular, the use of the moving blade in a low-pressure steam turbine appears to be particularly advantageous, because, due to the use of the cellular material, for example the metal foam, higher blade lengths, along with a lower centrifugal force load, can be implemented, as compared with the conventional moving blades. This has a beneficial effect directly on the efficiency of the turbomachine, for example of a low-pressure steam turbine.
The object directed at a turbomachine is achieved, according to the invention, by a turbomachine having a moving blade according to the statements made above.
The turbomachine is advantageously configured as a gas turbine, a steam turbine or a compressor.
The advantages of such a turbomachine may be gathered according to the statements relating to the moving blade.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a moving blade for a turbomachine and turbomachine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic, perspective view of a moving blade for a turbomachine according to the prior art;
FIG. 2 is a perspective view of the moving blade for a turbomachine that consists in regions of a cellular material according to the invention;
FIG. 3 is a perspective illustration of the moving blade modified in relation to FIG. 2;
FIG. 4 is a sectional view of the moving blade taken along the line IV—IV shown in FIG. 3;
FIGS. 5 and 6 are sectional views of the moving blade having a configuration that is modified in relation to FIG. 4;
FIG. 7 is an enlarged illustration of a detail VII of the moving blade shown in FIG. 6; and
FIG. 8 is a greatly simplified perspective view of a longitudinal section of a turbomachine having moving blades.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a perspective view of a moving blade 1 which extends along a longitudinal axis 25 . The moving blade 1 has, successively along the longitudinal axis, a fastening region 9 , a blade platform 23 contiguous to it and a blade leaf region 7 . In the fastening region 9 is formed a blade foot 11 which serves for fastening the moving blade 1 to the shaft of a turbomachine (see FIG. 8) not illustrated in FIG. 1 . The blade foot 11 is configured as a hammer head. Other configurations, for example as a pine tree or dovetail foot, are possible. In conventional moving blades 1 , solid metallic materials are used in all the regions 9 , 23 , 7 of the moving blade 1 . The moving blade 1 may in this case be manufactured by a casting method, a forging method, a milling method or combinations of these.
The moving blade 1 according to the invention is illustrated in FIG. 2 . As compared with the conventional moving blade 1 shown in FIG. 1, the moving blade 1 is formed of, in regions, of a cellular material 5 .
The cellular material 5 is in this case provided in the blade leaf region 7 of the moving blade 1 , the entire blade leaf region 7 having the cellular material 5 . The cellular material 5 has a multiplicity of cells 17 , 17 a , 17 b . The cellular construction of the cellular material 5 may be such that a closed porous structure is achieved, each of the cells 17 , 17 a , 17 b being closed. In an alternative configuration of the cellular material, the cells 17 , 17 A, 17 B may also form an at least partially non-closed porous structure. By the cellular material 5 being provided in the blade leaf region 7 , a region 7 with a markedly reduced material density is afforded in the blade leaf region 7 , as compared with conventional moving blades 1 with the use of solid material (see FIG. 1 ). This is achieved by virtue of the cellular structure of the material 5 . Due to the reduced density in the blade leaf region 7 , in an operational situation, that is to say, for example, when the moving blade 1 is used in a turbomachine, a considerable reduction in the load as a result of a centrifugal force F z directed radially outward along the longitudinal axis 25 is achieved. The region of the moving blade 1 which experiences a higher centrifugal force F z because of the greater radial distance from the axis of rotation, to be precise the blade leaf region 7 , is in this case provided specifically with the cellular material. The invention makes it possible to adapt to the respective requirements that depend on the application and on the loads prevailing as a result on the moving blade 1 . In this case, as compared with conventional concepts, the structural properties of the materials are for the first time taken into account and advantageously employed.
The cellular material 5 may be provided in different regions 9 , 23 , 7 of the moving blade 1 . In order to illustrate this flexibility, FIG. 3 shows a perspective illustration of the moving blade 1 with a configuration, modified as compared with the moving blade 1 illustrated in FIG. 2, in terms of the introduction of the cellular material 5 .
For the sake of simplicity and clarity, this is illustrated by the details X 1 and X 2 of the moving blade 1 . The cellular material 5 is introduced, according to detail X 1 , in the fastening region 9 and, according to detail X 2 , in the region of the blade platform 23 . The details X 1 and X 2 in this case represent, by way of example, part regions of the fastening region 9 and of the blade platform 23 respectively. Of course, in one advantageous embodiment, the entire fastening region 9 and/or the region of the blade platform 23 may consist of the cellular material 5 . The cellular material 5 in this case contains a multiplicity of the cells 17 .
FIG. 4 shows a sectional view of the moving blade 1 shown in FIG. 3, taken along a sectional line IV—IV. The moving blade 1 has an inlet edge 31 and an outlet edge 33 . Further, the moving blade 1 has a delivery side 35 and a suction side 37 located opposite the delivery side 35 . A typical blade profile is afforded thereby. The moving blade 1 has an inner region 13 and a casing region 15 surrounding the inner region 13 . The casing region 15 forms an outer surface 39 of the moving blade 1 , in an operational situation the outer surface 39 being acted upon by a flow medium, for example a hot gas or steam. According to FIG. 4, the casing region 15 is formed of a conventional, for example, metallic solid material 27 not specified in any more detail. The inner region 13 is formed of, at least in regions, of the cellular material 5 . The cellular material 5 being formed from a metal foam 21 with a multiplicity of the cells 17 contiguous to one another. Cooling ducts 29 , 29 A, 29 B are provided in the inner region 13 , so that the moving blade 1 is configured for interior cooling in an operational situation. In this case, the cooling ducts 29 , 29 A, 29 B are acted upon by a coolant, for example cooling air or cooling steam. The cooling duct 29 serves, for example, for supplying the coolant, while the cooling ducts 29 A, 29 B serve for discharging the coolant.
The cooling ducts 29 , 29 A, 29 B are formed in the inner region 13 by corresponding recesses of the cellular material 5 . The blade 1 of FIG. 3 may in this case be produced, for example, in that the thin-walled casing region 15 forming the blade profile is injection-molded as a hollow mold together with the metal foam 21 , corresponding removable or releasable molding cores for the formation of the cooling ducts 29 , 29 A, 29 B being positioned in the inner region 13 before the injection of the metal foam 21 . With the construction of the moving blade 1 , as shown, the thin-walled casing region 15 is produced, which is supported by the cellular material 5 in the inner region 13 as a supporting structure.
An alternative embodiment of the blade profile, shown in FIG. 4, of the moving blade 1 is illustrated in FIG. 5 . In this case, the casing region 15 is formed of the metal foam 21 that surrounds the inner region 13 . The inner region 13 forms a cavity of the moving blade 1 , so that interior cooling is possible. The casing region 15 has the outer surface 39 that is acted upon by a flow medium in an operational situation. In contrast to the variant shown in FIG. 4, the metal foam 21 forms the outer surface 39 .
A further variant of the moving blade 1 is shown in a sectional view in FIG. 6 . In this case, the blade profile is formed completely of the cellular material 5 , the metal foam 21 being provided for this purpose here again. At the same time, in a similar way to what was discussed in connection with FIG. 5, the metal foam 21 forms the outer surface 39 . The inner region 13 and the casing region 15 of the moving blade 1 thus are formed of the cellular material 5 .
FIG. 7 shows an enlarged detail VII of the moving blade 1 illustrated in FIG. 6 . The cellular structure of the material 5 , which is provided here by the metal foam 21 , is to be illustrated by this.
A multiplicity of cells 17 , 17 A, 17 B are shown, the cells 17 A, 17 B being contiguous to one another and forming part of the surface 39 of the moving blade 1 . In addition, the cells 17 not forming the outer surface 39 are also provided. These cells 17 may also be designated as inner cells 17 . The cells 17 , 17 A, 17 B have, for example, a polygonal structure in the sectional view. In a three-dimensional view, this corresponds to polyhedra or linear combinations of polyhedra. By virtue of the structure and configuration of the cells 17 A, 17 B, the cellular material 5 forms the outer surface 39 with a structure that is closed with respect to the cells 17 A, 17 B. The outer surface 39 of the moving blade 1 is thus provided, which has a sufficiently low surface roughness, so that, in accompaniment with this, correspondingly low flow losses are ensured when the moving blade 1 is used in a turbomachine (see FIG. 8 ). Thus, as compared with conventional moving blades 1 , a competitive, if not superior, solution is also shown in terms of as smooth a surface as possible. Advantageously, the local surface structure in the region of near-surface cells 17 A, 17 B contiguous to one another may additionally be markedly lower, in particular, the secondary losses as a result of transverse flows.
FIG. 8 shows a simplified illustration, in a longitudinal section, of a detail of a turbomachine 3 by the example of a low-pressure steam turbine 59 . The low-pressure steam turbine 59 has a rotor 43 that extends along an axis of rotation 41 of the steam turbine 59 . Further, the low-pressure steam turbine 59 has, successively along the axis 41 , an inflow region 49 , a blading region 51 and an outflow region 53 . Rotatable moving blades 1 and stationary guide vanes 45 are disposed in the blading region 51 . The moving blades 1 are in this case fastened to the turbine rotor 43 , while the guide vanes 45 are disposed on a guide vane carrier 47 surrounding the turbine rotor 43 .
An annular flow duct for a flow medium A, for example hot steam, is formed by the shaft 43 , the blading region 51 and the guide vane carrier 47 . The inflow region 49 serving for supplying the flow medium A is delimited in the radial direction by an inflow casing 55 disposed upstream of the guide vane carrier 59 . An outflow casing 57 is disposed downstream on the guide vane carrier 47 and delimits the outflow region 53 in the radial direction. When the steam turbine 59 is in operation, the flow medium A, here a hot steam, flows from the inflow region 49 into the blading region 51 , where the flow medium A, by expansion, performs work and thereafter leaves the steam turbine 59 via the outflow region 53 . The flow medium A is subsequently collected in a condenser, not illustrated in any more detail in FIG. 8, for the steam turbine 59 , the condenser being located downstream of the outflow casing 57 .
When flowing through the blading region 51 , the flow medium A expands and performs work on the moving blades 1 , with the result that these are set in rotation. The moving blades 1 of the low-pressure steam turbine 51 are formed of, at least in regions, of the cellular material 5 , as described in FIGS. 2 to 7 .
As a result, the moving blades 1 have a lower density, as compared with conventional moving blades 1 (see FIG. 1 ), and are not subjected to such high loads as a result of the centrifugal force. The moving blades 1 form the low-pressure blading of the low-pressure steam turbine 59 . By the cellular material 5 being used in regions for the moving blades 1 , moving blades 1 with a larger radial dimension can be used by virtue of the density advantage, so that a larger flow cross section with lower losses for the steam turbine 59 is implemented.
In addition to the moving blades 1 , the guide vanes 45 may also be formed of in regions of the cellular material 5 , so that both the moving blades 1 and the guide vanes 45 in a lightweight form of construction can be used in the blading region 51 . Furthermore, it is possible for the novel blade concept to be applied to other types of turbomachines 3 . Thus, the blading of a gas turbine, a compressor, a high-pressure or medium-pressure part turbine of a steam turbine plant may have moving blades 1 and/or guide vanes 45 with the cellular material 5 , in particular a metal foam 21 . | A novel blade configuration does not exceed the permitted stresses for particular loads, especially as a result of centrifugal forces and which at the same time, allows the turbomachine to function with a high degree of efficiency. To this end, a moving blade for the turbomachine contains at least partially a cellular material, especially a foamed metal. The cellular material can be provided e.g. in the hollowed-out part of the moving blade. | 5 |
PRIORITY STATEMENT
[0001] This is a continuation application of U.S. patent application Ser. No. 14/556,592, entitled “Interview Programming For an HVAC Controller”, filed Dec. 1, 2014, which is a continuation of U.S. patent application Ser. No. 13/413,604, entitled “Interview Programming For an HVAC Controller”, filed Mar. 6, 2012, now U.S. Pat. No. 8,903,552, which is a continuation of U.S. patent application Ser. No. 12/700,672, entitled “Interview Programming For an HVAC Controller”, filed Feb. 4, 2010, now U.S. Pat. No. 8,219,251, which is a continuation of U.S. patent application Ser. No. 12/424,931, entitled “HVAC Controller With Guided Schedule Programming”, filed Apr. 16, 2009, now U.S. Pat. No. 8,170,720, which is a continuation of U.S. patent application Ser. No. 11/421,833, entitled “Natural Language Installer Setup For Controller”, filed Jun. 2, 2006, now U.S. Pat. No. 5,090,881 which is a continuation-in-part of U.S. patent application Ser. No. 10/726,245, entitled “Controller Interface With Interview Programming”, filed on Dec. 2, 2003, now U.S. Pat. No. 7,181,317.
FIELD
[0002] The present invention relates generally to the field of programmable controllers for homes and/or buildings and their related grounds. More specifically, the present invention relates to simplified interfaces for such controllers having interview programming capabilities.
BACKGROUND
[0003] Controllers are used on a wide variety of devices and systems for controlling various functions in homes and/or buildings and their related grounds. Some controllers have schedule programming that modifies device parameter set points as a function of date and/or time. Some such device or system controllers that utilize schedule programming for controlling various functions in homes and/or buildings and their related grounds include, for example, HVAC controllers, water heater controllers, water softener controllers, security system controllers, lawn sprinkler controllers, and lighting system controllers.
[0004] HVAC controllers, for example, are employed to monitor and, if necessary, control various environmental conditions within a home, office, or other enclosed space. Such devices are useful, for example, in regulating any number of environmental conditions with a particular space including for example, temperature, humidity, venting, air quality, etc. The controller may include a microprocessor that interacts with other components in the system. For example, in many modern thermostats for use in the home, a controller unit equipped with temperature and humidity sensing capabilities may be provided to interact with a heater, blower, flue vent, air compressor, humidifier and/or other components, to control the temperature and humidity levels at various locations within the home. A sensor located within the controller unit and/or one or more remote sensors may be employed to sense when the temperature or humidity reaches a certain threshold level, causing the controller unit to send a signal to activate or deactivate one or more components in the system.
[0005] The controller may be equipped with an interface that allows the user to monitor and adjust the environmental conditions at one or more locations within the building. With more modern designs, the interface typically includes a liquid crystal display (LCD) panel inset within a housing that contains the microprocessor as well as other components of the controller. In some designs, the interface may permit the user to program the controller to activate on a certain schedule determined by the user. For example, the interface may include a separate menu routine that permits the user to change the temperature at one or more times during a particular day. Once the settings for that day have been programmed, the user can then repeat the process to change the settings for the other remaining days.
[0006] With more modern designs, the programmable controller may include a feature that allows the user to set a separate schedule for weekday and weekend use, or to copy the settings for a particular day and then apply them towards other selected days of the week. While these designs allow the user to copy settings from one day to another, a number of steps are often required to establish a program, adding to the complexity of the interface. In some cases, the interface may not permit the user to select multiple days outside of the normal weekday/weekend scheme. In other cases, the interface is simply too complex to be conveniently used to program a temperature scheme and is simply by-passed or not programmed by the user. Accordingly, there is an ongoing need in the art to decrease the time and complexity associated with programming a multi-day schedule in a programmable controller.
[0007] During the installation process, the steps required to program the controller to operate with other system components can also add to the time and complexity associated with configuring the controller. Typically, programming of the controller is accomplished by entering in numeric codes via a fixed segment user interface, by manually setting jumper switches on a circuit board, or by adjusting screws or potentiometers on a circuit board. In some cases, the codes or settings used to program the controller are obtained from a manual or table which must be consulted by the installer during the installation process. For example, to configure an HVAC system having a multistage heat pump, the controller may require the installer to enter a numeric or alphanumeric code (e.g. 91199) from a manual or table in order to program the controller to properly operate the various stages of the heat pump. Such process of referring to a manual or table of codes is not often intuitive to the user, and requires the user to store the manual in a safe place for subsequent use. Accordingly, there is also an ongoing need in the art to decrease the time and complexity associated with programming the controller during the installation process.
SUMMARY
[0008] Generally, the present invention pertains to simplified interfaces for controllers having interview programming capabilities.
[0009] In one illustrative embodiment, a method of programming a schedule of a controller having a user interface is described. The illustrative method includes the steps of providing one or more interview questions to a user via the user interface; accepting one or more user responses to the one or more interview questions from the user via the user interface; and creating and/or modifying or building a schedule based on the user responses.
[0010] In another illustrative embodiment, a method of programming configuration information within a controller is further described. An illustrative method can include the steps of providing one or more interview questions to a user via a user interface, prompting the user to selected between at least two answers simultaneously displayed on the user interface, accepting one or more user responses to the interview questions via the user interface, and modifying the operational parameters of the controller and/or one or more components controlled by the controlled based at least in part on the user responses. The interview questions can include at least one question relating to the installation or setup of the controller as well as any components controlled by the controller.
[0011] An illustrative controller having interview programming capabilities can include an interview question generator adapted to generate a number of interview questions relating to the installation or setup of the controller and/or any components controlled by the controller, a user interface including a display screen adapted to display interview questions to a user along with at least two answers for each interview question, and a memory unit for storing operational parameters within the controller based at least in part on the user responses to the interview questions.
[0012] The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures, Detailed Description and Examples which follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0014] FIG. 1 is a flow diagram of an illustrative HVAC interview program;
[0015] FIG. 2 is a block diagram of the illustrative HVAC interview program shown in FIG. 1 ;
[0016] FIG. 3 is a flow diagram of another illustrative HVAC interview program;
[0017] FIG. 4A is a block diagram of the illustrative HVAC interview program shown in FIG. 3 ;
[0018] FIG. 4B is an illustrative partial block diagram of the block diagram shown in FIG. 4A ;
[0019] FIG. 5 is a flow diagram of another illustrative HVAC interview program;
[0020] FIG. 6 is a block diagram of the illustrative HVAC interview program shown in FIG. 5 ;
[0021] FIGS. 7A-C are flow diagrams of another illustrative HVAC interview program;
[0022] FIGS. 8A-T are schematic drawings of an illustrative HVAC interface showing an embodiment of the flow diagram of the illustrative HVAC interview program shown in FIG. 7 ;
[0023] FIG. 9 is a block diagram of an illustrative HVAC system including a programmable controller having interview capabilities for configuring one or more HVAC components;
[0024] FIG. 10 is a block diagram showing the controller and user interface of FIG. 9 ;
[0025] FIG. 11 is a flow diagram showing several illustrative interview questions and answers that can be provided by the interview question generator of FIG. 10 ;
[0026] FIG. 12 is a flow diagram of an illustrative method of programming configuration information within a controller; and
[0027] FIGS. 13A-13J are schematic drawings of an illustrative user interface showing an illustrative implementation of the flow diagram depicted in FIG. 12 .
[0028] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION
[0029] The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
[0030] Generally, the present invention pertains to simplified interfaces for controllers having interview programming capabilities. These controllers can be used in a variety of systems such as, for example, HVAC systems, water heater systems, water softener systems, sprinkler systems, security systems, lighting systems, and the like. The Figures depict HVAC controllers. While the present invention is not so limited, an appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.
[0031] FIG. 1 is a flow diagram of an illustrative HVAC interview program 100 . The flow diagram starts at a normal thermostat operation block 110 . Normal thermostat operation block 110 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 120 , 130 provides one or more interview questions to a user via the user interface. The user interface can accept one or more responses to the one or more interview questions from the user via the user interface. The schedule is then built or modified, in some cases by adding or modifying one or more schedule parameters 140 , 150 , based on the user responses provided via the user interface. Once the schedule parameters 140 , 150 are modified, the controller can return to the normal operation block 110 , and follow the new schedule.
[0032] In some embodiments, the interview scheduling blocks 120 and 130 can provide interview questions that elicit an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. Alternatively, or in addition, the interview scheduling blocks 120 , and 130 can provide include interview questions that allow a user to select one (or more) answers from a predetermined list of answers.
[0033] In some embodiments, these interview questions can solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points such as, for example, the interview question may ask “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 120 preferably includes questions that are natural language questions, which may be phrases that have one, two, three, four, five, six, or seven or more words, although this is not required in all embodiments.
[0034] Alternatively, or in addition, interview scheduling block 130 can provide interview questions that require a numerical user response. For example, these interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 120 described above. Interview block 130 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. Like interview schedule block 120 above, interview scheduling block 130 can include questions that are natural language questions, which may be phrases that have one, two, three, four, five, six, or seven or more words, although this is not required in all embodiments.
[0035] The interview scheduling blocks 120 and 130 can provide one or more interview questions about, for example, which weekdays will have the same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in summer?, and/or what a comfortable sleeping temperature is in winter?
[0036] Alternatively, or in addition, the interview scheduling blocks 120 and 130 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
[0037] Alternatively, or in addition, once an initial schedule has been built, the interview scheduling blocks 120 , and 130 can display a previous answer that was accepted by the user interface based on the prior built schedule. This illustrative feature can provide the user with a convenient option to select and alter only the schedule parameters 140 , 150 that the user desires to modify. This feature can be utilized in all illustrative embodiments described herein, however it is not required.
[0038] FIG. 2 is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 1 . Controller 200 includes a control module 210 that can be a microprocessor or the like. The control module 210 communicates with a user interface 220 , and can include an interview question generator 225 , a response acceptor 240 and a programmable schedule 250 . The control module 210 can also generate a control signal 260 to a device (not shown), such as an HVAC system or device.
[0039] In an illustrative embodiment, the interview question generator 225 provides interview questions, such as those described above, to the user interface 220 . The user interface 220 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, and/or an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 225 by any suitable mechanism, such as by pressing a schedule button on a touchscreen of the user interface 220 . Alternatively, or in addition, the controller 210 may activate the interview question generator 225 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to questions posed by the interview question generator 225 , the user can enter one or more user responses into the user interface 220 . The response acceptor 240 accepts the user responses and provides the response to the programmable schedule 250 . In some embodiments, the programmable schedule 250 has a number of time and temperature set points that can be entered or modified by the response acceptor 240 . Once the schedule is built and/or modified, a control signal 260 is generated by the control module 210 based on the programmable schedule 250 .
[0040] FIG. 3 is a flow diagram of another illustrative HVAC interview program 300 . The flow diagram starts at a normal thermostat operation block 310 . Normal thermostat operation block 310 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 325 provides one or more interview questions to a user via a user interface. The user interface then accepts one or more responses to the one or more interview questions from the user via the user interface. A user response translator 360 translates the one or more user responses to form a translated response. One or more schedule parameters 370 are then modified based on the translated responses from the response translator 360 . Once the schedule parameters 370 are modified, the controller can return to the normal operation block 310 .
[0041] In some embodiments, the interview scheduling block 325 includes interview questions that require an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. In addition, the interview questions can solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points. For example, the interview question may ask “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 325 can include questions that are natural language questions such as, for example, phrases that can have one, two, three, four, five, six, or seven or more words.
[0042] In an illustrative embodiment, interview scheduling block 325 may also provide interview questions that require a numerical user response. These interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 325 described above. The interview block 325 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. The interview scheduling block 325 can include questions that are natural language questions such as, for example, phrases that can have one, two, three, four, five, six, or seven or more words.
[0043] In the illustrative embodiment, the interview scheduling block 325 can also provide one or more interview questions related to, for example, which weekdays will have the same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in the summer?, or what a comfortable sleeping temperature is in the winter?
[0044] The response translator 360 can translate the user responses to create appropriate schedule parameters 370 that help define the schedule of the controller. That is, the response translator 360 applies the user responses to one or more interview questions to establish the controller schedule. For example, the response translator 360 can take an affirmative user response to the interview question, “Do you want the same schedule for Saturday and Sunday?” and correlate with the interview question, “What temperature do you like when the heat is on?” to establish the schedule parameters for the heating temperature during at least selected periods on Saturday and Sunday.
[0045] Alternatively, or in addition, the interview scheduling block 325 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
[0046] FIG. 4A is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 3 . Controller 400 includes a control module 410 that can be a microprocessor or the like. The control module 410 communicates with a user interface 420 , and may include an interview question generator 425 , a response acceptor 440 , a response translator 460 , and a programmable schedule 470 . The control module 410 can also generate a control signal 465 to a device (not shown), such as an HVAC system or device.
[0047] In the illustrative embodiment, the interview question generator 435 provides interview questions, such as those described above, to the user interface 420 . The user interface 420 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, and/or an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 435 by any suitable mechanism, such as by pressing a mechanical schedule button on the controller, touching an appropriate region of a touchscreen, voice activation, etc. Alternatively, or in addition, the controller 410 may activate the interview question generator 425 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to questions posed by the interview question generator 425 , the user can enter one or more user responses into the user interface 420 . The response acceptor 440 accepts the user responses and provides the response to the response translator 460 . The response translator 460 provides a translated response to a programmable schedule 470 . In some embodiments, the programmable schedule 470 has a number of time and temperature set points that can be entered or modified by the response translator 470 . Once the schedule is built and/or modified a control signal 465 is generated by the control module 410 based on the programmable schedule 470 .
[0048] FIG. 4B is an illustrative partial block diagram of the block diagram shown in FIG. 4A showing one embodiment of the interaction of the interview question generator 425 , response acceptor 440 , response translator 460 and programmable schedule 470 . The illustrative programmable schedule 470 has a plurality of cells such as, for example, a Saturday wake cell 471 , a Sunday wake cell 472 , a Saturday sleep cell 473 , and a Sunday sleep cell 474 . In this embodiment, each cell 471 , 472 , 473 , 474 may include a number of schedule parameters such as, for example, a start time, a heat temperature and a cool temperature.
[0049] Interview questions 425 are posed to the user. As shown in the illustrative example: an interview question 425 of “Same schedule for Saturday and Sunday?” elicits an user response 440 of “YES”; an interview question 425 of “For the weekend, is someone home all day?” elicits an user response 440 of “YES”; an interview question 425 of “What time does the first person wake up?” elicits an user response 440 of “7:00 a.m.”; an interview question 425 of “What time does the last person go to sleep?” elicits an user response 440 of “10:00 p.m.”; an interview question 425 of “What temperature is comfortable when the heat is on?” elicits an user response 440 of “72° F.”; an interview question 425 of “What temperature is comfortable when the air conditioning is on?” elicits an user response 440 of “68° F.”; an interview question 425 of “What is a comfortable sleeping temperature in summer?” elicits an user response 440 of “67° F.”; and an interview question 425 of “What is a comfortable sleeping temperature in winter?” elicits an user response 440 of “65° F.”.
[0050] In the illustrative embodiment, the response translator 460 accepts the user responses provided in block 440 . The response translator 460 then builds and/or modifies the programmable schedule 470 . In the illustrative embodiment, each cell 471 , 472 , 473 , 474 includes a start time, a heat temperature and a cool temperature. The Saturday wake cell 471 and the Sunday wake cell 472 has a start time of 7:00 a.m., a heat temperature of 72° F., and a cool temperature of 68° F., all of the times and temperatures are provided by the response translator. The Saturday sleep cell 473 and the Sunday sleep cell 474 has a start time of 10:00 p.m., a heat temperature of 65° F., and a cool temperature of 67° F., all of the times and temperatures are provided by the response translator.
[0051] In this illustrative embodiment, the response translator 460 takes a plurality of user responses 440 to the interview questions 425 and builds and/or modifies a plurality of schedule parameters. The Saturday and Sunday Leave and Return cells 475 , 476 , 477 , and 478 are ignored and/or zeroed out by the response translator 460 since they are not required based on the user responses 425 for this example.
[0052] FIG. 5 is a flow diagram of another illustrative HVAC interview program 500 . The flow diagram starts at a normal thermostat operation block 510 . Normal thermostat operation block 510 can be an initial parameter setting operation or a modification of parameter settings. Interview scheduling block 525 provides one or more interview questions to a user via a user interface. The user interface then accepts one or more responses to the one or more interview questions from the user via the user interface. A sufficient information block 560 determines if enough information has been solicited from the user response to the interview questions sufficient to build or modify the schedule at block 570 . If not, the interview scheduling block 525 provides another interview question to the user via the user interface. If the sufficient information block 560 determines that enough information has been solicited, then the schedule is built or modified by the modify schedule block 570 . Once the schedule is built or modified by the modify schedule block 570 , the controller can return to the normal operation block 510 .
[0053] The sufficient information block 560 can, for example, help ensure that a sufficient number of schedule parameters are defined, such as, for example, a start time, a heating temperature and a cooling temperature for a particular time period such as, for example, a specific day or group of days wake period, leave period, return period and/or sleep period, as shown in FIG. 4B .
[0054] In some embodiments, the interview scheduling block 525 provides a number of predetermined interview questions in a predetermined sequential order. The number of questions or queries may be adapted to collect information from the user responses to generate at least a portion of the schedule parameters.
[0055] Like above, the interview scheduling block 525 can include interview questions that require an affirmative (e.g., “yes”) or negative (e.g., “no”) user response. For example, interview scheduling block 525 can provide interview questions solicit information from the user regarding the grouping of the controller set points entered or the temporal relationship of the controller set points such as, for example, “Do you want the schedule to apply to every day of the week?”, requiring the user to respond with a “YES” or “NO” answer. The interview scheduling block 525 can include questions that are natural language questions which can be phrases that have one, two, three, four, five, six, or seven or more words in length.
[0056] Alternatively or in addition, interview scheduling block 525 can provide interview questions that require a numerical user response. For example, these interview questions can solicit information from the user regarding the specific time and temperature set points for each grouping of controller set points solicited by the interview block 525 described above. The interview block 525 can provide a question such as, for example, “What is a comfortable sleeping temperature in the winter?”, requiring the user to respond with a numerical temperature answer. Again, the interview scheduling block 525 can include questions that are natural language questions that can be phrases which can be one, two, three, four, five, six, seven or more words, although this is not required in all embodiments.
[0057] The interview scheduling block 525 may also provide one or more interview questions about, which weekdays will have a same schedule?, when a first person wakes up?, when a last person goes to sleep?, when a last person leaves during the day?, when a first person arrives home?, what a comfortable temperature is when heat is on?, what a comfortable temperature is when air conditioning is on?, what a comfortable sleeping temperature is in the summer?, or what a comfortable sleeping temperature is in the winter?
[0058] Alternatively, or in addition, the interview scheduling block 525 may provide one or more interview questions that provide a plurality of predetermined answers or responses (e.g., multiple choice format) where the user selects an answer or response. For example, the interview question may provide a question such as, “What type of schedule do you desire?” In this illustrative embodiment, a series of predetermined responses or answers can be provided such as, “Every day of the week is the same,” “Weekdays are the same and Saturday/Sunday is the same,” “Weekday are the same and Saturday/Sunday is different,” “Each Weekday is different and Saturday/Sunday is the same,” and “Each day of the week is different.”
[0059] FIG. 6 is a block diagram of the illustrative HVAC controller with an illustrative interview function similar to that shown in FIG. 5 . Controller 600 includes a control module 610 that can be a microprocessor or the like. The control module 610 communicates with a user interface 620 , and may include an interview question generator 625 , a response acceptor 640 and a programmable schedule 650 . The control module 610 can also generate a control signal 660 to a device (not shown), such as an HVAC system or device.
[0060] In the illustrative embodiment, the interview question generator 625 provides interview questions, such as those described above, to the user interface 620 . The user interface 620 can be any form of user interface such as, for example, a physical interface including a touchscreen, an LCD with buttons, an aural interface including a speaker and microphone, or any other suitable user interface. A user can activate the interview question generator 625 by any suitable mechanism, such as by pressing a schedule button on a touchscreen of the user interface 620 . Alternatively, or in addition, the controller 610 may activate the interview question generator 625 on its own, such as when it believes additional scheduling information is needed or might otherwise be desired. In response to the questions posed by the interview question generator 625 , the user can enter one or more user responses into the user interface 620 . The response acceptor 640 accepts the user responses and provides the responses to the programmable schedule 650 if it determines that sufficient information has been provided by the user responses to establish a program schedule. If not, the response acceptor 640 instructs the interview question generator 625 to provide another interview question to the user via the user interface 620 . Once the response acceptor 640 determines that sufficient information has been provided by the user to establish a program schedule 650 the program schedule 650 is built and/or modified. In some embodiments, the programmable schedule 650 has a number of time and temperature set points that can be entered or modified by the response acceptor 640 . Once the programmable schedule 650 is built and/or modified, a control signal 660 is generated by the control module 610 based on the programmable schedule 650 .
[0061] FIGS. 7A-C are flow diagrams of another illustrative HVAC interview program 700 . The flow diagram starts at a normal thermostat operation block 710 , but this is not required in all embodiments. In the illustrative embodiment, the interview program 700 can be initiated by pressing a program initiation button or key such as, for example, an “EZ Schedule” button.
[0062] The program can begin by asking whether the user wants the same schedule to be used for every day of the week, as shown at block 720 . If the user responds with a “YES” response, then the program can move to ask context questions for that group of days, as shown at block 725 , which may set the schedule for the week assuming the same schedule for every 24 hour period or day. If the user responds with a “NO” response, the program may ask the user if the same schedule applies to both weekend days, Saturday and Sunday, as shown at block 730 . If the user responds with a “YES” response, then the program can ask if the user wants two schedules, one for weekdays and one for weekends, as shown at block 735 . A “YES response to block 735 can move the program to asking context questions for a weekend group of days and a weekdays group of days, as shown at block 725 , to set the schedule for the week assuming a first schedule for weekend days and a second schedule for weekdays. A “NO” response to block 730 can cause the program to ask whether the user wants three schedules including a weekday schedule, a Saturday schedule, and a Sunday schedule, as shown at block 740 . A “YES” response to block 740 moves the program to asking context questions for a week day group of days schedule, a Saturday schedule and a Sunday schedule, as shown at block 725 , to set the schedule for the week assuming a first schedule for weekdays, and a second schedule for Saturday and a third schedule for Sundays. A “NO” response to either block 740 or block 735 moves the program to asking the user to group each day of the seven days of the week into similar schedule groupings until all days are assigned to one group, as shown at block 750 . The program can ask if all days are assigned at block 755 , with a “NO” response returning the user to block 750 to assign a non-assigned day or days until all days have been assigned. Once all days have been assigned to a group, the program moves to asking context questions for each group of days schedule, as shown at block 725 , to set the schedule for the each grouping of days assuming a first schedule for a first group, a second schedule for a second group, a third schedule for a third group and so on until all groupings of days are scheduled.
[0063] The program 700 can ask a variety of context sensitive question to determine the desired schedule for each grouping of days identified by the program 700 above. For example, and as shown in FIG. 7B , the program 700 can inquire whether someone is home all day, as shown at block 760 . If the user enters a “YES” response to block 760 , the program can ask when the first person gets and request that the user to enter a wake time, as shown at block 770 . Then the program 700 can ask when the last person goes to sleep and request that the user to enter a sleep time, as shown at block 780 . If the user enters a “NO” response to block 760 , the program can ask when the first person gets up, and request that the user to enter a wake time, as shown at block 761 . Then the program can ask what time the first person leaves home and request that the user enter a leave time, as shown at block 762 . The program can also ask when the last person gets home for the day, and request the user to enter a return time, as shown at block 763 . The program can also ask when the last person goes to sleep, and request that the user enter a sleep time, as shown at block 764 . Once all the above information has been entered by the user for each grouping of days, the program may move to an end block 781 .
[0064] The program 700 can then request information from the user regarding comfortable awake, sleeping and away temperatures. For example, and referring to FIG. 7C , the program can request that the user enter a comfortable temperature when the heat is on, as shown at block 790 . The temperature information received in block 790 can be automatically inserted into a program schedule for each grouping of days to set the wake heat and return heat set points. The program can also request that the user enter a comfortable temperature when the air conditioning is on, as shown at block 791 . This information can be automatically inserted into a program schedule for each grouping of days to set the wake cool and return cool set points. This illustrative program can also request that the user enter a comfortable summer sleeping temperature, as shown at block 792 . This information can be automatically inserted into a program schedule for each grouping of days to set the sleep cool set point. The program can also request that the user enter a comfortable winter sleeping temperature, as shown at block 793 . This information can be automatically inserted into a program schedule for each grouping of days to set the sleep heat set point. The program can also request that the user to enter an energy savings offset at block 794 . This information can be automatically inserted into a program schedule for each grouping of days to set the leave cool and leave heat set points.
[0065] In some embodiments, the program 700 can allow the user to request a schedule review at block 795 , which can allow the user to review the built or modified schedule, as shown at block 796 . If the user does not wish to review the schedule or when the user is done reviewing the schedule, the program returns to normal thermostat operation block 710 under the newly built or modified schedule.
[0066] FIGS. 8A-T are schematic drawings of an illustrative HVAC interface 800 showing an illustrative embodiment of the flow diagram of the HVAC interview program shown in FIGS. 7A-7C . The schematic screen shots are taken in sequential order based on the user selections shown in each screen shot. At FIG. 8A , a user 810 selects an “EZ Schedule” 801 button located on the interface 800 to begin the interview scheduling program.
[0067] At FIG. 8B , the program asks the user 810 , via the interface 800 , if the user 810 wants the same schedule to apply to every day of the week. The user 810 is shown selecting a “NO” response 802 .
[0068] At FIG. 8C , the program asks the user 810 , via the interface 800 , if the user 810 wants Saturday and Sunday to follow the same schedule. The user 810 is shown selecting a “YES” response 803 .
[0069] At FIG. 8D , the program asks the user 810 , via the interface 800 , to verify the there will be two schedules, one for weekends and a second for weekdays. The user 810 is shown selecting a “YES” response 804 .
[0070] At FIG. 8E , the program asks the user 810 , via the interface 800 , whether someone will be home all day on weekdays. The user 810 is shown selecting a “NO” response 805 .
[0071] At FIG. 8F , the program asks the user 810 , via the interface 800 , to enter what time the first person wakes up on weekdays. The user 810 is shown pressing an “ENTER” button 806 after selecting a wake time.
[0072] At FIG. 8G , the program asks the user 810 , via the interface 800 , to enter what time the last person leaves the house on weekdays. The user 810 is shown pressing an “ENTER” button 807 after selecting a leave time.
[0073] At FIG. 8H , the program asks the user 810 , via the interface 800 , to enter what time the first person arrives home on weekdays. The user 810 is shown pressing an “ENTER” button 808 after selecting a return time.
[0074] At FIG. 8I , the program asks the user 810 , via the interface 800 , to enter what time the last person goes to sleep on weekdays. The user 810 is shown pressing an “ENTER” button 809 after selecting a sleep time.
[0075] At FIG. 8J , the program asks the user 810 , via the interface 800 , whether someone will be home all day on weekends. The user 810 is shown selecting a “YES” response 811 .
[0076] At FIG. 8K , the program asks the user 810 , via the interface 800 , to enter what time the first person wakes up on weekends. The user 810 is shown pressing an “ENTER” button 812 after selecting a wake time.
[0077] At FIG. 8L , the program asks the user 810 , via the interface 800 , to enter what time the last person goes to sleep on weekends. The user 810 is shown pressing an “ENTER” button 813 after selecting a sleep time.
[0078] At FIG. 8M , the program asks the user 810 , via the interface 800 , a comfort question such as, what temperature do you like when the heat is on? The user 810 is shown pressing an “ENTER” button 814 after selecting a desired temperature.
[0079] At FIG. 8N , the program asks the user 810 , via the interface 800 , a comfort question such as, what temperature do you like when the air conditioning is on? The user 810 is shown pressing an “ENTER” button 815 after selecting a desired temperature.
[0080] At FIG. 8O , the program asks the user 810 , via the interface 800 , a comfort question such as, what is a comfortable sleeping temperature in the summer? The user 810 is shown pressing an “ENTER” button 816 after selecting a desired temperature.
[0081] At FIG. 8P , the program asks the user 810 , via the interface 800 , another comfort question such as, what is a comfortable sleeping temperature in the winter? The user 810 is shown pressing an “ENTER” button 817 after selecting a desired temperature.
[0082] At FIG. 8Q , the program asks the user 810 , via the interface 800 , another comfort question such as, what energy saving offset is desired? The user 810 is shown pressing an “ENTER” button 818 after selecting a desired energy saving offset.
[0083] At FIG. 8R , the program informs the user 810 , via the interface 800 , that the schedule has been completed, and may allow the user to view a portion of the schedule or selected day groupings. The user 810 is shown pressing a “VIEW WEEKDAYS” button 819 .
[0084] At FIG. 8S , the program informs the user 810 , via the interface 800 , specifics of the selected schedule. The user 810 is shown pressing a “DONE” button 821 .
[0085] At FIG. 8T , the program displays, via the interface 800 , specifics of the currently running schedule.
[0086] Referring now to FIG. 9 , a block diagram of an illustrative HVAC system including a programmable controller having interview capabilities for configuring one or more HVAC components will now be described. The HVAC system 900 can include a programmable controller 902 in communication with a number of system components that can be activated to regulate various environmental conditions such as temperature, humidity, and air quality levels occurring within the space to be controlled. As shown in FIG. 9 , for example, the controller 902 can be connected to a heating unit 904 and cooling unit 906 that can be activated to regulate temperature. The heating unit 904 can include a boiler, furnace, heat pump, electric heater, and/or other suitable heating device. In some embodiments, the heating unit 904 can include a multistage device such as a multistage heat pump, the various stages of which can be controlled by the controller 902 . The cooling unit 906 can include an air-conditioner, heat pump, chiller, and/or other suitable cooling device which can likewise be either single staged or multistaged depending on the application.
[0087] A ventilation unit 908 such as a fan or blower equipped with one or more dampers can be employed to regulate the volume of air delivered to various locations within the controlled space. A filtration unit 910 , UV lamp unit 912 , humidifier unit 914 , and dehumidifier unit 916 can also be provided in some embodiments to regulate the air quality and moisture levels within the controlled space. One or more local and/or remote sensors 918 can be connected to the controller 902 to monitor temperature or humidity levels inside, and in some cases, outside of the space to be controlled. In some embodiments, the controller 902 can be connected to one or more other controllers 920 such as another HVAC controller for providing multi-zoned climate control. The system components can be directly connected to a corresponding I/O port or I/O pins on the controller 902 , and/or can be connected to the controller 902 via a network or the like.
[0088] The controller 902 can include a user interface 922 to permit an installer or service technician to input commands for programming the controller 902 to operate with the various system components and any other connected controllers 922 . The user interface 922 can include, for example, a touch screen, liquid crystal display (LCD) or dot matrix display, an aural interface including a speaker and microphone, a computer, or any other suitable device for sending and receiving signals to and from the controller 902 . Depending on the configuration, the user interface 922 can also include buttons, knobs, slides, a keypad, or other suitable selector means for inputting commands into the controller 902 .
[0089] FIG. 10 is a block diagram showing the controller 902 and user interface 922 of FIG. 9 in greater detail. As can be further seen in FIG. 10 , the controller 902 can include a control module 924 such as a microprocessor/CPU, a storage memory 926 , a clock 928 , and an I/O interface 930 that connects the controller 902 to the various system components in FIG. 9 . An internal sensor 932 located within the controller housing can be used to measure the temperature, humidity levels, and/or other environmental conditions occurring within the controlled space.
[0090] During installation, the control module 924 communicates with the user interface 922 to provide the installer with interview questions relating to the configuration of one or more of the system components. In the illustrative embodiment of FIG. 10 , the controller 902 includes an interview question generator 934 that prompts the installer to provide feedback to the controller 902 regarding the types of system components to be controlled, the dates and times such components are to be operated, the power or temperature levels in which such components are to be operated, the bandwidth or offsets at which such components are to be operated, the type of space to be controlled, as well as other operating parameters. Activation of the interview question generator 934 can occur, for example, by pressing an installation button on a touchscreen or keypad of the user interface 922 . Alternatively, or in addition, the controller 902 may activate the interview question generator 934 on its own when a new system component is connected to the I/O interface 930 or when additional setup information is needed or desired by the controller 902 .
[0091] Input commands received via the user interface 922 can be fed to a response acceptor 936 , which accepts the user responses to the interview questions generated by the interview question generator 934 . The response acceptor 936 can be configured to translate the user responses into operation parameters 938 that can be stored within the memory unit 926 along with other information such as prior usage, scheduling parameters, user preferences, etc. The operation parameters 938 can then be used by the controller 902 to generate control signals 940 to operate the various system components in a particular manner.
[0092] FIG. 11 is a flow chart showing several illustrative interview questions and answers that can be provided by the interview question generator of FIG. 10 . As shown in FIG. 11 , once the installation mode has been initiated, the user interface can be configured to prompt the installer to enter a desired language in which to display the interview question and answer queries, as indicated generally by block 1000 . For example, the user interface may prompt the installer to select between “English”, “Espanol”, or “Francais” as language choices. The selection of a particular language at block 1000 causes the user interface to subsequently display the interview questions and answers in that selected language.
[0093] Once the desired language is chosen, the user interface can be configured to provide interview questions pertaining to the various system components to be installed. At block 1002 , for example, the user interface can prompt the installer to select the type of equipment to be controlled by the controller. In certain embodiments, for example, the user interface can prompt the installer to select between a conventional heating/cooling unit, a heat pump, or heat only. Once the type of equipment has been selected, the user interface may then prompt the installer to enter the number of stages of heat and cool to be controlled by the controller, as indicated generally by blocks 1004 and 1006 . In some embodiments, the answers provided to the interview question at block 1004 may affect whether the user interface displays a follow-up query at block 1006 . For example, if the response to the interview question regarding the number of heat stages at block 1004 is “2”, the interview question generator may assume that there are 2 cooling stages, and thus skip the query at block 1006 .
[0094] For each stage of heat and cool, the user interface can be configured to prompt the installer to select the number of cycles per hour to be provided by the equipment, as indicated generally by block 1008 and 1010 , respectively. At block 1008 , for example, the user interface may prompt the installer to select the cycles per hour to be provided by each stage of heating selected at block 1004 . If, for example, the installer indicates at block 1004 that the equipment has 3 stages of heating, the user interface can be configured to repeat query block 1008 three separate times for each individual stage to be configured. A similar process can then be performed at block 1010 for each stage of cooling to be controlled by the controller. If at block 1004 the installer indicates that there are “0” stages of heat, the user interface can be configured to skip the query at block 1008 . In addition, if at block 1006 the installer indicates that there are “0” stages of cool, or if at block 1002 the installer indicates that the equipment is “Heat Only”, the user interface can be configured to skip the query at block 1010 .
[0095] In some embodiments, the user interface can be further configured to provide the installer with interview questions and answers that can be used to set other operational parameters within the controller. As indicated generally at block 1012 , for example, the user interface can be configured to prompt the installer to select the minimum amount of on time that the equipment operates. The user interface can further prompt the installer to select a lower and/or upper temperature limit at which the system operates, as indicated generally at blocks 1014 and 1016 , respectively. If desired, the temperature offset and proportional bandwidth of the system can be further set via query blocks 1018 and 1020 , respectively.
[0096] Although several exemplary interview questions and answers are illustrated in FIG. 11 , it should be understood that the type, number, and ordering of the interview questions and answers provided to the installer may be varied based on the type of equipment to be configured, the user's previous answers to interview questions, the number of stages to be controlled, as well as other factors. In some embodiments, the interview questions and answers can be grouped together to permit the installer to configure a particular system component or components without having to answer interview questions for the remaining system components. If, for example, the installer desires to only configure a newly installed heat pump, the user interface can be configured to provide the installer with interview questions and answers relating to the cooling unit, skipping those queries related to other components not affected by the installation.
[0097] FIG. 12 is a flow diagram of an illustrative method 1100 of programming configuration information within a controller. The method 1100 can begin generally at block 1102 in which an installation mode of the controller is activated to permit an installer to configure the controller to operate with one or more system components. Initiation of the installation mode can occur, for example, by the installer selecting an installation mode button on a touchscreen or keypad of the user interface, or automatically when the controller is activated for the first time or when one or more system components are connected to the controller.
[0098] Once the installation mode has been initiated, the controller can then be configured to provide one or more interview questions to the installer via the user interface, as indicated generally by block 1104 . The interview questions provided can be configured to solicit information from the installer regarding the type and configuration of the various system components to be controlled by the controller. In certain embodiments, for example, the interview questions can include a sequence of interview questions relating to the type of equipment to be controlled, the number of heat stages the equipment has, the number of cooling stages the equipment has, the number of cycles per hour each stage of heating requires, and the number of cycles per hour each stage of cooling requires.
[0099] In some embodiments, other interview questions pertaining to the type or configuration of the controller and/or any system components controlled by the controller can be further presented to the installer via the user interface. Examples of other interview questions can include, but are not limited to, the minimum operating time desired to operate the system, whether a pump exercise is to be enabled for any installed heat pumps, the upper temperature limit at which to operate the system, the lower temperature limit at which to operate the system, the temperature offset at which the controller operates, the proportional bandwidth of the equipment, the type and operating times of the ventilation fan employed, the type and rating of the UV lamp employed, and the type and rating of the humidifier or dehumidifier employed. Other interview questions relating to the user's preferences such as the date and time format, daylight savings options, schedule programming options, temperature display options, etc. can also be provided, if desired. It should be understood that the types of interview questions and their ordering will vary depending on the type of equipment to be controlled.
[0100] The interview questions may be provided to the installer in the form of natural language questions, which may be phrases having one or more words that prompt the installer to select between one or more answers from a predetermined list of answers. For example, the interview questions can include a question such as “What type of equipment is the thermostat controlling?” In some embodiments, one or more of the interview questions may elicit an affirmative “YES” or “NO” user response. Alternatively, or in addition, one or more of the interview questions can solicit information requiring a numeric or alphanumeric user response.
[0101] With certain interview questions, and in some embodiments, the controller can be configured to prompt the installer to select between at least two answers or responses displayed on the display screen of the user interface, as indicated generally by block 1106 . For example, in response to the interview question “What type of equipment is the thermostat controlling?”, the user interface can be configured to display the answers “Conventional”, “Heat Pump”, and “Heat Only”, prompting the installer to select the appropriate type of equipment to be installed and/or configured. The user interface can then be configured to accept the user responses to each of the questions and then modify the operational parameters of the controller based on the user responses, as indicated generally by blocks 1108 and 1110 , respectively.
[0102] In some embodiments, the user interface can be configured to display each of the answers simultaneously on the display screen of the user interface. In such configuration, the selection of a user response at block 1108 can be accomplished by the installer selecting an answer to the interview question from a list of multiple answers graphically displayed on the screen. In those embodiments in which the user interface includes a touchscreen, for example, the selection of a response can be accomplished directly by pressing the desired answer from a choice of answers provided on the screen, causing the controller to store that parameter and cycle to the next interview question in the queue. Alternatively, in those embodiments in which the user interface includes an LCD or dot matrix screen, the selection of the desired answer from the choice of answers can be accomplished via a button, knob, slide, keypad, or other suitable selector means on the user interface.
[0103] The user interface can vary the presentation of the interview questions based at least in part on the installer's previous responses to other interview questions. If, for example, the installer selects on the user interface that the type equipment being installed is “Heat Only”, the interview question generator can be configured to skip those questions pertaining to the stages and cycle times for cooling. The ordering of the interview questions can also be varied based on the particular piece of equipment being configured. If, for example, the installation mode at block 1102 is initiated in response to a new piece of equipment connected to the controller, the interview question generator can be configured to present to the installer only those questions pertaining to the new equipment.
[0104] The interview question generator can also be configured to suggest a default answer based on any previous responses, based on any previous controller settings, and/or based on settings which are commonly selected for that particular piece of equipment. For example, with respect to the selection of the number of stages for heating, the user interface can be configured to default to a common answer or response of “2” while providing the installer with the ability to select among other numbers of heating stages (e.g., “0”, “1”, “3”, “4”, “5”, “6”, etc.), if desired. The suggestion of a default answer can be accomplished, for example, by highlighting or flashing the answer on the display screen, by moving a selection indicator adjacent to the answer on the display screen, or by other suitable means.
[0105] FIGS. 13A-13Z are schematic drawings of an illustrative HVAC touchscreen interface 1200 showing an illustrative implementation of the flow diagram depicted in FIG. 12 . In a first view depicted in FIG. 13A , the interface 1200 can be configured to display a main installation menu screen 1202 on the display panel 1204 , providing the installer with the choice of configuring one or more HVAC system components. The main installation menu screen 1202 can include, for example, a “FULL SET-UP” icon button 1206 , a “COMPONENT BASED SET-UP” icon button 1208 , and a “MANUAL SET-UP” icon button 1210 .
[0106] The “FULL SET-UP” icon button 1206 can be selected on the display panel 1204 to permit the installer to fully configure the controller to work with the system components for the first time, or when the installer otherwise desires to cycle through each of the interview questions in sequence. The “COMPONENT BASED SET-UP” icon button 1208 , in turn, can be selected to permit the installer to configure only certain system components or to configure the system in a different order than that normally provided by the interface 1200 . The “MANUAL SET-UP” icon button 1210 can be selected to permit the installer to configure the controller manually using numeric or alphanumeric codes, if desired.
[0107] FIG. 13B is a schematic drawing showing the selection of the “FULL SET-UP” icon button 1206 on the main installation menu screen 1202 of FIG. 13A . As shown in FIG. 13B , the selection of icon button 1206 causes the interface 1200 to display a language setup screen 1212 that prompts the installer to select a desired language format for the remainder of the installation configuration. The interface 1200 can be configured to display, for example, an “ENGLISH” icon button 1214 , an “ESPANOL” icon button 1216 , and a “FRANCAIS” icon button 1218 . Other language choices can also be displayed on the language setup screen 1212 , if desired. A “BACK” icon button 1220 and “ENTER” icon button 1222 can be provided on the display panel 1204 to permit the installer to move back to the prior screen or to enter the current setting selected and move forward to the next question in the queue. A “QUIT” icon button 1224 can be provided on the display panel 1204 to permit the installer to quit the installation configuration mode, save any changes made, and then return the controller to normal operation.
[0108] FIG. 13C is a schematic view showing the interface 1200 after the selection of the “ENGLISH” icon button 1214 on the language setup screen 1212 of FIG. 13B . As shown in FIG. 13C , once the installer has selected a desired language, the interface 1200 can be configured to display an equipment type screen 1226 allowing the installer to select the type of equipment to be configured. In some embodiments, for example, the equipment type screen 1226 may prompt the installer to select among a “CONVENTIONAL” icon button 1228 , a “HEAT PUMP” icon button 1230 , or a “HEAT ONLY” icon button 1232 each simultaneously displayed on the display panel 1204 .
[0109] Once the installer has selected the desired equipment to be installed via the equipment type screen 1226 , and as further shown in FIG. 13D , the interface 1200 can be configured to display a screen 1236 prompting the installer to select the number of heat stages to be configured, if any. Several numeric icon buttons 1238 can be provided on the screen 1236 to permit the installer to select the desired number of heat stages to be controlled. If, for example, the equipment to be configured has 2 stages of heating, the installer may select a “2” icon button 1238 a on the screen 1236 . Conversely, if the equipment to be configured has no heating stages, the installer may select a “0” icon button 238 b on the display screen 1236 , causing the interface 1200 to thereafter skip those interview questions pertaining to heating stages and cycles.
[0110] Once the number of heat stages has been configured via screen 1236 , and as further shown in FIG. 13E , the interface 1200 can be configured to display another screen 1240 prompting the installer to select the number of cooling stages to be configured, if any. Several numeric icon buttons 1242 can be provided simultaneously on the screen 1240 to permit the installer to select the desired number of cooling stages. If, for example, the equipment to be configured has 2 stages of cooling, the installer may select a “2” icon button 1242 a on the screen 1240 . Depending on the response to the previous interview question on screen 1236 of FIG. 13D , the interface 1200 can be configured to default to a particular answer (e.g. “2”) by blinking or flashing the answer on the screen 1240 . In some cases, the interface 1240 may assume that the number of cooling stages is the same as the number of heating stages and skip screen 1240 altogether.
[0111] FIG. 13F is a schematic view showing the interface 1200 subsequent to the steps of configuring the heating and cooling stages in FIGS. 13D-13E . As shown in FIG. 13F , the interface 1200 can be configured to provide a screen 1244 initially prompting the installer to select a desired number of cycles per hour for the first stage of heating. Several numeric icon buttons 1246 can be provided simultaneously on the screen 1244 to permit the user to select the cycle rate at which the system operates for the particular stage number 1248 displayed on the screen 1244 . For the first stage of heating for a two-stage system, for example, the installer may select the “6” icon button 1246 a to operate the first heating stage for six cycles per each hour. Once a response is received for the first heating cycle, the interface 1200 may then prompt the installer to select the number of cycles for the second heating stage, as further shown in FIG. 13G . The process can be repeated one or more times depending on the number of heating stages to be configured.
[0112] FIG. 13H is a schematic view showing the presentation of another screen 1250 on the interface 1200 for selecting the cycle rate for each cooling stage to be configured within the controller. Similar to the screen 1244 depicted in FIGS. 13F-13G , the screen 1250 may prompt the installer to initially select a desired number of cycles per hour for the first stage of cooling, and then repeat the interview process for each additional stage to be programmed, if any. Several numeric icon buttons 1252 can be provided simultaneously on the screen 1250 to permit the installer to select the cycle rate at which the system operates for the particular stage number 1254 displayed on the screen 1250 . Once the installer has completed configuring each stage of heating and cooling, the interface 1200 can be configured jump to additional interview questions for any other components to be configured, or, alternatively, can exit the routine and return to normal operation using the newly programmed settings.
[0113] Once programming is complete, and as further shown in FIG. 13I , the interface 1200 can be configured to display a screen 1256 indicating that the configuration was successful along with a “VIEW SETTINGS” icon button 1258 allowing the installer to view the controller settings. A “BACK” icon button 1260 can be selected if the installer desires to go back and modify or change any settings. A “DONE” icon button 1262 , in turn, can be selected by the installer to return the controller to normal operation.
[0114] Referring back to FIG. 13A , if the installer desires to configure only selective components of the system, or prefers to enter configuration information in an order different than that generated by the interview question generator, the installer may select the “COMPONENT BASED SET-UP” icon button 1208 on the main installation menu screen 1202 . When selected, the interface 1200 can be configured to display a component selection screen 1264 , allowing the installer to select from among several different categories of equipment for configuration, as shown in FIG. 13J . The component selection screen 1264 can include, for example, a “HEATING” icon button 1266 , a “COOLING” icon button 1268 , a “VENTILATION” icon button 1270 , a “FILTRATION” icon button 1272 , a “UV LAMP” icon button 1274 , a “HUMIDIFICATION” icon button 1276 , and a “DEHUMIDIFICATION” icon button 1278 . The icon buttons can correspond, for example, to the system components described above with respect to FIG. 9 , although other combinations of system components are contemplated. An “OTHER” icon button 1280 provided on the screen 1264 can be selected by the installer to configure other system components such as any sensors or other connected controllers, if desired.
[0115] The selection of the icon buttons on the component selection screen 1264 causes the interface 1200 to display one or more interview questions and answers on the display panel 1204 based on the type of equipment to be configured. If, for example, the installer desires to configure only the heating and cooling system components, the installer may select both the “HEATING” icon button 1266 and “COOLING” icon button 1268 on the screen 1264 , causing the user interface 1200 to present only those interview questions that pertain to heating and cooling control. The process of providing the installer interview questions and answers in multiple-choice format can then be performed in a manner similar to that described above with respect to FIGS. 13C-13H . If desired, the process can be performed for any other system component or components to be configured.
[0116] The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention can be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification. | Controllers and methods are disclosed for aiding a user in programming a schedule of a programmable controller. In an illustrative embodiment, a guided programming routine can be activated by a user, which then guides a user through two or more screens that are designed to collect sufficient information from the user to generate and/or update at least some of the schedule parameters of the controller. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to optical switching devices. More particularly, the invention concerns reconfigurable optical switching devices for forming a switching system.
BACKGROUND OF THE INVENTION
[0002] One of the main components needed for optical interconnections is a dynamic switch. In order to make such a switch compatible with a planar interconnection system, it must be as compact as possible. It is preferable that the switch be an integral part of the planar optical system; that is, the switching should be effected within the planar substrate. Furthermore, the process of fabricating the dynamic switch must be simple enough so as to ensure that the entire system is suitable for mass production.
DISCLOSURE OF THE INVENTION
[0003] It is a broad object of the present invention to provide an optical switching device based on polarization-selective holographic elements.
[0004] A further object of the present invention is to provide an architecture for an optically dynamic switching system.
[0005] A still further object of the invention is to provide a method for producing an holographic plate having a plurality of holographic elements.
[0006] In accordance with the present invention, there is therefore provided an optical switching device, comprising a substrate having at least one polarization-selective multiplexing grating; at least one polarization-selective demultiplexing grating, and a polarization rotation element acting as a dynamic ½ λ plate, optically interposed between the optical path of said multiplexing grating and said demultiplexing grating.
[0007] The invention further provides a method for producing an holographic plate having a plurality of holographic elements, said method comprising the steps of (a) defining a first intermediate holographic element; (b) defining a second intermediate holographic element located at the plane parallel to the plane of said first holographic element; (c) determining, for each holographic element, a pair of parent holograms to be formed on said intermediate elements in such a way that combining said pair of parent holograms with a pre-defined readout wave will yield two coherent light waves wherein the interference of said two light waves in said holographic plate produces the desired final holographic effect; (d) determining the signs of the x components of the projections from the paraxial rays of said pairs of parent holograms for all of the holographic elements on said holographic plate; (e) dividing said holographic elements into two groups according to the signs of said x components; (f) producing, for each of said two groups, a different holographic plate comprising the parent holograms of the relevant holographic elements; (g) attaching the plates produced in step (f) to an optical prism in such a way that while illuminating said plates through the prism with said pre-determined readout wave, the first diffracted order from the intermediate hologram produces the desired holographic effect on the holographic plates, the zero order is coupled out of the prism by total internal reflections, and the other orders are evanescent waves; and (h) repeating the recording process for each group of holographic elements as defined in steps (d) and (e).
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures, so that it may be more fully understood.
[0009] With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0010] In the drawings:
[0011] [0011]FIG. 1 is a schematic illustration of a thick phase transmission hologram;
[0012] [0012]FIG. 2 is a graph showing the diffraction efficiencies of the s and p polarizations of a transmission thick phase hologram;
[0013] [0013]FIG. 3 is a schematic illustration showing top and side views of a first embodiment of a building block of a dynamic switching device according to the present invention;
[0014] [0014]FIG. 4 schematically illustrates a first embodiment of the geometry of an entire optical switching device according to the present invention;
[0015] [0015]FIG. 5 schematically illustrates a cross-sectional view of a further embodiment of the geometry of an entire optical switching device;
[0016] [0016]FIG. 6 is a schematic side view of the geometry of a still further embodiment of an entire optical switching device;
[0017] [0017]FIGS. 7 and 8 are plan views of the bottom and top surfaces, respectively, of the embodiment of FIG. 6;
[0018] [0018]FIGS. 9 and 10, respectively, are schematic illustrations of 4×4 and 8×8 optical switching systems according to the present invention;
[0019] [0019]FIG. 11 is an isometric view of a planar optical switching system according to the present invention;
[0020] [0020]FIG. 12 illustrates a recording scheme of the final holographic element, in the presence of a wavelength shift between recording and readout;
[0021] [0021]FIG. 13 is a schematic representation of a recording architecture of the final holographic element with an intermediate holographic plate;
[0022] [0022]FIG. 14 illustrates a PMMA coupling element consisting of an aspherical mirror and a reflection surface relief grating, and
[0023] [0023]FIG. 15 is an MTF graph showing the calculated spot size of the optical system illustrated in FIG. 14.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The diffraction efficiency of a thick phase transmission hologram (FIG. 1) is given by the expression:
η = sin 2 ϕ 2 + ψ 2 1 + ψ 2 ϕ 2 ( 1 )
[0025] in which the Bragg deviation coefficient ψ is defined as
ψ ≡ ( α r - α r B ) K → D sin ( α G - α r B ) 2 cos α s - ( λ - λ B ) K → 2 D 8 π v cos α s , ( 2 )
[0026] wherein:
[0027] {overscore (K)} is the three-dimensional grating function of the hologram;
[0028] D is the thickness of the emulsion,
[0029] α r , α s , and α G , are the off-axis angles of the readout wave, signal wave, and the grating function, respectively;
[0030] λ and λ B are the actual and the designed readout wavelengths, and
[0031] α r B is the off-axis angle of the designed readout wave.
[0032] The grating coupling coefficient is defined as
ϕ s = π v 1 D λ cos α s cos α r ( 3 )
[0033] for s-polarization, and as
φ p =−φ s ( {overscore (r)}·{overscore (s)} ) (4)
[0034] for p-polarization, wherein:
[0035] ν 1 is the maximum phase modulation of the refraction index of the emulsion, and
[0036] {overscore (r)} and {overscore (s)} are the unit vectors of the readout and the signal rays respectively.
[0037] Fulfilling Bragg conditions (namely, ψ=0) yields
η s,p =sin 2 (φ s,p ). (5)
[0038] It is clear from Equation (4) that, for an off-axis hologram, the coupling coefficient for the p polarization is smaller than that for the s polarization. Consequently, it can be deduced from Equation (5) that the diffraction efficiencies of the s and p polarizations will be different, as a function of the obliquity of the hologram.
[0039] [0039]FIG. 2 illustrates the diffraction efficiencies of the s and p polarizations of a hologram having the following parameters:
D=15 μm; α r =0; α s =45°; λ=850 nm; ν=151 (6)
[0040] where ν is the refractive index. It is important to emphasize that the angle α s is inside the emulsion; consequently, the signal wave is trapped inside the substrate due to total internal reflection.
[0041] Fabrication of an holographic element which is very efficient for one polarization and, at the same time, is actually transparent to the other, is possible with a variety of methods. Such an element is necessary for polarization multiplexing or demultiplexing. There are two distinct approaches that exploit the special behavior of a Bragg hologram when the signal wave is normal to the readout wave within the emulsion:
[0042] 1. The “Normal-Waves” Approach
[0043] Suppose that the holographic element is recorded in such a geometry that the signal wave is normal to the readout wave during the readout process. In this case, the unit vector of these two waves fulfill the condition:
{overscore (r)}·{overscore (s)}= 0. (7)
[0044] Inserting Equation (7) inside Equation (4) yields
φ p =0 η p =0. (8)
[0045] This result, that the diffraction efficiency of the p polarization is zero, does not depend on parameters which are difficult to precisely control, such as index modulation or emulsion thickness, but depends only on the readout geometry which is much easier to achieve with good accuracy.
[0046] [0046]FIG. 3 illustrates the building block of the “three-dimensional” version. As shown, the readout wave bounces inside the substrate with an off-axis angle α to the normal of the substrate plane. The holographic element diffracts the incoming wave in such a way that the bouncing angle remains α, but there is an angle β between the projections of the readout and the signal waves in the substrate plane.
[0047] In order to achieve the necessary condition of {overscore (r)}·{overscore (s)}=0, the following equation:
cos β=cot 2 α (9)
[0048] must be satisfied. Clearly, Equation (9) imposes the following constraint upon the bouncing angle inside the substrate:
α min =45°. (10)
[0049] A direct result of Equation (10) is that, even for substrate materials with low indices of refraction, such as BK-7 and other crown materials, the optical waves are trapped inside the substrate by total internal refraction and there is no need for a reflective coating on the substrate surfaces. Unfortunately, in order to couple the waves into the substrate with an off-axis angle higher than 45°, a holographic element with very high special frequency would be required (more than 1200 line-pairs/mm for λ=850 nm). This would indicate that the only practical way to realize the hologram is by interferometric recording, and that it will be very difficult to fabricate it by direct writing or lithographic methods.
[0050] A possible way of recording the desired hologram is to use an off-axis angle of α=60°. For example, inserting this value into Equation (10) yields
β=70.5°. (11)
[0051] As shown in FIG. 4, two light waves s and p, of orthogonal polarization, are coupled into the substrate 2 by coupling means such as the holograms H 1 and H 2 , respectively. The hologram H 3 diffracts the s in a direction so as to join it onto p. H 4 is the multiplexing hologram, which is shown and described with reference to FIG. 3. H 4 is very efficient to s polarization and is actually transparent top polarization. Here, it does not effect p, but rather, it diffracts s into the same direction of p. As a result, p and s are multiplexed together into a single optical wave which illuminates the dynamic switch. Instead of the holograms, other coupling means, such as reflective surfaces or prisms, can be utilized.
[0052] After passing through the switch S, which either rotates the polarizations by 90° (operation mode) or has no influence upon the waves (non-operation mode), the waves meet the demultiplexing hologram H 5 , which is identical to H 4 but to the opposite effect; that is, it separates p and s into different directions. H 6 , which is an optional hologram, rotates s so that it becomes parallel to p in the substrate. The final holograms, H 7 and H 8 , couple the light waves back out of the substrate onto the detectors. In order to minimize the cross-talk between the channels, special coating facets 4 may be added onto the surface of the substrate, to filter out the s-polarization from the p channel and vice-versa.
[0053] There are clear advantages to the switch shown in FIG. 4. Its dimensions can be very compact, it can be easily integrated into the planar optical interconnection scheme, it is appropriate for multi-stage devices, and finally, it has the potential to provide very high efficiency and negligible cross-talk between the channels. The device does, however, have some drawbacks: as described above, the switch can be realized only with interferometrically recorded Bragg holograms. Also, the recording process of holograms H 5 and H 6 is very complicated, and in addition, since the waves pass through the switch while bouncing inside the substrate at an oblique, off-axis angle, a special SLM, or similar device, must be fabricated in order to perform the desired polarization rotation in the correct fashion.
[0054] [0054]FIG. 5 illustrates the building block of a “two-tier” version. As with the two-dimensional embodiment of FIG. 4, the holograms H 1 and H 2 couple the input waves into the substrate 2 , but here the off-axis angle of wave propagation inside the substrate is set at 45°. The waves are multiplexed together by the hologram H 3 . Since the angle of the direction of propagation between the two waves is 90°, the hologram will be very efficient with respect to wave A and practically transparent with respect to wave B. The next hologram, H 4 , couples the waves out of the first substrate 2 . The waves then illuminate an SLM 6 , which acts as a dynamic ½ λ plate, normal to its surface. After passing through SLM 6 , the waves are coupled into a second substrate 8 by the hologram H 5 . The next hologram, H 6 , is the demultiplexing grating that diffracts the s polarization by 90°. The final holograms H 7 and H 8 couple the light back out of the substrate onto detectors (not shown). Clearly, the two substrates 2 and 8 , and the SLM, can be easily integrated into one piece, to minimize the overall size of the device.
[0055] The embodiment of the optical switch shown in FIG. 5 can also be very compact, is appropriate for multi-stage devices, and has the potential to provide very high efficiency and negligible cross-talk between the channels. In addition, it has some additional advantages over the embodiment of FIG. 4: with slight modification of the geometry, not only Bragg holograms, but also surface-relief gratings, can be used as the multiplexing/demultiplexing devices. This is a fairly simple process of recording the holograms, and furthermore, since the waves illuminate the SLM in a direction normal to its surface, a commercially available SLM 6 can be used as the dynamic ½ λ plate.
[0056] There are still some drawbacks to the embodiment of FIG. 5. First, the fan-in and fan-out gratings are each combined from a different pair of holograms (H 3 -H 4 and H 5 -H 6 , respectively). The holograms in each pair must be recorded separately on two different emulsion layers. This can be done either by recording the first layer, then adding a second emulsion layer and then making the next recording step, or alternatively, by recording two separate substrates and then combining them together. In both cases, the procedure is long, cumbersome and not very suitable for mass production.
[0057] The second area of concern is the geometry of the proposed switch. As can be seen in FIG. 5, the projection of the output waves, after they are separated by the fan-out gratings, is identical to the projection of the incoming waves. This constraint imposes a limit upon the feasibility of using the switch in a multi-stage architecture. Moreover, there are two differently-polarized waves inside the substrate having s and p polarizations. It is desirable, for the sake of achieving minimal cross-talk to filter undesired polarizations from the signals. This can be done with a simple coating for a single substrate, but is impossible to perform for two orthogonal polarizations.
[0058] 2. The “Different Coupling Coefficients” Approach
[0059] As can be seen in FIG. 2, one method to achieve polarization separation is by choosing parameters whereby the efficiency of one polarization is 0 and that of the second is close to 100%. For example, a holographic element with the parameters described in Equation (6), and wherein the index modulation is ν 1 =0.041, has diffraction efficiencies of 0 for the p polarization and 95% for the s polarization. It is comparatively easy to record this hologram for achieving the necessary polarization separation. In the following, how to calculate the exact conditions required for optimal polarization separation is shown.
[0060] For a diffraction angle smaller than 90°, there are two cases in which the hologram can perform a highly polarization-selective property:
η s =100% and η p =0 φ s =( n+ 0.5)π and φ p =nπ (12)
[0061] or
η s =0% and η p =100% φ s =nπ and φ p =( n− 0.5)π (13)
[0062] wherein:
[0063] n is a natural number.
[0064] In our particular case, we have the readout condition
α r =0° cos α r =1. (14)
[0065] Therefore, the coupling coefficients φ become
ϕ s = π v 1 D λ cos α s , ( 15 ) ϕ p = π v 1 D λ cos α s . ( 16 )
[0066] Substituting the values of φ s in Equation (15) and φ p in Equation (16) into Equation (12) yields
π v 1 D λ cos α s = n + 0.5 ; π v 1 D λ cos α s = n . ( 17 )
[0067] Solving Equation (17) yields
α s = arccos n n + 0.5 ; v 1 D λ = n ( n + 0.5 ) . ( 18 )
[0068] To illustrate the calculations, for the values of n=1, λ=830 nm, and D=17 mm, the desired phase modulation of the refractive index of the substrate is ν 1 =0.06, which can easily be achieved using recording materials such as DCG or photopolymer. The off-axis angle inside the substrate is α s =48.2°.
[0069] Using similar algebraic manipulations for Equation (13) yields another solution:
α s = arccos n - 0.5 n ; v 1 D λ = n ( n - 0.5 ) . ( 19 )
[0070] For the same parameters given above, the desired values now are ν 1 =0.034 and α s =60.0°.
[0071] FIGS. 6 to 8 illustrate a possible embodiment for the building block of a 2×2 optical switch. Two light waves, A and B, having orthogonal polarizations s and p, are coupled into the substrate 10 by the holograms H 1 and H 2 , respectively. The angle between the projection of the two waves on the substrate plane is 90° and the off-axis angle inside the substrate is set according to the solutions of Equations (18) or (19). Both light waves have an s polarization with respect to the plane of the holographic plate. The waves are multiplexed and coupled out of the plate by the hologram H 3 , which is a: combination of two orthogonal holograms, H 3A and H 3B . Since the angle between the two waves is 90°, their polarizations are mutually orthogonal. Hence, the hologram H 3A can be highly efficient in blocking wave A and practically transparent to wave B. Similarly, the hologram H 3B will be highly efficient in blocking wave B and transparent with respect to wave A. The waves then illuminate an SLM 6 , which acts as a dynamic ½ λ plate, normal to its surface. After passing through the SLM 6 , which either rotates the polarizations by 90° (operation mode), or has no influence on the waves (non-operation mode), the waves impinge upon the demultiplexing hologram H 4 in substrate 12 , which is identical to H 3 but has the opposite effect, i.e., separating A and B into two orthogonal directions. Holograms H 7 and H 8 couple the waves out of the substrate 12 . It should be noted that the axis system of the upper substrate 12 in FIG. 6 is rotated by 90° about the z axis in contrast to the axis system of the lower plate. Clearly, the two substrates 10 and 12 and the SLM 6 can easily be integrated into one piece so as to minimize the overall size of the device.
[0072] There are clear advantages to the configuration of this embodiment. The optical switch can be made very compact, and has the potential of very high efficiency and negligible cross-talk between channels. Not only Bragg holograms, but also surface-relief gratings, can be used for the polarization-sensitive element. Since the polarization of both waves is the s-polarization, a simple coating can filter out the undesired p-polarization in order to eliminate cross-talk. As shown below, a fairly simple fabrication process can be used to record the holograms. Building blocks of such configuration are very suitable for producing multi-stage devices.
[0073] It is important to note that the embodiment described with reference to FIG. 6 is merely an example of a method for coupling the input waves into a substrate. Input waves could also be coupled into a substrate by other optical means, including, but not limited to, integrated reflecting surfaces, folding prims, bundles of fiber optics, diffraction gratings, and the like. Also, in the example of FIG. 6, the input waves and the image waves are located on opposite sides of the substrate. Other configurations are envisioned in which the input and image waves can both be located on the same side of the substrate. There may even be applications in which the input waves can be coupled into the substrate through one of its edges.
[0074] [0074]FIGS. 9 and 10 illustrate possible arrangements for 4×4 and 8×8 optical switches, respectively. Seen in FIG. 9 are the relative dispositions of the light sources A, B, C and D; the optical switches I, II, III, IB, and the detectors E, F, G and I. FIG. 10 illustrates the architecture of an 8×8 configuration without reference numbers, for clarity.
[0075] The accuracy of the recording and developing processes of the Bragg holograms is very crucial for achieving optical switches with high efficiencies and minimal cross-talk. In addition, considering the mass production of the device, an appropriate recording procedure should be developed in which a large number of holographic facets can be recorded simultaneously onto the same substrate.
[0076] [0076]FIG. 11 illustrates the geometry of a switching device according to the present invention. The system consists of an opto-electronic circuit 14 and two holographic substrates 10 and 12 carrying holographic emulsion layers 16 and 18 , separated by a two-dimensional array of SLM devices 6 . The entire system can be very compact and compatible to utilizing VLSI architectures. Three-dimensional arrays of switching devices can likewise be arranged.
[0077] One of the more advantageous ways of achieving mass production of the device is the use of surface relief gratings that are very easy to replicate. Even with the use of Bragg holograms, a large number of holographic facets can be recorded simultaneously onto the same substrate. Hence, also with Bragg holograms, the mass production process is expected to be rather simple. It is possible to record the holographic elements one by one; however, this procedure is very long and cumbersome, and it certainly is not advantageous for mass production. Instead, a recording method is described herein which may exploit both binary optics and volume holographic elements, for relatively easy, large scale fabrication of the holographic switching devices.
[0078] The recording architecture of the final HOE, in the presence of a wavelength shift between recording and readout, is shown in FIG. 12. As described above, each HOE on the final holographic plate can be recorded using a pair of “parent” gratings, pre-prepared on an intermediate plate. As can be seen in FIG. 12, for each final HOE in the holographic substrate 10 , the sign of the x component of the projection from the paraxial rays of the intermediate HOEs is identical for both HOEs. Hence, the n final HOEs can be divided into two groups, according to the sign of this x component. Since there is a large number of HOEs in the holographic plate, it is apparent that each group contains about n/2 elements.
[0079] [0079]FIG. 13 shows the recording procedure for one of these groups. (The recording geometry of the second group is similar, with opposite x components.) Seen is an intermediate holographic plate 20 , carrying the final holographic substrate 10 . The readout wave for all the parent gratings is a plane wave which is entered into substrate 10 through a glass prism 22 with an off-axis angle. Several other schemes, likewise employing wedge devices, are also possible.
[0080] Due to the high obliquity of the intermediate holographic plate 20 , the only diffracted order is the first order. The zero order is coupled out of the prism by total internal reflections and the other orders are evanescent waves. Hence, the only order that illuminates the final holographic substrate 10 during the recording procedure is the desired first order; there is no undesired illumination from the other orders. Since the intermediate gratings 24 can be put very close to the final holographic substrate, possible overlapping between different parent gratings can also be eliminated.
[0081] The intermediate holographic plates 20 can be constructed by either one of the following methods. They can be recorded holographically, or can be fabricated directly as surface relief holograms. In both cases, the constructing procedure should be done only once for each of the intermediate holographic plates. The efficiency of the parent gratings is not a crucial point, i.e., the efficiency of these gratings need not be close to 100%; a much lower efficiency is sufficient for the procedure of recording the final plate. Hence, it is chosen to fabricate the intermediate plate as a surface relief holographic plate; only one level is necessary for these binary gratings, and their fabrication procedure is relatively simple. As for the final HOEs, it is clear that the two-step recording procedure of the final holographic plate is quite simple and can be performed with relative ease.
[0082] As mentioned above, an alternative method for fabrication of polarization-selective holograms is as surface relief gratings. High polarization-selectivity can be achieved with this approach when the angle between the readout and the image waves is 90°. For different off-axis angles, the situation is much more complicated.
[0083] [0083]FIG. 14 illustrates a preliminary design of a building block for an optical switching system 26 based on a surface relief grating. The light source 30 is located next to a transparent plate 32 , fabricated, e.g., of PMMA polymeric material. The light wave diverging inside the plate is reflected back to the front surface by an aspherical mirror (not shown) that collimates the input beam and is reflected back again by a reflection grating that couples the light inside the substrate.
[0084] [0084]FIG. 15 illustrates the optical performance of the above-described element. The element has a diffraction-limited performance. With minor changes, it can be used also as the building block for the polarization-selective element. Hence, the entire holographic plate can be fabricated into one monolith plate by injection molding, embossing, or other methods which are appropriate for mass production. Moreover, such an holographic plate is not only easy to duplicate, but it can also be easily integrated with the opto-electronic plate shown in FIG. 14.
[0085] As described above, there are only two gratings for each optical switch. For a system having N=2 n sources, the number of optical switches for each channel is Log 2 N=n. Hence, the diffraction efficiency for each interconnection is
η=[φ( 1−ρ)] 2n , (20)
[0086] wherein:
[0087] φ is the efficiency for the s polarization, and
[0088] ρ is the efficiency for the p polarization.
[0089] For φ=95%, ρ=5% and n=7 (128×128 switch), the total efficiency of each channel is
η=24% . (21)
[0090] The overall area of the system can now be calculated. As shown in FIG. 10, for a system having 2 n sources, the total number of switches in each step is 2 n−1 . For each switch there are two holographic elements, and there are n steps in each channel. In addition, there are 2 n elements which couple the light waves from the sources into the optical substrate and the same number to couple the light out from the plate onto the detectors. Hence, the total number of holographic elements on a single plate is:
M= 2·2 n +2· n· 2 n−1 =( n+ 2)2 n . (22)
[0091] For n=7 (128×128 switch) the number of the holographic elements is M=1152. Assuming that for each holographic element the necessary area on the holographic plate is a square of 200 μm, and that there are two separated plates, the total area of the system is in the order of 1 cm 2 .
[0092] It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | The invention provides an optical switcing device, including a substrate having at least one polarization-selective multiplexing grating; at least one polarization-selective demultiplexing grating, and a polarization rotation element acting as a dynamic ½ λ plate, optically interposed between the optical path of said multiplexing grating and said demultiplexing grating. The invention also provides a method for producing an holographic plate having a plurality of holographic elements. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of U.S. patent application Ser. No. 11/817,602, filed Aug. 31, 2007, which is a §371 U.S. National Phase application of International Application No. PCT/EP06/01837, filed Feb. 28, 2006, and which also claims benefit of U.S. patent application Ser. No. 10/529,968, filed Mar. 31, 2005, which in turn is a §371 U.S. National Phase application of International Application No. PCT/EP2003/008842, filed Aug. 8, 2003, the entire contents of all of which are incorporated by reference as if fully set forth.
BACKGROUND
[0002] The invention relates to a functional plumbing unit, which is embodied as an insertion cartridge which can be inserted into a liquid conduit of a discharging plumbing fixture and a housing, a jet regulator, as well as an attachment screen located at the inlet end wherein the housing includes an external thread on an external surface thereof that is screwable into an internal thread of the plumbing fixture.
SUMMARY
[0003] The present disclosure is directed to a functional plumbing unit, which is configured as an insertion cartridge insertable into a fluid conduit of a discharging plumbing fixture. The insertion cartridge includes a housing and a jet regulator. The housing includes an external thread on an outside thereof, configured to be screwed into an internal thread of the discharging plumbing fixture, a height of the housing, in a flow direction, generally corresponds to the external thread, a ring seal located in a downstream position therefrom and an upstream housing edge, the external thread is arranged between the downstream ring seal and the upstream housing edge, and at least a jet fractionating part, is arranged at an inlet end configured to be connected to the housing.
BRIEF DESCRIPTION OF THE DRAWING
[0004] The single FIGURE, which is shown to scale, shows:
[0005] a cross-section of a functional plumbing unit provided as an insertion cartridge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Introduction to the Embodiments
[0006] The object is to provide a functional plumbing unit embodied as an insertion part of the type noted at the outset which can be produced in a cost-effective and easy fashion and is functionally safe.
[0007] This object is attained according to the invention in particular in that the length of the housing is essentially dimensioned to accommodate the external thread and the subsequent ring seal, and that a jet fractionating part is arranged at the inlet end that can be connected to the housing.
[0008] The functional unit according to the invention therefore essentially comprises only two primary components, which can be produced in a relatively simple manner, namely the housing and the jet fractionating part, which are connected to each other and then form the jet regulator.
[0009] Another suggested solution with an importance by itself worth protecting provides that a perforated plate is formed in one piece at the outlet end of the housing. The functional unit embodied according to this solution is provided at its housing, which can be screwed into the discharging plumbing fixture, with a perforated plate formed in one piece at the outlet end, which serves as a protection from vandalism to effectively prevent any unauthorized pushing up of the parts located inside the housing leading to leaks.
[0010] Here, a further development according to the invention, in itself worth protecting, provides that the jet fractionating part and the housing each engage with a partial section of their longitudinal extension in the operational position and that at the jet fractionating part or the housing at the external or internal perimeter, a circular stop is provided, which in the operational position impinges the facing edge region of the respective other component. In this further developed embodiment, the jet fractionating part and the housing each engage in the operational position only with a partial section of their longitudinal extension. By this sectional engagement of these components, a horizontal separation level develops between the jet fractionating part and the housing; due to the fact that these parts impinge each other not in the direction of the flow but in a horizontal separation plane any potential leaks are counteracted without any additional O-ring or a similar ring seal being necessary. An increased sealing effect even without any additional ring seal between the jet fractionating part and the housing is promoted even further by a circular stop being provided at the perimeter of the jet fractionating part or the housing, which impinges in the operational state the facing edge region of the respective other part. Therefore no complex sealing of the jet fractionating part is necessary. In case that water passes the jet fractionating part, the leaking water flows into the normal water jet and is not perceived as disturbing by the user by it worsening the jet. Furthermore, such an embodiment has considerably fewer parts and a highly compact design. Further, the lower structural height offers considerably more design freedom for the design of the fixture.
[0011] Here, it is particularly advantageous when at the jet fractionating part, a circular stop is provided preferably at the external perimeter which in the operational position impinges the inlet end of the facing edge area of the housing.
[0012] It is advantageous when the housing as well as the jet fractionating part that can be connected thereto are each provided with a preferably encircling snapping formation, which engage each other in the assembled position. The two parts can therefore be easily snapped together, and be separated again from each other, if necessary. Due to the holding elements provided in one piece directly at the parts to be connected, no additional parts are necessary for the connection, which facilitates the design of the functional unit and also promotes such a short structural length.
[0013] The external thread provided at the housing part as well as the ring seal allow the direct installation in the liquid conduit of a discharging plumbing fixture without an adapter being necessary provided with the parts external thread/ring seal holding the parts together. This facilitates production and assembly.
[0014] The ability to separate the housing parts and the jet fractionating parts is particularly advantageous when the functional features of the jet regulator shall be changed. In the housing, between the perforated plate of the housing, preferably embodied as a honey-comb shaped plate, and the perforated plate of the jet fractionating part a intermediate space is provided, in spite of the low overall structural length, to accept one or more screen-like attachments.
[0015] The sizing of the length of the housing such that there is space for the external thread and the preferably directly adjacent ring seal, with the housing edge practically immediately following the external thread at the inlet end, a very compact design develops, by which then the functional unit can also be inserted in discharging plumbing fixtures, which for example for design reasons offer little space for accepting the functional unit. This way, compact functional units can be realized with an overall height of the insertion cartridge including the attachment screen amounting to approximately 1.5 cm.
[0016] Advantageously, the internal thread of the discharging plumbing fixture has a distance from its mouth smaller than a distance of the housing ring seal from the internal end of the external tread of the housing.
[0017] This way, the threaded connection already engages during the assembly of the functional unit, before the ring seal enters the discharge plumbing fixture so that in particular a manual assembly process is considerably facilitated. On the other hand, during the assembly the ring seal can be moved out of the seat in the fixture by rotating the functional unit in the axial direction until it is no longer engaged and before the threaded connection is disengaged.
[0018] This facilitated assembly and disassembly is particularly important because the insertion cartridge is arranged as a “hidden inserted cartridge” with at least the overwhelming portion of its longitudinal extension, preferably its entire longitudinal extension, inside the discharging plumbing fixture.
[0019] Beneficially the jet fractionating part is provided at the inlet end with an insertion opening for the attachment screen with an external circular wall and a support stop, with the holding elements for fastening the attachment screen being embodied as snapping elements and with, for this purpose, an external circular wall being provided at the inside with an undercut and the external edge of the attachment screen being preferably provided with an encircling snapping protrusion engaging the undercut.
[0020] The attachment screen can therefore be snapped at the top of the jet fractionating part and thus is held securely. This contributes to low production and assembly expenses because on the one hand the holding elements are formed at the parts to be connected during their production and on the other hand the assembly of the screen can occur quickly in a manual or automatic fashion.
[0021] An additional security of the snapped-on attachment screen can occur during the assembly in the discharging plumbing fixture. For this purpose, the inlet side of the circular wall of the jet fractionating part and at least a section of the external edge of the attachment screen form a stop contacting an insertion stop in the discharging plumbing fixture in the assembled position. Here, the insertion stop of the discharging plumbing fixture cover partially or entirely the edge of the screen so that the attachment screen is securely held even under disadvantageous conditions.
[0022] In order to additionally facilitate the production of the functional unit according to the invention and to reduce the number of parts necessary it is advantageous for the housing to be produced in one piece with a perforated plate at the outlet end as a part of the jet regulator.
[0023] A preferred further embodiment of the invention provides for the jet fractionating part being connected in one piece to an additional perforated plate arranged as a part of the jet regulator and/or that the jet fractionating part is provided with holding elements to fasten the attachment screen.
[0024] Additional features of the invention are discernible from the following description of exemplary embodiment according to the invention in connection with the claims and the drawing. The individual features can each by themselves or combined be implemented in an embodiment according to the invention.
DETAILED DESCRIPTION
[0025] A functional plumbing unit 1 is shown in the FIGURE as an insertion cartridge 2 , which can be inserted into a liquid conduit 3 of a discharging plumbing fixture 4 indicated only at one side in a dot-dash line.
[0026] The functional unit 1 is essentially provided with a housing 5 having a perforated plate 6 embodied in one piece therewith at the outlet end, a jet fractionating part 7 with a perforated plate 8 in one piece, as well as an attachment screen 9 . The perforated plate 6 formed in one piece at the housing 5 at the outlet end also serves as protection from vandalism which effectively prevents an unauthorized pushing up of the parts located inside the interior of the housing 5 , leading to leaks.
[0027] The housing 5 has at the outer periphery an external thread 10 and downstream adjacent thereto a ring seal 12 inserted into a circular groove 11 . The flow direction is indicated by the arrow Pf 1 . With the external thread 10 , the housing 5 can be screwed into an internal thread 13 of the discharging plumbing fixture 4 and is sealed via the ring seal 12 against the internal wall 14 of the discharging plumbing fixture 4 . It is clearly discernible here, that the internal thread of the discharging plumbing fixture 4 is recessed inwardly so that the ring seal 12 contacts at a thread-free section. In order to facilitate the assembly and also the disassembly of the insertion cartridge 2 into the discharging plumbing fixture 4 the internal tread 13 of the discharging plumbing fixture 4 , on the one hand, and the ring seal 12 of the housing 5 , on the other hand, are arranged such that the threads already engage when the ring seal 12 is still outside the mouth of the discharging plumbing fixture 15 . This is achieved by the internal threads 13 of the discharging plumbing fixture 4 having a distance a from the mouth 15 , which is shorter than the distance b of the housing ring seal 12 from the internal end of the external thread 10 of the housing. This causes the threads to remain engaged when the insertion cartridge 2 is screwed out of the discharging plumbing fixture 4 until the ring seal 12 exits or has left the mouth 15 .
[0028] In order to avoid leaks in the area between the jet fractionating part 7 and the housing 5 the jet fractionating part 7 and the housing 5 , each engage in the operational position with a partial section of their longitudinal extension. Here, at the jet fractionating part 7 or the housing 5 , a circular stop 40 is provided at the internal and/or external perimeter which in the operational position impinges the facing edge region 41 of the respectively other part 57 . From the FIGURE it is discernible that here the jet fractionating part 7 carries the circular stop 40 in the operational position impinging the inlet end of the facing edge region 41 of the housing 5 . Here, the jet fractionating part 7 is connected to the housing 5 via a snap connection 16 .
[0029] The snap connection 16 is provided at the edge 17 of the housing, which is immediately adjacent to the external thread 10 of the housing 5 . For this snap connection the housing edge 17 is provided with a circular groove 32 at the inside, while the jet fractionating part 7 has a circular bead 33 engaging the circular groove. Both snapping forms are preferably embodied in an encircling fashion.
[0030] The snap connection 16 provided is embodied such that the jet fractionating part 7 can be separated from the housing 5 and then the interior space of the housing is accessible.
[0031] The attachment screen 9 is also connected to the jet fractionating part 7 via a snap connection 20 . This jet fractionating part 7 is provided at the top and/or at the inlet end with an insert opening 21 having an external circular wall 22 and a support stop 23 . The circular wall 22 has at the interior side an undercut 24 and the external edge 25 of the attachment screen 9 has a particularly encircling snapping protrusion 26 engaging the undercut 24 . The attachment screen 9 can therefore be snapped into the insert opening 21 of the jet fractionating part 7 from the inlet side and is therefore securely connected to the jet fractionating part 7 .
[0032] Due to the fact that the parts of the insertion cartridge 2 to be connected with each other, thus the housing 5 , the jet fractionating part 7 , and the attachment screen 9 themselves provide the connection elements in one piece, they can be connected to each other without requiring any additional holders.
[0033] The housing 5 of the insertion cartridge 2 can be provided with a profiled external perimeter and/or a profiled end at the outlet side to contact an assembly tool. In the exemplary embodiment, at the outlet end, a profiled circular edge 29 is provided at which an assembly tool can be contacted to screw in and out the insertion cartridge 2 . It is particularly advantageous when this profiling of the circular edge is embodied such that another insertion cartridge 2 can be used as the assembly tool in the upside-down position and can engage with the profiling of its circular edge the insertion cartridge 2 to be screwed in and out. For this purpose the circular edge 29 is provided in the exemplary embodiment with a circular wall section 30 having interruption 31 located therebetween. The interruptions 31 are sized in the circumferential direction such that the circular wall sections 30 fit into an identically embodied other insertion cartridge 2 . Instead of this profiling differently embodied profiling can also be provided. | A functional plumbing unit is provided, which is configured as an insertion cartridge insertable into a fluid conduit of a discharging plumbing fixture. The insertion cartridge includes a housing and a jet regulator. The housing includes an external thread on an outside thereof, configured to be screwed into an internal thread of the discharging plumbing fixture, a height of the housing, in a flow direction, generally corresponds to the external thread, a ring seal located in a downstream position therefrom and an upstream housing edge, the external thread is arranged between the downstream ring seal and the upstream housing edge, and at least a jet fractionating part, is arranged at an inlet end configured to be connected to the housing. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to firearm ammunition and more particularly to a jacketed bullet that shear fragments on impact and a method of making the bullet.
BACKGROUND ART
[0002] It is desirable for a bullet to have good flight performance, including good range and accuracy, and limited penetration ability. The depth of bullet penetration is directly proportional to velocity and size. Bullets that fragment prior to impact or immediately upon impact have limited penetration ability. Such bullets have little or no path of travel after impact, and therefore will not ricochet or pass through the intended target and strike an unintended target. However, bullets that fragment or disintegrate before impact may not be able to achieve desire flight performance.
[0003] U.K. Patent No. 11,087 to Weiss discloses a hollow base bullet with a mantle and a core pressed into the mantle through an open posterior end. The mantle is weakened by grooves in the anterior end. The core is a single solid leaden piece with incisions therein, or several twisted pieces of lead wire. Wiess states that the disclosed bullet will pass through a target and burst on impact with a hard body.
[0004] U.S. Pat. No. 122,620 to Maduell discloses an unjacketed bullet having four interlocking segments. The segments of Maduell would separate upon firing, and prior to impact, from a rifled firearm barrel due to centrifugal force.
[0005] U.S. Pat. No. 3,208,386 to Schneider et al. discloses a bullet having several elongated metal segments with the ends of the segments fitted into a base cup, and the segments are then swaged to form the desired bullet shape. The bullet of Schneider et al. separates upon firing and prior to impact due to centrifugal force to provide a shotgun type pattern.
[0006] U.S. Pat. No. 5,569,874 to Nelson discloses a bullet having a larger central copper wire and several smaller copper wires around the central wire, with the tail ends of the wires swaged into a jacket. After impact the tip ends of the wires separate while the tail ends of the wire are retained in the jacket.
[0007] U.S. Pat. No. 5,528,989 to Briese discloses a bullet having a jacket and a leaden core with the core being formed by swaging a plurality of straight wires into a cylinder. The wires, after swaging, interlock with each wire having end sections that extend parallel to the longitudinal axis of the core. Each wire has a kinked intermediate section that includes two oblique sections, the oblique sections connecting together and each oblique section connecting to an end section.
[0008] U.S. Pat. No. 5,679,920 to Hallis et al. discloses a bullet with a copper jacket and a core of segments of zinc, iron, steel or copper. The core is created by forming a hollow roll or cylinder of twisted wires, and work hardening the wires by high impact swaging to make the wires brittle. The wires in the core after swaging are distorted and have an interlocking pattern similar to the pattern disclosed in U.S. Pat. No. 5,528,989 to Briese, and are not arranged helically. The disclosed bullet fragments upon impact with a hard barrier such as a sheet of metal.
[0009] U.S. Pat. No. 5,582,255 to Hallis et al. discloses a bullet with a copper jacket and a core having wires of zinc, iron, steel or copper. The core includes heart having a plurality of wires extending parallel to the longitudinal axis of the core and a plurality of wires twisted around the heart. The core is high impact swaged to deform the wires and to make the wires brittle. The disclosed bullet fragments upon impact with a hard barrier such as a sheet of metal.
DISCLOSURE OF THE INVENTION
[0010] A fully jacketed bullet is disclosed including a metal jacket and a core. The jacket has a base and a cylindrical body extending from the base. The core includes a plurality of strands of malleable material having a low shear modulus. The strands are helically formed or twisted together, and swaged into a uniform cylindrical shape. The core is seated into the jacket and the jacket is then point formed. The method disclosed includes providing a plurality of helically formed strands, swaging the strands to form a uniform cylindrical core, providing a jacket, seating the core in the jacket and point forming the jacket. The strands each have a uniform pitch around the core so that the shock wave that is created by the impact of the bullet and that travels longitudinally rearwardly along the bullet, uniformly and predictably shear fragments and disintegrates the strands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Details of this invention are described in connection with the accompanying drawings that bear similar reference numerals in which:
[0012] [0012]FIG. 1 is a side view of a bullet embodying features of the present invention.
[0013] [0013]FIG. 2 is a perspective view of the core of the bullet of FIG. 1 prior to swaging.
[0014] [0014]FIG. 3 is a perspective view of the jacket and core of the bullet of FIG. 1 after swaging of the core.
[0015] [0015]FIG. 4 is a top view of the bullet of FIG. 1 prior to point forming.
[0016] [0016]FIG. 5 is sectional view taken through the line 5 - 5 of FIG. 4.
[0017] [0017]FIG. 6A is a side view of a core of a bullet with a plurality of strands parallel to the direction of travel.
[0018] [0018]FIG. 6B is a side view of the fragmentation pattern of the bullet of FIG. 6A upon impact.
[0019] [0019]FIG. 6C is an end view of the damage track of the bullet of FIG. 6A.
[0020] [0020]FIG. 7A is a side view of a core of a bullet with two kinks in a plurality of strands.
[0021] [0021]FIG. 7B is a side view of the fragmentation pattern of the bullet of FIG. 7A upon impact.
[0022] [0022]FIG. 7C is an end view of the damage track of the bullet of FIG. 7A.
[0023] [0023]FIG. 8A is a side view of a strand of a core of a bullet with a smoothly helically formed strands.
[0024] [0024]FIG. 8B is a perspective side view of the fragmentation pattern of a core of a bullet having the strands of FIG. 8A upon impact.
[0025] [0025]FIG. 8C is a side view of the fragmentation pattern of the strand of FIG. 8A upon impact.
[0026] [0026]FIG. 8D is an end view of the damage track of the bullet of FIG. 8A.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring now to FIGS. 1 to 5 , a bullet 10 embodying features of the present invention includes a jacket 11 and a core 12 . As shown in FIG. 2 the core consists of a plurality of strands 14 , of a selected length, helically formed together in a spiral configuration so that each strand 14 extends rotationally around a longitudinal axis 15 of the core 12 and obliquely to the axis 15 .
[0028] The strands 14 are made of a malleable metal. Metals having a low shear modulus are preferred. Lead, with a shear modulus of about 0.8 million pounds per square inch (psi) or lead alloy are preferred. Other suitable metals include tin and magnesium, both with a shear modulus of about 2.4 million psi, and aluminum, with a shear modulus of about 3.0 million psi. Less suitable metals include copper and zinc, each with a shear modulus in the range of 6 million psi.
[0029] The helically formed strands 14 of the core 12 are low impact swaged into a uniform cylinder 16 as shown in FIG. 3. The term low impact swaging as used herein refers to swaging metal through high pressure, such as in a low speed hydraulic press, rather than through a sudden, violent impact. Low impact swaging is distinguished from high impact swaging in that high impact swaging uses a sudden, violent impact to form metal. High impact swaging work hardens metal and makes metal brittle. The process of swaging bullets is known in the art, and well described in U.S. Pat. No. 5,528,989, incorporated herein by reference.
[0030] Swaging the helically formed strands 14 of the core 12 provides a dynamically balanced core 12 with no voids for good flight performance. Prior to swaging the helically formed strands 14 of the core 12 have a mass slightly greater than the selected mass of the resultant cylinder so that excess material can be pushed out of bleed holes in the swaging die and the core 12 for each bullet 10 for a specific application will have exactly the selected mass.
[0031] The diameter of the combined helically formed strands 14 of the core 12 , prior to swaging, is slightly less than the diameter of cylinder 16 and the length of the helically formed strands 14 of the core 12 is slightly longer than the cylinder 16 . Swaging compresses the helically formed strands 14 of the core 12 so that the rotations per inch or pitch of the helically formed strands 14 of the core 12 increases.
[0032] The jacket 11 has a base 18 and an elongated, hollow, cylindrical side wall 19 of uniform thickness, attached to and extending transverse the base 18 . The length of wall 19 is greater than the length of core 12 . The base 18 and wall 19 form a cylindrical cavity 20 that is open opposite the base 18 . The jacket shown has a flat base 18 , however other configurations are suitable, such as the rebated boattail. The diameter of the core 12 after swaging is slightly less than the diameter of the cavity 20 so that the core 12 may be readily inserted into cavity 20 and no air will be entrapped between core 12 and base 18 when core 12 is inserted into cavity 20 .
[0033] As shown in FIGS. 4 and 5, the core 12 is seated in the jacket 11 against the base 18 after insertion of core 12 into cavity 20 . The seating of core 12 includes pressing core 12 so that core 12 shortens and deforms outward to solidly contact wall 19 . After the core 12 is seated in jacket 11 , the bullet 10 is point formed such that the jacket 11 , opposite base 18 , has an inwardly tapering tip 21 , as shown in FIG. 1. The core 12 that extends into tip 21 will also be deformed into an inwardly tapering configuration by the point forming.
[0034] [0034]FIG. 6A shows a bullet 30 with eight strands 32 that extend parallel to the direction of bullet travel. At impact the leading edge of bullet 30 is momentarily compressed. This compression induces a pressure wave that travels in the direction directly opposite the flight direction of bullet 30 . Bullet 30 may have a velocity of about 3000 feet per second. The pressure wave travels at the speed of sound. The speed of sound in lead is about 4000 feet per second. Therefore, the pressure wave travels rearwardly the length of bullet 30 before bullet 30 penetrates the length of bullet 30 .
[0035] The pressure wave separates the strands 32 as shown in FIG. 6B. The pattern of the damage track for the bullet 32 shown in FIG. 6A resembles an eight pointed star as shown in FIG. 6C. The separation of bullet 30 into the eight strands 32 significantly reduces the penetration.
[0036] [0036]FIG. 7A shows a bullet 40 , similar to several prior known bullets, with eight strands 42 that extend generally parallel to the direction of bullet travel with each strand 42 having two kinks 43 . The pressure wave created at impact travels parallel to, but in the opposite direction to, the direction of bullet travel. Strands 42 , at the kinks 43 , are not parallel to the direction of bullet travel. When the pressure wave reaches a kink 43 , a shear stress is created in the strand 42 . Strand 42 breaks if the shear stress exceeds the shear fracture limit.
[0037] As shown in FIG. 7B, each strand 42 breaks at kinks 43 into three pieces, creating twenty-four fragments 44 from the eight strands 42 . The damage track for the bullet 40 of FIG. 7A is shown in FIG. 7C and has twenty-four spokes. Since each strand 42 separates into three fragments 44 , the penetration of bullet 40 of FIG. 7A is significantly less than the bullet 30 of FIG. 6A.
[0038] [0038]FIG. 8A shows a smoothly helically formed strand 14 of the bullet 10 embodying features of the present invention. The strand 14 is continually oblique to the pressure wave, so the pressure wave produces shear stresses along the whole length of strand 14 and strand 14 separates at shear fractures 24 into many fragments 23 , as shown in FIGS. 8B and 8C. The fragments 23 are more nearly uniform in size than prior known fragmenting bullets. FIG. 8C shows the damage track of the bullet 10 . The damage track has a diffuse uniform circular pattern. Since each strand 14 of bullet 10 separates into many fragments 23 , the penetration of bullet 10 embodying features of the present invention is significantly less than the bullet 40 of FIG. 7A.
[0039] The shear stresses increase as the angle of strand 14 increases relative to the direction of the pressure wave. The number of fragments 23 increases, and the size of the fragments 23 decreases and therefore the penetration depth decreases, as the pitch or turns per inch of the strands 14 increases. The number of fragments 23 also increases as the number of strands 14 increases. Between one half and five turns are suitable for the bullet 10 , and between two and fifteen strands 14 are suitable for bullet 10 . Since the fragments 23 are more uniform in size than prior known bullets, the penetration and impact pattern of bullet 10 are more predictable.
[0040] Bullet 10 has a full jacket 11 to minimize drag in flight and to assure that core 12 does not disintegrate prior to impact. Jacket 11 has a uniform wall thickness for balance. Similarly, core 12 is swaged into a uniform cylinder 16 for balance and further seated in jacket 11 for balance. Bullet 10 must be well balanced to prevent tumbling and disintegration before impact. Core 12 is preferably swaged into cylinder 16 before seating so that each bullet 10 will have a uniform selected precise mass. Jacket 11 and core 12 do not have incisions or grooves that would unbalance the bullet 10 . Jacket 11 does not have grooves that would weaken the jacket 11 and cause the jacket 11 to burst from the pressure required to seat core 12 .
[0041] The method of making the bullet 10 includes the steps of providing a plurality of strands helically formed together in a spiral configuration, low impact swaging the strands into a cylindrical core with the strands maintaining the spiral configuration, providing a cylindrical jacket with a closed base, seating the core into the jacket, and point forming the jacket opposite the base.
[0042] Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. | A bullet has a jacket and a core seated into the jacket. The core consists of helically formed strands of malleable material swaged into a cylindrical shape. The strands have a uniform pitch along the core, and fragment uniformly into small portions upon impact. A method of making a bullet includes providing helically formed strands of malleable material, swaging the strands, and seating the strands into a jacket. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 398,312 filed Sept. 18, 1973, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of and apparatus for cooling and cleaning the lower sealing valves of the storage hoppers of shaft furnace charging installations. More particularly, this invention is directed to cleaning and cooling the sealing valves of a bell-less blast furnace charging installation in which the sealing valves are directly subjected to the temperature prevailing at the furnace throat. This invention is thus generally directed to a novel and improved method and apparatus for sealing the storage hoppers or bins of a shaft furnace charging installation.
2. Description of the Prior Art
On modern high capacity blast furnaces, in place of the hitherto conventional furnace-top distributors comprising a charging hopper arranged on the furnace throat and sealed by means of upper and lower bell-type charge distributors, increasing use is being made of one or more charge material intermediate storage bins which are selectively isolated from the conditions prevailing within the furnace and the ambient atmosphere by sealing valves or flaps. These valves or flaps are removed from the flow of charge material during the furnace charging operation.
U.S. Pat. No. 3,693,812 discloses a bell-less shaft furnace charging installation including a distribution chute, which is rotatable and adjustable in pitch angle, positioned in the blase furnace throat. In the apparatus of U.S. Pat. No. 3,693,812 the charge material or burden is stored in two or more intermediate storage bins or hoppers and is supplied to the distribution chute in controlled quantities, through use of a metering device, via a central feed channel. In the manner known in the art, the storage bins are operated in accordance with a predetermined cycle, i.e., while one of the bins is being filled with charge material the other will be discharging its contents to the central feed channel and thence onto the furnace hearth via the distribution chute.
Prior to each charging operation and before the start of the refilling of a previously discharged storage bin with charge material from the material pit, the pressure in the storage bin to be discharged or filled must be equalized with the pressure existing in the blast furnace throat or with the ambient atmospheric pressure. This requisite pressure equalization is accomplished by supplying blast furnace gas at furnace pressure to the storage bin or releasing this gas to the atmosphere as appropriate. In the interest of sealing the storage bins relative to the blast furnace port or to the atmosphere, the bins are preferably provided with upper and lower sealing valves or flaps.
Due to the relatively large size and weight of the sealing valves, and also as a consequence of the high temperature and other harsh operating conditions encountered in the environment of a shaft furnace, metal-to-metal seals rapidly degrade and will not provide adequate sealing of the high pressures established inside of the furnace after a relatively short operational life. The rapid deterioration of metal-to-metal seals dictates the use of soft or resilient materials to achieve adequate sealing. To insure that the quality of the seal is maintained during operation for a reasonably long period of time, steps must be taken to insure that the sealing surfaces of the sealing flaps of a shaft furnace charging installation are not subjected to erosion induced wear by the charge material. Also, a sealing material which can withstand the heat and pressure stresses of the operating environment must be selected. The requirement that the sealing surfaces of the valves be protected against erosion induced wear is partially satisfied by insuring that the sealing flaps do not perform a material retaining function; separate flow control members located upstream of the lower sealing valves in the direction of material flow being employed for this purpose. Additionally, in the open condition, during the charging or burdening of the furnace the sealing valve flaps are rotated so as to be completely removed from the material flow path.
A sealing material which satisfactorily withstands, over a sufficiently long operational life, the heat and pressure stresses to which the lower sealing flaps of the storage bins are subjected is not presently available. A furnace charging operation necessarily produces great temperature differences in the region surrounding the lower sealing flaps. During the "dead" time between individual charging operations the blast furnace heat is lead, by convection of the throat gas, to the underside of the lower sealing flaps. The conductivity of the gas, and thus the temperatures to which the sealing flaps are exposed, is increased by the high counterpressure at the throat in modern blast furnaces. During the charging process, however, the temperature in the area of the opened lower sealing flaps falls abruptly as a result of the presence and flow of the charge material which is at the temperature of the ambient atmosphere surrounding the furnace. Due to the large temperature differences and the sudden changes in temperature, sealing materials mounted in or on the lower sealing valves of a blast furnace charging installation could be expected to be considerably stressed and deformed leading to early impairment of the sealing characteristics.
Moreover, the temperature in the blast furnace can vary from the normal operating temperature of 200° to 250°C to 500°C or more. It is even possible that brief temperature surges of approximately 1000°C may occur. As a result of these high temperature influences the sealing material of the lower sealing flap is stressed to its limits and consequently the life and sealing characteristics of the lower flap seal are considerably impaired.
In addition, after each charging operation the storage bins and their discharge channels are filled with very hard and sharp-edged dust particles. These particles cling to the sealing surfaces of the sealing valves, especially when the charging material has a high moisture content. If these particles are not removed they will begin to accumulate between the sealing surfaces on the valve or flap members and their cooperating stationary bearing or seating surfaces. With each closing operation of the sealing flap the sealing material becomes further incrusted with these deposits of dust particles whereby the sealing action is considerably reduced or destroyed after a relatively short period of time.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to lower and keep approximately constant the temperature in the area of the lower sealing flaps of the storage bins of a shaft furnace charging installation whereby commercially available soft or resilient materials can be employed for sealing. A further related objective of this invention is the cleaning and keeping the sealing surfaces of the sealing valves or flaps free, to the extent possible, from deposits of dust and mud.
In accordance with the present invention a gaseous cooling medium is caused to continuously impinge upon or skirt the sealing valves or flaps of a shaft furnace charging apparatus during operation of the furnace. The cooling medium is introduced into the charging installation at a appropriate point between the blast furnace port or top and the lower sealing flaps. The pressure of the cooling medium thus introduced is maintained somewhat higher than the pressure at the furnace throat so that a small flow of cooling medium into the blast furnace will be established and fresh cooling medium can be continuously supplied from outside the furnace.
The introduction of the cooling medium into the furnace charging installation is accomplished in such a manner that the sealing surfaces of the sealing flaps are continuously impinged upon by the cooling medium flow in their open position and during their closing action.
In accordance with a preferred embodiment cleaned and cooled blast furnace gas is employed as the cooling medium. However, it is also possible to use an inert gas as the cooling medium or mixture of inert gas and cleaned and cooled blast furnace gas.
The present invention is accordingly based on the knowledge that it is possible to introduce a certain quantity of a gaseous cooling and cleaning medium into the top of a blast furnace during operation of the furnace without disturbing the ore reduction process which is occurring within the furnace.
BRIEF DESCRIPTION OF THE DRAWING
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawing, which illustrates one embodiment of the invention as applied to a bell-less charging and distribution system for a blast furnace, wherein like reference numerals refer to like elements in the two figures and in which:
FIG. 1 is a schematic side elevation view, partially in section, depicting a preferred embodiment of the invention; and
FIG. 2 is an enlarged cross-sectional view of the sealing flaps of the apparatus of FIG. 1, FIG. 2 clearly depicting the delivery and flow of the cooling medium in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, the bell-less charging installation shown comprises a distributor chute 2 arranged in the blast furnace top or throat 1, a central feed channel 3 and two intermediate storage bins or hoppers 4 and 4'. The drive for distributor chute 2, which has been omitted from the drawing in the interest of facilitating understanding of the invention, is located in drive chamber 5 and permits chute 2 to be rotated while its pitch angle is independently varied. Communication between the storage bins 4 and 4' and the central feed channel 3 is established through respective discharge channels indicated generally at 8 and 8'. Material retaining and metering members, in the form of dome-like or arcuate adjusting flaps 6 and 6', are provided in respective discharge channels 8 and 8'. Lower sealing flaps or valve members 7 and 7' associated with respective storage bins 4 and 4' are also installed in the discharge channels 8 and 8' downstream, in the direction of charge material flow, from the metering members 6 and 6'.
Cleaned and cooled blast furnace gas and/or inert gas is introduced into the drive chamber 5 in order to clean and cool the drive unit for chute 2. This cooling gas is supplied via conduits 9 and 10. Since a suitable cooling medium is present in the charging installation, this cooling medium may also be used for cooling the components of the lower pressure sealing valves associated with the storage bins 4 and 4'. To this end the main supply conduit 9 is branched and the cooling medium is supplied, in accordance with the present invention, to the vicinity of the two sealing flaps 7 and 7' via conduit 11. In accordance with a preferred mode of operation, the cooling medium is caused to flow constantly around the housing of the cooling flaps so that the housing is correspondingly cooled. The source of the cooling gas is controlled such that the coolant is always at a slightly higher pressure than the counter-pressure at the furnace throat. Thus, in the open position of the sealing flaps 7 and 7', as shown in the case of flap 7' in FIG. 2, the cooling medium flow impinges directly on and flows over the sealing surfaces of the flap thus "working" the flap. During the opening action, and particularly during the closing movement of the sealing flaps 7 and 7', the flow of cooling medium is also directed onto the stationary sealing surfaces; i.e. the valve seats which cooperate with the flaps 7; on the discharge channels 8 and 8'. The manner by which this is accomplished is shown in FIG. 2 and will be discussed in greater detail below.
Also in accordance with the present invention, a separate supply of cooling medium can be provided for each of the different sealing surfaces. Due to the impingement of the cooling medium on the sealing surfaces these surfaces will be kept free, to the largest possible extent, from deposits of the dust and mud; the sealing surfaces being cleaned by the coolant flow during each valve closing operation. For coolant pressure and quantity regulation, regulating valves 13 and 14 are provided respectively in conduits 10 and 11. A main control valve 15 incorporated in main supply conduit 19 serves as a pressure reducer or flow regulator.
A particularly important feature of the present invention is the maintenance of the cooling medium flow even during the charging process. In this manner a continual cooling of the sealing flaps and an immediate removal of particulate matter therefrom will be achieved after each charging process.
Referring now to FIG. 2, the lower ends of the discharge channels 8 and 8' wherein are mounted the metering members 6 and 6' and the sealing flaps 7 and 7' are shown on an enlarged scale when compared to FIG. 1. In FIG. 2 the sealing flap 7 is shown in the closed position which it might be caused to assume when the intermediate storage hopper 4 is being refilled with charge material; i.e., when atmospheric pressure and temperature exists within hopper 4 and thus also within the discharge channel 8. Conversely, the sealing flap 7' is shown in the open position. Since the metering member 6' is shown as closed, it may be assumed that sealing flap 7' is shown in the position it would assume just immediately prior to or subsequent to the discharge of the charge in intermediate storage hopper 4' onto the furnace hearth via discharge channel 8' and the distribution chute 2 (not shown in FIG. 2).
The flow of cooling medium over the stationary sealing or valve seat surfaces which cooperate with the sealing flaps 7 and 7' is achieved by means of installing a plenum chamber 16 in the branch supply conduit 11 and tapping off cooling gas from plenum chamber 16 via further branch conduits 18 and 18'and a continuation 11' of conduit 11. As noted above, in accordance with a preferred embodiment of the invention the flow of coolant onto the stationary resilient sealing members of the sealing valves, indicated respectively at 20 and 20', is necessary only during the opening and closing of the valves and particularly during closing. Accordingly, the conduits 18 and 18' are respectively provided with valves 22 and 22' which may be operated from a remote location.
As may be clearly seen from FIG. 2, the lower ends of the discharge channels 8 and 8' are respectively provided with valve seat defining members 24 and 24'. These valve seat defining members are removably attached to the lower ends of the discharge channels 8 and 8' by means of bolts. The stationary resilient sealing members 20 and 20', which may be comprised of a soft metal, are attached by hard facing to the valve seat members 24 and 24'. Members 24 and 24' are each provided with an annular internal passage which discharges, via a slot, downwardly over the sealing members 20, 20'. Thus, considering the valve which includes movable flap 7', during the opening and particularly during the closing of flap 7' the valve 22' will be open and the coolant gas will be delivered via conduit 11, plenum chamber 16 and conduit 18' to the channel within the valve seat defining member 24' from which it will be discharged through the slot in the valve seat defining member. During this discharge the cooling gas will both cool and clean the sealing material 20' whereby, upon closing of the valve, no particular matter will be wedged between the stationary and movable sealing surfaces. In the embodiment shown, sealing flap 7 is in the closed position and there is accordingly no need for the delivery of coolant gas to the channnel in the valve seat defining member 24 and thus valve 22 will be closed. In accordance with the preferred embodiment, the valve 14 of FIG. 1 will remain open at all times during furnace operation and thus cooling gas will be continuously discharged into the furnace throat via conduit 11, plenum chamber 16 and conduit 11'.
As may also be seen from FIG. 2, the sealing flaps 7 and 7' provide support for annular sealing members such as member 26' on flap 7'. The sealing members 26, 26', which may be comprised of silicon rubber, are retained in position on the sealing flap by means of a retaining ring such as ring 28' of flap 7'. The retaining ring 28 may be comprised of steel and is attached to sealing flaps 7' by means of screws The materials comprising the sealing members 20 and 26, as well as the retaining rings 28, are chosen such that their coefficient or expansion is sufficiently compatible with the other materials employed in the furnace so that the sealing members will be retained in position and will not be "lost" should there be a failure in the coolant supply.
As may be seen by the arrows provided on FIG. 2, the continuous flow of cooling gas discharged into the furnace throat will, because of the pressure differential maintained, flow downwardly over both the open and closed sealing valves thereby continuously cooling and cleaning the movable valve members or flaps 7 and 7'. The amount of cooling gas discharged into the furnace will not, however, be sufficient to have a deleterious effect upon the operation being performed within the furnace.
The present invention greatly reduces the stressing of the sealing material. As a consequence of the resultant increased life of the sealing material the amount of time during which the blast furnace is shut down in greatly reduced. In addition, the sealing of the counterpressure at the furnace throat relative to atmosphere is insured and the blast furnace can be operated with a higher counterpressure.
It is of particular advantage that the temperature in the area of the distributor chute in the blast furnace throat is reduced by the cooling medium flow into the blast furnace throat. The cooling medium, after performing its function of cleanng and cooling the stationary and movable parts of the sealing valves, flows around the distributor chute and keeps a large proportion of the blast furnace dust away from the movable parts of the distributor chute.
While a preferred embodiment has been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A method of and apparatus for cooling and cleaning the sealing surfaces of the sealing valves of a material storage hopper which are subjected to the high temperature and pressure within a shaft furnace. The method comprises introducing a cooling medium into the charging installation of the furnace and causing the coolant to continuously impinge upon the sealing valves. The apparatus includes a rotatable sealing flap having a sealing surface of resilient material and a cooling fluid supply conduit for directing a flow of cooling fluid towards the sealing surface of the flap when the flap is in its opened position. | 8 |
This is a continuation-in-part of copending application Ser. No. 283,601, filed on Dec. 13, 1988, now U.S. Pat. No. 4,946,315.
BACKGROUND OF THE INVENTION
This invention relates to roof support systems and, more particularly, to a roof support apparatus for a mine.
Roof trusses or roof support systems for mines, although a fairly recent innovation, are now commonly used in, for example, coal mines to provide support to the immediate roof strata. A typical roof truss system utilizes a tie rod or truss member placed parallel to the roof of the mine, and a roof bolt angled into the mine roof at each end of the member. The truss member is placed in tension to create stresses in the immediate roof area; these stresses being compressive stresses exerted in both the vertical and horizontal directions. One such system is described in U.S. Pat. No. 4,601,616 (Barisha et al) which discloses the use of single connector plates between the inclined anchor rods and a compound tie rod which utilizes turnbuckle-like coupling sleeves.
While the roof truss support systems are generally useful, present systems do have some shortcomings. Among these are a failure to physically apply upward thrust to the immediate roof strata away from the angle bolts; truss systems must be installed outside of normal production cycle because of long installation time required; the truss systems are not capable of controlled yielding as ground movements occur; and, there is no load measuring device for reading the load acting on the system at any one time.
The present apparatus solves these and other problems in a manner not disclosed in the known prior art.
SUMMARY OF THE INVENTION
Among the several objects of the present invention may be noted the provision of apparatus for supporting a roof and exerting a compressive load thereon; the provision of such apparatus which is quickly and easily installed in a mine; the provision of such apparatus which applies a compressive load to the immediate roof strata after installation; the provision of such apparatus in which the tension to which the system is subjected can be adjusted; the provision of such apparatus in which the load to which the system is subjected is readily ascertainable; and, the provision of such apparatus which is capable of controlled yielding if ground movement occurs.
Among the further objects of the invention is the provision of an articulated, single pin quick connect/disconnect connection system which provides easier and quicker installation of the mine roof truss, even under uneven roof conditions without the necessity of accurate initial set up.
It is an aspect of this invention to provide first and second connection means positionable against a mine roof at opposite sides thereof adjacent the opposing pillars, each connection means having an upset surface contacting the mine roof for exerting a compressive load on the roof; means for anchoring the connection means to the roof; and tie means interconnecting the first and second connection means, the tie means being adjustable to vary the compressive load exerted on the mine roof by the connection means and said connection means upset surface being offset from said tie means.
It is another aspect of this invention to provide that each connection means comprises a connector plate and a truss plate and means interconnecting said plates.
It is yet another aspect of this invention to provide that each connector plate has an upper section and a lower section and side reinforcing sections, the connector plate upper section having a concave surface providing said upset surface the outer portion of which bears against the roof of the mine.
It is still another aspect of this invention to provide that the means connecting the connector plate to the truss plate include pin means to simplify the connection between said plates and another aspect to provide that the lower section of each connector plate has a pair of spaced apart keyhole slots and each truss plate has a pair of openings and said pin means includes pins received in the slots to connect the plates together.
Yet another aspect of this invention is to provide that the anchor means includes a pair of bolts, each bolt being set into the roof at an angle.
Still another aspect of this invention is to provide that the tie means comprises a tie rod interconnecting the connector plates.
It is an aspect of this invention to provide means permitting slippage of the apparatus if loads on the apparatus become excessive, and another aspect to provide that the slippage means includes a hollow non-rotating cylinder attachable to said connector plate, the slippage means further includes a tapered plug having a longitudinal bore to receiving the tie rod, the cylinder having a tapered inner diameter to accommodate the plug, the taper angle of the plug and the inside of the cylinder providing suitable load deformation characteristics for the apparatus.
It is another aspect of the invention to provide means for indicating the amount of tension on the tie rod, and another aspect to provide that the cylinder has a longitudinal elongate slot in the side thereof with markings on the outside of slot to indicate different levels of tension and to provide that the plug has a circumferential marking on its outer face which is visible through the slot as the position of the plug moves relative to the slot.
Yet another aspect of this invention is to provide intermediate anchor means and coupling means, attached to said roof by said intermediate anchor means and cooperating with said tie means to connect said anchor means to said intermediate anchor means, and another aspect to provide that the intermediate anchor means is a vertical bolt and the coupler is U-shaped.
It is another aspect of this invention to provide first and second connection means positionable against the roof at opposite sides thereof adjacent the opposing pillars, each connection means including a truss plate, a connector plate and means detachably interconnecting said truss plate and said connector plate; means for anchoring the truss plates to the roof; and tie rod means interconnecting the first and second connector plates.
It is another aspect of this invention to provide that each connector plate includes an upset surface offset from the tie rod means and contacting the mine roof and exerting a compressive upward load on the roof.
It is yet another aspect of this invention to provide that the means connecting the connector plate to the truss plate include a single pin providing relative pivotal and axial movement between said plates.
Another aspect of this invention is to provide that said pin has a section received by said connector plate having a length greater than the thickness of said connector plate to provide said relative axial movement between said connected plates and another aspect to provide that said pin has a concave surface area to facilitate relative axial movement between said connected plates.
Yet another aspect of this invention is to provide that each connector plate has a single keyhole slot and each truss plate has a single opening receiving an associated pin in depending relation.
It is an aspect of this invention to provide that said truss plate is substantially wider than said connector plate.
It is an aspect of this invention to provide a mine roof support apparatus which is relatively inexpensive, easy to install and effective in operation.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a mine opening with apparatus of the present invention installed;
FIG. 2 is a sectional view taken along line 2--2 in FIG. 1;
FIG. 3 is a sectional view taken along line 3--3 in FIG. 2;
FIGS. 4 and 5 are sectional views taken along lines 4--4 and 5--5, respectively, in FIG. 3;
FIG. 6 is a sectional view taken along line 6--6 in FIG. 2;
FIG. 7 is an exploded view of a slip mechanism of the apparatus;
FIG. 8 is a sectional view taken along line 8--8 in FIG. 5;
FIG. 9 is a perspective view of a connector plate of the apparatus;
FIG. 10 is a perspective view of a truss plate of the apparatus;
FIG. 11 is a plan view similar to FIG. 1 but showing an alternate embodiment of the apparatus;
FIG. 12 is a perspective view of a coupler used in the alternate embodiment;
FIG. 13 is a perspective view of a modified connector plate;
FIG. 14 is a similar view to FIG. 2 illustrating a modified apparatus connection utilizing a single pin connection;
FIG. 15 is a sectional view taken along line 15--15 of FIG. 14;
FIG. 16 is a perspective view of a connector plate of the modified connection; and
FIG. 17 is a perspective view of a truss plate of the modified connection.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now by reference numerals to the drawings and first to FIG. 1, it will be understood that the mine opening M is defined by a roof R and opposed side pillars SL and SR. Apparatus to support roof R and for exerting a compressive load thereon is indicated generally by numeral 1.
Apparatus 1 includes a first connection means 3 and second connection means 5 which are positionable against opposite sides of roof R adjacent respective side pillars SL and SR and act in conjunction with inclined anchor means provided adjacent each of said side pillars. The connection means 3 and 5 are interconnected by a truss tie rod 4 for the purpose of inducing compression and thrust forces into the mine roof as indicated by arrows. Since the connection means at both ends are substantially identical except for the ends of the truss rod, the connection means will be described with reference to connection means 5.
As shown in FIGS. 9 and 10, connection means 5 includes a connector plate 7 and a truss plate 9. Connector plate 7 has an upper section 11 which is concave in cross-section so the section has a contoured or upset surface 13. When apparatus 1 is installed, surface 13 bears against roof R to impart a compressive force against the immediately adjacent roof strata by virtue of the line of action of the tie rod 4 being offset from the plane of the truss plate 9. One end of the concave section 11 transitions into a flat lower section 15 while the other end of the section adjoins a front, vertical section 17. A pair of reinforcement plates 19, one on each side, connect diagonally between sections 13 and 17 and act as reinforcement for the curved section 11. Section 15 has two spaced apart, parallel, keyhole shaped slots 21 which are parallel to the longitudinal axis of plate 7. Slots 21 are used to connect plates 7 and 9 and the wider end of each slot is adjacent the rear face of concave section 11.
Truss plate 9 has a flat upper surface 23 which bears against roof R. The truss plate 9 has a forward section 25, which overlays section 15 of connector plate 7. As best shown in FIGS. 3 and 6 a pair of quick disconnect pins 27 are secured to section 25 and depend from the underside of this section. Pins 27, which are received in slots 21, fit through openings 29 formed in the truss plate 9. During manufacture of the truss plate, a pair of circular recesses 31 are formed in the plate, as, for example, by punching; and, openings 29 are formed in the base of each recess for the pins to be inserted. The pins 27 have base 33 whose diameter is greater than that of opening 29, a shaft 35 of the same diameter as the opening 29, a head 39 of the same diameter of the shaft and the enlarged portion of the keyhole slot 21 of the connector plate 7 and an intermediate, smaller diameter section 37 which is slightly smaller than the smaller width of the keyhole slot 21. This arrangement provides that when plates 7 and 9 are connected (see FIGS. 2, 3 and 6), the reduced diameter section of pins 27 is fitted in the smaller width portion of slots 21 thereby holding the connector plate 7 and the truss plate 9 together against movement away from each other.
Plate 9 has a rearward section 41 in which is formed a recess 43 having a rectangular opening; also, for example, by stamping. Forming of recess 43 creates an attaching section 45 for attaching the truss plate 9 to the mine roof. Section 45 is triangular in cross-section and depends from the underside of the plate. An opening 47 is formed in the forward face 49 of section 45.
Apparatus 1 includes anchor means 51 for anchoring truss plate 9 plate to roof R. As shown in FIG. 1, holes HL and HR are drilled diagonally upwardly and outwardly in roof R and anchor means 51 includes bolts 53 which are inserted into these holes. In operation, both sets of plates 7 and 9 are connected together as previously described. The shaft of each bolt 53 is inserted through opening 47 in each plate 9 and an expansion nut 55 is installed on the threaded end of each bolt. The bolt is then inserted into hole HL or HR and the head 57 of the bolt is turned with a wrench or pneumatic tool until the nut expands to secure the bolt in the hole.
The tie rod 4 is connected between opposed connector plates 7 of each of the connection means 3 and 5 and to this end section 17 of each plate 7 has a centrally located bore 63 sized to receive the rod 4 which includes a bolt head 61 and a threaded end 65. Tie rod 4 is of an appropriate length so the rod can be loosely installed between plates 7 prior to the installation of connection means 3 and 5 to the roof of the mine as above described. Once the connection means 7 and 9 are installed, a nut (not shown) can be provided on the threaded end of the tie rod 4 and tightened until the appropriate loading is attained. Alternatively and preferably, as will now be described, a slip anchor 67 can be provided.
The provision of the slip anchor 67 permits slippage of the apparatus if the load on the apparatus becomes excessive. The slip anchor 67, as best shown in FIGS. 7 and 8 comprises a hollow cylinder 69 attachable to the inside of section 17 of connection plate 7. Cylinder 69 has a base 71 which abuts the inner face of section 17 of connector plate 7 of connection means 5. A shoulder 73 extending longitudinally outwardly from the base has an outer diameter sized to fit in opening 63. The shoulder is bored to a diameter allowing the threaded end 65 of tie rod 4 to fit through the shoulder. On the periphery of base 71, and diametrically opposed to each other are a pair of pins 75 attached to said base, as by welding. Section 17 of connector plate 7 has a pair of openings 77 of the same diameter as the pins 75. Openings 77 have the same spacing with respect to the centerline of opening 63 as pins 75 which fit through opening 77 to hold cylinder 69 in place and prevent its rotation during adjustment of tie rod 4.
As shown in FIGS. 3, 7 and 8, cylinder 69 has a tapered inner wall and a tapered plug 81 is received in the opposite end of the cylinder from base 71. Plug 81 has a longitudinal threaded bore 83 in which is received threaded end 65 of tie rod 4. When the apparatus is installed, the loading on the apparatus can be adjusted by the degree to which plug 81 is drawn into cylinder 69 by turning tie rod 4 the appropriate direction.
Cylinder 69 also has an elongate slot 85 in its sidewall, the slot being parallel to the longitudinal axis of the cylinder. Calibration marks 87 are inscribed on the side wall of the cylinder adjacent slots 85, and plug 81 has a circumferential inscribed line 89 which can be seen through the slot as shown in FIG. 8. It will be understood that the taper angle of plug 81 can be selected to suit the load deformation characteristics of the apparatus. The calibration markings on cylinder 69 and plug 81 allow a ready determination of the tension level to which the apparatus is adjusted upon installation. In addition, the taper angle of the plug permits slippage of the apparatus if excessive ground loads occur. Thus the apparatus tends to yield to these variations without an abrupt collapse of the apparatus.
Referring to FIG. 11, there is disclosed an embodiment of the apparatus IA similar to that previously described but which includes an intermediate coupling means 91 for a pair of tie rods 4A. Coupling means 91 comprising a U-shaped coupler 93 which is positioned at the mid-point of roof R intermediate plate means 3 and 5. Coupler 93 is installed in an inverted position by an anchor bolt 53A set in a center hole HC which is vertically drilled into the roof. As shown in FIG. 12, the coupler 93 has an opening 95 in its base 97 to accommodate bolt 53A and it is intended that the coupler be fixedly attached to the roof R by said bolt 53A which, except for its vertical disposition, can be identical to inclined anchor bolts 53 and constitutes intermediate anchor means. The coupler also has openings 99 in each arm 101 for connecting associated tie rods 4A between the coupler and the connector plate 7 of the respective plate means 3 and 5. In this modified apparatus each tie rod 4A includes a bolt head 61A and a threaded end 65A. The threaded ends 65 can be provided with regular nuts 66 or with slip anchors 67. In effect, because of the fixed nature of coupler 93, each tie rod 4A cooperates with an inclined anchor bolt 53 and the anchor bolt 53A to provide a pair of independent systems rather than the single system previously described.
FIG. 13 discloses a modified connector plate 107 which fulfills the same purpose as connector plate 7 described above. Connector plate 107 is generally tapered to be narrower at the tie rod end and has an upper section 111 which is similarly offset from the axis of the tie rod axis. However, the sloping surface 113 between the flat lower section 115 and the upper section 111 tends to be straight rather than curved to produce a relatively flat offset upper section. The reinforcing plates 119 are integrally formed with sections 111, 113 and 115 and the tie rod end is reinforced by indentations at the upper 120 corner and the front face is stiffened by ribs 122. The keyhole slots 121 are substantially identical to those shown in FIG. 9.
A modified connection means 205 (203) is shown in FIGS. 14-17. This connection means performs the same function as the connection means 5 described with respect to FIGS. 2-10 but with the important difference that only a single connection pin is used to connect the connector plate and the truss plate.
As shown in FIGS. 14-17, connection means 205 includes a connector plate 207 and a truss plate 209. Connector plate 207 has an upper section 211 which is displaced upwardly so the section has an upset surface 213. When the connection means is installed, surface 213 bears against roof to impart a compressive force against the immediately adjacent roof strata by virtue of the line of action of the tie rod 4 being offset from the plane of the truss plate 209. One end of the upset section 211 transitions by means of inclined section 212 into a flat lower section 215 while the other end of the section adjoins a front, vertical section 217. A pair of unitarily formed reinforcement plates 219, one on each side, connect between sections 212, 213, 215 and 217 and further reinforcement is provided by a base flange 218. Section 215 has a single keyhole shaped slot 221 which is parallel to the longitudinal axis of plate 207. Slot 221 is used to connect plates 207 and 209 and the wider end of each slot is adjacent the rear face of displaced section 211.
Truss plate 209 has a flat upper surface 223 which bears against roof R. The truss plate 209 is substantially wider than connector plate 207 and has a forward section 225 which overlays section 215 of connector plate 207. As best shown in FIGS. 14 and 15, a quick connect pin 227 is secured to section 225 and depends from the underside of this section. Pin 227, which is received in slot 221, fits through openings 229 formed in the truss plate 209. During manufacture of the truss plate, a circular recess 231 is formed in the plate, as, for example, by punching, and openings 229 are formed in the base of each recess for the pins to be inserted. The pin 227 has a base 233 whose diameter is greater than that of opening 229, a shaft section 235 of the same diameter as the opening 229, a head 239 of the same diameter as the shaft portion 235 and the enlarged portion of the keyhole slot 221, and a relatively long intermediate, "necked-in" section 237, received by the keyhole slot, having a concave surface area. Section 237, at its minimum, is slightly smaller than the minimum width 222 of the keyhole slot 221 and has a length which is greater than the thickness of said connector plate 207. This arrangement provides that when plates 207 and 209 are connected, the pin reduced diameter section 237 is fitted into the smaller width portion of slots 221 thereby holding the connector plate 207 and the truss plate 209 together against movement away from each other. Truss plate 209 is otherwise similar to truss plate 9 described above. Likewise, except as described connector plate 207 is otherwise similar to connector plate 7 described above.
As shown in FIGS. 14 and 15 in phantom outline, the single pin 237 with the relatively long, "necked-in" pin section 237 permits the connector plate 207 to pivot horizontally relative to the truss plate 209 and to angle vertically from the axis of the tie rod 4. The engagement between the pin 237 and the connector plate slot 221, constituting the load transfer point between said plate and said pin, is at a point displaced from the axis of the tie rod 4 which tends to rotate the connector plate 207 in a clockwise direction tending to urge surface 213 into engagement with the roof R. The configuration of the pin base 233 and the recess 231 tends to hold the pin in the truss plate 209.
With this arrangement, a quick connect pin 237 located along the longitudinal axis of the truss plate 209 is used to connect the truss plate 209 to the connector plate 207. The connector plate has a single opening to receive the pin 227, and the pin 227 with the "necked-in" elongated section 237 is, in effect, configurated to act as a universal joint so that the connector plate 207 can pivot in the longitudinal as well as the transverse direction in the presence of an uneven roof R. The connector plate 207 can also rotate in the horizontal plane around the single pin 227 with the result that the truss plates 209 do not have to be accurately aligned in the same vertical plane or horizontal plane. Also, the connection between the connector plates, the truss plates and the tie rod will be, to some extent, self-aligning. This arrangement permits easier and quicker installation of the apparatus as a whole; and provides for improved installation of the apparatus under uneven roof conditions.
It will be understood that the arrangement is shown for the right hand connection means 205 but that the same arrangement is provided for the left hand connection means 203. It will also be understood that details not specifically described such as the tie rod 4 and the connections of the tie rod to the roof R and the roof bolt connection can be the same as described above with respect to the embodiment shown in FIGS. 2-10.
In view of the above it will be seen that various aspects and features of the invention are achieved and other advantageous results attained. While a preferred embodiment of the invention has been shown and described, it will be clear to those skilled in the art that changes and modifications may be made therein without departing from the invention in its broader aspects. | Apparatus (1) for supporting a mine roof (R) has connected plates (7, 9) positioned against the roof at opposite sides of the mine roof. One plate (7) has an upset surface (13) contacting the roof to exert a compressive load on it. Bolts (53) anchor the plates to the roof. A tie rod (64) interconnects the plates and is adjustable to vary the compressive load, and in one embodiment a slip anchor (67) is provided at one end of the tie rod which can also be utilized to estimate the tie rod load. In another embodiment a single quick connect pin (227) is provided between connected plates (207, 209). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/973,034 filed 17 Sep. 2007. The disclosure of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to deuterium-enriched sitagliptin, pharmaceutical compositions containing the same, and methods of using the same.
BACKGROUND OF THE INVENTION
[0003] Sitagliptin, shown below, is a well known dipeptidyl peptidase-4 (DPP-4) inhibitor.
[0000]
[0000] Since sitagliptin is a known and useful pharmaceutical, it is desirable to discover novel derivatives thereof. Sitagliptin is described in U.S. Pat. Nos. 6,303,661 7,078,381, 6,890,898, and 6,699,871; the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide deuterium-enriched sitagliptin or a pharmaceutically acceptable salt thereof.
[0005] It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0006] It is another object of the present invention to provide a method for treating type 2 diabetes mellitus, comprising administering to a host in need of such treatment a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0007] It is another object of the present invention to provide a novel deuterium-enriched sitagliptin or a pharmaceutically acceptable salt thereof for use in therapy.
[0008] It is another object of the present invention to provide the use of a novel deuterium-enriched sitagliptin or a pharmaceutically acceptable salt thereof for the manufacture of a medicament (e.g., for the treatment of type 2 diabetes mellitus).
[0009] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventor's discovery of the presently claimed deuterium-enriched sitagliptin.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Deuterium (D or 2 H) is a stable, non-radioactive isotope of hydrogen and has an atomic weight of 2.0144. Hydrogen naturally occurs as a mixture of the isotopes 1 H (hydrogen or protium), D ( 2 H or deuterium), and T ( 3 H or tritium). The natural abundance of deuterium is 0.015%. One of ordinary skill in the art recognizes that in all chemical compounds with a H atom, the H atom actually represents a mixture of H and D, with about 0.015% being D. Thus, compounds with a level of deuterium that has been enriched to be greater than its natural abundance of 0.015%, should be considered unnatural and, as a result, novel over their non-enriched counterparts.
[0011] All percentages given for the amount of deuterium present are mole percentages.
[0012] It can be quite difficult in the laboratory to achieve 100% deuteration at any one site of a lab scale amount of compound (e.g., milligram or greater). When 100% deuteration is recited or a deuterium atom is specifically shown in a structure, it is assumed that a small percentage of hydrogen may still be present. Deuterium-enriched can be achieved by either exchanging protons with deuterium or by synthesizing the molecule with enriched starting materials.
[0013] The present invention provides deuterium-enriched sitagliptin or a pharmaceutically acceptable salt thereof There are fifteen hydrogen atoms in the sitagliptin portion of sitagliptin as show by variables R 1 -R 15 in formula I below.
[0000]
[0014] The hydrogens present on sitagliptin have different capacities for exchange with deuterium. Hydrogen atoms R 1 -R 2 are easily exchangeable under physiological conditions and, if replaced by deuterium atoms, it is expected that they will readily exchange for protons after administration to a patient. The remaining hydrogen atoms are not easily exchangeable for deuterium atoms. However, deuterium atoms at the remaining positions may be incorporated by the use of deuterated starting materials or intermediates during the construction of sitagliptin.
[0015] The present invention is based on increasing the amount of deuterium present in sitagliptin above its natural abundance. This increasing is called enrichment or deuterium-enrichment. If not specifically noted, the percentage of enrichment refers to the percentage of deuterium present in the compound, mixture of compounds, or composition. Examples of the amount of enrichment include from about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 21, 25, 29, 33, 37, 42, 46, 50, 54, 58, 63, 67, 71, 75, 79, 84, 88, 92, 96, to about 100 mol %. Since there are 15 hydrogens in sitagliptin, replacement of a single hydrogen atom with deuterium would result in a molecule with about 7% deuterium enrichment. In order to achieve enrichment less than about 7%, but above the natural abundance, only partial deuteration of one site is required. Thus, less than about 7% enrichment would still refer to deuterium-enriched sitagliptin.
[0016] With the natural abundance of deuterium being 0.015%, one would expect that for approximately every 6,667 molecules of sitagliptin (1/0.00015=6,667), there is one naturally occurring molecule with one deuterium present. Since sitagliptin has 15 positions, one would roughly expect that for approximately every 100,005 molecules of sitagliptin (15×6,667), all 15 different, naturally occurring, mono-deuterated sitagliptins would be present. This approximation is a rough estimate as it doesn't take into account the different exchange rates of the hydrogen atoms on sitagliptin. For naturally occurring molecules with more than one deuterium, the numbers become vastly larger. In view of this natural abundance, the present invention, in an embodiment, relates to an amount of an deuterium enriched compound, whereby the enrichment recited will be more than naturally occurring deuterated molecules.
[0017] In view of the natural abundance of deuterium-enriched sitagliptin, the present invention also relates to isolated or purified deuterium-enriched sitagliptin. The isolated or purified deuterium-enriched sitagliptin is a group of molecules whose deuterium levels are above the naturally occurring levels (e.g., 7%). The isolated or purified deuterium-enriched sitagliptin can be obtained by techniques known to those of skill in the art (e.g., see the syntheses described below).
[0018] The present invention also relates to compositions comprising deuterium-enriched sitagliptin. The compositions require the presence of deuterium-enriched sitagliptin which is greater than its natural abundance. For example, the compositions of the present invention can comprise (a) a μg of a deuterium-enriched sitagliptin; (b) a mg of a deuterium-enriched sitagliptin; and, (c) a gram of a deuterium-enriched sitagliptin.
[0019] In an embodiment, the present invention provides an amount of a novel deuterium-enriched sitagliptin.
[0020] Examples of amounts include, but are not limited to (a) at least 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, to 1 mole, (b) at least 0.1 moles, and (c) at least 1 mole of the compound. The present amounts also cover lab-scale (e.g., gram scale), kilo-lab scale (e.g., kilogram scale), and industrial or commercial scale (e.g., multi-kilogram or above scale) quantities as these will be more useful in the actual manufacture of a pharmaceutical. Industrial/commercial scale refers to the amount of product that would be produced in a batch that was designed for clinical testing, formulation, sale/distribution to the public, etc.
[0021] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0022] wherein R 1 -R 15 are independently selected from H and D; and the abundance of deuterium in R 1 -R 15 is at least 7%. The abundance can also be (a) at least 13%, (b) at least 20%, (c) at least 27%, (d) at least 33%, (e) at least 40%, (f) at least 47%, (g) at least 53%, (h) at least 60%, (i) at least 67%, (j) at least 73%, (k) at least 80%, (l) at least 87%, (m) at least 93%, and (n) 100%.
[0023] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 2 is at least 50%. The abundance can also be (a) 100%.
[0024] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 3 -R 4 is at least 50%. The abundance can also be (a) 100%.
[0025] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 9 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0026] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 15 is at least 17%. The abundance can also be (a) at least 33%, (b) at least 50%, (c) at least 67%, (d) at least 83%, and (e) 100%.
[0027] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0028] wherein R 1 -R 15 are independently selected from H and D; and the abundance of deuterium in R 1 -R 15 is at least 7%. The abundance can also be (a) at least 13%, (b) at least 20%, (c) at least 27%, (d) at least 33%, (e) at least 40%, (f) at least 47%, (g) at least 53%, (h) at least 60%, (i) at least 67%, (j) at least 73%, (k) at least 80%, (l) at least 87%, (m) at least 93%, and (n) 100%.
[0029] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 2 is at least 50%. The abundance can also be (a) 100%.
[0030] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 3 -R 4 is at least 50%. The abundance can also be (a) 100%.
[0031] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 9 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0032] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 15 is at least 17%. The abundance can also be (a) at least 33%, (b) at least 50%, (c) at least 67%, (d) at least 83%, and (e) 100%.
[0033] In another embodiment, the present invention provides novel mixture of deuterium enriched compounds of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0034] wherein R 1 -R 15 are independently selected from H and D; and the abundance of deuterium in R 1 -R 15 is at least 7%. The abundance can also be (a) at least 13%, (b) at least 20%, (c) at least 27%, (d) at least 33%, (e) at least 40%, (f) at least 47%, (g) at least 53%, (h) at least 60%, (i) at least 67%, (j) at least 73%, (k) at least 80%, (1) at least 87%, (m) at least 93%, and (n) 100%.
[0035] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 2 is at least 50%. The abundance can also be (a) 100%.
[0036] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 3 -R4 is at least 50%. The abundance can also be (a) 100%.
[0037] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 9 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0038] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 15 is at least 17%. The abundance can also be (a) at least 33%, (b) at least 50%, (c) at least 67%, (d) at least 83%, and (e) 100%.
[0039] In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0040] In another embodiment, the present invention provides a novel method for treating type 2 diabetes mellitus comprising: administering to a patient in need thereof a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0041] In another embodiment, the present invention provides an amount of a deuterium-enriched compound of the present invention as described above for use in therapy.
[0042] In another embodiment, the present invention provides the use of an amount of a deuterium-enriched compound of the present invention for the manufacture of a medicament (e.g., for the treatment of type 2 diabetes mellitus).
[0043] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. This invention encompasses all combinations of preferred aspects of the invention noted herein. It is understood that any and all embodiments of the present invention may be taken in conjunction with any other embodiment or embodiments to describe additional more preferred embodiments. It is also to be understood that each individual element of the preferred embodiments is intended to be taken individually as its own independent preferred embodiment. Furthermore, any element of an embodiment is meant to be combined with any and all other elements from any embodiment to describe an additional embodiment.
DEFINITIONS
[0044] The examples provided in the definitions present in this application are non-inclusive unless otherwise stated. They include but are not limited to the recited examples.
[0045] The compounds of the present invention may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention. All tautomers of shown or described compounds are also considered to be part of the present invention.
[0046] “Host” preferably refers to a human. It also includes other mammals including the equine, porcine, bovine, feline, and canine families.
[0047] “Treating” or “treatment” covers the treatment of a disease-state in a mammal, and includes: (a) preventing the disease-state from occurring in a mammal, in particular, when such mammal is predisposed to the disease-state but has not yet been diagnosed as having it; (b) inhibiting the disease-state, e.g., arresting it development; and/or (c) relieving the disease-state, e.g., causing regression of the disease state until a desired endpoint is reached. Treating also includes the amelioration of a symptom of a disease (e.g., lessen the pain or discomfort), wherein such amelioration may or may not be directly affecting the disease (e.g., cause, transmission, expression, etc.).
[0048] “Therapeutically effective amount” includes an amount of a compound of the present invention that is effective when administered alone or in combination to treat the desired condition or disorder. “Therapeutically effective amount” includes an amount of the combination of compounds claimed that is effective to treat the desired condition or disorder. The combination of compounds is preferably a synergistic combination. Synergy, as described, for example, by Chou and Talalay, Adv. Enzyme Regul. 1984, 22:27-55, occurs when the effect of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at sub-optimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
[0049] “Pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of the basic residues. The pharmaceutically acceptable salts include the conventional quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include, but are not limited to, those derived from inorganic and organic acids selected from 1,2-ethanedisulfonic, 2-acetoxybenzoic, 2-hydroxyethanesulfonic, acetic, ascorbic, benzenesulfonic, benzoic, bicarbonic, carbonic, citric, edetic, ethane disulfonic, ethane sulfonic, fumaric, glucoheptonic, gluconic, glutamic, glycolic, glycollyarsanilic, hexylresorcinic, hydrabamic, hydrobromic, hydrochloric, hydroiodide, hydroxymaleic, hydroxynaphthoic, isethionic, lactic, lactobionic, lauryl sulfonic, maleic, malic, mandelic, methanesulfonic, napsylic, nitric, oxalic, pamoic, pantothenic, phenylacetic, phosphoric, polygalacturonic, propionic, salicyclic, stearic, subacetic, succinic, sulfamic, sulfanilic, sulfuric, tannic, tartaric, and toluenesulfonic.
EXAMPLES
[0050] Table 1 provides compounds that are representative examples of the present invention. When one of R 1 -R 15 is present, it is selected from H or D.
[0000]
1
2
3
4
5
[0051] Table 2 provides compounds that are representative examples of the present invention. Where H is shown, it represents naturally abundant hydrogen.
[0000]
6
7
8
9
10
[0052] Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein. | The present application describes deuterium-enriched sitagliptin, pharmaceutically acceptable salt forms thereof, and methods of treating using the same. | 2 |
BACKGROUND
Since its origins in the 1960s and commercialization in the 1990s, the Internet has expanded worldwide to become ubiquitous in social and business activities. When combined with wireless and high speed data links, many new applications have emerged. While the Internet was initially conceived as a communication medium for collaboration between users and applications, it relied on early web browsers that were limited to displaying static content to users. Web browsers now provide an increasingly rich execution platform that supports a variety of programming languages which allow web pages to respond to user input, dynamically update display screens, and issue asynchronous requests for new information. Web browsers can receive and transmit information between applications and the web browsers over the Internet in near real-time. Examples of these applications include handheld game controllers, meteorological data collection sites, webcam devices, and mobile phones and tablet computers that include cameras, Global Positioning System (GPS) receivers and removable data storage.
Despite increased sophistication and complexity of these applications, web browsers have been slow to allow low-level hardware devices to be accessed using JavaScript, the most popular client-side scripting language. This limitation has become particularly problematic as mobile processing units such as cellular phones and tablet computers include applications that leverage data from hardware devices including accelerometers, GPS receivers and removable storage. Concurrently, mobile processing units include increasingly powerful computational and storage capabilities. As the use of such mobile processing units increase, the requirement to access data from hardware devices will also increase.
In General, software programs must access hardware devices to interact with the outside world. Examples of hardware devices include hard disks, computer monitors, accelerometers, cameras, and microphones. Programs typically access hardware directly through the use of low-level assembly instructions, or indirectly through services provided by the underlying operating system. These traditional ways of device access are problematic for three reasons. First, these low-level programming interfaces are often inconsistent and difficult to use, making it hard for developers to write programs that access hardware in sophisticated ways. Second, these programming interfaces often grant the software program wide-ranging capabilities to read and write to hardware devices. If the software program is buggy or malicious, it can wreak havoc with other programs and the user's data through the improper use of hardware devices. Third, low-level interfaces make it difficult for programs to interact with devices that are not directly co-located with the machine that is running a software program. For example, accessing a locally resident microphone is easily expressed, but accessing a microphone on a remote machine is difficult to express or impossible.
Ideally, applications could access hardware devices in a location-agnostic way using network protocols. These protocols would provide a narrow, simple interface, making them easy to secure and obviating the need for a large trusted computing base such as a browser.
SUMMARY
The invention disclosed herein solves the problems discussed above by introducing a new programming model. Within this model, hardware devices are treated like a web server where client programs access the devices by sending Hypertext Transfer Protocol (HTTP) requests to the devices. More specifically, a program known as a hardware device server acts as an intermediary between a client program and each hardware device. To access a particular device, a client program sends an HTTP request to an appropriate hardware device server. The hardware device server examines the request and authenticates the client in some way. If the authentication is successful, the hardware device server accesses the particular hardware device as specified by the client program, and returns a result in a HTTP response sent to the requesting client program.
This architecture solves the three problems identified earlier. First, the programming interface is much cleaner, since all hardware devices are uniformly presented to client applications as web servers which use HTTP as a communication protocol. Second, the new architecture improves security, since clients can be sandboxed (i.e., prevented from directly accessing hardware). The hardware device server can prevent unauthorized access by safeguarding the narrow HTTP protocol. Third, since HTTP can trivially be used to access both local and remote web servers, the new architecture makes it trivial for clients to access local and remote devices in the same way.
One embodiment of the disclosed invention allows a web page to securely access hardware devices. The web page can include a device protocol translator which engages an HTTP device protocol with hardware device servers running locally or on remote machines. To access hardware, the page passes a request to the device protocol translator. The device protocol translator crafts the appropriate HTTP request and sends it to the hardware device server. If the requests are authorized, the hardware device server performs the requested actions and returns any data and status information to the requesting web page using a standard HTTP response. The device commands and responses may or may not include data. Users may authorize individual web domains to access each hardware device, and the hardware device server may authenticate each hardware request by ensuring that an HTTP referrer field represents an authorized domain. The device server may also inform the user about which domains are currently authorized and actively using the system. For example, the device server may use sensor widgets, which are small graphical icons that change their visual appearance and make a sound when hardware devices are accessed.
A hardware device server is a computing device implemented in either hardware or software that enables applications to access hardware devices by issuing HTTP requests to the hardware device server. A device protocol translator may provide an API to a web application which allows the web application to issue high-level device requests without having to know the low-level details of the HTTP device access protocol. The device protocol translator may be implemented by a JavaScript library. The hardware device server is an application which runs in a separate process on a local or remote machine. The hardware device server may receive commands from the device protocol translator, process the commands and cause designated hardware devices to respond according to the commands. To access hardware devices, applications or device protocol translators send hardware device requests to the hardware device server in the form of HTTP requests and, if the requests are authorized, the hardware device server performs the requested actions and returns any data and status information to the requesting web page with a standard HTTP response. The device commands and responses may or may not include data. Users may authorize individual web domains to access each hardware device, and the hardware device server authenticates each hardware request by ensuring that a requester represents an authorized domain.
The hardware device server does not require an associated browser to be trustworthy, and indeed, the user or the device server itself can sandbox the browser such that the browser cannot access hardware devices directly, and instead must access all such devices using the HTTP access protocol; in this fashion, the device server tightly restricts what the browser can and cannot do. However, a corrupted or malicious browser which contains snooped referrer fields from authorized user requests can send requests to the hardware device server. The hardware device server may use authentication processes to limit these attacks. Methods for authentication and authorization may include manifest authorization, security token exchanges, sensor widget notifications and iframes for device handling encapsulation. Before a web page can access hardware devices, it is desirable that any request be authenticated by the hardware device server.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description and accompanying drawings wherein:
FIG. 1A is a functional diagram of a software architecture with a web server computer connected to a processing unit and a remotely connected processing unit attached to the processing unit for controlling sensors, processors and storage devices over the Internet;
FIG. 1B is a functional diagram of a software architecture with a web server computer connected to a remotely connected processing unit for controlling sensors, processors and storage devices;
FIG. 1C is a functional diagram of a software architecture with a web server computer having an embedded hardware device server and web application for controlling sensors, processors and storage devices local to the web server;
FIG. 2A represents an exemplary hardware block diagram of a processing unit and FIG. 2B represents an exemplary hardware block diagram of a remotely connected processing unit that may communicate with the processing unit for controlling sensors, processors and storage devices;
FIG. 3 is a flow chart illustrating an exemplary implementation of the operation of API calls to a device protocol translator for controlling sensors, processors and storage devices by a hardware device server; and
FIG. 4 is a flow chart illustrating an exemplary implementation of the operation of the hardware device server.
DETAILED DESCRIPTION
The disclosed hardware device server may be a software program or equivalent hardware implementation that enables applications to access hardware devices in a manner similar to that used for accessing a web server. The hardware device server acts as a mediator between software applications and hardware devices enabling the hardware devices to be accessed by HTTP network protocols. The platform containing a hardware device of interest runs the hardware device server, which is a small program that exposes an externally visible web server interface to software applications. Other software applications may access a hardware device by sending HTTP requests to a hardware device server associated with the targeted hardware device. The hardware device server accesses the hardware on behalf of the requesting software application and sends a HTTP response back to the requesting software application. The hardware device server may or may not reside on the same platform as the requesting software application. Thus, a requesting software application may use the same HTTP protocol to access local devices and remote devices.
The following detailed description illustrates a very specific implementation of the hardware and software environment surrounding the disclosed hardware device server that is illustrated in the context of an Internet application accessing a web page running within a browser, and communicating with hardware devices using a HTTP protocol. Note, however, that the core inventive entity is not the specific implementation including the Internet and a web server. The disclosed invention describes the notion of an abstract client application, such as a web page, a C program, or a Python program, accessing hardware via HTTP messages exchanged with a hardware device server in order to access hardware devices associated with the hardware device server. It should be noted that the disclosed device server may be a standalone software program or an equivalent hardware implementation.
Software Architecture
This detailed description below is directed to methods, systems and devices that are particularly useful for accessing local sensors, processors and storage devices by processing units that may be accessed via a HTTP protocol interface. It includes descriptions of hardware and software architectures, application programming interface (API) calls for accessing sensors, processors and storage devices, authentication of hardware requests, and hardware device server implementation. These methods, systems and devices rely on a hardware device server that includes an interface to the localhost domain which uses HTTP Internet protocol as a hardware access protocol for accessing hardware devices, such as sensors, processors and storage devices. The hardware device server is a relatively simple native code application that runs in a separate process on the local machine and exports a web server interface on the localhost domain. This configuration provides device-aware, cross-platform web pages that require no installation and whose security does not depend on a huge trusted computing base such as a web browser.
FIG. 1A is a functional diagram of a software architecture 100 , where a web server computer 110 connected to a user's machine 140 via a network 118 using HTTP Internet protocol for communication 158 . The user's machine 140 includes an operating system 142 that provides services to a web browser 144 , and the web browser enables operation of the web application 146 . The web application 146 accesses a local hardware device server 156 and a remote hardware device server 124 via a device protocol translator 148 . After the web server computer 110 delivers a web application 146 to the user's machine 140 , the user 105 interacts with the web application 146 . The device protocol translator 148 is a particular client side implementation of a HTTP device protocol. The web application 146 includes the device protocol translator 148 that accepts API calls 147 from the web application 146 . The API calls 147 are described below in relation to Table 1 and FIG. 3 . The device protocol translator 148 transmits commands using HTTP protocol 154 to a local hardware device server 156 for controlling various hardware devices such as sensors 130 , processors 132 and storage devices 134 attached to the mobile hardware device 140 . The various hardware devices are hardwired to interface with the hardware device servers 124 , 156 . The device protocol translator 148 may also transmits commands using HTTP protocol 136 to the remote hardware device server 124 for controlling various hardware devices such as sensors 130 , processors 132 and storage devices 134 attached to remotely connected processing unit 120 . The transmitted commands to the hardware device servers using HTTP protocol are described below in relation to Table 2. The sensor devices 130 may include cameras, microphones, GPS devices, accelerometers, and the like. Processor devices 132 may include other processor cores, graphical processor units, floating point processors, and the like. Storage devices 134 may include internal storage or various removable storage media. The remotely connected hardware device 120 also includes an operating system 122 for controlling operation of the remote hardware device server 124 . The device protocol translator 148 may be implemented with a JavaScript library.
When a user 105 wants to access data from sensors 130 , processors 132 and storage devices 134 attached to the user's machine 140 or the remotely connected processing unit 120 , a web application 146 is sent from the web server computer 110 via the network 118 to the web browser 144 in the user's machine 140 . The web browser 144 commands the web application 146 via the device protocol translator 148 to access the sensors 130 , processors 132 and storage devices 134 connected to either the processing unit 140 or the remotely connected processing unit 120 . The device protocol translator 148 then accesses a selected hardware device 130 , 132 , 134 in either the processing unit 140 or the remotely connected processing unit 120 via the hardware device servers 124 , 156 .
The hardware device servers 124 , 156 are small native code applications that reside in separate processes from the web browser 144 . They execute hardware requests on behalf of the web application 146 via the device protocol translator 148 . The device protocol translator 148 authenticates requests from the authentication engines 128 of the hardware device servers 124 , 156 for allowing authorized web domains access the hardware devices 130 , 132 , 134 attached to the user's machine 140 and the remotely connected processing unit 120 . Device manifests, sensor widgets and authentication tokens may be used for authenticating requests. The hardware device servers 156 , 124 have to be local to the hardware devices, but not local to client host 146 .
FIG. 1B is a functional diagram of a software architecture 102 where a web server computer 112 includes a web application 160 and device protocol translator 160 connected to a remote processing device 120 . The web server computer 112 includes a web application 160 for accessing hardware devices and a device protocol translator 162 that presents an API to the web application 160 . After the web server computer 112 instantiates a web application 160 , the user 105 interacts with the web application 160 . The device protocol translator 148 is a particular client side implementation of a HTTP device protocol. The device protocol translator 162 transmits commands using HTTP protocol 136 to a hardware device server 124 within the remotely connected processing unit 120 . The hardware device server 124 is controlled by an operating system 122 and also includes an authentication engine 128 . Before a web page 160 can access hardware devices, requests must be authenticated by the authentication engine 128 by identifying a requestor as being legitimate. The web server computer 112 includes an operating system that provides services to applications running on the web server computer 112 .
FIG. 1C is a functional diagram of a software architecture 103 where a web server computer 114 includes an embedded hardware device server 188 and web application 180 for controlling sensors 130 , processors 132 and storage devices 134 local to the web server computer 114 . After the web server computer 114 instantiates a web application 180 , the user 105 interacts with the web application 180 . The web server computer 114 includes the web application 180 for accessing hardware devices and a device protocol translator 182 that presents an API to the web application 180 . The device protocol translator 148 is a particular client side implementation of a HTTP device protocol. The device protocol translator 182 transmits commands using HTTP protocol 186 to a hardware device server 188 within the web server computer 114 for controlling various hardware devices such as the sensors 130 , processors 132 and storage devices 134 attached to web server computer 114 . The device server 188 also includes an authentication engine 128 for authenticating the requestor of hardware device server requests. The web server computer 114 includes an operating system that provides services to applications running on the web server computer 114 .
Hardware Architecture
FIG. 2A and FIG. 2B are block diagrams 200 , 202 of exemplary processing units 210 , 212 for controlling sensors, processors and storage devices over the Internet and local to web server computers. FIG. 2A represents a configuration 210 with a capability of implementing the operations of a user's machine ( 140 in FIG. 1A ) and FIG. 2B represents a configuration 212 with a capability of implementing the operations of the remotely connected processing unit ( 120 in FIG. 1A and FIG. 1B ). FIG. 2B is a subset of the configuration shown in FIG. 2A , and operates in accordance with the description of FIG. 2A . The memory 250 shown in FIG. 2A may be a combination of volatile or non-permanent memory and non-volatile or permanent memory. Generally, the operating system 252 , web browser 254 and hardware device server 260 are installed in non-volatile memory. The web application 256 and device protocol translator 258 located within the web application 256 are generally downloaded and installed in non-volatile memory. The processor 220 is controlled by the operating system 252 , and controls the other functions shown in FIG. 2A . The web application interface 232 connects to a web server computer via the Internet, the remote interface 234 connects between a remotely connected processing unit and a local processing unit such as shown in FIG. 2B ( 120 in FIG. 1A and FIG. 1B ), the sensor interface 236 connects to hardware sensor devices, the external processor interface 238 connects to processor hardware devices external to the user' 210 (or 212 in FIG. 2B ), and the storage device interface 240 connects to hardware storage devices.
API Calls
The API calls merely represent examples of interfaces that a client application could invoke in order to access a hardware device server. Different applications may require definition of a different set of APIs. The API call definition is determined by the device protocol translator that connects to the hardware device server. Implementation of the device protocol translator for determining the selected API call may be by a JavaScript library.
Table 1 is a summary of exemplary API calls to a client side implementation of HTTP device protocol for accessing hardware devices via the hardware device server by a web application. FIG. 3 is a flow chart illustrating an exemplary implementation of the operation of API calls to the device protocol translator for implementation of HTTP device protocols for controlling sensors, processors and storage devices by a hardware device server. The API calls shown in Table 1 and illustrated in FIG. 3 define the interface (see 147 in FIG. 1 ) between a web application and the a device protocol translator (see 146 and 148 , respectively, in FIG. 1 ). The process is started 310 when a requester application is authenticated and a session is created 312 . All API calls require authentication and manifest validation 314 from a user to receive permission to access certain devices, as shown in the first and second set of calls in Table 1 and FIG. 3 . Authentication is used for identifying a requestor as being legitimate while the session is open. A manifest is a list of devices that a page wishes to access. A manifest validation is an authorization by a user for a requesting domain to access specific hardware devices. Before a web page can initiate hardware requests to the device protocol translator 310 , it must be authenticated via createSession ( ) 312 , which authenticated the legitimacy of the web page. Then it must send its device manifest to the hardware device server via requestAccess ( ) 314 . The hardware device server presents the manifest to the user and asks for validation of the requested hardware permissions if the user has not previously validated the hardware permissions to the hardware device server. Prior to granting each device request, each request is requires authentication and validation 312 , 314 , 340 . Upon completion of a session and there are no more requests 340 , the API call destroySession ( ) cancels authentication 348 and ends the session 350 . If the hardware device server does not receive a valid authentication or manifest validation, it ignores the createSession ( ) call.
TABLE 1
CALL
DESCRIPTION
1
createSession ( )
Authenticate requester.
destroySession ( )
Cancel authentication.
2
requestAccess (manifest)
Ask for permission to access
certain devices.
3
singleQuery (name, params)
Get a single sensor sample.
continuousQuery (name,
Start periodic fetch of sensor
params, period)
samples.
4
startSensor (name)
Turn on sensor.
stopSensor (name)
Turn off sensor.
sensorAdded (name)
Upcall fired when a sensor is
added.
sensorRemoved (name)
Upcall fired when a sensor is
removed.
getSensorList ( )
Get available sensors.
5
enqueueKernel (kernel)
Queue a computation kernel
for execution.
setKernelData (parameters)
Set the input data for the computation
pipeline.
executeKernels ( )
Run the queued kernels on the input
data.
6
put (storename, key, value)
Put value by key.
get (storename, key)
Get value by key.
Sensor API
The API may control several device types 316 . To provide access to sensors 318 like cameras, accelerometers, and GPS units and the like, the API provides a single-sample query interface 324 , 344 and a continuous query interface 324 , 330 as shown in the third set of calls in Table 1 and in FIG. 3 . The API calls singleQuery (name, params) and continuousQuery (name, params, period) accept an application-defined callback which is invoked when the data has arrived from the sensor. The data, for example, may be picture information if the sensor is a camera or position information if the sensor is a GPS receiver. The singleQuery (name, params) call accepts the name of the sensor device to query and a device-specific params value which controls sensor-specific properties such as audio sampling rate of data from a microphone. The continuousQuery (name, params, period) call also accepts the name of the sensor device to query and a device-specific params value, and also includes an additional parameter representing the period of the sampling rate frequency for continuous query calls when the continuous query is started 330 .
The fourth set of calls in Table 1 and shown in FIG. 3 provide a sensor management interface. The API calls startSensor (name) and stopSensor (name) provide power controls that allow a web page to turn on or shut off devices that is not needed. The hardware device server ensures that a device is left on if at least one application still needs it. The API calls sensorAdded (name) and sensorRemoved (name) let applications register callbacks which provide notification to the application when devices arrive or leave. These events are common for off-platform devices such as Bluetooth headsets and some shoe sensors that track motion and distance traveled of the individual wearer. Inserting and removing USB port devices may also cause callbacks to provide notification of this status in some applications. The API call getSensorList ( ) produces a list of all available sensors available to a hardware device server.
Processor API
Multi-core processors and programmable GPUs 320 are available on desktops and transitioning to mobile devices. Simple multi-processor computing models are available for exporting to mobile devices. A kernel represents a computational task to run on a core. Kernels are restricted to executing two types of predefined functions, primitive functions and built-in functions. Primitive functions are geometric, trigonometric, and comparator operations. Built-in functions are higher-level functions that have been identified as being particularly useful for processing hardware data, and may include the use of primitive functions. For example, built-in functions may include Fast Fourier Transform signal transforms and matrix operations.
Considering the fifth set of calls in Table 1, a web page passes a kernel to the API by calling enqueueKernel (kernel), 326 as shown in FIG. 3 . To execute a parallel vector computation with that kernel, the web page calls setKernelData (parameters) with vector arguments 332 . A new copy of the kernel will be instantiated for each argument, the kernels being run in parallel. A web page can also create a computational pipeline by calling enqueueKernel (kernel) multiple times with the same or different kernel. The kernels inputs and outputs will be chained in the order that the kernels were passed to enqueueKernel (kernel). The web page sets the input data for the pipeline by passing a scalar value to setKernelData (parameters). Once an application has created its kernels and set their input data, it calls executeKernels ( ) to start the computation to run the queued kernels on the input data 336 . The kernels are distributed to various cores in the system, cross-kernel communication is coordinated, and an application-provided callback is executed when the computation is complete 342 .
Storage API
The sixth and final set of API calls in Table 1 and FIG. 3 provide a key/value storage interface 322 . The namespace is partitioned by web domain and by storage device. A web domain can only access data that resides in its partitions. To support removable devices, connection and disconnection notification events are provided similar to off platform sensors. The API call put (storename, key, value) stores a value by key in storename 328 , 346 , and get (storename, key) accesses a value by key in storename 338 .
Authenticating Hardware Requests
Privilege separation is used to provide a web page with hardware access while reducing security vulnerabilities. It lets parts of an application run with different levels of privilege, which may be used to prevent non-privileged or low-privileged parts of an application from gaining unauthorized access to parts with higher privileges. The web page and an enclosing web browser that executes the page's code are both considered to be untrusted. The web browser is placed in a sandbox which limits its access to certain services, including preventing direct access to hardware devices controlled by the hardware device server. The small, native code hardware device server resides in a separate process from the web browser, and executes hardware requests on behalf of the device protocol translator embedded within the web page application and browser, exchanging data with the device protocol translator via HTTP protocol and HTTP commands. The device protocol translator defines and implements the API described above. It provides for authentication purposes and translates page-initiated hardware requests into HTTP fetches. The hardware device server requires three housekeeping tasks to occur prior to enabling access to the hardware devices. These tasks include manifest authorization, session establishment and session teardown. It should be noted that remote or off-platform devices (see 120 in FIG. 1 ) are seamlessly accessed in the same manner as the local devices.
FIG. 4 is a flow chart illustrating an exemplary implementation of the operation of a hardware device server. It represents an exemplary life cycle of a session of the hardware device server. At the start of a session 410 , the hardware device server receives request to create a session 415 . To create a session, a manifest validation 425 and requester authentication 435 are required to allow access to certain devices. A manifest validation 425 is an authorization by a user for allowing a requesting domain to access specific hardware devices. Upon receipt of a request for a session 415 by the hardware device server from a web page, the web page includes a device manifest in its HTTP request. The manifest is merely a list of devices that the page wishes to access. The hardware device server compares the received manifest with previously stored authenticated manifests 420 . If a match is found between the received manifest and a stored manifest 430 , the next step of creating a new capability token and sending it to the requesting domain 435 is conducted. If a match is not found 430 (normally because this is the first time the web page is requesting a session), the hardware device server presents this new manifest to the user ( 105 in FIG. 1 ) and requests a grant of the specified access permissions to the web page's domain 440 . If the requested manifest permission is authenticated by a grant from the user 450 , the hardware device server stores the authenticated manifest 460 in a database and continues to the next step of requesting authentication from the user 435 . If the user does not authenticate the request, the session is ended 490 . If a web page requests access to a new device, the manifest will be authenticated as previously described. Subsequent web page requests 480 for devices in the manifest will not require explicit user action. The manifest validation and request authentication 465 are implemented by the authentication engine ( 128 in FIG. 1 ) within the hardware device server.
If the manifest is authorized 450 , the hardware device server sends an authentication request to the requesting domain 435 . Any subsequent request by the requesting web page must be authenticated by comparing the received authentication with a previously stored corresponding authentication 470 . Authentication must be received 445 before a session may be established 455 .
Before a web page can open a session and initiate hardware requests to the device protocol translator, it must get a new authentication from the hardware device server 435 . Once a session is established 455 , each request must be authenticated 465 by comparing the received authentication with a corresponding authentication stored in memory 470 . If a mapping does not exist between the received authentication and that stored in memory, the request is ignored by the hardware device server 470 , 485 . Authentication identifies a requestor as being legitimate for every request made while the session is open. If a mapping does exist between the received authentication and that stored in memory 470 , the request is validated and the appropriate hardware device is accessed 475 . If additional requests are made 480 , another authentication 465 is required. Upon receipt of a request to terminate the session 480 , access to the selected hardware device is terminated and the session is ended 485 .
Since the hardware device server receives requests expressed as HTTP fetches, a natural way for the hardware device server to authenticate requester identification is to inspect the referrer field in the HTTP request. This is a standard HTTP field which indicates the URL, and thus the domain, of the page that generated the request. Unfortunately, a misbehaving browser can subvert this authentication scheme by examining which domains successfully receive hardware data, and then generating fake requests containing these snooped referrer fields. This is essentially a replay attack on a weak authenticator.
To prevent these replay attacks, the hardware device server grants authentication to each authorized domain to prevent access by unauthorized domains. Before a page in a trusted domain can access the hardware device server, it must send a session establishment message 415 to the hardware device server. The hardware device server examines the referrer of the HTTP message and checks whether the domain has already been granted authentication. If not, the server generates an authentication, stores the mapping between the domain and that authentication, and sends the authentication to the page. Later, when the page sends an actual hardware request to establish a session 455 , it includes the authentication in its HTTP request. If the authentication does not match the mapping found in the hardware device server's table 470 , the hardware device server ignores the hardware request 485 . If the authentication does match 470 , a session may be established 455 and access to sensors, processors and storage devices is enabled 475 .
A page sends a session tear down message to the hardware device server 480 when it no longer needs to access hardware attached to the hardware device server. Upon receipt of the tear down message 480 , the server deletes the relevant domain/token mapping and the session ends 485 . The device protocol translator detects when a page is about to unload by registering a handler for the device protocol translator unload event.
Given the capability scheme, a misbehaving browser that can only spoof referrers cannot fraudulently access hardware, since the browser must also steal another domain's token or retrieve a new one from the hardware device server. However, nothing prevents a browser from autonomously downloading a new authentication in the background under the guise of an authorized domain, and then using this authentication in its HTTP request to the hardware device server.
Although the device protocol translator hides the details of the HTTP protocol used for accessing the hardware device server from the web application, the web application can still issue HTTP requests directly to the hardware device server without going through the device protocol translator. This may disrupt logic in the device protocol translator that buffers device output or otherwise attempts to optimize device accesses. If the browser is not compromised, access attempts can be forced to go through the device protocol translator using techniques by splitting the device protocol translator into two pieces, the public component that exports a standardized interface and a private component that is generated by the hardware device server and handles platform-specific optimizations and quirks. For example, if the device protocol translator is implemented as a JavaScript library running inside a web browser, the library can create an HTML frame in the localhost domain that cannot be accessed by the outer application frame that runs in the domain of the application's originating web server. The private component can be placed in the localhost frame, and the public component can be placed in the enclosing application frame, allowing the two frames to pass messages to each other, but keeping secrets in the localhost frame safe from the untrusted outer frame. The application passes device access requests to the public component; in turn, the public component passes the request to the private component. The private component, which has established a secret with the device server, includes this secret in the forwarded application-generated device request. Thus, the device server can detect that the request originated from the private component, and not from a web application that is trying to directly issue requests without going through the device protocol translator.
Hardware Device Server Implementation
The device protocol translator encodes device requests to the hardware device server as HTTP commands using simple XML strings embedded in HTTP requests. Whereas API calls ( 147 in FIG. 1 ) constitute the interface between a web application ( 146 in FIG. 1 ) and the device protocol translator ( 148 in FIG. 1 ), the HTTP commands ( 154 and 136 in FIG. 1 ) described herein constitute the interface between the device protocol translator ( 148 in FIG. 1 ) and the hardware device server ( 156 and 124 in FIG. 1 ). The API calls shown in Table 1 and illustrated in FIG. 3 define the interface (see 147 in FIG. 1 ) between a web application and the device protocol translator (see 146 and 148 , respectively, in FIG. 1 ). The device protocol translator ( 148 in FIG. 1 ) transmits commands using HTTP protocol ( 154 and 136 in FIG. 1 ) to a local hardware device server and remotely connected hardware device server ( 124 and 156 in FIG. 1 ) for controlling various hardware devices. The commands using HTTP protocol are described below in relation to Table 2. Table 2 is an XML template for accessing the hardware device server.
An exemplary XML string for a command sent to a hardware device server from a device protocol translator requesting an action and a corresponding result sent from the hardware device server to the device protocol translator that includes audio data generated by a microphone are shown in Table 2. Each request includes a command and a corresponding result. A command may include a security authenticate as described above, an action to be performed such as “record”, a target device such as a “microphone”, and optional device-specific params field such as recording “durationLength” and optional data field to be sent to recipient devices such as memory devices. The optional data field is not used in this example. When a hardware device server responds to a command, the responses are also encoded as a simple XML string. In response to the exemplary command shown in Table 2, a result may be returned to the device protocol translator from the hardware device server that may include a value field indicating whether the associated command succeeded or failed. The result may also include a data field such as the requested audio data from a microphone.
TABLE 2 <command> <authenticate>0fdb53ac3d2...</authenticate> <action>record</action> <device>microphone</device> <params>durationLength=10</params> <data></data> </command> <result> <value>OK</value> <data>bcd32abfe029e...</data> </result>
On the client side, the device protocol translator encapsulates the low level decoding routines and other protocol functionality and responds to API calls from a web page with any requested data or status information.
Although the subject matter has been described in language specific to structural features and methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | In the new architecture, a client that desires access to a piece of hardware sends HTTP requests to a device server. The server receives a HTTP requests, accesses a device on behalf of the client, and send the device's response back to the client in the form of an HTTP response. This architecture has three primary advantages. First, it offers a clean interface for clients where all devices are accessed as if they are web servers. Second, it helps make devices more secure whereby clients can be prevented from accessing hardware directly, and all device access is forced through the narrow HTTP access protocol and checked for compliance with a desired security policy. Third, since HTTP allows local and remote servers to be contacted, the proposed architecture makes it easy for clients to communicate with devices that are not physically co-resident with the client but which are accessible via a network connection. | 7 |
This application claims the benefit of Provisional application Ser. No. 60/282,967, filed Apr. 11, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to organic-inorganic hybrid composites which have unique and useful electronic and optical properties. More specifically, the invention relates to II-VI semiconducting chalogenides with modified structures and properties based upon the incorporation of organic components via coordination or covalent bonds.
Group II-VI semiconducting chalcogenide compounds such as CdTe and ZnSe are of great interest currently for use in semiconductor devices because of their relatively wide band gaps. Semiconductor nanostructures with uniform arrangement, such as periodic arrays of quantum dots, are necessary to achieve a sharp line width and strong intensity for practical applications in optoelectronic devices. Quantum dots grown by colloidal methods are highly attractive because of their small size and strong capability for modifying electronic and optical properties of semiconductor bulk materials. For example, InP dots with sizes ranging from two to six nanometers in diameter can shift optical gaps by as much as one electron volt. The great challenge, however, is to generate uniformly sized dots and to organize them into periodic arrays in order to obtain sharp line width, and control over intensity and other optical properties. Self-assembled strain dots have some uniform structures, but their ability to change optical properties is severally limited. This substantially restricts their uses.
There remains a need for quantum confined systems combining uniformity in structure with the ability to significantly modify the electronic and optical properties of semiconducting materials.
SUMMARY OF THE INVENTION
This need is met by the present invention. Applicants have discovered a new type of quantum confined nanostructures that are not only capable of modifying optical, electronic and other properties of a semiconductor on the same large scale as colloidal dots, but also present uniform structures that are particularly advantageous to device making. Compounds of the present invention are covalent or coordinate bonded organic-inorganic hybrid materials with a uniform, periodic nanostructure exhibiting significant quantum confinement effects.
The structures of the hybrid materials of the present invention are constructed in such a way that they contain uniformly sized II-VI semiconductor fragments as sources of the desired semiconductor functionality, and organic spacers as links or nodes to the inorganic fragment motifs in an ordered fashion. The quantum confinements induced in such systems are unusually strong, as a result of highly confined, single-atomic inorganic layers with a thickness less than one nanometer. This leads to a significant blue shift in their optical absorption edges (as high as 1.2-1.5 electron volts), compared to 1.0 electron volt shift obtained by the best-grown III-V and II-VI semiconductor quantum dots.
Therefore, according to one of the embodiment of the present invention, a quantum confined system is provided that is a crystalline organic-inorganic hybrid compound containing alternating layers of a bifunctional organic ligand and a II-VI semiconducting chalcogenide, wherein:
the semiconducting chalcogenide has the formula MQ, in which M represents one or more II-VI semiconductor cationic species and Q is a chalcogen element selected from S, Se or Te; and
the bifunctional organic ligands of each organic ligand layer are bonded by a first functional group to an element M of an adjacent II-VI semiconducting chalcogenide layer and by a second functional group to an element M from the adjacent opposing II-VI semiconducting chalcogenide layer so that the adjacent opposing II-VI semiconducting chalcogenide layers are linked by the bifunctional organic ligands of the organic ligand layers.
Among the bifunctional organic ligands, organic diamines are preferred, with organic diamines having the formula R—(NH 2 ) 2 being more preferred, with R being C 2 -C 6 straight-chained or branch, substituted or unsubstituted, saturated or unsaturated aliphatic or cycloaliphatic hydrocarbons.
For purposes of the present invention, quantum confined systems are defined as systems exhibiting electronic confinement in at least one dimension. This includes systems that function as quantum wells by exhibiting electronic confinement in one dimension, systems that function as quantum wires by exhibiting electronic confinement in two dimensions, and systems that function as quantum dots by exhibiting electronic confinement in three dimensions.
Furthermore, II-VI semiconducting chalcogenides are defined according to their well-understood meaning, in which the term chalcogenide is limited to S, Se and Te, and the semiconductor has a zinc blende or wurtzite structure. Cationic species of such semiconductor compounds include Zn, Cd, Hg and Mn.
The quantum confined systems of the present invention are prepared by a method that organizes periodic three-dimensional II-VI semiconductor host lattice segments between organic layers by way of stable coordinate or covalent bonds in an ordered manner. Because the quantum confinement effect induced in the hybrid composite materials of the present inventions is the result of inherent structural properties, the restriction on size distribution is lifted and the synthesis methods of present invention can be used to generate particles of unlimited size, with no effect upon their electronic and optical properties. This is in contrast to the properties of nanoparticles grown by colloidal methods, which depend strongly on particle size, and which are formed via uncorrelated nucleus cores, making it difficult to generate particles with the requisite narrow size distribution and ordered structure.
Therefore, according to another aspect of the present invention, a method is provided for the preparation of the crystalline, covalent or coordinate bonded, organic-inorganic hybrid chalcogenide quantum confined systems of the present invention, in which a mixture is heated containing:
(a) a salt of a II-VI semiconductor cationic species; (b) a chalcogen selected from S, Se and Te; and (c) a bifunctional organic compound capable of covalent or coordinate bonding with the cationic species;
at a temperature effective to form the hybrid chalcogenide, until the hybrid chalcogenide is formed.
The alternating semiconductor and organic layers of the hybrid material of the present invention, prepared by the methods described herein, mimic a superlattice structure. However, unlike the conventional semiconductor superlattices where the band offset introduces only a weak confinement, the insulating organic layer will impose a strong confinement on the semiconductor layer, giving rise to a large variation with respect to the bulk semiconductor properties. In addition, the hybrid organic-inorganic nature of the composites of the present invention provides advantages, features and properties that are important for the miniaturization of electronic and optical devices. Representative features include superior electronic and optical properties, as well as rigidity and stability provided by the inorganic component, and high processibility, flexibility, weight reduction and structural diversity provided by the organic component. Therefore, according to another aspect of the present invention, a semiconductor device is provided containing multiple layers of the crystalline organic-inorganic hybrid compounds of the present invention. The semiconductor devices of the present invention are fabricated by known techniques.
As can be appreciated by one skilled in the art, variation of the II-VI semiconducting chalcogenide and bifunctional organic compounds will provide a broad range of hybrid compounds exhibiting a wide range of properties
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a diagrammatic representation of the crystal structure of [α-ZnTe(ethyl-enediamine), ½ ] (I) shown along the b-axis;
FIG. 1 b is a diagrammatic representation of the inorganic slab in I shown along the c-axis;
FIG. 2 a is a diagrammatic representation of [β-ZnTe(ethylenediamine) ½ ] (II) shown along the c-axis;
FIG. 2 b is a diagrammatic representation of the inorganic slab in II shown along the b-axis;
FIG. 3 is a graphic depiction of the optical absorption spectra of compounds I, II, ZnTe(1,3-propanediamine) ½ ] (III) and bulk ZnTe.
FIG. 4 a is a diagrammatic representation of the crystal structure of [MnSe(ethyl-enediamine) ½ ] (IV) shown along the b-axis;
FIG. 4 b is a diagrammatic representation of the inorganic slab in IV shown along the c-axis;
FIG. 5 a is a diagrammatic representation of the crystal structure of [MnSe(1,3-propanediamine) ½ ] (V) shown along the c-axis;
FIG. 5 b is a diagrammatic representation of the inorganic slab in V shown along the a-axis; and
FIG. 6 is a graphic depiction of the optical absorption spectra of [ZnSe(ethyl-enediamine) ½ ] (VI, dotted line), [ZnSe (1,3-propanediamine) ½ ] (VII, doffed dash), and bulk ZnSe(Stilleite, solid line).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The inorganic portion of the hybrid compounds of the present invention is a II-VI semiconducting chalcogenide having the formula MQ, where M is a II-VI semiconductor cationic species and Q is a chalcogen selected from S, Se and Te. M is preferably selected from among the above-listed cationic species, and more preferably, M is Zn or Cd. Q is a chalcogen selected from S, Se and Te. Q is preferably Se or Te.
As noted above, the bifunctional organic ligand is preferably an organic diamine having the structure R—(NH 2 ) 2 , wherein R a C 2 -C 6 straight-chained or branched, substituted or unsubstituted, saturated or unsaturated, aliphatic or cycloaliphatic hydrocarbon. Particularly preferred organic diamines are ethylenediamine and 1, 3-propanediamine.
The hybrid compounds of the present invention are prepared by the reaction of metal salts of one or more II-VI semiconductor cationic species, for example, a halide, sulfate or nitrate salt, with one or more chalcogen elements selected from S, Te and Se, optionally in the form of A 2 Q (A=alkali metal, Q═S, Se or Te). Preferred cationic species include Zn and Cd. The metal salt and the chalcogen are reacted in the presence of the bifunctional organic compounds, with the molar ratio of metal to chalcogen being between about 4:1 and about 1:1. Preferably, the molar ratio is between about 2:1 and about 1:1.
The bifunctional organic compounds may serve the dual functions of solvent and reactant. However, the invention also encompasses methods wherein an inert solvent such as water, dimethylformamide, and the like are employed. In a preferred embodiment, the bifunctional organic compound serves as reactant and solvent wherein the molar ratio of metal salt to chalcogen to bifunctional organic compound is a ratio between about 2:1:5 and about 2:1:600.
Selected changes in the molar proportions of reactants provide desired changes in the chemical and/or physical properties of the inventive compounds, including, for example, the thickness of the hybrid structure, the selection for which is readily understood by those skilled in the art. In a preferred embodiment in which the bifunctional organic compound functions as both reactant and solvent, the molar proportion of the bifunctional organic compound is about 5 to 600 times that of the amount of chalcogen employed.
The compounds of the present invention are prepared in closed or sealed vessel, such as a stainless steel acid digestion bomb. The reactions are carried out under an elevated pressure of about three to four atmospheres up to about 100 atmospheres.
Suitable reaction temperatures range from 100° to about 220° C., and preferably from about 120° to about 180° C., and the reaction period is suitably from about one to ten days.
Solid products are collected by conventional means, washed free of starting materials and impurities with appropriate solvents such as alcohol-water, and then dried with an anhydrous solvent such as ethyl ether.
In an alternative embodiment, the II-VI semiconductor chalcogenide component is provided as a precursor which is reacted directly with the bifunctional organic compounds at elevated temperatures and pressure to form the compounds of the present invention. For example, the II-VI semiconducting chalcogenide can be reacted with ethylenediamine or 1, 3-propanediamine at 200° C. for three days.
The compounds of the present invention may be configured into structures that are useful in the fabrication of electrical and optical devices by conventional means. For example, the compounds of the present invention may be formed into structures that function as quantum dots, quantum wells and quantum wires. Generally speaking, the compounds of the present invention will find applications in devices where these quantum confined structures are useful. These include, but are not limited to, interlayer dielectric devices in microelectronics, thermoelectric devices for cooling, beating and generating electricity, and quantum well laser structures useful in optoelectric devices for the generation or modulation of light radiation, including the modulation of light radiation for the transmission of information. The semiconductor compounds of the present invention may also be used in infra-red photodetectors, lasers for spectroscopic and fiber optic applications, electroluminescent lasers and electronic phosphors.
The following non-limiting examples set forth hereinbelow illustrate certain aspects of the invention. All parts and percentages are molar unless otherwise noted and all temperatures are in degrees Celsius.
EXAMPLES
Materials and Instruments. MnCl 2 (97%, Alpha Aesar), ZnCl 2 (98%, Aldrich), Zn(NO 3 ) 2 .6H 2 O (99.7%, Fisher), Se (99.5%, Strem), Te (99.8%, Strem), ethylenediamine (99%, anhydrous, Aldrich), and 1, 3-propanediamine (98%, anhydrous, Alfa Aesar) were used as received without further purification. Powder X-Ray Diffraction (PXRD) of samples was performed on a Rigaku D/M-2200T automated diffraction system (Ultima + ). The structure analyses were carried out using JADE (Windows) and GSAS software packages. The calculated PXRD patterns were generated from the single crystal data. Optical diffuse reflectance spectra were measured at room temperature with a Shimadzu UV-3101PC double beam, double monochromated spectrophotometer. Thermogravimetric analyses (TGA) were performed on a computer controlled TA Instrument TGA-2050 system.
Example 1
Preparation of [α-ZnTe(Ethylenediamine) ½ ] I
To a 23 mL acid digestion bomb was charged 0.272 g ZnCl 2 (2 mmol), 0.128 g Te (1 mmol) and 6 mL ethylenediamine. The mixture was allowed to react at 200° C. for a period of three days. A solid product was collected, washed with 30 and 80% ethanol, and then dried in anhydrous ethyl ether giving brownish column-like crystals of the title compound in 90.0% yield.
Example 2
Preparation of [β-ZnTe(Ethylenediamine) ½ ] II
A reaction mixture of 0.595 g Zn(NO 3 ) 2 .6H 2 O (2 mmol), 0.128 g Te (1 mmol), and ethylenediamine (6 mL, 90 mmol) was heated in a 23 mL acid digestion bomb at 190° C. for three days. A solid product was collected, washed with 30 and 80% ethanol, and dried in anhydrous ethyl ether, affording brownish platelike crystals of the title compound (92.4% yield).
Example 3
Preparation of [ZnTe(1,3-Propanediamine) ½ ] III
The title compound was prepared as in Example 2 with the exception that 1,3-propanediamine (5 mL, 60 mmol) was used in place of ethylenediamine and the reaction temperature was 200° C. The title compound was obtained in 91.3% yield.
Example 4
Preparation of [MnSe(Ethylenediamine) ½ ] IV
Single crystals of IV were obtained by the solvothermal reaction of 0.063 g MnCl 2 (0.50 mmol) and 0.020 g Se (0.25 mmol). The starting materials were weighed and mixed, and then transferred to a thick-walled Pyrex tube, after which 0.4 mL ethylenediamine was added. After the liquid was condensed by liquid nitrogen, the tube was sealed with a torch under vacuum (about 10 −3 Torr). The sample was then heated at 160° C. for seven days. After being cooled to room temperature, the mixture was washed with 30% and 80% ethanol followed by drying in anhydrous ethyl ether. Orange-reddish plate-like crystal (0.040 g, 96.3% yield based on Se) of IV were obtained.
Example 5
Preparation of [MnSe(1, 3-Propanediamine) ½ ] V
The reaction of MnCl 2 (0.0310 g, 0.25 mmol), Se (0.020 g, 0.25 mmol) and 1, 3-propanediamine (0.4 mL) in an molar ratio of 1:1:19 at 125° C. for twelve days in thick-walled Pyrex tubes afforded orange plate-like crystals of V (0.031 g, 71.6% yield based on Se). The same experimental procedure used for the synthesis of IV was applied here.
Example 6
Preparation of [ZnSe(Ethylenediamine) ½ ] VI
Compound VI was obtained from the reaction of ZnCl 2 (0.273 g, 2 mmol), Se (0.079 g, 1.0 mmol) and ethylenediamine (5.0 mL) in a molar ratio of 2:1:75 in a 23 mL acid digestion bomb at 140° C. for eight days. The product was washed with 30% ethanol and water followed by drying in anhydrous ethyl ether. A tan powder of VI (0.155 g, 88.9% yield based on Se) was isolated.
Example 7
Preparation of [ZnSe(1, 3-propanediamine) ½ ] VII
Compound VII was prepared from the reaction of ZnCl 2 (0.273 g, 2.0 mmol), Se (0.079 g, 1.0 mmol) and 1, 3-propanediamine (6.0 mL) in a molar ratio of 2:1:75 in a 23 mL acid digestion bomb at 140° C. for eight days. The product was washed with 30% ethanol and water followed by drying in anhydrous ethyl ether. A tan powder of VII (0.130 g, 71.7% yield based on Se) was isolated.
CRYSTAL STRUCTURE OF I-VII
Single crystal X-ray diffraction analysis of compound I revealed a crystal structure of a three-dimensional network containing inorganic monolayers of ZnTe that are interconnected by bridging ethylene diamine molecules. The inorganic slab of each monolayer is in the form of a honeycomb network of Zn and Te interconnected by coordinate bonds to the organic spacer, ethylenediamine (see FIG. 1 ). The slab can also be regarded as a slice cut from the parent zinc blende or wurtzite-type structure of ZnTe. Each Zn atom within the slab achieved a stable tetrahedral configuration through four bonds, three with adjacent Te atoms and the fourth with a nitrogen atom of the ligand bridge as shown in FIGS. 1 a and 1 b . The compound [β- ZnTe(ethylene-diamine) ½ ] II is a polymorph of I. Its crystal structure is depicted in FIG. 2 .
Compound IV is isostructural to I. FIG. 4 a illustrates a view of IV along the b-axis. Structure V is isostructural to III. As depicted in FIG. 5, the inorganic slabs in IV and V are almost identical in the two structures. The only difference is in the organic pillars, with ethylenediamine in IV and 1, 3-propanediamine in V. Compounds VI and VII are isostructural to I (and IV), and III (and V) respectively. The MSe slabs (M═Mn, Zn) have a thickness that falls well below the nanometer regime (e.g. 0.262 and 0.265 nm for IV and V, respectively). In fact this thickness is at a single atomic monolayer, the smallest possible length scale that can be achieved by a quantum confined II-VI system. These highly correlated, yet well separated nanometer-sized semiconductor fragments thus represent an unprecedented type of nanostructure with a very strong quantum confinement effect.
OPTICAL ABSORPTION SPECTROSCOPY
The optical absorption spectra of compounds I, II and III were compared graphically in FIG. 3 with the spectrum of bulk ZnTe. The analyses were conducted by diffuse reflectance using a Shimadzu UV-3101 PC double-beam, double monochromator spectrophotometer. The results show a substantial blue shift of 1.2-1.4 eV for the three hybrid compounds as compared to bulk ZnTe.
The optical absorption spectra of VI and VII were measured by the same experimental method, with the results depicted in FIG. 6, along with that of ZnSe(Stilleite). The absorption edges for VI and VII are found to be 4.0 and 3.9 eV, respectively. Compared to the measured value of 2.5 eV for ZnSe(Stilleite), it clearly indicates a very large blue shift (1.4-1.5 eV), one that has not been achieved by any chemically grown colloidal dots. The optical properties of IV and V were also assessed by the same experiments conducted at room temperature. The estimated absorption edges are 1.8 and 1.7 eV for IV and V, respectively, compared to about 1.6 eV measured for the α-MnSe bulk sample (NaCl structure). Note that this value is somewhat smaller than the previously reported E g for MnSe. While ZnSe and ZnTe-based hybrid compounds (I-III, VI, VII) exhibit significant changes (1.2-1.5 eV) in their optical absorption edge, it is noted that IV and V give rise to changes in the same direction (increase in energy) with respect to bulk MnSe, but to a much smaller extent (0.1-0.2 eV). This is attributable to the Mn 3d bands that are highly localized and, therefore, the quantum confinement induced by organic spacers via coordinate bonds leads to a much smaller variation in these bands.
THERMAL PROPERTIES
The thermogravimetic analyses were performed on polycrystalline samples of VI and VII. Both compounds underwent a single-step weight loss process and were thermally stable up to 250° C. The measured weight losses of the organic species are 17.7% (2.006 mg) for ethylenediamine (VI) and 21.9% (2.270 mg) for 1, 3-propanediamine (VII), respectively, in excellent agreement with the calculated values, 17.3% for ethylenediamine and 20.4% for 1, 3-propanediamine, respectively. The decomposition process completed at approximately 400° C. for both VI and VII. Powder X-ray diffraction analysis immediately following the thermogravimetric experiments showed that the residues of both samples contained two isomorphic phases of ZnSe, with the major phase being wurtzite structure (P6 3 mc) and the minor one, zinc blende structure (F 4 3 m, Stilleite). The optical diffuse reflectance measurement gave an estimated band gap of about 2.7 eV for ZnSe of the wurtzite structure, indicating a small blue shift of 0.2 eV with respect to ZnSe of the zinc blende structure.
The foregoing examples demonstrate that an unprecedented type of nanostructure with both strong quantum confinement and periodic arrangement can be synthesized in high yield. Other II-VI semiconductors have also been determined to form the same type of hybrids with strong quantum confinement effects being a general phenomenon in the systems. The quantum confined systems of the present invention are particularly advantageous because the electrons are confined within the thin semiconductor slabs by coordinated organic spacers, which direct and organize the semiconductor slab into an ordered, crystalline three-dimensional lattice rather than be uncorrelated nanoparticles as in the case of colloidal dots. Because such confinements are induced internally as a consequence of inherent structural properties, there is no dependence upon particle size. Consequently, new hybrid nanostructures can be prepared by means of ordinary synthetic routes without limitation or restriction on their physical dimensions, in contrast to quantum dots to which size distribution directly effects performance. This uniformity in structure and the capability for modification of material properties makes the hybrid materials of the present invention ideal materials for new-generation nanodevices.
Numerous variations and combinations of the features described above can be utilized without departing from the invention. For example, modifications in the II-VI semiconductor bulk structure have been explored by varying the thickness of inorganic slabs (n) between the organic ligand layers. While the strongest quantum confinement effect was achieved at n=1, synthesis of hybrid structures having n greater than one allow a controllable tuning of electronic electrical properties. The foregoing examples and description of the preferred embodiment should be taken as illustrating, rather than as limiting the present invention as defined by the claims. | Hybrid crystalline organic-inorganic quantum confined systems are disclosed, which contain alternating layers of a bifunctional organic ligand and a II-VI semiconducting chalcogenide, wherein the semiconducting chalcogenide layers contain chalcogenides have the formula MQ, in which M is independently selected from II-VI semiconductor cationic species and Q is independently selected from S, Se and Te; and the bifunctional organic ligands of each organic ligand layer are bonded by a first functional group to an element M of an adjacent II-VI semiconducting chalcogenide layer and by a second functional group to an element M from the adjacent opposing II-VI semiconducting chalcogenide layer, so that the adjacent opposing II-VI semiconducting chalcogenide layers are linked by the bifunctional organic ligands of the organic ligand layers. Optical absorption experiments show that these systems produce a significant blue shift in their optical absorption edges, 1.2-1.5 eV, compared to a shift of 1.0 electron volt by the best grown II-VI or II-V semiconducting quantum colloidal dots. In addition, the II-VI confined layers in these systems possess a perfectly periodic arrangement. | 2 |
This is a continuation of application Ser. No. 350,725 filed May 12, 1989, and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to domestic appliances and more particularly to a support structure for a combined washer/dryer appliance with a front loading dryer positioned above a top loading washer.
The vertical arrangement of washers and dryers is known in the art wherein substantially complete and independent washer and dryer appliances are stacked one above the other with various support elements carrying the load of the upper appliance. Such an arrangement is employed to conserve floor space and increase the ease of use of the appliances by positioning the openings of the two appliances closely adjacent to one another to reduce movement required by the operator while moving articles from one appliance to the other. Such a stacked arrangement is disclosed in U.S. Pat. No. 2,793,518.
U.S. Pat. Nos. 4,507,942, and 4,680,948 disclose external support brackets or carriers for stacking a front loading dryer above a top loading washer. These external support systems apparently rely on the lower appliance cabinet for structural support of the upper cabinet. The lower appliance cabinet must support operating and handling loads and can permanently deform when the machine is being moved about.
U.S. Pat. No. 4,454,732 discloses a structural assembly for stacking two appliances. This assembly transfers the upper appliance weight to supporting feet. The lower appliance is supported by separate and independent supporting feet.
SUMMARY OF THE INVENTION
The present invention relates to domestic appliances and more particularly to a vertically arranged washer/dryer combination appliance wherein a single appliance, having multiple components, such as a washer component and a dryer component, is constructed as a unitary appliance onto a single support frame.
It is an object of the invention to provide a support structure for a unitary appliance which adequately supports the combination appliance during transportation and during usage; which improves operating performance as compared to stacked type appliance structure concepts; and which accomplishes these tasks without compromising the unitary appliance characteristics of the appliance cabinetry. In a structural support system as initially described, these objectives are accomplished in that:
1. A structural support system consisting of vertical, horizontal and diagonal framing members provides overall vertical support rigidity. Vertically arranged combination appliances are more susceptible to handling damage because of their bulk and weight. In a unit without the internal structure utilized by the present invention, the cabinetry of the appliance must support operating and handling loads, and can be permanently deformed when the machine is being moved about. The present invention alleviates this problem.
2. The structural support system, with dryer assembly and washer assembly supported on a common base, causes the total mass of the combination appliance to be coupled more rigidly to the floor through the supporting feet of the common base. The support system provides superior operating performance during off balance washer spin conditions or dryer tumbling. The support system provides a framework which minimizes deflection of the combination appliance during off balance load conditions, resulting in a combination appliance which has reduced exterior vibration during operation.
3. The structural support framework, as an integral part of the combination appliance assembly, residing entirely inside the cabinetry of the combination appliance, maintains unitary appliance characteristics more so than other stacked type combination appliances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a dryer assembly positioned above a washer assembly showing the external appearance of the appliance cabinetry, with appliance components in phantom.
FIG. 2 is a right side elevation view of the washer and dryer combination appliance support structure embodying the principles of the present invention with the appliance cabinetry in phantom.
FIG. 3 is a front elevational view of the washer and dryer combination appliance support structure embodying the principles of the present invention.
FIG. 4 is a top plan view of the washer and dryer combination appliance support structure embodying the principles of the present invention.
FIG. 5 is a fragmentary sectional view taken generally along line V--V of FIG. 3.
FIG. 6 is a fragmentary elevational view of the left side of the support structure taken generally along line VI--VI of FIG. 3.
FIG. 7 is a sectional view of a means of attachment of the support structure members taken generally along line VII--VII of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is illustrated a combination washer/dryer appliance at 10 comprising a clothes washing machine assembly or washer assembly generally at 12 which is enclosed by side panels 14 and a top panel 16. In the top panel 16 there is a hinged access door 18 which provides access to the interior of the washer assembly wherein a wash basket 20 is concentrically mounted within a wash tub 22. A vertical axis agitator 24 is carried within the wash basket 20 and is selectively driven by an electric motor gear case 26. The clothes washing machine assembly is supported on base frame members 66 shown in FIGS. 2, 3 and 4.
A dryer assembly 28 is mounted in a vertical relationship above the washer assembly 12. The dryer assembly 28 is enclosed by side panels 30 and a top panel 32. A front panel 34 has a hinged door 36 which provides access to the interior of a rotatable drum 38 in which the clothes are to be placed for drying. The drum 38 is rotated by means of an electric motor 40, and an air handling system 42 is provided to supply tempered air to the interior of the drum. Moist air is exhausted from the appliance through a selected opening in the cabinet such as openings 44A (FIG. 2) or 44B (FIG. 3) depending on the placement of the combination washer/dryer appliance. Controls 46 are also provided on the front panel 34 of the dryer assembly through which the user can operate the washer/dryer combination appliance.
A unitary support structure 48 embodying principles of the present invention is shown in greater detail in FIGS. 2-4 as having a right-hand frame 50A, a left-hand frame 50B and bottom connecting cross members 52 and 54. In FIG. 2, it is seen that the right-hand frame 50A is composed of a plurality of components. A vertical main support member 56, a horizontal dryer support member 58, and a lower horizontal dryer base support member 60 are connected together by an angled brace member 64. Horizontal dryer support 58 and lower horizontal dryer base support 60 carry a portion of the supported weight of the dryer assembly 28. Lower horizontal dryer base support member 60 directly supports a dryer assembly base plate 62 upon which various components of the dryer assembly are directly mounted such as the motor 40, an electrical terminal block, and exhaust duct work. Support member 58 carries, among other things, a front panel assembly, including a front bulk head for the dryer. Main vertical support member 56 and brace member 64 support members 58 and 60, along with the portion of the supported weight of the dryer assembly 28 which members 58 and 60 support. Main vertical support member 56 also directly carries an additional portion of the supported weight of the dryer assembly 28 such as rear panel assembly including a rear bulk head of the dryer assembly. The vertical main support member 56 is connected to a base frame member 66, and both are connected by diagonal brace member 68. The vertical main support member 56 acts as a rear support of the washer side panels 14. The vertical main support member 56 and diagonal brace member 68 transfer support loads from the dryer assembly 28 to the base frame members 66 which in turn transfer such support loads to a supporting surface, such as a floor, via adjustable leveling feet 72 at a front of the support structure 48, and via self-leveling supporting feet 74 at a rear of the support structure 48.
FIG. 3 shows both the right-hand frame 50A and the left-hand frame 50B of the support structure 48. The left-hand frame 50B of the support structure 48 is similar to the right-hand frame 50A. Similar to the right-hand frame 50A of the support structure 48, vertical main support member 56 of the left-hand frame 50B of the support structure, connected to the diagonal brace member 68 and also connected to a base frame member similar to base frame member 66, supports the dryer assembly 28 and acts as a rear support of the washer side panels 14. The diagonal brace member 68 connects the bottom base frame member 66 and vertical main support member 56. The main vertical support member 56 and diagonal brace member 68 transfer support loads to the base frame member 66 which in turn transfers such support loads to the supporting surface, such as the floor, via adjustable leveling feet 72 and self-leveling supporting feet 74 (shown in FIG. 2) as described above.
FIG. 3 also shows that both the left-hand frame 50B of the support structure 48 and the right-hand frame 50A of the support structure 48 are entirely interior of washer assembly side panels 14 and dryer assembly side panels 30, maintaining the visual characteristics of a unitary appliance.
FIG. 3 shows the left-hand frame 50B and base frame member 66 connected to the right-hand frame 50A and base frame member 66 by cross member 52. Cross member 52 adds stability to the support structure near the rear of the support structure and cross frame member 54 adds further stability to the support structure near the front of the support structure.
FIG. 4 shows the relative location of the cross members 52 and 54 with respect to the left-hand frame 50B and the right-hand frame 50A of the support structure 48 and to the base frame members 66.
FIG. 5, which is a section generally along line V--V of FIG. 3, details the connection between the vertical main support member 56, brace member 64 and lower horizontal dryer base support member 60. In the preferred embodiment, vertical main support member 56 is a U-shaped channel member, open to the exterior of the appliance, lower horizontal dryer base support member 60 is an L-shaped member with an integral offset end extension 76 which connects to an inside (left side in FIG. 5) vertical face 78 of a web portion 80 of the right-hand frame 50A vertical main support member 56 such that the inside face 78 of the web portion 80 is co-planar with a lateral inside vertical surface 82 of the lower horizontal dryer base support member 60. Thus, the brace member 64, which preferably is formed of a U-shaped channel member, will lie flush against surfaces 78 and 82 and also flush against a vertical surface 83 of the support member 58 (FIG. 3), being oriented so as to open toward the interior of the appliance. The connection of the left-hand frame 50A of the support structure members 56, 64, and 60 is similar as shown in FIG. 6. The dryer assembly can be secured to the vertical surface 78, 83 of the support members 56 and support members 58 by appropriate fastening means such as threaded fasteners as well known to those skilled in the art.
FIG. 6 shows that the left-hand frame 50B of the support structure 48 comprises the vertical main support member 56, the horizontal dryer support member 58, and the lower horizontal dryer base support member 60 all connected by the brace member 64. Members 56, 58, 60 and 64 act together to support the dryer assembly 28. Similar to the right-hand frame 50A of the support structure the dryer assembly base 62 (shown in FIG. 2) is supported by lower horizontal dryer base support member 60. The brace member 64 is illustrated as having a bend 84 therein, which is provided merely to allow clearance in a particular dryer assembly construction utilized by the assignee of applicant, and is not critical to the invention. The left-hand frame and right-hand frame brace members 64 as illustrated in FIGS. 6 and 2 respectively, appear to be configured differently, however, one is merely inverted relative to the other so that different right-hand frame brace member 64 and left-hand frame brace member 64 are not required, a single configuration being useable for both left-hand and right-hand frames.
FIG. 7, which is the section through VII--VII of FIG. 5, details a preferred method of connecting the members: 56 to 58, 58 to 64, 64 to 60, 60 to 56, and 64 to 56. The members are mashed and coined together, providing a tight connection with virtually no play and minimal assembly labor required. No separate fasteners are required, nor is labor intensive welding needed.
As is apparent from the forgoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonable and properly come within the scope of our contribution to the art. | A support structure for a vertically arranged combination household appliance, more particularly a front loading dryer assembly arranged above a top loading washer assembly, includes vertical main support members, horizontal members and other members. The structure adequately supports both appliance assemblies of the combination appliance during transportation and usage, provides improved operating performance during off balance washer spin conditions or dryer tumbling, and maintains unitary appliance characteristics by being an integral part of the combination appliance design and by being located entirely interior to the appliance cabinetry. | 3 |
EARLIER FILED APPLICATION
[0001] The instant application is a continuation-in-part of applicant's prior application filed Apr. 27, 2001 and having Ser. No. 09/843,347, the disclosure of which is specifically incorporated by reference herein.
FIELD OF INVENTION
[0002] The invention pertains to dispensers for plastic produce bags. More particularly, the invention relates to dispensers for expandable plastic film gusseted bags having integral carrying handles designed for roll dispensing.
BACKGROUND OF THE INVENTION
[0003] Roll mounted produce bags are commonly found in modern grocery stores and supermarkets. These bags are designed for customers to use when purchasing fresh produce. The bags currently available are difficult for customers to use for several reasons. First, the bags tend to cling together and are difficult to separate from the roll. Second, it is difficult to tell the open end of the bag from the closed end of the bag. Third, the bags are difficult to open, as the sides tend to cling together. Fourth, the bags do not provide carrying handles. A roll-mounted produce bag that identifies the proper end to open is partially opened by the dispensing rack and that provides carrying handles would save time and effort for produce purchasers.
[0004] Various designs have been developed for dispensers for roll mounted bags, incorporating a number of different technologies. U.S. Pat. No. 4,179,055 issued to Milner discloses a device for separating a continuous strip of plastic bags mounted on a roll separated by score lines. The bags pass between a plate and a pressure bar. A prong projects outwardly from the center portion of the plate to facilitate separation of the bags along the score lines and to display the next bag for easy grasping by an operator.
[0005] U.S. Pat. No. 4,714,191 issued to Richardson, describes a one piece paperboard carton blank folded into a rectangular shape for packaging and dispensing from a roll of individual plastic bags, particularly disposable milk bags for feeding babies. The individual bags are connected by perforations. The carton includes a tab protruding in the direction opposite to the direction of withdrawal of bags from the roll. When the center of the perforated edge of a bag is impaled on the tab, further withdrawal of a succeeding bag is restrained and the first bag is readily separated to facilitate its dispensing while locating the leading edge of the succeeding bag where it may be easily reached for withdrawal.
[0006] U.S. Pat. No. 5,558,262 issued to Simhaee, discloses a plastic bag dispenser that holds a continuous roll of bags connected by perforated separation lines. The dispenser is provided with a tongue, which the bags are dispensed over, that engages the separation line between the bag at the end of the roll and the next bag. The roll of bags rests in curved grooves in the dispenser that cause the roll to abut and frictionally engage an interior surface of the dispenser, preventing freewheeling of the roll.
[0007] U.S. Pat. No. 5,556,019 issued to Morris, describes a bag separator and dispenser for use with bags wound on a core and separated by perforation lines at each end of the bags. The perforation lines include a slot that is collinear with the perforations and is used to engage a separator projection. The projection enters the slot as the bags are pulled from the roll. The dispenser includes two braking devices to control the removal of bags from the roll, a braking bar underneath the roll of bags and a pair of fingers that are attached to the channel for the core and are designed to engage the core as the number of bags on the roll decreases.
[0008] U.S. Pat. No. 5,934,535, issued to Kannankeril discloses a roll of bags having a core with an indexing member on at least one end. The dispenser comprises a wire frame formed into channels to support the core. The dispenser includes at least one brake attached to a support member and disposed at an angle to the support member to provide tension to the edges of the roll of bags as the core passes through the channel passageway as bags are removed from the roll. Spaced apart from the support is a separating tongue. The tongue engages the slot regardless of whether the bags are drawn over or under the tongue.
[0009] While other variations exist, the above-described designs for dispensers for roll mounted bags are typical of those encountered in the prior art.
[0010] It is an objective of the present invention to provide a dispenser for a T-shirt type produce bag that can be mounted on a continuous roll. It is a further objective to provide such a dispenser that can be easily and inexpensively manufactured in a variety of sizes that is durable and easy to use. It is a still further objective of the invention to provide a dispenser that initiates opening of the roll-mounted bag for a user. It is yet a further objective to provide a dispenser that will permit a user to open a bag with one hand. In is another objective of the invention to provide a dispenser that can dispense bags from the top or the bottom of the roll. It is still another objective to provide a dispenser that will insure that the bag roll cannot be inadvertently pulled from the dispenser, allowing contamination of the bag roll. Finally, it is an objective of the invention that the dispenser is capable of identifying for the user the open end of the bags.
[0011] While some of the objectives of the present invention are disclosed in the prior art, none of the inventions found include all of the requirements identified. The present invention addresses many of the deficiencies of prior art roll mounted bags and dispensers and satisfies all of the objectives described above.
SUMMARY OF THE INVENTION
[0012] A roll mounted plastic produce bag providing the desired features may be constructed from the following components. A front panel has first and second parallel linear side edges, a top edge and a bottom edge. A rear panel has first and second parallel linear side edges, a top edge and a bottom edge. Two front gusset panels of a first predetermined dimension are provided. Each front gusset panel has a top edge, a bottom edge, first and second parallel side edges. The front gusset panels are connected at the first side edge to one of the linear side edges of the front panel and extend from the top edge to the bottom edge of the front panel.
[0013] Two rear gusset panels of the first predetermined dimension are provided. Each rear gusset panel has a top edge, a bottom edge, first and second parallel side edges. The rear gusset panels are connected at the first side edge to one of the linear side edges of the rear panel and extend from the top edge to the bottom edge of the rear panel. Each front gusset panel is also connected to a respective one of the rear gusset panels at the second side edge. Each of the front and rear gusset panels is folded inwardly relative to the front and the rear panel.
[0014] The top edges of the front panel, the rear panel, the front gusset panels and the rear gusset panels terminate in a first perforation line. The first perforation line is perpendicular to the linear side edges of the front and rear panels. An upper seam connects the front panel, the rear panel, the front gusset panels and the rear gusset panels at a level spaced downwardly from and parallel to the first perforation line. The bottom edges of the front panel, the rear panel, the front gusset panels and the rear gusset panels terminate in a second perforation line. The second perforation line is perpendicular to the linear side edges of the front and rear panels. A lower seam connects the front panel, the rear panel, the front gusset panels and the rear gusset panels at a level spaced upwardly from and parallel to the second perforation line.
[0015] A U-shaped cutout is located in an upper portion of the bag. The U-shaped cutout begins at a first point along the first perforation line. The point is spaced inwardly from the first linear side edge and extends to a second point along the first perforation line. The second point is spaced inwardly from the second linear side edge. The cutout extends downwardly toward the lower seam, forming an open mouth and a pair of bag handles. The second perforation line attaches the bag to a subsequent bag. The bags are rolled from their upper seams toward their lower seams onto a cylindrical core to form a compact roll from which the bags are dispensed.
[0016] In a variant of the invention, the bag is folded inwardly from the first and second linear side edges for a third predetermined dimension prior to rolling the bags onto a cylindrical core, thereby providing a more compact roll of bags.
[0017] In a further variant, a dispenser for roll mounted plastic produce bags includes a supporting base and a surrounding upper member. The upper member is spaced upwardly from the supporting base and sized and shaped to enclose at least a rear portion of a bag roll. An attachment member is provided. The attachment member is fixedly attached to the supporting base and the surrounding upper member and provides means for securing the dispenser to either a vertical surface or a horizontal surface.
[0018] First and second parallel, upwardly angled slots are provided. Each of the slots has a front edge member and a rear edge member. The slots extend upwardly from the supporting base and connect to and extend above the surrounding upper member. The slots are sized, shaped and located to slidably constrain first and second ends of a cylindrical produce bag core on which the bags are wound in a roll. The angled slots permit the bag core to slide downwardly within the slots. First and second core supports are provided. The core supports are located adjacent upper ends of the first and second slots and provide a bearing surface for the produce bag core.
[0019] A bag constraining ring is provided. The constraining ring is mounted between the front edge members of the upwardly angled slots and is sized and shaped to fit frictionally about a bag as it is removed from the bag roll. Upper and lower separating tongues are provided. The upper and lower tongues are affixed to upper and lower portions of the bag constraining ring, respectively. The upper and lower tongues point toward an interior of the ring and are sized and shaped to locate the U-shaped cutout in the upper portion of the bags as bags are pulled from the bag roll.
[0020] When a roll of T-shirt style bags is mounted in the dispenser with its core resting upon the first and second core supports, the roll may be arranged to dispense bags from either of a top and bottom of the bag roll. When a leading bag from the roll is fed through the constraining ring adjacent either the upper or lower separating tongues, one of the tongues will serve to engage the U-shaped cutout in the upper portion of the bag and facilitate tearing of the perforation joining the leading bag to a subsequent bag on the roll.
[0021] In still a further variant of the invention, a dispenser is sized and shaped to accommodate produce bags that have been folded inwardly from the first and second linear side edges for a third predetermined dimension prior to rolling the bags onto a cylindrical core, thereby providing a more compact roll of bags.
[0022] In another variant of the invention, a dispenser for roll mounted plastic produce bags includes a supporting base and a surrounding upper member. The upper member is spaced upwardly from the supporting base and is sized and shaped to enclose at least a rear portion of a bag roll. A surrounding intermediate member is provided. The intermediate member has a first side, a second side and a rear portion. The intermediate member is spaced upwardly from the supporting base and downwardly from the surrounding upper member and is sized and shaped to enclose at least a rear portion of the bag roll. An attachment member is provided. The attachment member is fixedly attached to the supporting base, the surrounding intermediate member and the surrounding upper member and provides means for securing the dispenser to either a vertical surface or a horizontal surface.
[0023] First and second parallel, upwardly angled slots are provided. Each of the slots has a front edge member and a rear edge member and extends upwardly from the surrounding intermediate member and above the surrounding upper member and is sized, shaped and located to slidably constrain first and second ends of a cylindrical produce bag core on which the bags are wound in a roll. The angled slots permit the bag core to slide downwardly within the slots. At least one roll bearing bar is provided. The roll bearing bar extends from the first side of the surrounding intermediate member to the second side of the surrounding intermediate member.
[0024] A bag constraining ring is provided. The constraining ring is mounted between the front edge members of the upwardly angled slots and is sized and shaped to fit frictionally about a bag as it is removed from the bag roll. Upper and lower separating tongues are provided. The upper and lower tongues are affixed to upper and lower portions of the bag constraining ring, pointing toward an interior of the ring. The upper and lower tongues are sized and shaped to locate the U-shaped cutout in the upper portion of the bags as bags are pulled from the bag roll.
[0025] When a roll of T-shirt style bags is mounted in the dispenser with its core disposed between the front edge member and the rear edge member of the first and second parallel, upwardly angled slots, the roll may be arranged to dispense bags from either a top or bottom of the bag roll. The bag roll rests upon the roll bearing bar and the bar controls movement of the bag roll. When a leading bag from the roll is fed through the constraining ring adjacent either of the upper and lower separating tongues, one of the tongues will serve to engage the U-shaped cutout in the upper portion of the bag and facilitate tearing of the perforation joining the leading bag to a subsequent bag on the roll.
[0026] In yet another variant of the invention a dispenser for roll mounted plastic produce bags is sized and shaped to accommodate produce bags that have been folded inwardly from the first and second linear side edges for a third predetermined dimension prior to rolling the bags onto a cylindrical core, thereby providing a more compact roll of bags.
[0027] 7—In still another variant, a dispenser for roll mounted plastic produce bags includes a supporting base and a surrounding upper member. The upper member is spaced upwardly from the supporting base and sized and shaped to enclose at least a rear portion of a bag roll. An attachment member is provided. The attachment member is fixedly attached to the supporting base and the surrounding upper member and provides means for securing the dispenser to either a vertical surface or a horizontal surface.
[0028] First and second parallel, upwardly angled slots are provided. Each of the slots has a front edge member and a rear edge member. The slots extend upwardly from the supporting base and connect to and extend above the surrounding upper member. The slots are sized, shaped and located to slidably constrain first and second ends of a cylindrical produce bag core on which the bags are wound in a roll. The angled slots permit the bag core to slide downwardly within the slots. First and second core supports are provided. The core supports are located adjacent upper ends of the first and second slots and provide a bearing surface for the produce bag core.
[0029] A tongue mounting loop is provided. The mounting loop is attached between the front edge members of the upwardly angled slots and is positioned at an acute angle to the supporting base. A separating tongue is provided. The separating tongue is affixed to a perimeter of the tongue mounting loop, pointing inwardly from the perimeter, upwardly at the acute angle to the supporting base and is sized and shaped to locate the U-shaped cutout in the upper portion of the bags as bags are pulled from the bag roll.
[0030] When a roll of T-shirt style bags is mounted in the dispenser with its core resting upon the first and second core supports, the roll is arranged to dispense bags from the bottom of the bag roll, a leading bag from the roll is fed over the tongue mounting loop adjacent the separating tongue, the tongue will serve to engage the U-shaped cutout in the upper portion of the bag and facilitate tearing of the perforation joining the leading bag to a subsequent bag on the roll.
[0031] 8—In yet another variant of the invention, a dispenser is sized and shaped to accommodate produce bags that have been folded inwardly from the first and second linear side edges for a third predetermined dimension prior to rolling the bags onto a cylindrical core, thereby providing a more compact roll of bags.
[0032] 9—In still another variant of the invention, a dispenser for roll mounted plastic produce bags includes a supporting base and a surrounding upper member. The upper member is spaced upwardly from the supporting base and is sized and shaped to enclose at least a rear portion of a bag roll. A surrounding intermediate member is provided. The intermediate member has a first side, a second side and a rear portion. The intermediate member is spaced upwardly from the supporting base and downwardly from the surrounding upper member and is sized and shaped to enclose at least a rear portion of the bag roll. An attachment member is provided. The attachment member is fixedly attached to the supporting base, the surrounding intermediate member and the surrounding upper member and provides means for securing the dispenser to either a vertical surface or a horizontal surface.
[0033] First and second parallel, upwardly angled slots are provided. Each of the slots has a front edge member and a rear edge member and extends upwardly from the surrounding intermediate member and above the surrounding upper member and is sized, shaped and located to slidably constrain first and second ends of a cylindrical produce bag core on which the bags are wound in a roll. The angled slots permit the bag core to slide downwardly within the slots. At least one roll bearing bar is provided. The roll bearing bar extends from the first side of the surrounding intermediate member to the second side of the surrounding intermediate member.
[0034] A tongue mounting loop is provided. The mounting loop is attached between the front edge members of the upwardly angled slots and is positioned at an acute angle to the supporting base. A separating tongue is provided. The separating tongue is affixed to a perimeter of the tongue mounting loop, pointing inwardly from the perimeter, upwardly at the acute angle to the supporting base and is sized and shaped to locate the U-shaped cutout in the upper portion of the bags as bags are pulled from the bag roll.
[0035] When a roll of T-shirt style bags is mounted in the dispenser with its core disposed between the front edge member and the rear edge member of the first and second parallel, upwardly angled slots, the roll is arranged to dispense bags from the bottom of the bag roll. The bag roll rests upon the roll bearing bar, the bar controlling movement of the bag roll and when a leading bag from the roll is fed over the tongue mounting loop adjacent the separating tongue, the tongue will serve to engage the U-shaped cutout in the upper portion of the bag and facilitate tearing of the perforation joining the leading bag to a subsequent bag on the roll.
[0036] 10—In a final variant of the invention, a dispenser is sized and shaped to accommodate produce bags that have been folded inwardly from the first and second linear side edges for a third predetermined dimension prior to rolling the bags onto a cylindrical core, thereby providing a more compact roll of bags.
DESCRIPTION OF THE DRAWINGS
[0037] [0037]FIG. 1 is a perspective view of the preferred embodiment of the T-shirt style bag of the present invention illustrating a pair of side gussets, upper and lower seams and an openable mouth;
[0038] [0038]FIG. 1A is a perspective view of the FIG. 1 bag folded inwardly from the parallel side edges;
[0039] [0039]FIG. 2 is a perspective view of a plurality of the FIG. 1 embodiment bags rolled onto a cylindrical core suitable for a dispenser;
[0040] [0040]FIG. 2A is a perspective view of a plurality of the FIG. 1 bags folded inwardly from the parallel side edges and rolled onto a cylindrical core suitable for a dispenser;
[0041] [0041]FIG. 5 is a cross sectional view of the FIG. 1A bags taken along the line 5 - 5 ;
[0042] [0042]FIG. 6A is a cross sectional view of the FIG. 2 bags taken along the line 6 A- 6 A;
[0043] [0043]FIG. 14 is a perspective view of a first embodiment of a dispenser suitable for the FIG. 1 rolled bags;
[0044] [0044]FIG. 15 is a perspective view of a second embodiment of a dispenser suitable for the FIG. 1 rolled bags;
[0045] [0045]FIG. 16 is a perspective view of the first embodiment of a dispenser suitable for the FIG. 1A rolled bags;
[0046] [0046]FIG. 17 is a perspective view of the second embodiment of a dispenser suitable for the FIG. 1A rolled bags;
[0047] [0047]FIG. 18 is a perspective view of the FIG. 14 dispenser with a bag roll installed and the bags feeding from the top of the roll;
[0048] [0048]FIG. 19 is a perspective view of the FIG. 17 dispenser with a bag roll installed and the bags feeding from the bottom of the roll;
[0049] [0049]FIG. 20 is a perspective view of the FIG. 16 dispenser with a bag roll installed and the bags feeding from the bottom of the roll;
[0050] [0050]FIG. 21 is a perspective view of a third embodiment of a dispenser suitable for the FIG. 1 rolled bags;
[0051] [0051]FIG. 22 is a perspective view of the third embodiment of a dispenser suitable for the FIG. 1A rolled bags;
[0052] [0052]FIG. 23 is a perspective view of a fourth embodiment of a dispenser suitable for the FIG. 1 rolled bags;
[0053] [0053]FIG. 24 is a perspective view of the fourth embodiment of a dispenser suitable for the FIG. 1A rolled bags; and
[0054] [0054]FIG. 25 is a perspective view of the FIG. 23 embodiment of the dispenser with a roll of FIG. 1 rolled bags installed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] [0055]FIGS. 1, 2, 3 and 6 A illustrate a roll mounted plastic produce bag 10 providing the desired features that may be constructed from the following components. A front panel 14 has first 18 and second 22 parallel linear side edges, a top edge 26 and a bottom edge 30 . A rear panel 34 has first 38 and second 42 parallel linear side edges, a top edge 46 and a bottom edge 50 . Two front gusset panels 54 , 58 of a first predetermined dimension 62 are provided. Each front gusset panel 54 , 58 has a top edge 62 , a bottom edge 66 , first 70 and second 74 parallel side edges. The front gusset panels 54 , 58 are connected at the first side edge 70 to one of the linear side edges 18 , 22 of the front panel 14 and extend from the top edge 26 to the bottom edge 30 of the front panel.
[0056] Two rear gusset panels 78 , 82 of the first predetermined dimension 62 are provided. Each rear gusset panel 78 , 82 has a top edge 86 , a bottom edge 90 , first 94 and second 98 parallel side edges. The rear gusset panels 78 , 82 are connected at the first side edge 94 to one of the linear side edges 38 , 42 of the rear panel 34 and extend from the top edge 46 to the bottom edge 50 of the rear panel 34 . Each front gusset panel 54 , 58 is also connected to a respective one of the rear gusset panels 78 , 82 at the second side edge 98 . Each of the front 54 , 58 and rear gusset panels 78 , 82 is folded inwardly relative to the front 14 and the rear panel 34 .
[0057] The top edges 26 , 46 , 62 , 86 of the front panel 14 , the rear panel 34 , the front gusset panels 54 , 58 and the rear gusset panels 78 , 82 terminate in a first perforation line 102 . The first perforation line 102 is perpendicular to the linear side edges 18 , 22 , 38 , 42 of the front 14 and rear 34 panels. An upper seam 106 connects the front panel 14 , the rear panel 34 , the front gusset panels 54 , 58 and the rear gusset panels 78 , 82 at a level 110 spaced downwardly from and parallel to the first perforation line 102 . The bottom edges 30 , 50 , 66 , 90 of the front panel 14 , the rear panel 34 , the front gusset panels 54 , 58 and the rear gusset panels 78 , 82 terminate in a second perforation line 114 . The second perforation line 114 is perpendicular to the linear side edges 18 , 22 , 38 , 42 of the front 14 and rear 34 panels. A lower seam 118 connects the front panel 14 , the rear panel 34 , the front gusset panels 54 , 58 and the rear gusset panels 78 , 82 at a level 122 spaced upwardly from and parallel to the second perforation line 114 .
[0058] A U-shaped cutout 126 is located in an upper portion 130 of the bag 10 . The U-shaped cutout 126 begins at a first point 134 along the first perforation line 102 . The first point 134 is spaced inwardly from the first linear side edge 18 , 38 and extends to a second point 138 along the first perforation line 102 . The second point 138 is spaced inwardly from the second linear side edge 22 , 42 . The cutout 126 extends downwardly toward the lower seam 118 , forming an open mouth 142 and a pair of bag handles 146 . The second perforation line 114 attaches the bag 10 to a subsequent bag 10 . The bags 10 are rolled from their upper seams 106 toward their lower seams 118 onto a cylindrical core 148 to form a compact roll 150 from which the bags 10 are dispensed.
[0059] In a variant of the invention, as illustrated in FIG. 1A, 2A and 5 , the bag 10 is folded inwardly from the first 18 , 38 and second 22 , 42 linear side edges for a third predetermined dimension 154 prior to rolling the bags 10 onto a cylindrical core 156 , thereby providing a more compact roll 158 of bags 10 .
[0060] In a further variant, as illustrated in FIGS. 14 and 18, a dispenser 162 for roll mounted plastic produce bags 10 includes a supporting base 166 and a surrounding upper member 170 . The upper member 170 is spaced upwardly from the supporting base 166 and sized and shaped to enclose at least a rear 168 portion of a bag roll 150 . An attachment member 174 is provided. The attachment member 174 is fixedly attached to the supporting base 166 and the surrounding upper member 170 and provides means for securing the dispenser 162 to either a vertical surface 178 or a horizontal surface 182 .
[0061] First 186 and second 190 parallel, upwardly angled slots are provided. Each of the slots 186 , 190 has a front edge member 194 and a rear edge member 198 . The slots 186 , 190 extend upwardly from the supporting base 166 and connect to and extend above the surrounding upper member 170 . The slots 186 , 190 are sized, shaped and located to slidably constrain first (not shown) and second 200 ends of a cylindrical produce bag core 146 on which the bags 10 are wound in a roll 150 . The angled slots 186 , 190 permit the bag core 148 to slide downwardly within the slots 186 , 190 . First 202 and second 206 core supports are provided. The core supports 202 , 206 are located adjacent upper ends 210 , 214 of the first 186 and second 190 slots and provide a bearing surface 218 for the produce bag core 146 .
[0062] A bag constraining ring 222 is provided. The constraining ring 222 is mounted between the front edge members 194 of the upwardly angled slots 186 , 190 and is sized and shaped to fit frictionally about a bag 10 as it is removed from the bag roll 150 . Upper 226 and lower 230 separating tongues are provided. The upper 226 and lower 230 tongues are affixed to upper 234 and lower 238 portions of the bag constraining ring 222 , respectively. The upper 226 and lower 230 tongues point toward an interior 242 of the ring 222 and are sized and shaped to locate the U-shaped cutout 126 in the upper portion 130 of the bags 10 as bags 10 are pulled from the bag roll 150 .
[0063] When a roll 150 of T-shirt style bags 10 is mounted in the dispenser 162 with its core 148 resting upon the first 202 and second 206 core supports, the roll 150 may be arranged to dispense bags 10 from either of a top 246 and bottom 250 of the bag roll 150 . When a leading bag 10 from the roll 150 is fed through the constraining ring 222 adjacent either the upper 226 or lower 230 separating tongues, one of the tongues 226 , 230 will serve to engage the U-shaped cutout 126 in the upper portion 130 of the bag 10 and facilitate tearing of the perforation 102 joining the leading bag 10 to a subsequent bag 10 on the roll 150 .
[0064] In still a further variant of the invention, as illustrated in FIGS. 16 and 20, a dispenser 254 is sized and shaped to accommodate produce bags 10 that have been folded inwardly from the first 18 , 38 and second 22 , 42 linear side edges for a third predetermined dimension 154 prior to rolling the bags 10 onto a cylindrical core 156 , thereby providing a more compact roll 158 of bags 10 .
[0065] In another variant of the invention, as illustrated in FIG. 15, a dispenser 258 for roll mounted plastic produce bags 10 includes a supporting base 262 and a surrounding upper member 266 . The upper member 266 is spaced upwardly from the supporting base 262 and is sized and shaped to enclose at least a rear portion 168 of a bag roll 150 . A surrounding intermediate member 270 is provided. The intermediate member 270 has a first side 274 , a second side 278 and a rear portion 282 . The intermediate member 270 is spaced upwardly from the supporting base 262 and downwardly from the surrounding upper member 266 and is sized and shaped to enclose at least a rear portion 168 of the bag roll 150 . An attachment member 286 is provided. The attachment member 286 is fixedly attached to the supporting base 262 , the surrounding intermediate member 270 and the surrounding upper member 266 and provides means for securing the dispenser 258 to either a vertical surface 178 or a horizontal surface 182 .
[0066] First 290 and second 294 parallel, upwardly angled slots are provided. Each of the slots 290 , 294 has a front edge member 298 and a rear edge member 302 and extends upwardly from the surrounding intermediate member 270 and above the surrounding upper member 266 and is sized, shaped and located to slidably constrain first (not shown) and second 200 ends of a cylindrical produce bag core 148 on which the bags 10 are wound in a roll 150 . The angled slots 290 , 294 permit the bag core 148 to slide downwardly within the slots 290 , 294 . At least one roll bearing bar 306 is provided. The roll bearing bar 306 extends from the first side 274 of the surrounding intermediate member 270 to the second side 278 of the surrounding intermediate member 270 .
[0067] A bag constraining ring 222 is provided. The constraining ring 222 is mounted between the front edge members 298 of the upwardly angled slots 290 , 294 and is sized and shaped to fit frictionally about a bag 10 as it is removed from the bag roll 150 . Upper 226 and lower 230 separating tongues are provided. The upper 226 and lower 230 tongues are affixed to upper 234 and lower 238 portions of the bag constraining ring 222 , pointing toward an interior 242 of the ring 222 . The upper 226 and lower 230 tongues are sized and shaped to locate the U-shaped cutout 126 in the upper portion 130 of the bags 10 as bags 10 are pulled from the bag roll 150 .
[0068] When a roll 150 of T-shirt style bags 10 is mounted in the dispenser 258 with its core 148 disposed between the front edge member 298 and the rear edge member 302 of the first 290 and second 294 parallel, upwardly angled slots, the roll 150 may be arranged to dispense bags 10 from either a top 246 or bottom 250 of the bag roll. The bag roll 150 rests upon the roll bearing bar 306 and the bar 306 controls movement of the bag roll 150 . When a leading bag 10 from the roll 150 is fed through the constraining ring 222 adjacent either of the upper 226 and lower 230 separating tongues, one of the tongues 226 , 230 will serve to engage the U-shaped cutout 126 in the upper portion 130 of the bag 10 and facilitate tearing of the perforation 102 joining the leading bag 10 to a subsequent bag 10 on the roll 150 .
[0069] In still another variant of the invention, as illustrated in FIG. 17, a dispenser 314 for roll mounted plastic produce bags 10 is sized and shaped to accommodate produce bags 10 that have been folded inwardly from the first 18 , 38 and second 22 , 42 linear side edges for a third predetermined dimension 154 prior to rolling the bags 10 onto a cylindrical core 156 , thereby providing a more compact roll 158 of bags 10 .
[0070] In still another variant, as illustrated in FIG. 21, a dispenser 318 for roll mounted plastic produce bags 10 includes a supporting base 322 and a surrounding upper member 326 . The upper member 326 is spaced upwardly from the supporting base 322 and sized and shaped to enclose at least a rear portion 168 of a bag roll 150 . An attachment member 330 is provided. The attachment member 330 is fixedly attached to the supporting base 322 and the surrounding upper member 326 and provides means for securing the dispenser 318 to either a vertical surface 178 or a horizontal surface 182 .
[0071] First 334 and second 338 parallel, upwardly angled slots are provided. Each of the slots 334 , 338 has a front edge member 342 and a rear edge member 346 . The slots 334 , 338 extend upwardly from the supporting base 322 and connect to and extend above the surrounding upper member 326 . The slots 334 , 338 are sized, shaped and located to slidably constrain first (not shown) and second 200 ends of a cylindrical produce bag core 146 on which the bags 10 are wound in a roll 150 . The angled slots 334 , 338 permit the bag core 146 to slide downwardly within the slots 334 , 338 . First 350 and second 354 core supports are provided. The core supports 350 , 354 are located adjacent upper ends 358 , 362 of the first 334 and second 338 slots and provide a bearing surface 366 for the produce bag core 146 .
[0072] A tongue mounting loop 370 is provided. The mounting loop 370 is attached between the front edge members 342 of the upwardly angled slots 334 , 338 and is positioned at an acute angle 374 to the supporting base 322 . A separating tongue 378 is provided. The separating tongue 378 is affixed to a perimeter 382 of the tongue mounting loop 370 , pointing inwardly from the perimeter 382 , upwardly at the acute angle 374 to the supporting base 322 and is sized and shaped to locate the U-shaped cutout 126 in the upper portion 130 of the bags 10 as bags 10 are pulled from the bag roll 150 .
[0073] When a roll 150 of T-shirt style bags 10 is mounted in the dispenser 318 with its core 146 resting upon the first 350 and second 354 core supports, the roll 150 is arranged to dispense bags 10 from the bottom 250 of the bag roll 150 , a leading bag 10 from the roll 150 is fed over the tongue mounting loop 370 adjacent the separating tongue 378 , the tongue 378 will serve to engage the U-shaped cutout 126 in the upper portion 130 of the bag 10 and facilitate tearing of the perforation 102 joining the leading bag 10 to a subsequent bag 10 on the roll 150 .
[0074] In yet another variant of the invention, as illustrated in FIG. 22, a dispenser 386 is sized and shaped to accommodate produce bags 10 that have been folded inwardly from the first 18 , 38 and second 22 , 42 linear side edges for a third predetermined dimension 154 prior to rolling the bags 10 onto a cylindrical core 156 , thereby providing a more compact roll 158 of bags 10 .
[0075] In still another variant of the invention, as illustrated in FIGS. 23 and 25, a dispenser 390 for roll mounted plastic produce bags 10 includes a supporting base 394 and a surrounding upper member 398 . The upper member 398 is spaced upwardly from the supporting base 394 and is sized and shaped to enclose at least a rear portion 168 of a bag roll 150 . A surrounding intermediate member 402 is provided. The intermediate member 402 has a first side 406 , a second side 410 and a rear portion 414 . The intermediate member 402 is spaced upwardly from the supporting base 394 and downwardly from the surrounding upper member 398 and is sized and shaped to enclose at least a rear portion 168 of the bag roll 150 . An attachment member 418 is provided. The attachment member 418 is fixedly attached to the supporting base 394 , the surrounding intermediate member 402 and the surrounding upper member 398 and provides means for securing the dispenser 390 to either a vertical surface 178 or a horizontal surface 182 .
[0076] First 422 and second 426 parallel, upwardly angled slots are provided. Each of the slots 422 , 426 has a front edge member 430 and a rear edge member 434 and extends upwardly from the surrounding intermediate member 402 and above the surrounding upper member 398 and is sized, shaped and located to slidably constrain first (not shown) and second 200 ends of a cylindrical produce bag core 146 on which the bags 10 are wound in a roll 150 . The angled slots 422 , 426 permit the bag core 146 to slide downwardly within the slots 422 , 426 . At least one roll bearing bar 438 is provided. The roll bearing bar 438 extends from the first side 406 of the surrounding intermediate member 402 to the second side 410 of the surrounding intermediate member 402 .
[0077] A tongue mounting loop 370 is provided. The mounting loop 370 is attached between the front edge members 430 of the upwardly angled slots 422 , 426 and is positioned at an acute angle 374 to the supporting base 394 . A separating tongue 378 is provided. The separating tongue 378 is affixed to a perimeter 382 of the tongue mounting loop 370 , pointing inwardly from the perimeter 382 , upwardly at the acute angle 374 to the supporting base 394 and is sized and shaped to locate the U-shaped cutout 126 in the upper portion 130 of the bags 10 as bags 10 are pulled from the bag roll 150 .
[0078] When a roll 150 of T-shirt style bags 10 is mounted in the dispenser 390 with its core 146 disposed between the front edge member 430 and the rear edge member 434 of the first 422 and second 426 parallel, upwardly angled slots, the roll 150 is arranged to dispense bags 10 from the bottom 250 of the bag roll 150 . The bag roll 150 rests upon the roll bearing bar 438 , the bar 438 controlling movement of the bag roll 150 and when a leading bag 10 from the roll 150 is fed over the tongue mounting loop 370 adjacent the separating tongue 378 , the tongue 378 will serve to engage the U-shaped cutout 126 in the upper portion 130 of the bag 10 and facilitate tearing of the perforation 102 joining the leading bag 10 to a subsequent bag 10 on the roll 10 .
[0079] In a final variant of the invention, as illustrated in FIG. 24, a dispenser 442 is sized and shaped to accommodate produce bags 10 that have been folded inwardly from the first 18 , 38 and second 22 , 42 linear side edges for a third predetermined dimension 154 prior to rolling the bags 10 onto a cylindrical core 156 , thereby providing a more compact roll 158 of bags 10 .
[0080] The roll mounted plastic produce bag 10 and related dispensers 162 , 254 , 258 , 314 , 318 , 386 , 390 and 442 have been described with reference to particular embodiments. Other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow. | A roll mounted T-shirt bag and dispensers for same are described. The bag is designed for fresh produce and includes front and rear panels, first and second side gussets, a bottom seam, a top seam and a U-shaped cutout forming an openable bag mouth and a pair of carrying handles. The bags are joined above and below the upper and lower seams at first and second perforation lines. The bags are wound onto a cylindrical core to form a compact roll. In a variant of the invention, the bags are folded inwardly from the side edges prior to rolling onto the core to form a more compact roll. Dispensers are described that are designed to hold the roll mounted bags in both folded and unfolded form. The dispensers include a separating tongue designed to engage the U-shaped cutout and permit the bags to be dispensed from the bottom of the bag roll. The dispensers are designed for mounting to either vertical or horizontal surfaces and function efficiently in very limited spaces. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention.
[0002] The invention relates to a method and an apparatus for transferring a web made of a flexible material, especially a paper web, from a web guide surface that outputs the web to a web conveying apparatus.
[0003] 2. Description of the Related Art.
[0004] Normally, web transfer concerns the transfer of a threading tail, which is part (for example, an edge strip) of the aforementioned paper web. The transfer takes place, for example, from a first machine section to a following second machine section. Such machine sections can be, in particular, parts of a machine for producing or converting a paper web. For example, it concerns the transfer of the tail within or at the end of the press section of a paper making machine; within or to a winder; and/or from the end region of the drying section of the paper making machine to a following calender. This “tail transfer” is used to make threading the paper web into the machine easier.
[0005] It is the intention of the present invention to improve the methods and apparatuses which are described in U.S. Pat. Nos. 3,355,349 and 4,501,643, and also in the brochure “Double Tail Elimination” from the FIBRON Machine Corporation, New Westminster B.C., Canada. Reference is also made to German patent application DE 199 62 731.2.
[0006] U.S. Pat. No. 3,355,349 describes a vacuum belt conveyor for conveying a threading strip or tail of a paper web from the drying section of a paper making machine to the first nip of the calender thereof. The belt conveyor includes an elongated body and an air-permeable endless belt, which is mounted such that it can be moved on the body with the aid of two rollers. The endless belt has a conveying run (for example, its upper run). The conveying run travels from the region of the last drying cylinder to the region of the first nip of the calender. The belt is arranged in such a way that it picks up the threading strip from the last drying cylinder. The elongated body of the conveyor is designed as a vacuum box having a perforated upper part. The length of the vacuum box extends underneath the conveying run of the belt. Measures are provided to produce a vacuum in the box, in order to hold the threading strip on the moving belt.
[0007] At the infeed end of the known belt conveyor, a severing device or tail cutter is fixed. The severing device or tail cutter is a toothed knife which extends in the transverse direction, i.e., parallel to the roller axis. Before the belt conveyor begins to transport the tail of a web, the complete web, including the tail, runs downward from the last drying cylinder “outputting the web”, past the inlet region of the belt conveyor, the web finally reaching a broke container or a broke pulper. A narrow “tail doctor” is provided on the last drying cylinder, in order to separate the tail from the outer of the drying cylinder and to transfer the tail to the belt conveyor. When the latter comes into action, the tail cutter severs the tail and, in this way, forms a new start of the tail, which is then transported to the calender. If no tail cutter were to be present, the belt conveyor would pull a piece of the tail upwards again out of the broke container and therefore transport a “double tail”. Transporting a “double tail” would cause problems during the threading operation (as addressed in the abovementioned brochure “Double Tail Elimination”).
[0008] The belt conveyor design which is disclosed by US '349 and by the referenced brochure has been tried and tested in operation. However, improvements are desirable with the aim that the belt conveyor be able to operate still more reliably and/or at an even higher working speed. In addition, a tail doctor should be avoided, since such an element causes impermissible wear of the outer surface of the drying cylinder.
[0009] According to US '643, an apparatus for the transverse severing and guidance of a tail is designed in such a way that it avoids moving parts and a cutting blade or knife. The tail is separated from the last drying cylinder with the aid of two edge blowing nozzles and is severed transversely with the aid of two pneumatic guide plates, which pull the tail in two different directions. The onward transport of the tail is then carried out exclusively by one of the pneumatic guide plates. It is doubtful whether this known design operates satisfactorily, at least when a paper web is to be transferred at a relatively high speed and/or when a very high operating speed is to be used.
SUMMARY OF THE INVENTION
[0010] The invention is based on further developing methods and apparatuses with the effect that as many as possible of the requirements specified below are satisfied:
[0011] 1. It should be possible to carry out the transferring of the web or the threading tail more reliably than hitherto possible and to do so in the production as many different paper grades as possible, even at the extremely high operating speeds of a modem paper making or converting machine (for example, at 2000 m/min or above);
[0012] 2. On the web guiding surface that outputs the web (for example, roll or cylinder outer surface), a tail doctor that has previously frequently been required should be made superfluous;
[0013] 3. Likewise, a mechanical severing device (knife) for the transverse severing of the web or the tail is to be avoided;
[0014] 4. During the transverse severing of the web or the tail, damage to the web or tail edges is to be avoided as much as possible in the region of the new start of the web or the tail, in order that the web or the tail does not tear in its further course, even at an extremely high running speed. For the same reason, the most stable run possible of the web or the tail from the web guide surface that outputs the web to the following web conveying apparatus, possibly to the vacuum belt conveyor, is desired to be achieved; and
[0015] 5. It is to be possible to arrange the following web conveying apparatus (in particular, if present, the vacuum belt conveyor) as close as possible to the normal web running path, for example close to the web running path which runs through a scanner, as it is known.
[0016] An important finding which has led to the invention is that the edge nozzles already known previously (see, for example, U.S. Pat. No. 1,688,267, FIG. 4, numbers 80 and 82 ) can be used not only to separate the paper web, in particular the tail, from the web guide surface that outputs the web, but, in addition, can also be used for the transverse severing of the web or the tail. This severing succeeds under the precondition that the edge nozzles eject a high-energy air jet, whose flow velocity is as high as possible yet only briefly so (ideally, if possible, only for a fraction of a second).
[0017] According to additional concepts relating to the advantageous refinement of the apparatus according to the invention, in the inlet region, e.g., of a vacuum belt conveyor or a rope conveyor (e.g., a rope guidance system), a transfer subassembly is provided which is used specifically for the safe transfer of the web or the tail from the web guide surface that outputs the web. This subassembly includes a pneumatic guide plate with devices for producing an air flow running on the guide plate in the web running direction. In addition, the subassembly for the transverse severing of the web or the tail includes a separating and severing device, which is designed as at least one edge nozzle. The air supply to the at least one edge nozzle is designed in such a way that a high-energy air jet is ejected briefly, specifically being done so between the web guide surface that outputs the web and the web or the tail, so that the web or the tail is severed transversely immediately as it is separated from the web guide surface.
[0018] An important idea which furthers the invention is making the aforementioned transfer subassembly (i.e., including guide plate and severing device) movable (for example, relative to the vacuum belt conveyor) such that the distance between the web guide surface that outputs the web and the aforementioned subassembly can be varied. In this way, during the threading operation, the subassembly can be positioned temporarily at a very short distance from the web guide surface that outputs the web. It is therefore possible for the gap between the web guide surface that outputs the web and the web conveying apparatus to be reduced, so that the size of the web or of the tail during the threading operation is reduced to the greatest possible extent. Before the threading operation (and possibly between successive threading attempts), the aforementioned subassembly can be positioned at a certain distance from the roll or cylinder that outputs the web. As a result, the web or the tail can run downwardly without hindrance (for example, into a broke pulper), so that blockages and/or damage to the web conveying apparatus are avoided.
[0019] Because, according to the invention, both the separating of the web or the tail from the web guide surface that outputs the web and the transverse severing are carried out pneumatically with the aid of the edge nozzles, both an additional tail doctor, often required earlier, and a mechanical severing device are dispensed with.
[0020] The transfer subassembly including a guide plate and severing device can be further configured to better promote the most secure transfer possible of the new start of the web or the tail. It is possible to provide additional blower openings immediately at the infeed end of the guide plate in order to produce an air flow that supports the transport of the web or the tail. These additional blower openings should preferably briefly eject high-energy air jets or a corresponding air curtain, preferably at the same time as the edge blower nozzles. As an alternative or an addition to such blower openings, the guide plate should have at its infeed end a so-called Coanda nozzle, such a nozzle having a rounded edge which, by using the Coanda effect, deflects an air flow (of the highest possible speed) in the direction of the guide plate. By this device, a vacuum zone is produced at the rounded edge and ensures secure guidance of the tail. This produced Coanda effect avoids the situation where the edge blower nozzles, in spite of only brief effect, compress the new start of the tail laterally after the transverse severing thereof. If the guide plate has a plurality of further blowing devices arranged one after another in the manner of a cascade, at least one of these further blowing devices can also be designed as a Coanda nozzle.
[0021] According to a further, supplementary embodiment of the invention, at its end on the outlet side (i.e., close to the conveying run of the belt conveyor), the guide plate has an air guide channel, which is curved in such a way that it leads away from the running path of the web or the tail. This air guide channel has two effects. First, it ensures deflection of the air boundary layer carried along by the belt and therefore renders the latter undamaging (i.e., it is ensured that at most part of this air boundary layer passes to the point where the tail is gripped by the vacuum belt conveyor). In addition, the air flow led along on the guide plate is led on the shortest route into the suction zone of the vacuum belt conveyor, and the major part of such air flow is extracted there. As a result, the web or the tail is gripped securely by the vacuum belt conveyor and conveyed onwards as intended. The air guide channel acts in a similar way when the tail is transferred into the rope pinch of a rope guidance system.
[0022] In operation, the operations mentioned above proceed at the full operating speed of the paper making or converting machine, for example at around 2000 m/min, and occur within a fraction of a second. Therefore, the features according to the invention form the basis for improved, successful threading operations, in particular in modem high-speed paper machines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0024] [0024]FIG. 1 is a schematic, side view of a tail transfer apparatus having a vacuum belt conveyor, arranged between a drying cylinder and a multi-roll calender of a paper machine;
[0025] [0025]FIG. 2 is an enlarged view of the inlet region of the vacuum belt conveyor shown in FIG. 1;
[0026] [0026]FIG. 2A is a view in the direction of the arrow A from FIG. 2;
[0027] FIGS. 3 - 5 are schematic, side views of different embodiments of the tail transfer apparatus, located in the inlet region of the belt conveyor;
[0028] [0028]FIG. 6 is a cross-sectional view of an edge nozzle designed as a Laval nozzle; and
[0029] [0029]FIG. 7 is a schematic, side view of a tail transfer apparatus having a rope conveyor.
[0030] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate at least one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0031] [0031]FIG. 1 reveals a vacuum belt conveyor 8 which is used to transport a moving web, preferably a threading tail 9 , specifically from last drying cylinder 6 of a paper making machine, for example, to a multi-roll calender 7 . As is known, threading tail 9 is part of a moving web (for example, a paper or board web). It is used to thread the web into the paper making or paper converting machine. Before the threading operation, severed web 9 a runs downward as indicated (FIGS. 1 and 2), being guided by a machine-width doctor 18 from cylinder 6 into a broke chest (not illustrated).
[0032] Vacuum belt conveyor 8 includes an air-permeable, endless conveyor belt 10 , which runs over two rollers 11 , 12 and a suction box or vacuum box 15 . Rollers 11 , 12 are arranged such that they can rotate in holders (not illustrated) which are fixed to suction box 15 . One of rollers 11 , 12 is provided with a drive, not illustrated. Indicated schematically is a vacuum source 17 for producing vacuum in suction box 15 .
[0033] The conveying run of conveyor belt 10 , which runs in the web running direction, is the upper run in the present case; a converse arrangement is likewise possible. A suction box 15 has a top plate 16 , in which slots (or similar openings) are provided. The conveying run of air-permeable conveyor belt 10 slides on plate 16 . As a result, threading tail 9 is sucked onto conveyor belt 10 and transported thereby. For the further guidance of tail 9 into calender 7 , a nose shoe 50 , as it is known, and a pivotable guide plate 63 (which are known from EP 1 076 130) are provided at the outlet end of conveyor 8 . Following a successful threading procedure, tail 9 is widened in a known manner; and the complete web, designated by 9 ′ in FIGS. 1 and 2, then runs from cylinder 6 over paper guide rolls 13 and 14 onto uppermost roll 7 ′ of calender 7 . Suction box 15 is formed as an elongated body. Other designs which, for example, have an internal apparatus for producing a vacuum on the conveying run of belt 10 , can likewise be used.
[0034] Provided in the inlet region of belt conveyor 8 is a transfer subassembly 20 . Transfer subassembly 20 is a tail transfer apparatus according to the invention. Transfer subassembly 20 includes a pneumatic guide plate 22 ; a low-pressure chamber 24 , which is connected via a line 25 to a compressed-air source 26 ; and a tail severing device 21 in the form of two edge nozzles. In operation, each edge nozzle 21 is arranged in one of the edge regions of tail 9 (see FIG. 2A). Each edge nozzle 21 is suitable for ejecting a high-energy air jet onto outer surface 6 a of cylinder 6 that outputs the web. This jet achieves the situation where tail 9 running downwards is separated from cylinder outer surface 6 a and, at the same time, tail 9 is severed transversely. From this point on, tail 9 runs with a new tail start over guide plate 22 to conveyor belt 10 and, with the latter, in the direction of calender 7 .
[0035] As can be seen from FIG. 2A, width b (order of magnitude 0.2 m) of tail 9 is only a fraction of the usual width of paper web 9 ′ produced or to be converted. It goes without saying that the working width of entire web conveying apparatus 20 is matched to tail width b. However, it is also conceivable to design transfer apparatus 20 according to the invention to be as wide as the machine in a relatively narrow paper converting machine.
[0036] [0036]FIG. 2 reveals that transfer subassembly 20 is supported on a rail 30 that is connected to suction box 15 and specifically so by a support 31 which can be displaced on rail 30 and by a pivoting lever 32 . As a result, transfer subassembly 20 can optionally assume an operating position, illustrated by solid lines, or a rest position, which is illustrated by dash-dotted lines in FIG. 2. In the operating position, distance a (see FIG. 3) between edge nozzles 21 and cylinder outer surface 6 a is only a few millimeters. In addition, guide plate 22 is inclined with respect to belt conveyor 8 . By using this configuration, two outcomes are facilitated:
[0037] 1. The conveying run of conveyor belt 10 runs rather close along the normal running path of paper web 9 ′ between guide rolls 13 and 14 . This running path often rises upwards, as illustrated in FIG. 1, but in other cases may be approximately horizontal; and
[0038] 2. At the same time, it is advantageous for the point at which edge nozzles 21 separate tail 9 from cylinder outer surface 6 a to be located rather far above the inlet region of belt conveyor 8 (i.e., in the region between cylinder 6 and paper guide roll 13 ). The tail separation position is determined, inter alia, by the desired position of dryer-fabric guide roll 5 following cylinder 6 (FIG. 1).
[0039] In the rest position of transfer subassembly 20 , guide plate 22 lies approximately parallel to belt conveyor 8 . Here, the distance between cylinder outer surface 6 a and edge nozzles 21 is many times greater than in the operating position. If required, transfer subassembly 20 can also be placed temporarily in a central, intermediate position provided between the rest and operating positions. In addition, a pivoting device, not illustrated, can be provided in order to pivot the entire apparatus (belt conveyor 8 with transfer subassembly 20 ) out of the region of the machine.
[0040] As illustrated, edge nozzles 21 are preferably fixed immovably in transfer subassembly 20 . However, it is also conceivable for edge nozzles 21 to be movable relative to guide plate 22 .
[0041] In order that edge nozzles 21 are capable of ejecting the required brief high-energy air jets, the following, by way of example, is provided: transfer subassembly 20 includes a high-pressure chamber 34 , to which both edge nozzles 21 are connected (FIGS. 2 and 3). High-pressure chamber 34 can be connected via a high-pressure line 36 to a high-pressure source 35 , producing compressed air having a pressure of about 5 to 15 bar (preferably about 7 to 10 bar). Provided in line 36 is a control valve 23 which, by of a timer signal carried by line 38 , can be opened briefly (for example, for 0.05 to 0.5 seconds). It is important that edge nozzles 21 eject the high-energy air jet only briefly, in order that the new start of tail 9 runs onward as far as possible without damage. In order to shorten the ejection time still further, each edge nozzle 21 can be assigned its own control valve 23 (FIG. 2A). As an alternative to FIGS. 2 and 3, edge nozzles 21 can form with each other a C-shaped tubular piece 40 or 41 into which high-pressure line 36 opens, as shown in FIGS. 4, 5. If a particularly high air outlet velocity (for example, ultrasonic velocity) is needed at edge nozzles 21 , it is possible to design edge nozzles 21 as Laval nozzles 21 A, as shown in FIG. 6.
[0042] According to FIG. 3, transfer subassembly 20 includes high-pressure chamber 34 , formed so as to have a rectangular hollow profile, and guide plate 22 which, at 42 and possibly at 42 a, has at least one step, and which at 43 is fixed in a stepped manner to high-pressure chamber 34 . Guide plate 22 and high-pressure chamber 34 , together with other walls 45 , 46 , bound low-pressure chamber 24 , already mentioned. On step 42 (and possibly on step 42 a ) there is a row of blower openings 44 , which extend transversely over plate 22 and through which the air flows out of chamber 24 . At step 43 , additional blower openings 44 are provided on high-pressure chamber 34 and are configured to eject high-energy air jets briefly at the same time as edge nozzles 21 . All blower openings 44 produce air streams which guide tail 9 along guide plates 22 in the direction of belt conveyor 8 . The number of steps 42 , 42 a and 43 can be greater than or less than shown in the drawing.
[0043] Wall 45 , running approximately parallel to outer surface 6 a , can have an extension which extends downwards, in order to guide severed part 9 a of tail 9 downwards. Here, too, if necessary, a step 48 with blower openings 44 can be provided.
[0044] A further special feature is that guide plate 22 has an air guide channel 49 at its end on the outlet side thereof, close to the conveying run of belt 10 . Air guide channel 49 is curved in the direction opposite to the running direction of the conveying run. The effect of such curvature has already been described further above. In further refinement (illustrated by dash-dotted lines), a resilient seal 60 slightly touching belt 10 can be provided.
[0045] According to FIG. 4, high-pressure chamber 34 a is configured in such a way, including C-shaped tubular piece 40 (which forms edge nozzles 21 ), that blower openings 44 which are active at the same time as edge nozzles 21 are positioned at a shortest possible distance a from cylinder outer surface 6 a.
[0046] [0046]FIG. 5 shows a very advantageous further development: at the infeed end of transfer subassembly 20 ′ there is a Coanda nozzle 50 , 51 with the following features: by use of a rounded edge of nose shoe 50 and thereby using the Coanda effect, an air stream led upwards from blower openings 51 is deflected in the direction of guide plate 22 . As a result, in the region of rounded edge 50 , a negative pressure zone is produced, which increases the security of the start of the transfer of tail 9 still further. In addition, within guide plate 22 , air can be supplied by at least one Coanda nozzle 52 , in order to produce a negative pressure zone. By such at least one Coanda nozzle 52 , tail 9 is supplied to belt 10 in a flat state, without any risk of fluttering.
[0047] [0047]FIG. 7 shows that a tail transfer apparatus 20 ″ according to the invention, including edge nozzles 21 and a pneumatic guide plate 22 , can also be used to transfer a tail 9 separated from a cylinder outer surface 6 a to another transport apparatus, e.g., to a rope guidance system 70 , instead of to a belt conveyor 8 . Illustrated schematically are two ropes 71 and 72 which run towards a roll 75 (in each case, over a rope pulley 73 , 74 ) and there form a rope pinch, thereat gripping incoming tail 9 in order to transport tail 9 onwards together.
[0048] Here, too, provision is made for edge nozzles 21 to eject a brief high-energy air jet, in order to separate tail 9 from cylinder outer 6 a and, at the same time, to sever tail 9 transversely, so that a new tail start is supplied to rope guidance system 70 without forming a double tail. Double arrow 69 indicates that transfer apparatus 20 ″ can be displaced to and fro between an operating and a rest position, in a manner similar to that described above with respect to FIG. 2.
[0049] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | An apparatus transfers a moving web of a flexible material from a web guide surface. The web guide surface outputs the moving web, and the moving web has at least one web edge. The apparatus includes at least one edge nozzle, each edge nozzle being positioned so as to be proximate one at least one web edge. Each edge nozzle is configured for separating the moving web from the web guide surface and is further configured to function as a severing device. Each edge nozzle is thereby configured for transversely severing the moving web and forming a new start portion thereof. Each edge nozzle briefly ejects therefrom a high-energy air jet, each high-energy air jet being ejected between the web guide surface and the moving web. | 3 |
This application is a continuation of application Ser. No. 116,604, filed Jan. 24, 1980, now abandoned.
FIELD OF THE INVENTION
This invention relates to a pressure pulse damping device for use in damping a pressure pulse in a liquid pipe and, more particularly, to a pressure pulse damping device for use in a liquid inlet for a paper machine, or for use in a pipe through which a liquid is fed to a stock inlet, or for use in preventing variations in the feed rate of a liquid to a stock inlet, or for subsequently preventing variations in the discharge rate of a liquid from a stock inlet and thereby obtaining uniformity in production. A pressure pulse absorbing device according to the present invention produces a specially good effect when it is utilized in a hydraulic stock inlet because these devices are highly sensitive to pressure pulses.
Conventional pressure pulse damping devices include surge tank and attentuator types.
First, a prior art surge tank type pressure pulse damping device will be described with reference to FIG. 1.
An inlet for a liquid is provided below the bottom wall of a surge tank 2, and an outlet 3 for the liquid is provided at a lower portion of the side wall thereof. Compressed air is supplied into the surge tank 2 from an upper air inlet to form a free liquid level 5 therein.
When the pressure at the inlet 1 is increased, the liquid level 5 is raised which compresses the air in the upper portion of the tank 2, and this increase in pressure is sensed by D/P cells 6, 6'. The pressure at the outlet 3 is increased by the sum of a value representing an increase in pressure which has caused the liquid level 5 to be raised and a value representing an increase in pressure in the upper portion of the tank 2. In order to maintain the pressure at the outlet 3 at a constant level, the air in the upper portion of the tank 2 is discharged into the atmosphere from a regulator valve 8 via a regulator gauge 7.
When the pressure at the inlet 1 is decreased, a suitable amount of air is introduced into the upper portion of the tank 2 via the inlet 4 or the valve 8.
Problematic pressure pulses are generally ones of 0.2-30 Hz. It has heretofore been difficult or impossible to sense pressure pulses of not less than 1 Hz by D/P cells 6, 6' in a surge tank type pressure pulse damping device as described above. Even when an electron tube type regulator gauge 7 is used, an operational delay of 1-2 seconds occurs between the pulse sensing and the actuation of the regulator valve 8 which responds to the regulator gauge 7. Furthermore, the presence of air in the surge tank 2 complicates the detection of a pressure pulse. The above mentioned problems have been obstacles to the easy and reliable detection of pressure pulses of not less than 1 Hz by a control system.
The above is a description of a system where the liquid level 5 in the tank 2 is varied without delay with respect to variations in pressure at the inlet 1. However, since an inertia force due to the mass of the liquid in the tank 2 occurs during operation when the liquid level 5 is varied it is difficult to vary the liquid level in accordance with variations in a high-frequency pressure. Consequently, the above-described pressure pulse damping device can be used mainly for sensing variations in a low-frequency pressure.
Additionally, variations in pressure of not more than 0.1 Hz can be sensed only if the number of revolutions of a liquid feed pump is controlled. Aside from the problems relating to the performance of the above-mentioned pressure pulse damping device, the portion of the inner surface of the tank 2 which is in contact with the air-liquid interface tends to become soiled. Furthermore, the tank 2 is substantially as large as the liquid stock inlet. The above described characteristics cause an increase in the manufacturing cost of the device.
Now, a prior art attenuator will be described with reference to FIG. 2. An inlet 9 of a liquid passage 11 has a circular cross section, and the passage 11 is gradually reduced in cross section from the inlet 9 to an intermediate portion thereof and finally to a semicircular cross section 10 as shown in FIG. 2b. A flat wall 10a is thus formed at the upper wall of the passage 11, and a diaphragm 12 consisting of a rubber plate is provided in the flat wall 10a. An air chamber 13 is provided atop the diaphragm 12, and air is introduced into the chamber 13 at a predetermined flow rate.
A tubular nozzle 14 having a bore in the central portion thereof is provided above and extended close to the upper surface of the central portion of the diaphragm 12 and is communicated with the atmosphere via a manually operable throttle.
The portion of the passage 11 which is on the downstream side of the diaphragm 12 is gradually enlarged in cross section until the downstream portion extends to an outlet 15.
Referring to FIG. 2a the reference numeral 16 denotes an air source, 17 an air filter, and 18 a porous plate.
When the pressure of the liquid is increased, the diaphragm 12 is moved upwardly toward and eventually abuts the open end of the nozzle 14 so that the discharging of air from the air chamber 13 is terminated. However, air is still fed into the air chamber 13 from a feed inlet 16 so that the pressure in the air chamber 13 is continuously increased.
When the pressure in the air chamber 13 becomes greater than the liquid pressure in the passage 11, or when the liquid pressure in the passage 11 is decreased, the diaphragm 12 moves downwardly and the air in the air chamber 13 is discharged to the atmosphere via the nozzle.
The diaphragm 12 is thus vertically moved to vary the capacity of the passage 11 so that variations in pressure of the liquid are damped. The volume of liquid which is required to effect the variations in capacity of the passage 11 corresponds to the variations in the flow rate of the liquid and are minimal as compared to the volume of liquid required in the above-mentioned surge tank type pressure pulse damping device. Accordingly, the operational delay due to an inertia force can be minimized in the attentuator device as compared to a surge tank device. Since the pressure in the air chamber 13 is controlled by the diaphragm 12 exhibiting only a small inertia force and without using a measuring instrument, the attentuator type device can be smoothly operated thereby producing a good effect with respect to high-frequency pressure pulses of not less than 3 Hz.
However, when the pressure pulse of liquid in a system as shown in FIG. 2 is decreased to around 0.5 Hz, the system works as a pressure pulse amplifier because the cycle of pressure increase, for example, in the passage 11 (containing the liquid) is long. Therefore, when the pressure in the passage 11 is increased, the pressure in the air chamber 13 is also increased due to the air being continuously fed thereinto from the air source 16 until the liquid which has been passed through the rubber plate 13 is forced out by the upward movement of the rubber plate 13. As a result, the pressure of the liquid is increased.
When the pressure of liquid is decreased for an extended period of time, the air in the air chamber 13 is discharged therefrom to allow the liquid in the passage 11 to be act on the diaphragm 12. As a result, the pressure of the liquid is decreased. Variations in flow rate per cycle of low-frequency pulses are generally greater than that of high-frequency pulses. If the low-frequency pulses are amplified by an attenuator, the attenuator may lose its significance as a pulse damping device.
Moreover, the diaphragm 12 is expanded and deformably stretched with the lapse of time of use, and therefore the portion of the diaphragm 12 which contacts the nozzle 14 is waved or wrinkled which causes air leaks at all times. As a result, the diaphragm 12 ceases to function effectively as an exhaust valve. In the worst of situations, the effect of the attenuator is remarkably decreased with only a day's use.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the drawbacks encountered in the above-described conventional pressure pulse damping devices.
Another object of the present invention is to provide a pressure pulse damping device having a stable attenuating effect over a long period of time with respect to pressure pulses of not more than 1 Hz and also substantially the same effect over a long period of time with respect to pressure pulses of 1-30 Hz.
A pressure pulse damping device according to the present invention is characterized by the following.
(a) A flat wall is provided at the bottom periphery of a liquid passage, and a diaphragm coprising a rubber plate, which has a small mass and which is easily deformable is provided in the flat wall. A chamber is provided on the opposite side of the flat wall defining the liquid passage and on the opposite side of the diaphragm. This chamber is substantially a sealed chamber in which a gas, the pressure of which is substantially equal to the average pressure of the liquid, is contained. The diaphragm is deformed in accordance with the pressure pulses of the liquid so as to vary the capacity of the liquid passage and thereby damp the pressure pulses. Since the sealed chamber contains a gas therein, the chamber merely cooperates in damping the pressure pulses irrespective of the amplitude of cycle of the pressure pulses and never causes the pressure pulses to be amplified. Since the amount of the liquid stored or discharged in accordance with the deformation of the diaphragm can be set equal to the amount of pulse current corresponding to the pressure pulse, an inertial resistance occurring due to the movement of liquid can be minimized.
(b) The diaphragm is provided in a lower portion of the wall of the liquid passage such that the diaphragm can be vertically moved. The gas sealed in the chamber is adiabatically expanded or compressed in accordance with the vertical displacement of the diaphragm so that the pressure in the chamber is decreased or increased. In the meantime, the pressure of the liquid cannot be kept constant unless the pressure applied thereto by the diaphragm is decreased or increased in accordance with the vertical movements of the diaphragm. Therefore, if the chamber is provided in a lower portion of the wall of the liquid passage, to suitably vary the capacity of the chamber, the pressure of the liquid can be kept constant irrespective of the position of the diaphragm.
(c) Since a gas of a pressure equal to an average pressure of the liquid is sealed in the chamber to allow the diaphragm to be vertically displaced in accordance with the pressure pulses such that the diaphragm is not forced to an upper or lower limit position, the position of the diaphragm can be detected by limit switches, differential transformers, potentiometers, or proximity switches so that the introduction or discharge of gas into or from the chamber is conducted only when the diaphragm comes close to a stroke end. The introduction or discharge of gas into or from the chamber is not conducted when the diaphragm is in other position than the ones mentioned above. Thus, the above-mentioned characteristics can be obtained.
(d) The capacity of the gas chamber which is referred to in paragraph (c) above varies as a function of the average pressure of the liquid. Therefore, a substantially compressible fluid or gas is utilized in the chamber or a tank communicating with the chamber such that the characteristic referred to in paragraph (b) can be obtained even when the operational conditions are altered such that the average pressure of the liquid has changed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a conventional prior art surge tank type pressure pulse absorbing device;
FIG. 2a is a sectional view of a principal part of a conventional prior art attenuator;
FIG. 2b is a sectional view taken along the line X--X in FIG. 2a;
FIG. 3a is a side elevational partially sectional view of a pressure pulse absorbing device embodying the present invention;
FIG. 3b is a sectional view taken along the line Y--Y in FIG. 3a;
FIG. 4 is a sectional view taken along the line Z--Z in FIG. 3a, with pipes schematically shown;
FIG. 5 is a diagram of an electric circuit of the embodiment shown in FIG. 4;
FIG. 6 is a perspective view of a principal portion of another embodiment of the present invention;
FIG. 7 is a side elevational sectional view of still another embodiment of the present invention;
FIG. 8 is a side elevational view of another type of guide mechanism for a support rod;
FIG. 9 is a side elevational sectional view of a further embodiment of the present invention;
FIG. 10 is a side elevational sectional view of a further embodiment of the present invention; and
FIG. 11 is a side elevational sectional view of a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 3a and 3b, the fluid passage 19 in the area adjacent a chamber 22 is hemispherical in cross section. At least part of the flat wall thereof is replaced with a diaphragm 21. The chamber 22 is positioned under the diaphragm 21, and a gas, such as air is contained in the chamber 22. When the volume of gas in the chamber 22 is low, a volume tank 23 is communicated therewith in a suitable manner. A level gauge 24 is provided in the volume tank 23, which is adapted to allow a gas to be placed therein and discharged therefrom. The chamber 22 contains a gas and its pressure is equal to the average pressure of the liquid.
An diaphragm 21 can be moved from an upper limit position T to a lower limit position B. The embodiment as shown in FIG. 4 employs limit switches as means for detecting the upper and lower limit positions T and B.
A support frame 25 comprising of a porous plate is secured to the diaphragm 21, and a support rod 26 is fixed to the central portion of the support frame 25. A control member 27 is fixed to the support rod 26. A limit switch 28 for detecting an upper limit position of the diaphragm and a limit switch 29 for detecting a lower limit position thereof are provided within the chamber 22. The limit switches 28, 29 are actuated by the control member 27 when the diaphragm 21 reaches the upper limit position and the lower limit position, respectively.
A guide member 30 is fixed to the wall of the chamber 22 via a porous plate 31 such that the support rod 26 can be moved in the vertical direction within the guide 30.
When the diaphragm 21 reaches the lower limit position B, the peripheral portion of the porous plate 31 serves as a support for the diaphragm, and the central portion of the porous plate 31 as a support for the support frame 25. Even when the diaphragm 21 is moved downward vertically the space thereunder is kept in communication with the interior of the chamber 22 via bores in the support frame 25 and the porous plate 31 so that the pressure in the space can be kept equal to that of the interior of the chamber 22.
Referring to FIG. 4, reference numeral 32 denotes a drain valve; 33 a safety valve; 34 an air charge valve; 35, 36, and 37 air filters; 38, 39 electromagnetic valves; 40 an air supply source in a factory; 41 an air discharge valve; 42 an air relief pipe; 43 a water feed pipe; and 44 a water discharge pipe.
The operation of the above embodiment will be described with reference to FIGS. 4 and 5.
When the pressure of a liquid in the liquid passage 19 is increased, the diaphragm is moved downwardly, and the limit switch 29 which detects the lower limit position of the diaphragm 21 is actuated, and the air charge valve 34 is gradually opened so that air begins to be gradually introduced into a volume tank 23 which is connected to the chamber 22. The gas influx causes the diaphragm to move upwardly. When a predetermined period of time has elapsed after the control member 27 is moved from the limit switch 29, the air charge valve 34 is gradually closed. As a result, the feed rate of air into the volume tank 23 is gradually decreased and finally stopped.
When, on the contrary, the pressure of the liquid is decreased, the diaphragm is moved upwardly, and the limit switch 28 which defects the upper limit position of the diaphragm 21 is actuated, and the air discharge valve 41 is gradually opened so that the air in the volume tank 23 begins to be gradually discharged therefrom. The gas discharge causes the diaphragm to move downwardly. When a predetermined period of time has elapsed after the control member 27 is moved from the limit switch 28, the air discharge valve 41 is gradually closed. As a result, the discharge rate of air from the volume tank 23 is gradually decreased and finally stopped.
Diagrams of examples of air circuit and electric circuit for carrying out the above-described operation are shown in FIGS. 4 and 5.
If the air charge valve 34 and air discharge valve 41 are actuated as mentioned above, the time for feeding and discharging air can be suitably adjusted by timers TMB, TMT. The diaphragm 21 can be moved between the upper and lower limit positions when the pressure of the liquid is changed. When the pressure of the liquid is increased or decreased in accordance with the pulsation of the liquid, the diaphragm 21 can be moved between the upper and lower limit positions if the magnitude of the resulting pulse current is within the range of levels which can be damped while the diaphragm 21 is vertically moved.
When the pressure of the liquid is increased by the pulsation thereof with the average pressure of the liquid and of the air in the chamber 22 being in a state of equilibrium, the diaphragm 21 is downwardly swelled such that it abuts the support frame 25. Assuming that the pressure of the air in the chamber 22 is not changed at all, the pressure of the liquid in the passage 19 is decreased by a level corresponding to the pressure of that portion of the liquid which is displaced by the downwardly swelled diaphragm 21.
In fact, the gas in the chamber 22 is adiabatically compressed by a level corresponding to that portion of the gas which is displaced by the downwardly swelled diaphragm 21, so that the pressure of the air in the chamber 22 is increased. Thus, a decrease in the pressure of the liquid can be prevented. The same situation applies to a case where the pressure of the liquid is decreased due to the pulsation thereof. Accordingly, if a total capacity of the chamber 22 and volume tank 23 is set to a suitable level, the pressure of the liquid can be kept constant.
When the frequency of a pulse is increased, the amplitude may be increased but variations in the flow rate of the liquid per cycle of pulse is small as compared with that flow rate variation per cycle of a low-frequency pulse. Therefore, a high-frequency pulse can be effectively damped by the swelling of the diaphragm 21 alone as shown in chain line in FIG. 4 without moving the support frame 25. As is clear from the above disclosure the stroke of the diaphragm 21 of the device can be minimized and a high-frequency pulse can be effectively eliminated.
The embodiment described above and shown in FIGS. 3 and 4 employs a trapezoidal diaphragm. A diaphragm of a respectively greater diameter is required for a liquid having a respectively greater flow rate. However, the characteristics of the present invention do not reside in the shape of the diaphragm; and therefore, the diaphragm may be of a truncated pyramid or of a plate type if it is made of a material of a high elasticity.
FIG. 6 shows another embodiment of the present invention which includes a porous plate 45. Unlike the embodiment shown in FIGS. 3 and 4, in which the portion of the liquid passage 19 which is provided with the diaphragm 21 has a semicircular cross section, the liquid passage in the embodiment shown in FIG. 6 may have a rectangular cross section since the passage need only have a flat lower wall for the convenience of providing a diaphragm therein. In addition, in a pressure pulse damping device according to the present invention there is no criticality as to the shape of the liquid leading into and going out of the passage section where the diaphragm is positioned. Accordingly, a liquid-introducing and discharging passage can be circular in cross section and gradually changed in cross section toward the diaphragm-carrying portion. However the cross section of the passage, accommodating the diaphragm should substantially resemble that of FIG. 3a. Thus, the liquid passage may comprise a plurality of different cross-sectional parts which are joined together with flanges in those positions of the passage which are immediately before and after the diaphragm-carrying portion.
A pulse damping device in general is adapted to easily damp pressure pulses in a fluid passage. Accordingly, the pulse damping device of the present invention in essence constitutes a node of a stationary wave. The pulse damping device may be disposed with respect to any portion of a passing wave but it should be disposed at an abdominal portion rather than a nodular portion of a stationary wave. Consequently, a combination system is also effective in which a porous plate 45 as shown in FIG. 6 is provided immediately before a diaphragm-carrying portion of a fluid passage so as to prevent a node of a stationary wave from coinciding with the diaphragm-carrying portion of a fluid passage.
In the embodiment shown in FIGS. 3 and 4, a support rod 26 is connected to the support frame 25 and can be moved along a guide 30. A support frame 46 in an embodiment as shown in FIG. 7 is provided with a link 47 so as to allow a diaphragm 21 to be vertically moved.
In a guide mechanism, as shown in FIG. 8, rollers 48 are provided around a support rod 26 which function like the guide 30 the function thereof being disclosed with respect to the embodiment as shown in FIGS. 3 and 4.
In short, a guide mechanism need only to be constructed so as to substantially eliminate mechanical resistance and inertial resistance due to the mass of a diaphragm. These resistances present obstacles to the diaphragm's movement because the diaphragm is moved by the differential pressure the liquid and the air. Additionally, the guide mechanism also must be constructed such that the diaphragm can reach the upper and lower limit positions and can be detected when these respective positions have been reached.
The detection of a respective position of a diaphragm will be described. The embodiment shown in FIGS. 4 and 5 employs limit switches for the detection of the diaphragm 21 when in upper and lower limit positions, but these limit switches may be replaced with other means. A means for detecting the diaphragm when in the upper and lower limit positions may be constructed, for example, as shown in FIG. 9. The detection means shown in FIG. 9 comprises a reflector member 49, made of a metal foil and fastened to the surface of the diaphragm 21 which is facing the chamber 22, a light projector 50, fixed to the inner surface of the chamber 22, and light receivers 51, 52, fixed to the inner surface of the chamber 22 to receive light from the diaphragm 21 when it is in the upper and lower limit positions.
Other detection means may be used as those skilled in the art can readily appreciate for example, proximity switches, potentiometers, servo-motors and differential transformers may be used. Where anyone of the above-mentioned detection means is used, a diaphragm 21 may be supported as shown in FIG. 10. Referring to FIG. 10, a connecting rod 53 is joined at its one end with a pin to a support frame 46, and a swing arm 54 is pivotally connected at its one end to the other end of the connecting rod 53. The swing arm 54 is pivotally connected at the other end thereof to the inner surface of a side wall of a chamber 22. When the diaphragm 21 reaches the upper or lower limit position, the swing arm 54 is respectively moved upwardly or downwardly. As a result, proximity switches 57, 58 provided on the inner surface of a side wall of the chamber 22 are actuated by projections 55, 56 which extend respectively upwardly and downwardly from the swing arm 54. Thus, when the diaphragm 21 is in the upper or lower limit position, this information is sensed by proximity switches 57, 58.
Further an ultrasonic position detector may be provided in the bottom portion of a chamber 22, so that when the diaphragm 21 is in the upper or lower limit position the ultrasonic waves reflected on the diaphragm 21 serve as a means to indicate this fact.
In the embodiment as shown in FIG. 4, an air charge valve 34 and an air discharge valve 41 are provided so as to respectively feed or discharge air from the volume tank when a diaphragm 21 reaches the upper or lower limit position. In this case, the feeding or discharging of gas is gradually initiated and gradually terminated in order to prevent the liquid from being influenced by an external force. In order to carry out the this operation, the electric valves may be used.
A pressure pulse damping device according to the present invention may be utilized in a stock inlet structure. In order to apply a device according to the present invention to the structure as shown in FIG. 11, the device is positioned in the bottom wall of a staling chamber 59. A volume tank 23 can be provided within the stock inlet body, or a part of the stock inlet body can be utilized as a volume tank. Therefore, it is not necessary to provide additional space for installing the pressure pulse damping device and the accompanying volume tank.
A pressure pulse damping device according to the present invention has a construction essentially as described in detail above. Therefore, under certain conditions when pressure pulses occur in the liquid, the diaphragm is moved upwardly or downwardly. When the pressure of the liquid is increased whereby the diaphragm is moved downwardly to the lower position B, since the diaphragm is provided in the lower portion of the wall in the liquid passage, it is necessary that the pressure on the other side of the diaphragm be increased by an amount corresponding to the amount by which the lower surface of the liquid passage is lowered. Since the sealed chamber contains gas initially at a pressure equal to the average pressure of the liquid because the gas in the chamber is compressed by a volume equal to that by which the volume of the chamber is reduced when the diaphragm is lowered the pressure of the gas in the chamber is increased. When the pressure of the liquid is decreased, the pressure in the chamber is decreased by the expansion of the gas in the chamber. Consequently, if a chamber of a suitable capacity is provided under the diaphragm, a gas pressure increase due to an adiabatic compression of the gas places the gas pressure in equilibrium with the liquid pressure even though there is a resistance to the displacement of the diaphragm and a resistance to the deformation of the diaphragm.
A pressure pulse damping device according to the present invention is actuated for the damping of pulses in a manner unlike a surge tank type pressure pulse damping device. However, the mass of a pressure pulse damping device according to the present invention is small as compared to the devices as discussed as prior art herein; and therefore, it has relatively excellent high frequency characteristics.
In addition, a device according to the present invention contains sealed air so that it has improved low frequency damping characteristics which are irrespective of the responding and sensing capabilities of gauges etc.
A device according to the present invention can be manufactured at a relatively low cost and can be installed substantially anywhere. Moreover, no parts therein are exposed to a gas-liquid interface, and, consequently, the device is seldom soiled thereby increasing its useful life.
A device according to the present invention is more responsive to low-frequency pulses than a conventional attenuator, and, even when the diaphragm is expanded through use, it does not adversely affect the performance of the device.
Although a device according to the present invention is slightly inferior to a prior art attenuator with respect to the capability of eliminating high-frequency pulses, it is sufficiently effective in damping pressure pulses of up to forty Hz. Accordingly, a device according to the present invention can be used to substantially damping to high-frequency pulses.
In practice both, low and high frequency pulses are propagated in a system. Therefore, a conventional attenuator may not be effective with respect to intermediate and high frequency pulses particularly when the diaphragm is fully displaced by a low frequency component of a large variation in the flow rate per cycle. However, a device according to the present invention does not have this drawback. | A pressure pulse damping device which is used in a liquid passage having a bottom flat wall. The flat wall has an opening therethrough with a flexible diaphragm positioned therein. The side of the diaphragm opposite the liquid passage is in communication with a gas chamber having gas therein. The diaphragm is movable such that the effective volume of the gas chamber is varied to ensure that the average pressure of the gas therein is substantially equal to the average pressure of liquid in the liquid passage. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/285,284, filed Dec. 10, 2009, and entitled “Wakeboard Tower System,” incorporated by reference herein in its entirety.
FIELD
[0002] The present disclosure relates to boat towers, such as wakeboard towers, radar arches, and the like. More particularly, the disclosure relates to boat towers in the nature of wakeboard towers which utilize cast structural members.
BACKGROUND
[0003] Structures such as wakeboard towers, radar arches and other arch systems of the type found on boats are conventionally made using as structural members aluminum tubing of various cross-sectional configurations welded together. The use of such tubing members requires substantial hand-treatment in the nature of bending, sanding, polishing, painting, powder coating, and the like to provide the tower structure with an aesthetically pleasing shape and smooth finish. In addition to these shortcomings, the use of structural members made from tubing also limits the compatibility of the tower for incorporating other aesthetic features as well as other components, particularly electrical components such as speakers, illumination, and the like.
[0004] The present disclosure relates to improved arch or tower structures which utilizes structural members that do not require bending of the components or significant buffing, polishing, and the like in the manner of tubing and are thus less labor intensive to produce. The structural members may also readily include additional aesthetic features as well as components such as speakers, illumination, and the like.
SUMMARY
[0005] The above and other needs are met by a composite member especially suitable for use in a wakeboard tower. In one aspect of the disclosure, the composite member includes a structural member having molded decorative members attached to opposite sides of the structural member. The structural member may be, for example, a cast aluminum structural member, a fabricated beam structural member, or a tubular structural member.
[0006] In an additional aspect of the disclosure, the structural member includes a pair of spaced apart side rails, between which spans an intermediate section, with the decorative members substantially covering the intermediate section and adjacent surfaces of the side rails so that such portions of the structural member do not require sanding or finishing.
[0007] In another aspect of the disclosure, the decorative members are vacuum formed plastic panels or fiberglass or plastic sheet panels. In certain embodiments, the panels include electrical speakers or electrical lights or other electrical components integrated therein.
[0008] In a further aspect of the disclosure, the decorative members may be removed from the wakeboard tower provided by the composite member and replaced with other decorative members.
[0009] The disclosure also relates to a method of manufacturing a boat tower, including the steps of: providing a structural member having exterior surfaces requiring finishing in order to have suitable aesthetics; providing decorative members having a desired aesthetic appearance; and attaching the decorative members to opposite sides of the structural member so as to substantially cover the exterior surfaces of the structural member to yield a composite boat tower structure.
[0010] The resulting composite boat tower structure has suitable aesthetics and requires substantially less finishing of the surfaces of the structural members as compared to conventional boat tower structures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Further advantages of the disclosure are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
[0012] FIGS. 1 and 2 are exploded perspective views of structural members and decorative members for use in providing wakeboard towers according to the disclosure.
[0013] FIG. 3 is a perspective view of a structural member according to the disclosure.
[0014] FIG. 4 is a perspective view of a wakeboard tower according to the disclosure.
[0015] FIG. 5 . is a side view of a portion of a wakeboard tower according to the disclosure, and
[0016] FIG. 6 is a cross-sectional view taken along line A-A of FIG. 5 .
[0017] FIG. 7 depicts a wakeboard tower according to the disclosure and which incorporates speakers with the decorative member.
[0018] FIG. 8 depicts a wakeboard tower according to the disclosure and which incorporates lighting elements with the decorative member.
DETAILED DESCRIPTION
[0019] With reference to the drawings, the disclosure relates to a composite member 10 especially suitable for use in a wakeboard tower 12 ( FIG. 4 ). The composite member 10 includes a structural member 14 having decorative members 16 and 18 attached to opposite sides of the structural member 14 . The composite member 10 is mountable to a structure, such as a boat B ( FIG. 1 ).
[0020] The composite member 10 advantageously minimizes sanding and finishing typical to conventional wakeboard tower construction, while offering decorative appearances atypical to conventional wakeboard towers, and which may be customized and changed.
[0021] While the structures are described herein in the context of a wakeboard tower, it will be understood that the structures are applicable to other raised structures, such as radar arches, flying bridges, and the like used on boats.
[0022] In one embodiment, the structural member 14 is a unitary member of cast construction. For example, the structural member 14 may be of aluminum or polymeric cast construction or a fabricated beam structural member. The use of a cast member is desirable to avoid the need for bending as is required in tubing structures or other structures having a plurality of joined members. However, it will be appreciated that tubular structural members assembled from a plurality of smaller members joined together as by bolts or other fasteners, or welding, such as is common for tubular structural members, may be used, with the decorative members 16 and 18 configured for use with a tubular structural member if desired. In this regard, structures according to the disclosure also advantageously enable elimination of a substantial portion, if not all, of the need for sanding, polishing, painting, and powder coating of the tubular or other assembled member. For the purpose of describing a preferred embodiment, the structural member 14 is described in the context of a unitary cast member.
[0023] The structural member 14 includes a pair of spaced apart side rails 20 and 22 , between which spans an intermediate section 24 . The intermediate section 24 may be formed having a lattice or oval strut design, as a thin wall with open port holes, or using various other designs which further reduce materials costs and weight of the structural member 14 . In certain alternate embodiments, the intermediate section 24 between the side rails 20 and 22 may substantially be void of any structure.
[0024] To receive the decorative members 16 and 18 in a snap fit or other fastened manner, the structural member 14 , or other structural member used if not cast, may include attachment features, such as projections 26 ( FIG. 3 ) to promote a snap-fit engagement of the decorative members 16 and 18 . The projections 26 are preferably located on the intermediate section 24 of the structural member 14 . In this regard, it will be understood that the decorative members 16 and 18 may also be reliably mounted to withstand use conditions of wakeboard towers, but preferably removably mounted onto the structural member 14 utilizing adhesives, hook and loop material, fasteners, and the like.
[0025] The exterior surfaces of the side rails 20 and 22 will typically be visible and represent surfaces that may be sanded and finished, such as by painting or powder coating. The remaining surfaces of the side rails 20 and 22 and the intermediate section 24 are covered by the decorative members 16 and thus are not sanded or finished, thus greatly reducing the amount of surface area of the side rails 20 and 22 that are sanded and finished. However, if desired it will be understood that the decorative members 16 and 18 may be configured to cover substantially all exterior surfaces of the side rails 20 and 22 of the structural member 14 , thus virtually eliminating all need for sanding or other finishing.
[0026] For the purpose of example, and with reference to FIG. 6 , the structural member 14 has surfaces S 1 -S 16 . However, when the decorative members 16 and 18 shown in FIGS. 1-6 are used, only surfaces S 1 , S 2 , and S 16 associated with the rail 20 and surfaces S 8 , S 9 , and S 10 associated with the rail 22 are exposed and typically need to be sanded and finished to provide the desired appearance and aesthetics. The majority of the surfaces, i.e., the surfaces S 3 -S 7 and S 11 -S 15 , are covered by the decorative members 16 and 18 and need not be significantly sanded and/or finished. In this regard, it will be understood that FIG. 6 is a cross-sectional view showing the decorative member 18 not installed and the other decorative member 16 installed on the structural member 14 .
[0027] The decorative members 16 and 18 may be the same or different to one another and may represent the same or different aesthetic appearances and functional structures. For example, the members 16 and 18 may be vacuum formed plastic panels, or fiberglass or plastic sheet panels incorporating various color schemes, graphics, or other visual effects, such as lenticular materials and printing that provides a three-dimensional visual effect. The decorative members 16 and 18 may have a fabric or other finish, with the members 16 and 18 being of relatively lightweight and rigid construction. The decorative members 16 and 18 are preferably removably mounted to the structural members 14 to enable them to be readily changed out if desired so that another decorative or aesthetic expression may be presented on either or both sides of the structural member 14 .
[0028] As mentioned above, various snap-fit or other fastening arrangements may be utilized to attach the decorative members 16 and 18 to the structural member 14 . In this regard, it will be understood that the attachment features may be provided on the decorative members 16 and 18 or the structural member 14 or both. For example, the decorative member 16 is shown ( FIG. 1 ) having apertures 28 for passage of fasteners, such as screws or the like. With reference to FIGS. 2 and 6 , it will be seen that interior surfaces of the side rails 20 and 22 adjacent the intermediate section 24 are contoured, with the decorative member 16 having matching or corresponding contours to yield a snap-fit relationship. The decorative members 16 and 18 may also be permanently attached if desired, as by adhesives, sonic welding, overmolding, or the like.
[0029] The decorative members 16 and 18 may also incorporate other components, including electrical components such as speakers, illumination, and the like. For example, FIG. 7 shows one of the decorative members 16 or 18 having a plurality of audio speakers 30 located thereon, and FIG. 8 shows one of the decorative members 16 or 18 having a plurality of illumination devices 32 , such as electrical lights or light emitting diodes, located thereon. The wiring for the speakers 30 or the illumination devices 32 may be located either within the decorative member 16 or 18 or on the back side thereof so as to be hidden from view.
[0030] Utilizing the composite members 10 in accordance with the disclosure to manufacture wakeboard towers enables significant reductions in the labor needed to manufacture wakeboard towers. For example, it is believed that towers made using the composite members 10 involve only about 10 to 20 percent of the handwork (sanding and finishing) required in the manufacture of conventional wakeboard towers. As will be appreciated, this results in considerable economy. The towers according to the disclosure also have substantial advantages in that customized decorative appearances may be readily provided and repeatedly changed if desired. Also, the towers may incorporate other components, such as electrical components including speakers and lighting in an integrated manner. This is advantageous both from an ease of installation and incorporation standpoint, as well as an aesthetic standpoint.
[0031] The foregoing description of preferred embodiments for this disclosure has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the disclosure and its practical application, and to thereby enable one of ordinary skill in the art to utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. | A boat tower and methods for making in which the tower is made of one or more composite members, each including a structural member and molded decorative members attached to opposite sides of the structural member, resulting in a tower system that requires substantially less finishing of the surfaces of the structural members as compared to conventional boat towers. | 8 |
INVENTION PRIORITY
[0001] The present patent application claims priority as a continuation-in-part of U.S. patent application Ser. No. 13/324,118, filed Dec. 13, 2011, entitled “VOICE ALERT METHODS, SYSTEMS AND PROCESSOR-READABLE MEDIA”, which was also filed with priority to provisional patent application serial number 61/489,621, on May 24, 2011.
TECHNICAL FIELD
[0002] The present invention is related to emergency communications systems. The present invention is also related to unmanned vehicles (air, ground, and maritime). More particularly, the present invention is related to systems and methods using unmanned vehicles within an improved communications system to provide real-time data for civil emergency notification purposes.
BACKGROUND
[0003] Most mass notification technologies send the same message to everyone, regardless of their role, responsibilities, location, or involvement in a critical situation by means of a large-scale telephone call out to pre-determined contact lists. These initial notifications include and usually start with 911 calls or official notifications to regulatory agencies if the situation requires it. An increasing number of notification systems provide two-way telephone communication with feedback loops, short response messages, and conference bridging to facilitate teamwork. City website also exists to keep information flowing from official sources to help residents respond to all types of emergencies.
[0004] Unmanned Aerial Vehicles (UAVs) have become the leaders in persistent surveillance over the past several years for federal and state agencies (e.g., U.S. Military, FBI, local and state police, U.S. Forest Service, U.S. Border Patrol, etc). Private commercial applications are also feasible and foreseeable (e.g., large private land holdings or leased open space, environmental and geographical data gathering, university research). UAVs have the distinctive capability of providing better-than-human, aerial, visual information to ground units that may not have the time or means to use a manned plane for their surveillance/reconnaissance. The RQ-11 Raven, for example, is a man-packable, hand-launched, unit-controlled UAV that is used primarily by Air Force Special Operations Command (AFSOC) to easily scout ahead without unnecessary risk to personnel or risk of detection. The RQ-11 Raven, however, has a short dwell time (e.g., the total time of operation in air) limited data acquisition capabilities (e.g., restricted camera and sensor payload). More robust UAVs are larger, require more sophisticated launch systems, can operate for longer durations of time, and can carry an array of sensors and communications capabilities.
[0005] A ground control operator can remotely fly and control an unmanned aerial vehicle (UAV), also known as a pilotless drone. Land- and maritime-based vehicles are similarly controlled. These unmanned vehicles are equipped with camera equipment and are best known for capturing real-time images during warfare, but now these drones have become increasingly affordable for use in civilian high risk incidents such as search missions, border security, wildfire and oil spill detection, police tracking, weather monitoring, and natural disasters. During its mission, the airborne drone acquires image data from the camera and flight parameters from onboard systems. The aerial footage captured by the camera onboard the UAV is transmitted to the Ground Control Station which transfers it to their work station for analysis and possible enhancement. A frame grabber digitizes image data and transfers it to a Host PC and multiple embedded processor boards to achieve real time image processing. UAV software can be used in the playback of the flight video image and data captured by the unmanned mission in a form of DVD connected to the embedded vision system. Such a system typically processes the images using Image processing application software in the form a GUI menu, which displays input and processed images for analysis.
[0006] The size of the image to be processed by remote sensing end users is typically 20-40 Mbytes per spectral band. Digital image processing involves the implementation of computer algorithms aimed to fulfill several tasks in acquisition, management, and enhancement and processing of images in digital format. Thus, with the widespread development of computer technology, it has become the subject of many useful computer applications.
[0007] Land based unmanned vehicles can also be utilized to collect data. Like UAVs, ULVs (unmanned land vehicles) are operated at a distance by wireless remote control. A remote operator manages most operations, while data collection can occur automatically with onboard sensors and cameras.
[0008] Despite the increasing rollout of unmanned vehicles (air and land), their use and data collection is generally restricted to government users and for government activity. Some data that is collected by these modern resources can, however, provide important, life-saving information to civilians. The present inventors believe that some collected data can be chosen for real-time public release to assist civilians at times of state or national emergency. Many current examples are in the press on a regular basis where additional data could have assisted civilians faced with emergency situations. For example, during the 2011.Las Conchas Fire near Los Alamos, N. Mex., a number of New Mexico citizens living near the fire had to form a telephone circle to keep up with the latest and that they were still angry because this form of “old school media” was too slow and not specific enough. These New Mexico citizens complained how the Internet was falling short of its potential, and because of this, they needed to check and recheck many sources to keep up to date and that another downer was that these sources turned out to be updating information intermittently. Those monitoring the fire praised Facebook and Twitter feeds for keeping them informed on their friends, but said that the Los Alamos County Government had very little information on its fire-related site. The Las Conchas Fire 2011 Wildfire in New Mexico burned more than 150,000 acres, threatening Los Alamos National Laboratory and the town of Los Alamos. After five days of burning, it became the largest wildfire in New Mexico's state history.
[0009] Currently, existing emergency services continue to operate solely within their own limited spheres with no sourcing real-time drone images for the rapid integration of such intelligence within the architecture of their emergency system. None of these mass notification services are deploying up-to-the-minute UAV aerial imagery to automatically notify the public in real-time via transmission to public recipient computers, portable devices, and smartphones, and with a secondary purpose of providing the notified recipients with the ability to engage others by retransmitting received messages along with their own typed notations so as to be able to communicate continually in an ongoing and multilingual manner, thus forming their own real-time Civic Communications Hub for ongoing situational awareness and providing age-appropriate advice to family and friends, according to the ongoing dangers of the situation being faced.
[0010] Most mass notification technologies send the same message to everyone, regardless of their role, responsibilities, location, or involvement in a critical situation by means of a large-scale telephone call out to a pre-determined contact lists. These initial notifications include and usually start with 911 calls or official notifications to regulatory agencies, if the situation requires it. An increasing number of notification systems provide two-way telephone communication with feedback loops, short response messages, and conference bridging to facilitate teamwork. City websites also exist to keep information flowing from official sources and to help residents respond to all types of emergencies. But none of these services are contributing real-time drone images as an alternative means of spreading critical information to the endangered public as quickly as possible.
[0011] Based on the foregoing, there is clearly a growing civilian need fir improved emergency applications by providing citizens with selected unmanned vehicle images through push notifications via a data communications network such as the Internet, and that are not dependent on an aging public switched telephone network (PTSN), which is known to fail during certain crisis. A push notification can arrive in a manner comprised of separate technologies such as cellular/Internet voice (voice to text, voice recognition), video stills (embedded with personalized iconographic identifiers), and can further include the capability of a secondary purpose of allowing notified recipients to engage others by retransmitting the message received, along with their own typed notations, so as to create their own real-time civil communications hub for ongoing situational awareness (a system that currently doesn't exist, but can be achievable by software applications running on servers). Once software is in place within a system (e.g., including servers), the only major expense can be largely limited to yearly system maintenance and data management.
SUMMARY OF INVENTION
[0012] It is a feature of the present invention to provide a method for providing public users with data collected by an unmanned vehicle by receiving data collected by remote unmanned vehicle by a server, identifying the data as restricted data and public data at the server, and providing public data to users registered by the server to receive the public data.
[0013] It is also a feature of the present invention to provide a method for providing public users with data collected by an unmanned vehicle that registers mobile devices authorized to receive data collected by said remote unmanned vehicle at a server, wherein data collected by the remote unmanned vehicle is identified as restricted data and public data, and providing the public data to mobile devices registered by the server.
[0014] It is also a feature of the present invention to provide a system that can provide public users with data collected by an unmanned vehicle. The system can include a server programmed to receive data collected by an unmanned vehicle and identify the data as public data and restricted data, the server further programmed to register mobile devices and provide the mobile devices with the public data automatically or upon request by user of the mobile devices.
[0015] It is another feature of the invention to provide a mass notification push application and a civic-communication application combined into one, with the primary purpose of allowing up-to-the-minute UAV aerial imagery, as selected by drone ground-based commanders, to be automatically transmitted to subscribed end-users via the current mobile operating systems for smartphones, iPads, laptops, and web-enabled devices in a manner comprised of separate technologies such as voice (voice to text, voice recognition), video stills, and data that can be embedded with personalized iconographic identifiers and messages.
[0016] The present invention can also provide a public-use notification and communication application that transmits data after ground station enhancement so as to keep the public alerted as first as possible. The invention can enable civil UAV authorities to transmit UAV video along with their voice-and-text notations to the public via their smartphones, iPads, laptops, and web-enabled devices, thus enabling these application registrants to form a civil awareness hub that would allow them to stay connected in times of emergency.
[0017] It is yet another feature of the invention to provide a mass notification push application and a civic-communication application with a secondary purpose of allowing the notified recipients to engage others by retransmitting the message received, along with their own typed notations, so as to create their own real-time civic communications hub for ongoing situational awareness. The civil communications hub can allow users to forward messages to other recipients and the forwarded messages can include sending user annotations together with captured data sent by authorities.
[0018] It is another feature of the present invention to provide a new communication service and platform that enables unmanned vehicles commanders with a real-time central distribution hub in order to furnish commanders with the capability of instantly converging selected incoming UAV imagery-information as determined for actionable crisis management, and afterwards, giving commanders the capability of instantly transmitting these up-to-the-minute notifications straight to selected end-users via the current OS mobile operating systems for smartphones, iPads, laptops, and web-enabled devices, and to transmit these notifications in a manner comprised of separate technologies such as voice (voice to text, voice recognition), video stills (embedded with personalized iconographic identifiers), thus allowing end-users to automatically receive the messages, while in turn, providing these same end-users with the modifying capabilities of retransmitting those incoming messages with the addition of their own specialized information, thus creating a composite real-time picture of the scenario unfolding, one that could only be achieved by the app's integration of on-the-spot and on-the-fly notifications and without the looping-needs of pre-recorded phone messaging that are common from a fixed-remote Robo Call Center.
[0019] It is a feature of the present invention to use a customized push application for the transmission of imagery as captured by unmanned vehicles, and as collected by the UAV ground control servers, in order to provide up-to-the-minute non-restricted UAV imagery via the Internet.
[0020] It is also a feature of the present invention for its push app to transmit such data via the Internet whereby registered civic authorities and public end-users can automatically receive such data on their smartphones, iPads, laptops and web-enabled devices.
[0021] It is also a feature of the present invention to provide a system that can provide registered end-users with such data as collected by an unmanned vehicle. The system can include a server programmed to receive such data, whereby certain imagery can be classified as public, non-restricted data, thus allowing the further instant transmission of this data to registered mobile devices as dictated by server's data base listings.
[0022] It is another feature of the invention to provide a mass notification push application and a civil communications application combined into one with the primary purpose of allowing up-to-the-minute UAV aerial imagery as selected by Drone Ground Base Commanders to be automatically transmitted to subscribed end-users via the current mobile operating systems for smartphones, iPads, laptops, and web-enabled devices in a manner comprised of separate technologies such as voice (voice to text, voice recognition), video stills (embedded with personalized iconographic iconographic identifiers).
DETAILED DESCRIPTION
[0023] The present invention (which can also be referred to herein as “SkySpeak”) differs from city websites and telephone-based emergency notification systems in as much as the SkySpeak application can deploy a software-centric web platform to automatically transmit instant voice notifications and enriched data to those who have installed the application onto their smartphone and Internet devices. Unlike being notified by an incoming phone call, the SkySpeak Application can automatically voice its message and display the video stills (embedded with personalized iconographic identifiers) on user handheld devices (e.g., smartphones, iPads, etc.) and can automatically voice its message as a multilingual transmission without the recipients having do anything to devices in use on their end.
[0024] Most UAV software seems to be for navigational and image enhancement purposes. The present invention can be provided as a web-based communication system using push-notifications to provide UV (Unmanned Vehicle) base stations with an emergency alert network for transmission of UV video and other components to Internet-connected end-users.
[0025] Referring to FIG. 1 , an unmanned aerial vehicle (UAV) system 100 in accordance with an embodiment of the invention is illustrated that includes avionics and guidance module 101 , a motor 103 , propeller hardware 105 , and a fuel source 107 . Reference to an unmanned aerial vehicle (UAV) is not meant to limit application of features of the present invention to a particular vehicle system. It should be appreciated that the vehicle is unmanned but can also be land-based or maritime-based. Reference to an unmanned vehicle (UV) can more accurately set the scope for vehicles that can be used to collect data for the present invention. The UV is managed by a controller 110 . An onboard controller can also manage sensors 111 , imaging equipment 113 , and location/GPS modules 115 engaged in navigation and data collection within the unmanned vehicle. Data collected by the UV can be separated into restricted data 121 and public data 123 . Separation into these categories can occur onboard the UV or after transmission to a server (to be discussed in FIG. 2 ). A communications module 125 enables communication of the UV with remote resources (e.g., servers) via any means of wireless communications (e.g., cellular, microwave, satellite, etc.) reasonably available in the unmanned vehicle field.
[0026] Referring to FIG. 2 , a system 200 in accordance with features of the present invention is shown. UVs 100 are shown transmitting data through wireless communications means 203 (e.g., cellular transmission) through a data network 210 wherein data can be received and managed by a server 215 . The server 215 can organize data into restricted data and public data. Restricted data can go to clients 220 controlled by authorities (e.g., police, government operators), wherein public data can be provided to mobile devices 230 (e.g., smartphones) that are registered with the server to receive public data.
[0027] Referring to FIG. 3 , a flow chart of a method in accordance with features of the present invention is shown. Data collected by a remote unmanned vehicle can be transmitted to be received by a server, as shown in step 301 . Data can then be identified as restricted data and public data at the server, as shown in step 302 . Then, as shown in step 303 , public data can be provided to users registered at the server to receive the public data. Restricted data can be accessed by cleared civil personnel such as police or government operators (e.g., homeland security, ICE, FBI), while public data can be received by civilians and reporters and the cleared civil personnel.
[0028] Referring to FIG. 4 , a flow diagram is shown in accordance with features of the invention. As shown in step 401 , users can register their mobile devices with a server to receive data collected by remote unmanned vehicles. Then as shown in step 402 , users can request data from the server, wherein the data can be collected by an unmanned vehicle and identified as public data by the server. The server, as shown in step 403 , can then provide public data to registered user mobile devices.
[0029] Referring to FIG. 5 , another flow diagram is shown wherein users can register their mobile devices with a server to receive data collected by remote unmanned vehicles, as shown in step 501 . Then, as shown in step 502 , the server can automatically provide public data to registered user mobile devices.
[0030] Instant Knowledge is king in-times-of-emergency. The present invention can be used to instantly inform authorities and members of a community with instant voice notifications, which can also supplement other emergency services as the FEMA National Radio System (FNARS), the Emergency Alert System (EAS), which is a national warning system in the United States which uses AM, FM, and Land Mobile Radio Service as well as broadcasts via VHF, UHF, and cable television including low-power stations and with EAN (Emergency Action Notification), and with AMBER Alerts and with their existing robo-calling, telephone-based centers serving 911 Reverse and NG 911.
[0031] Robo-callers are often connected to a pubic switched telephone network by multiple phone lines because they can only send out one message at a time per phone line. The advantage of the robo-caller is that it is compatible with the most basic phone service. That very basic service has essentially stayed unchanged for a century because it is just a simple phone on a landline.
[0032] On the other hand, the present invention does not make phone calls. It cannot get a busy signal because it is not making a phone call. It receives the alert as data regardless if the alert is vocal or text, an application operating on a user's handheld devices then plays the message. The recipient simply gets the message. Text can be transmitted to user handheld device where it can also be converted to speech. One benefit is lower bandwidth, which means you can alert more people more quickly. The other is that the text goes through a non-voice channel to the phone.
[0033] The present invention can use communications methods other than the phone's voice channel. Alerts can be received by people already talking on their smartphones. Alerts can be somewhat intrusive in that they can nag recipients until they at least acknowledge the alert.
[0034] The registration process can be far simpler in that the user only needs to download the application on their mobile device, everything else (e.g., communications with a data providing server) can be automated. The present invention can be fully capable of delivering vocally recorded alerts, visuals, text alerts, and supplemental information.
[0035] A data recipient should not need to answer the telephone in order to receive basic alert information because a message can be played on their handheld device display and/or announced via their handheld device speaker with the present invention. Spoken data is especially important for drivers and similarly occupied people that cannot take a moment to read a display.
[0036] As an example of the inventions use, a UAV ground base station notifier can select a drone-image and enters it onto the application's screen display. The notifier can then use the application's voice recognition to dictate an accompanying voice-activated message that is typed and that can be uttered automatically. The combined content can be transmitted to selected recipients who can then type their own comments to other recipients thus forming an ongoing web-enabled hub for the constant updating of information over OS mobile operating systems for smartphones, iPads, and laptops.
[0037] Once the UAV Ground Base Station (land, maritime or air) notifier selects a screen image and enters on to the interface of a server-based application, the notifier can have the ability to modify his notifications with a voice-activated message that is automatically typed as text and/or uttered via speaker when transmitted to end-user handheld devices.
[0038] In accordance with an optional feature, once the notification is received recipients in turn can use the present system to type their own comments and forward them to other recipients, thus forming an ongoing web-enabled hub for the constant updating of information. The system can also recognize that notification is not communication, and that the notification, in itself, does not guarantee an ongoing communication. The system can, for example, allow the imagery expert at a drone base stations video terminal to quickly transmit a still frame as captured from the incoming video and automatically resize it, such as to 460 kb, and attach it to the application's user interface (UI) such as a display screen on which a voice and text symbol can appear so that an imagery expert can easily dictate the text caption to be submitted with a photo (such as using Google HTML+CSS code for implementation) and then can automatically submit the notification to the registered recipients smartphone or web-enabled devices along with the expert's voice.
[0039] In light of the foregoing and using the forest fire example, suppose that the sheriff who spots a fire could use an application to notify UAV Control to send up a drone then, when a drone takes flight, incoming video from the UAV can be sent automatically to all authorities over a data communication network (wired or wireless). In the aforementioned Las Conchas Fire, it is conceivable that a forest ranger could have been in such a position so as to have mitigated the extent of damages by quickly providing more information to the public. Authorities can analyze data and determine a risk assessment for the situation. Authorities can then decide to send a new request for more data and also whether the data should be shared publically. If data (e.g., video, still images) is approved for public dissemination by authorities (this needs to be “authorized”), then data can be provided to the public using automatic instant voice alerts to mobile devices registered with the system. Notification can be sent to registered users along with the authorities desired voice/text/map additions without the registered citizens having to do anything. Registered users can also send the notification and their own notes to other recipients using the system or other communications (e.g., SMS) and form a community awareness hub. | A mass notification push application and a civic-communication application combined into one with the primary purpose of allowing up-to-the-minute UAV aerial imagery as selected by drone ground-based commanders to be automatically transmitted to subscribed end-users via the current OS mobile operating systems for smartphones, iPads, laptops, and web-enabled devices in a manner comprised of separate technologies such as voice (voice to text, voice recognition), video stills (embedded with personalized iconographic identifiers), and with a secondary purpose of allowing the notified recipients to engage others by allowing the retransmitting of received messages along with (or without) registered user annotations so as to create a civil communications hub for wider, real-time dissemination of ongoing situational awareness data. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/972,769 filed 15 Sep. 2007. The disclosure of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to deuterium-enriched ibandronate, pharmaceutical compositions containing the same, and methods of using the same.
BACKGROUND OF THE INVENTION
[0003] Ibandronate, shown below, is a well known nitrogen-containing bisphosphonate.
[0000]
[0000] Since ibandronate is a known and useful pharmaceutical, it is desirable to discover novel derivatives thereof. Ibandronate is described in U.S. Patent Publication No. 2006094898; the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide deuterium-enriched ibandronate or a pharmaceutically acceptable salt thereof.
[0005] It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0006] It is another object of the present invention to provide a method for treating osteoporosis, comprising administering to a host in need of such treatment a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0007] It is another object of the present invention to provide a novel deuterium-enriched ibandronate or a pharmaceutically acceptable salt thereof for use in therapy.
[0008] It is another object of the present invention to provide the use of a novel deuterium-enriched ibandronate or a pharmaceutically acceptable salt thereof for the manufacture of a medicament (e.g., for the treatment of osteoporosis).
[0009] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventor's discovery of the presently claimed deuterium-enriched ibandronate.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Deuterium (D or 2 H) is a stable, non-radioactive isotope of hydrogen and has an atomic weight of 2.0144. Hydrogen naturally occurs as a mixture of the isotopes 1 H (hydrogen or protium), D ( 2 H or deuterium), and T ( 3 H or tritium). The natural abundance of deuterium is 0.015%. One of ordinary skill in the art recognizes that in all chemical compounds with a H atom, the H atom actually represents a mixture of H and D, with about 0.015% being D. Thus, compounds with a level of deuterium that has been enriched to be greater than its natural abundance of 0.015%, should be considered unnatural and, as a result, novel over their non-enriched counterparts.
[0011] All percentages given for the amount of deuterium present are mole percentages.
[0012] It can be quite difficult in the laboratory to achieve 100% deuteration at any one site of a lab scale amount of compound (e.g., milligram or greater). When 100% deuteration is recited or a deuterium atom is specifically shown in a structure, it is assumed that a small percentage of hydrogen may still be present. Deuterium-enriched can be achieved by either exchanging protons with deuterium or by synthesizing the molecule with enriched starting materials.
[0013] The present invention provides deuterium-enriched ibandronate or a pharmaceutically acceptable salt thereof There are twenty-three hydrogen atoms in the ibandronate portion of ibandronate as show by variables R 1 -R 23 in formula I below.
[0000]
[0014] The hydrogens present on ibandronate have different capacities for exchange with deuterium. Hydrogen atoms R 1 -R 5 are easily exchangeable under physiological conditions and, if replaced by deuterium atoms, it is expected that they will readily exchange for protons after administration to a patient. The remaining hydrogen atoms are not easily exchangeable for deuterium atoms. However, deuterium atoms at the remaining positions may be incorporated by the use of deuterated starting materials or intermediates during the construction of ibandronate.
[0015] The present invention is based on increasing the amount of deuterium present in ibandronate above its natural abundance. This increasing is called enrichment or deuterium-enrichment. If not specifically noted, the percentage of enrichment refers to the percentage of deuterium present in the compound, mixture of compounds, or composition. Examples of the amount of enrichment include from about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 21, 25, 29, 33, 37, 42, 46, 50, 54, 58, 63, 67, 71, 75, 79, 84, 88, 92, 96, to about 100 mol %. Since there are 23 hydrogens in ibandronate, replacement of a single hydrogen atom with deuterium would result in a molecule with about 3% deuterium enrichment. In order to achieve enrichment less than about 3%, but above the natural abundance, only partial deuteration of one site is required. Thus, less than about 3% enrichment would still refer to deuterium-enriched ibandronate.
[0016] With the natural abundance of deuterium being 0.015%, one would expect that for approximately every 6,667 molecules of ibandronate (1/0.00015=6,667), there is one naturally occurring molecule with one deuterium present. Since ibandronate has 23 positions, one would roughly expect that for approximately every 153,341 molecules of ibandronate (23×6,667), all 23 different, naturally occurring, mono-deuterated ibandronates would be present. This approximation is a rough estimate as it doesn't take into account the different exchange rates of the hydrogen atoms on ibandronate. For naturally occurring molecules with more than one deuterium, the numbers become vastly larger. In view of this natural abundance, the present invention, in an embodiment, relates to an amount of an deuterium enriched compound, whereby the enrichment recited will be more than naturally occurring deuterated molecules.
[0017] In view of the natural abundance of deuterium-enriched ibandronate, the present invention also relates to isolated or purified deuterium-enriched ibandronate. The isolated or purified deuterium-enriched ibandronate is a group of molecules whose deuterium levels are above the naturally occurring levels (e.g., 3%). The isolated or purified deuterium-enriched ibandronate can be obtained by techniques known to those of skill in the art (e.g., see the syntheses described below).
[0018] The present invention also relates to compositions comprising deuterium-enriched ibandronate. The compositions require the presence of deuterium-enriched ibandronate which is greater than its natural abundance. For example, the compositions of the present invention can comprise (a) a μg of a deuterium-enriched ibandronate; (b) a mg of a deuterium-enriched ibandronate; and, (c) a gram of a deuterium-enriched ibandronate.
[0019] In an embodiment, the present invention provides an amount of a novel deuterium-enriched ibandronate.
[0020] Examples of amounts include, but are not limited to (a) at least 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, to 1 mole, (b) at least 0.1 moles, and (c) at least 1 mole of the compound. The present amounts also cover lab-scale (e.g., gram scale), kilo-lab scale (e.g., kilogram scale), and industrial or commercial scale (e.g., multi-kilogram or above scale) quantities as these will be more useful in the actual manufacture of a pharmaceutical. Industrial/commercial scale refers to the amount of product that would be produced in a batch that was designed for clinical testing, formulation, sale/distribution to the public, etc.
[0021] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0022] wherein R 1 -R 23 are independently selected from H and D; and the abundance of deuterium in R 1 -R 23 is at least 4%. The abundance can also be (a) at least 9%, (b) at least 13%, (c) at least 17%, (d) at least 22%, (e) at least 26%, (f) at least 30%, (g) at least 35%, (h) at least 39%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 61%, (n) at least 65%, (o) at least 70%, (p) at least 74%, (q) at least 78%, (r) at least 83%, (s) at least 87%, (t) at least 91%, (u) at least 96%, and (v) 100%.
[0023] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 5 is at least 100%.
[0024] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 6 -R 9 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%, (d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, (j) at least 85%, (k) at least 92%, and (l) 100%.
[0025] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 12 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 17%, (b) at least 25%, (c) at least 33%, (d) at least 42%, (e) at least 50%, (f) at least 58%, (g) at least 67%, (h) at least 75%, (i) at least 83%, (j) at least 92%, and (k) 100%.
[0026] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 13 -R 23 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0027] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0028] wherein R 1 -R 23 are independently selected from H and D; and the abundance of deuterium in R 1 -R 23 is at least 4%. The abundance can also be (a) at least 9%, (b) at least 13%, (c) at least 17%, (d) at least 22%, (e) at least 26%, (f) at least 30%, (g) at least 35%, (h) at least 39%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 61%, (n) at least 65%, (o) at least 70%, (p) at least 74%, (q) at least 78%, (r) at least 83%, (s) at least 87%, (t) at least 91%, (u) at least 96%, and (v) 100%.
[0029] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 5 is at least 100%.
[0030] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 6 -R 9 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%, (d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, (j) at least 85%, (k) at least 92%, and (l) 100%.
[0031] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 12 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 17%, (b) at least 25%, (c) at least 33%, (d) at least 42%, (e) at least 50%, (f) at least 58%, (g) at least 67%, (h) at least 75%, (i) at least 83%, (j) at least 92%, and (k) 100%.
[0032] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 13 -R 23 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0033] In another embodiment, the present invention provides novel mixture of deuterium enriched compounds of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0034] wherein R 1 -R 23 are independently selected from H and D; and the abundance of deuterium in R 1 -R 23 is at least 4%. The abundance can also be (a) at least 9%, (b) at least 13%, (c) at least 17%, (d) at least 22%, (e) at least 26%, (f) at least 30%, (g) at least 35%, (h) at least 39%, (i) at least 43%, (j) at least 48%, (k) at least 52%, (l) at least 57%, (m) at least 61%, (n) at least 65%, (o) at least 70%, (p) at least 74%, (q) at least 78%, (r) at least 83%, (s) at least 87%, (t) at least 91%, (u) at least 96%, and (v) 100%.
[0035] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 -R 5 is at least 100%.
[0036] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 6 -R 9 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%,(d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, (j) at least 85%, (k) at least 92%, and (l) 100%.
[0037] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 10 -R 12 is at least 8%, provided that the compound is other than one where only R 22-31 or R 20-21 are D. The abundance can also be (a) at least 17%, (b) at least 25%, (c) at least 33%, (d) at least 42%, (e) at least 50%, (f) at least 58%, (g) at least 67%, (h) at least 75%, (i) at least 83%, (j) at least 92%, and (k) 100%.
[0038] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 13 -R 23 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0039] In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0040] In another embodiment, the present invention provides a novel method for treating osteoporosis comprising: administering to a patient in need thereof a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0041] In another embodiment, the present invention provides an amount of a deuterium-enriched compound of the present invention as described above for use in therapy.
[0042] In another embodiment, the present invention provides the use of an amount of a deuterium-enriched compound of the present invention for the manufacture of a medicament (e.g., for the treatment of osteoporosis).
[0043] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. This invention encompasses all combinations of preferred aspects of the invention noted herein. It is understood that any and all embodiments of the present invention may be taken in conjunction with any other embodiment or embodiments to describe additional more preferred embodiments. It is also to be understood that each individual element of the preferred embodiments is intended to be taken individually as its own independent preferred embodiment. Furthermore, any element of an embodiment is meant to be combined with any and all other elements from any embodiment to describe an additional embodiment.
Definitions
[0044] The examples provided in the definitions present in this application are non-inclusive unless otherwise stated. They include but are not limited to the recited examples.
[0045] The compounds of the present invention may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention. All tautomers of shown or described compounds are also considered to be part of the present invention.
[0046] “Host” preferably refers to a human. It also includes other mammals including the equine, porcine, bovine, feline, and canine families.
[0047] “Treating” or “treatment” covers the treatment of a disease-state in a mammal, and includes: (a) preventing the disease-state from occurring in a mammal, in particular, when such mammal is predisposed to the disease-state but has not yet been diagnosed as having it; (b) inhibiting the disease-state, e.g., arresting it development; and/or (c) relieving the disease-state, e.g., causing regression of the disease state until a desired endpoint is reached. Treating also includes the amelioration of a symptom of a disease (e.g., lessen the pain or discomfort), wherein such amelioration may or may not be directly affecting the disease (e.g., cause, transmission, expression, etc.).
[0048] “Therapeutically effective amount” includes an amount of a compound of the present invention that is effective when administered alone or in combination to treat the desired condition or disorder. “Therapeutically effective amount” includes an amount of the combination of compounds claimed that is effective to treat the desired condition or disorder. The combination of compounds is preferably a synergistic combination. Synergy, as described, for example, by Chou and Talalay, Adv. Enzyme Regul. 1984, 22:27-55, occurs when the effect of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at sub-optimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
[0049] “Pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of the basic residues. The pharmaceutically acceptable salts include the conventional quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include, but are not limited to, those derived from inorganic and organic acids selected from 1,2-ethanedisulfonic, 2-acetoxybenzoic, 2-hydroxyethanesulfonic, acetic, ascorbic, benzenesulfonic, benzoic, bicarbonic, carbonic, citric, edetic, ethane disulfonic, ethane sulfonic, fumaric, glucoheptonic, gluconic, glutamic, glycolic, glycollyarsanilic, hexylresorcinic, hydrabamic, hydrobromic, hydrochloric, hydroiodide, hydroxymaleic, hydroxynaphthoic, isethionic, lactic, lactobionic, lauryl sulfonic, maleic, malic, mandelic, methanesulfonic, napsylic, nitric, oxalic, pamoic, pantothenic, phenylacetic, phosphoric, polygalacturonic, propionic, salicyclic, stearic, subacetic, succinic, sulfamic, sulfanilic, sulfuric, tannic, tartaric, and toluenesulfonic.
EXAMPLES
[0050] Table 1 provides compounds that are representative examples of the present invention. When one of R 1 -R 23 is present, it is selected from H or D.
[0000]
1
2
3
4
5
[0051] Table 2 provides compounds that are representative examples of the present invention. Where H is shown, it represents naturally abundant hydrogen.
[0000]
6
7
8
9
10
[0052] Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein. | The present application describes deuterium-enriched ibandronate, pharmaceutically acceptable salt forms thereof, and methods of treating using the same. | 2 |
FIELD OF THE INVENTION
This invention relates to a process for the restoration of the chemical lighting potential of a chemiluminescent system. More particularly, it relates to the restoration of the initial light emission of a two component liquid phase oxalate ester chemical light system.
DESCRIPTION OF THE PRIOR ART
The procedure of practical quantities of light directly from chemical energy with high efficiency has only recently been accomplished. One of the factors which has made this achievement difficult is the fact that emission lifetimes can be markedly accelerated or slowed by the presence of extremely low concentrations of bases or acids, respectively; in some cases, the presence of extremely low concentrations of impurities can completely inhibit the production of light.
The general disclosure of U.S. Pat. No. 3,597,362, which is hereby incorporated by reference, discloses a composition for generating light by reacting an oxalic ester with a hydroperoxide in the presence of a solvent and a fluorescent compound.
Copending commonly assigned U.S. Pat. applications Ser. No. 842,134 filed July 16, 1969, now abandoned and Ser. No. 813,862 filed Apr. 7, 1969, now abandoned, also disclose compositions for generating light by a similar reaction.
The two-component, liquid phase oxalate ester chemical light system must comprise an "oxalate component" comprising an oxalic acid diester and a solvent, and a "peroxide component" comprising hydrogen peroxide and a solvent or mixture of solvents. In addition, an efficient fluorescer must be contained in one of the components and an efficient catalyst, necessary for intensity and lifetime control, must be contained in one of the components. The oxalate component must provide an oxalate ester-solvent combination which permits suitable ester solubility and which permits storage stability. The peroxide component must provide a hydrogen peroxide-solvent combination which permits suitable hydrogen peroxide solubility and permits storage stability. The solvents for the two components may be different but should be miscible. At least one solvent must solubilize the efficient fluorescer and at least one solvent must solubilize the efficient catalyst. The fluorescer and at least one solvent must solubilize the efficient catalyst. The fluorescer and catalyst must be placed as to permit both solubility and storage stability in the final components.
The oxalate component is selected from the group comprising at least 0.01M (preferably at least 0.03M) of a bis-(2,4,5-trichloro-6-carboalkoxyphenyl)oxalate and at least 0.0001M (preferably at least 0.001M) of a fluorescer selected from the group comprising 9,10-bis(phenylethynyl) anthracene, monochloro and dichloro substituted 9,10-bis(phenylethynyl) anthracenes, 5,12-bis(phenylethynyl)tetracene, 9,10-diphenyl anthracene, perylene and 16,17-dihexyloxyviolanthrone and an aromatic solvent such as benzene, chlorobenzene, ethylbenzene, dimethyl phthalate, dibutyl phthalate, o-dichlorobenzene, ethylbenzoate, butyl benzoate and 1,3-butyleneglycol dibenzoate; and wherein the peroxide component is selected from the group comprising (1) at least 0.01M hydrogen peroxide (preferably at least 0.10M hydrogen peroxide) in a tertiary alcohol such as t-butyl alcohol, 3-methyl-3-pentanol, 3,6-dimethyloctanol-3 or an ester such as dimethyl phthalate, or combinations of both, and a catalyst in the concentration range 1×10 - 4 M to 1×10 - 1 M (preferably 1×10 - 3 M) comprising the anion of a carboxylic acid or phenol having an aqueous dissociation constant between about 1×10 - 6 and 1×10 - 1 (preferably between about 5×15 - 4 and about 5×10 - 2 ) (examples are sodium salicylate, tetrabutyl ammonium salicylate, tetrabutylammonium 2,3,5-trichlorobenzoate, potassium pentachlorophenolate and tetraethyl ammonium benzoate).
It is particularly important that admixture of the oxalate component and activator component immediately produces the highest level of light intensity rather than producing the highest intensity after 10 minutes have elapsed.
Occasionally, for reasons that are not fully understood, the two component composition fails to produce good initial light intensity and the brightness-lifetime performance of the system is unsatisfactory. Investigation of this phenomena has resulted in a finding that the cause resides in the oxalate component. Several attempts to rejuvenate the oxalate component by treating it with silica gel or macromolecular resins were unsuccessful.
It is therefore an object of the present invention to provide a method for restoring full activity to an oxalate component of chemiluminescent system.
This and other objects of the invention will become apparent as the description thereof proceeds.
DESCRIPTION OF THE INVENTION
I have discovered a simple, economical process for restoring good brightness-lifetime performance to solutions of oxalate esters as described in U.S. Pat. No. 3,597,362 and in U.S. Pat. applications Ser. Nos. 813,862, now abandoned; 813,973, now abandoned; 842,134, now abandoned; 124,142, now U.S. Pat. No. 3,749,679; and 261,888.
This process involves the treatment of an oxalate component containing the fluorescing agent, which fails to produce good initial light intensity after admixing with hydrogen peroxide and the catalyst, with an alkali-metal alumino-silicate at room temperature. Subsequent separation of the alkali-metal alumino-silicate at room temperature. Subsequent separation of the alkali-metal alumino-silicate gives an oxalic component which produces excellent initial light intensity on mixing with hydrogen peroxide and catalyst.
I have found that by simply stirring, at room temperature, an oxalate component which has unacceptable brightness lifetime performance with from 1 to 5% by weight of Linde 5A molecular sieves on the weight of the oxalate component restores the ability of the oxalate component to produce good initial light intensity. The rejuvenated oxalate component continued to give excellent initial brightness after storage at room temperature for two months.
EXAMPLES I to III
Three 500 g. aliquots of an unsatisfactory oxalate component containing bis(2,4,5-trichloro-6-carbopentoxyphenyl) oxalate (0.133M) and 9,10-bis(phenylethynyl)anthracene (0.003M) in dibutyl phthalate were slurried at 25°C. for 3 hours with 5.0, 10.0, and 25.0 g., respectively, (which is 1%, 2% and 5% based on the oxalate weight), of Linde Molecular Sieve-Type 5A (molecular Sieve Type 5A, the calcium form of the Type A crystal structure, is an alkali metal alumino-silicate manufactured by Union Carbide Corporation) and the oxalate component was decanted therefrom after allowing the slurry to stand overnight. The treated and untreated oxalate components were evaluated by mixing 7.5 cc of oxalate component with 2.5 cc of an activator component comprising hydrogen peroxide (1.5M), and sodium salicylate (6.25 × 10 - 4 M) in 80% dimethyl phthalate --20 % tertiary butanol, by volume, in a polyethylene lightstick, shaking well, and measuring, by means of a broadband photometer, the intensity of the emitted light versus time. These intensities are reported as luminosity values (lumens per liter) in Tables I through III, representing Examples I to III, for the untreated sample and the treated sample, initially and after storage for 60 days at 25°C. The results clearly demonstrate the increase in initial luminosity effected by this treatment.
EXAMPLE I
TABLE 1______________________________________Oxalate Component Rejuvenated with 1% (by weight) LindeMolecular Sieve -- Type 5A______________________________________LUMINOSITY (1m.1..sup.-.sup.1) vs. Time 0 10 30 60 90 120Comment Min. Min. Min. Min. Min. Min.______________________________________Before Treatment 000 236 174 93 51 32After Treatment 1185 259 169 87 51 32After Treatment 1296 264 170 88 52 32After 60 DaysStorage at 25°C. 1488 219 193 100 49 26______________________________________
EXAMPLE II
TABLE II______________________________________Oxalate Component Rejuvenated with 2% (by weight) LindeMolecular Sieve --Type 5A______________________________________LUMINOSITY (1m.1..sup.-.sup.1) vs. Time 0 10 30 60 90 120Comment Min. Min. Min. Min. Min. Min.______________________________________Before Treatment 000 236 174 93 51 32After Treatment 1397 248 182 94 49 28After 60 daysStorage at 25°C. 1488 219 193 100 49 26______________________________________
EXAMPLE III
TABLE III______________________________________Oxalate Component Rejuvenated with 5% (by weight) of LindeMolecular Sieve --Type 5A______________________________________LUMINOSITY (lm.1..sup.-.sup.1) vs. Time 0 10 30 60 90 120Comment Min. Min. Min. Min. Min. Min.______________________________________Before Treatment 000 236 174 93 51 32After Treatment 1616 199 162 98 57 35After 60 DaysStorage at 25°C. 1871 200 152 93 53 33______________________________________ | A process for the restoration of the initial chemical lighting potential of a chemiluminescent lighting system. More particularly, a process for the restoration of the chemical lighting potential of a two component chemiluminescent lighting system. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/648,898, filed May 18, 2012, and entitled “Acceleration of Hematopoietic Reconstitution by Placental Endothelial and Endothelial Progenitor Cells”, which is hereby expressly incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] Disclosed are compositions useful for treatment of patients needing hematopoietic stimulation. In one embodiment patients are administered a cellular mixture derived from allogeneic placenta, said cellular mixture comprising substantially of endothelial cells and endothelial progenitor cells.
BACKGROUND
[0003] This application relates to the field of stem cell biology, cell culture, and hematopoietic stimulation. In particular, the invention relates to the area of adjuvant therapies for hematopoietic reconstitution, more specifically, the invention relates to placental cellular populations and products thereof derived from the placenta that are useful for regenerative applications.
[0004] Endothelial cells have been previously shown in the art to stimulate hematopoietic reconstitution. Endothelial progenitor cells (EPC) have been shown to possess various regenerative abilities. Despite some data showing autologous/syngeneic endothelial cells having ability to accelerate hematopoietic reconstitution, these cells are not practical for clinical use. Compared to EPC or endothelial cells found in younger tissue such as placenta.
SUMMARY
[0005] Embodiments herein are directed to a composition useful for accelerating reconstitution of the hematopoietic compartment, said composition comprising cells isolated from placenta. Said cells isolated from placenta can be endothelial cells. Said cells isolated from placenta can be isolated from placenta perivascular tissue. Cells isolated form placenta perivascular tissue can expresses a marker selected from a group of markers consisting of: CD144, CD105, and CD31. The placenta perivascular tissue can be isolated from fetal vascular lobules of a hemochorial placenta. Said cells can be prepared by: a) dissociating fetal vascular lobules from a full-term human placenta; b) successively digesting the homogenized lobules of step a) with a preparation of about 2% collagenase, about 0.25% trypsin and about 0.1% DNAse in tissue culture medium; c) filtering the digestion product of step b) to remove particulates; d) obtaining a mononuclear cells from the filtered digestion product of step c) by density gradient centrifugation; e) plating the mononuclear cells on a collagen I-coated tissue culture plate; f) growing the mononuclear cells to confluency; g) detaching the confluent cells from the plate; and h) sorting the detached cells for expression of CD144 and substantially lack of expression of CD45. Said cells isolated by enzymatic digestion of the placenta can be administered into a patient in need of treatment without an expansion step. Said cells isolated by enzymatic digestion of placenta can be grown in a media that allows stem cell proliferation and differentiation activity in vitro. Said cells isolated by enzymatic digestion of placenta substantially lack expression of a marker selected from a group of markers consisting of: CD14, CD34, CD38 and CD45. Said cells can form capillary-like tubules when plated on a Matrigel substrate. Said cells can take up DiI-acetylated-lowdensity-lipoprotein. Said cells can be cultured in a media selected from DMEM, RPMI, EMEM, Iscove's Media, and Ham's F12 media. Said cells can be cultured in a media containing fetal calf serum. Said fetal calf serum can be added to said media at a concentration ranging from approximately 2% to approximately 20%. Said fetal calf serum can be added to said media at a concentration of approximately 10%. Said cells can constitute a population of cells containing endothelial progenitor cells.
[0006] Additional embodiments are directed to a composition useful for acceleration of hematopoietic reconstitution, said composition comprising of endothelial cells and endothelial progenitor cells derived from fetal vascular lobules of a hemochorial placenta. Said endothelial progenitor cells can substantially express at least one marker selected from: CD144, CD105, and CD31. Said endothelial progenitor cells can lack substantial expression of a marker selected from a group of markers comprising of: a) CD14; and b) CD45. Said endothelial progenitor cells can form capillary-like tubules when plated on a Matrigel substrate. Said endothelial progenitor cells can be capable of taking up DiI-acetylated-low-density-lipoprotein. Said endothelial precursor cells can be manufactured by: a) dissociating fetal vascular lobules from a full-term human placenta; b) successively digesting the homogenized lobules of step a) with a preparation of about 2% collagenase, about 0.25% trypsin and about 0.1% DNAse in tissue culture medium; c) filtering the digestion product of step b) to remove particulates; d) obtaining mononuclear cells from the filtered digestion product of step c) by density gradient centrifugation; e) plating the mononuclear cells on a collagen I-coated tissue culture plate; f) growing the mononuclear cells to confluency; g) detaching the confluent cells from the plate; and h) sorting the detached cells for expression of CD144 and substantially lack of expression of CD45.
[0007] Said compositions herein can be administered intravenously prior to, at the moment of, or subsequent to exposure to an agent or plurality of agents causing destruction of hematopoietic tissue. Said compositions can be administered together with a growth factor capable of stimulating proliferation and/or differentiation of hematopoietic stem cells. Said growth factor can be selected from a group of growth factors selected from the group consisting of: a) G-CSF; b) M-CSF); c) GM-CS; d) stem cell factor; e) IL-1; f) IL-6; g) thrombopoietin; h) IL-7; and i) PDGF.
[0008] Additional embodiments include a method of augmenting hematopoiesis in a patient, said method consisting of: a) selecting a patient in need of therapy; b) obtaining a population of cells containing allogeneic placental derived endothelial progenitor cells; and c) infusing into said patient said population of allogeneic placental derived endothelial progenitor cells. According to further embodiments, the patient in need of therapy suffers from a disorder selected from a group of disorders consisting of: a) acute radiation syndrome; b) radiation exposure; c) treatment with chemotherapy and/or radiotherapy; d) bone marrow failure; e) bone marrow transplantation; and f) cord blood transplantation. The method can include placental derived endothelial progenitor cells that are obtained from an allogeneic placenta from which; a) the fetal vascular lobules have been dissociated; b) the dissociated (homogenized) lobules of step a) are enzymatically digested with a preparation of approximately 2% collagenase, about 0.25% trypsin and about 0.1% DNAse in tissue culture medium; c) filtering the digestion product of step b) to remove particulates; d) obtaining a mononuclear cells from the filtered digestion product of step c) by density gradient centrifugation; e) plating the mononuclear cells on a collagen I-coated tissue culture plate; f) growing the mononuclear cells to confluency; g) detaching the confluent cells from the plate; and h) sorting the detached cells for expression of CD144 and substantially lack of expression of CD45. Said isolated placental vascular lobe endothelial progenitor cells can be expanded in vitro.
[0009] Further embodiments include a method of accelerating hematopoietic reconstitution by administration of placentally-derived endothelial progenitor cells. The method can be conducted wherein said placentally-derived endothelial progenitor cells are allogeneic to the recipient in need of hematopoietic reconstitution. Additionally, a method of accelerating hematopoietic reconstitution by administration of placentally-derived endothelial cells is provided herein. Said method of claim can be conducted wherein said placentally-derived endothelial cells are allogeneic to the recipient in need of hematopoietic reconstitution.
DETAILED DESCRIPTION
[0010] This application provides compositions of isolated EPC and endothelial cell populations populations derived from fetal vascular lobules of a hemochorial placenta, particularly a hemochorial placenta from a human that are useful for the stimulation of hematopoietic reconstitution. In one embodiment of the invention the EPC express CD144, CD105, and/or CD31, either immediately upon isolation or after culturing. In certain aspects, EPC derived from placental tissue do not express CD45. In one embodiment of the invention, the stem and/or endothelial progenitor cells express CD144, CD105, and CD31 but do not express do not express CD45. Certain isolated EPC or endothelial cell populations of the invention can form capillary-like tubules when plated on a Matrigel substrate and can take up DiI-acetylated-low-density-lipoprotein.
[0011] In certain embodiments, the isolated stem and/or endothelial progenitor cell populations of the invention are prepared by homogenizing fetal vascular lobules from a full-term placenta; successively digesting the homogenized lobules with a preparation of about 2% collagenase, about 0.25% trypsin and about 0.1% DNAse, in tissue culture medium such as DMEM. The digestion product is then filtered to remove particulates, and mononuclear cells are obtained therefrom by density gradient centrifugation. The mononuclear cells can then be plated on collagen I-coated tissue culture plates and grown to confluency. Detached cells from the confluent plates are then sorted to obtain stem and/or progenitor cells that express of CD144 but lack of expression of CD45.
[0012] The present application also provides methods for treating patients in need of accelerated hematopoietic reconstitution, including patients exposed to radiation, chemotherapy, bone marrow transplant, cord blood transplant, or suffering from bone marrow failure.
EXAMPLES
Example 1
Radioprotection by Placental Vascular Lobule EPC
[0013] Fetal vascular lobules are placed in a blender with HBSS and homogenized. The homogenate is centrifuged at 600.times.g for 6 minutes and washed three times with PBS. The pelleted cells are then digested with 2% collagenase in DMEM, 0.25% trypsin and 0.1% DNase in sequence. The resulting preparation is filtered and the mononuclear cell fraction (MNC) are isolated with Ficoll gradient centrifugation. Cells are washed 2 times in PBS.
[0014] Female BALB/c mice 6-8 weeks of age are irradiated twice with 575-600 cGy 3 hours apart using a J. L. Shepherd Co. Cesium irradiator. Placental vascular lobule EPC are diluted in 200 μl of modified HBSS at doses of 3×10(4), 1×10(4) and 1×10(3). Following the second dose of irradiation, donor cells are injected into the retroorbital plexus of recipients anesthetized with isoflurane. Irradiated control mice received 200 μl modified HBSS only. Recipient mice that had been maintained acidified water were switched to non-acidified water containing antibiotics (106 unit/liter Polymyxin B sulfate and 1.1 g/liter neomycin sulfate) and monitored daily over 60 days.
[0015] Peripheral blood is obtained from primary or secondary recipients by retroorbital puncture. Aliquots of 200 μl are analyzed for complete blood counts and platelet counts (Antech Diagnostics, Portland, Oreg.). For the determination of donor-derived hematopoiesis, peripheral blood is collected and nucleated cells were prepared by sedimenting erythrocytes in 2% Dextran (T-500) followed by hypotonic lysis. Cell pellets were washed and incubated with anti-CD45.1-FITC and anti-CD45.2-PE in combination with lineage specific markers for Tcells (CD3-APC), B-cells (B220-APC) or myelomonocytic cells (Mac-1-APC and Gr-1-APC) (BD Pharmingen). The co-expression of these cell surface antigens is determined by using a FACscan II and dead cells were excluded using scatter gates and propidium iodide. Up to 50 thousand events were analyzed to provide a sensitivity of 0.5%. Hemoglobin analysis was performed on peripheral blood isolated as described previously in the art. Approximately 70 μl of peripheral blood is collected from each recipient mouse, centrifuged and the pellets were lysed with 1× cystamine solution. Hemoglobin lysates are applied to a cellulose acetate plate (Helena Laboratories, Beaumont, Tex.) and electrophoresed at 300 volts for 30 minutes. Following electrophoresis, plates were stained with Ponceau S for 20 minutes, rinsed in deionized water, and destained in 2 changes of 7% glacial acetic acid prior to imaging.
[0016] A dose-dependent increase in survival is noted in animals receiving EPC as compared to controls. Acceleration of hematopoietic reconstitution is observed, as well as increased recovery of red blood cells and hemoglobin content.
Example 2
Augmentation of Cord-Blood Reconstitution after Nuclear Incident
[0017] A nuclear attack on a populated city occurs exposing 50 individuals to an estimated 10 Gy Eq of neutron and gamma irradiation. All 50 patients presented with symptoms of acute radiation syndrome including severe pancytopenia. Based on previous experiences (Nagayama, et al., 2002. Int J Hematol 76:157-164, which is incorporated by reference herein in its entirety), and the lack of sibling related donors or possibility of autotransplantation, the use of cord blood as a hematopoietic graft is performed after HLA-matching allowing for only one allele mismatch.
[0018] Pretransplantation conditioning consists of antithymocyte equine 3 globulin alone (2.5 mg/kg for 2 consecutive days), and GVHD prophylaxis consists of the combined use of cyclosporine A (CyA) and methylprednisolone (mPSL). Patients are administered 3.times.10.sup.7 nucleated cord blood cells per kilogram through intravenous infusion. All patients are administered filgrastim (neupogen) at a concentration of 10 .mu.g/kg/day for 14 days in order to accelerate leukocytic recovery. Of the 50 patients, 25 receive concurrently with filgrastim, a concentration of 1 million allogeneic placental vascular EPC/kg/day. The cells are prepared under GMP conditions based on the description of Example 1. At day 15 after cellular transplantation, 23% of patients treated with filgrastim alone have granulocytic counts of more than 500/mm.sup.3. In contrast, 100% of the patients receiving the combination of filgrastim and EPC have granulocytic counts of more than 500/mm.sup.3 by day 12 post transplantation. Chimeric hematopoiesis is observed at day 50 in 46% of patients treated with filgrastim alone, whereas 100% of patients receiving the combination had achieved this milestone. Additionally, opportunistic infections are predominantly associated with the patient group that received filgrastim alone. This example suggests the use of placental vascular EPC as an adjuvant agent to standard hematopoiesis stimulating regimens. Additionally, although GVHD is not observed in any of the patients in the prior example, most likely due to the low levels of cord blood cells administered, higher doses of cord blood cells can predispose to this. Accordingly, placental vascular lobule EPC can be used in combination with immune suppressive cytokines to preferential stimulate expansion of natural immune regulatory cell subsets.
[0019] One skilled in the art will appreciate that these methods and devices are and can be adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The methods, procedures, and devices described herein are presently representative of preferred embodiments and are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the disclosure.
[0020] It is apparent to one skilled in the art that varying substitutions and modifications can be made to the invention disclosed herein without departing from the scope and spirit of the invention. Furthermore, those skilled in the art recognize that the aspects and embodiments of the invention set forth herein can be practiced separate from each other or in conjunction with each other. Therefore, combinations of separate embodiments are within the scope of the invention as disclosed herein. | Compositions useful for treatment of patients needing hematopoietic stimulation. In one embodiment patients are administered a cellular mixture derived from allogeneic placenta, said cellular mixture comprising substantially of endothelial cells and endothelial progenitor cells. | 0 |
This is a continuation-in-part of application Ser. No. 08/298,816 filed on Aug. 31, 1994, now abandoned.
BACKGROUND OF THE INVENTION
The measurement of triglycerides in clinical chemistry is important as an indicator of the presence of pancreatic disease, hyperlipidemia, coronary artery occlusive disease, etc. In the clinical laboratory, in order to have confidence in these measurements a quality control system needs to be in place. Controls, calibrators, and standards are integral components of this quality control system and well known to those in the clinical chemistry field ( see pg 430, Textbook of Clinical Chemistry, by N. W. Tietz, W. B. Saunders Co., 1986). There is considerable literature on the use of triglycerides for controls, calibrators, and standards. These triglycerides include those extracted from egg yolk, purified olive oil (triolein) or others isolated from animal or human blood. However, there are inherent difficulties in using these materials in multiconstituent controls, calibrators or standards such as:
1. They are unstable to freeze-thaw processing.
2. They can precipitate, and this precipitation can concomitantly affect other analytes such as calcium and phosphate.
3. They tend to become easily and quickly contaminated by microbes, such contamination adversely affecting the products in which they are used.
4. They are usually poorly characterized mixtures causing reproducibility problems.
5. Their assayed values are not stable and continue to rise over time.
6. Some are too insoluble in protein solutions to be useful (controls, calibrators, or standards commonly contain triglyceride levels as high as 400 mg/dl).
Some clinical chemistry control manufacturers attempt to circumvent these difficulties by substituting glycerol for the triglyceride to mimic the chemistry of the true triglyceride. This approach has met with limited success because the hydrolysis step which is essential in certain assays is eliminated, and, for some assays requiring measurement of hydrolyzed fatty acids, glycerol is totally unsuitable.
Manufacturers could theoretically use synthetic triglyceride analogs such as, 2,3-dimercaptopropan-1-ol tributyrate, beta-naphthyl laurate, beta-naphthyl myristate, phenyl laurate and sorbitan esters, methylumbelliferone- and N-methylindoxyl myristate as components in controls, calibrators, or standards, but these materials are vastly too expensive and/or insoluble in a protein matrix to be practically useful. Normally, aqueous insoluble triglycerides are insufficiently soluble to be practically used in clinical controls. They can sometimes be made soluble by the use of a surfactant, but the surfactant often adversely affects other constituents, e.g. enzymes.
This invention relates to the new and innovative use of existing material as substitutes for human, animal or egg yolk triglycerides in multiconstituent clinical chemistry controls, calibrators, standards and related preparations. The substitute materials include medium carbon length (e.g. C 8 , C 10 , C 18 ) fatty acids esterified to glycerol to form mono- and di-glyceride mixtures, which are currently commercially used as vehicles for water-insoluble, oil-soluble pharmaceuticals and as emollient oils for facial creams and cosmetics. They are sufficiently soluble in protein solutions and yield stable triglyceride measurements on standing, without extraneous additional stabilizers required in other preparations. Similar materials which can also be used include, but are not limited to, glycerol tripropionate, and glyceryl tributrate. The use of these materials has avoided the problems of freeze-thaw instability, precipitation, microbial contamination, and poor characterization (and hence reproducibility) which are encountered with the previous materials. These new materials also are much less expensive to use than the previous materials and methods, thus making them practical for use in the manufacture of the multiconstituent clinical control materials. The invention covers not only the identification of the material but also techniques for its use.
SUMMARY OF THE INVENTION
Triglyceride substitutes (pseudotriglycerides or PSTG) have been identified for use in clinical chemistry controls, calibrators, standards and related preparations. The substitute materials are mixtures of medium carbon length (C 3 -C 18 ) fatty acids esterified to glycerol that are relatively inexpensive, making them useful for the control materials. In addition, single components used in different chemistry areas, were found to be usable in the instant application without the need for emulsifiers. This invention also relates to the process of using the substitute materials.
DETAILED DESCRIPTION OF THE INVENTION
This invention deals with the identification of novel sources of PSTG's for use in multiconstituent clinical chemistry controls, calibrators, standards and related preparations (together referred to as control materials) . This invention also relates to the use of the substitute materials. The preferred PSTG's were found to be those that were inexpensive, soluble in a protein solution, chemically characterized, (and as a result reproducible) and stable making them practical for usage in manufacturing the commercial control materials. These PSTG's are also safe to handle. These materials were generally mixtures, rather than pure, single component items.
PSTG's were analyzed in protein based matrices to determine performance characteristics, as shown in examples hereafter. To analyze the solutions, commercially available clinical analyzers were utilized e.g., Ektachem (manufactured by Kodak), Dimension D-380 (from DuPont), Express (from Ciba Coming), and ACA (from DuPont) to read serum triglyceride levels. Procedures involve the specific measurement of glycerol after the hydrolysis of the fatty acid-containing moieties. The substitutes included Capmul MCM and Capmul MCM-90 (trademarks of Karlshamns Inc. for mixtures of mono- and di-glycerides of capylate and caprate), 1-mondecanoyl-rac-glycerol, glycerol tributyrate (tributyrin), glycerol tripropionate (tripropionate), monocaproyloyl glycerol (Sigma Chemical Co.) and monoglyceride of linoleic acid (e.g., Myverol from Eastman Chemical Co.). The above is a representative but not exhaustive list of the possible substitutes. It has been found that the solubility of these compounds is affected not only by the number of glycerol substituents, but also by the chain length of each substituent. For example, if all three hydroxyl groups on glycerol are esterified with fatty acids of chain lengths of less than 6 carbons (e.g. triproprionate or tributyrin) then the compounds are sufficiently soluble in an aqueous protein solution to be useful. However, the solubility of glycerides of substituents exceeding 6 carbons (C 6 ) in length become sufficiently insoluble as to be rendered useless without addition of emulsifying agents (surfactants). If only one hydroxyl group is esterified, leaving two hydroxyl groups to help solubility, glycerides with substituent fatty acid chains as long as C 18 can be used.
As indicated above, the materials used herein are frequently mixtures. For example, Capmul MCM is a mixture of ≧80% monoglyceride and ≦20% diglyceride. The fatty acid composition thereof is a further unspecified mixture of caprylic and capric acids esterified to glycerol to form the above glyceride composition. It contains <1% free fatty acid and <1% free glycerol. Capmul MCM-90 is a mixture of the following composition: ≧90% monoglyceride and ≦10% diglyceride. The fatty acid composition thereof is a further unspecified mixture of caprylic and capric acids esterified to glycerol to form the above glyceride composition. It contains <1% free fatty acid and <1% free glycerol.
The control being used in the assay could contain solely PSTG in an aqueous protein solution and, thus, function only as a control for triglyceride. In addition to the triglyceride component the control may contain components to control other assays (e.g. glucose and enzymes), preservatives, buffers, etc. and, thus, function as a multiconstituent control.
Triglyceride levels in normal fasting human serum range from 44-210 mg/dL. To determine if normal and abnormal triglyceride levels could be simulated by use of the substitute materials, serial dilutions were prepared from a concentrated solution of Capmul MCM in human serum (See Example 3). The results of these tests showed the linearity and quantitative recovery of PSTG in a human serum base. (See Example 3.) This quantitative recovery does not appear to be time dependent (See Example 1).
In addition, further work was done to determine that quantitative recoveries of PSTG are consistent over the majority of clinical analyzers and over a range of PSTG materials (See Examples 4-7).
To be useful in clinical materials, minimal stability criteria must be met, e.g. after 14 days refrigerated storage (2°-8° C.), a recovery of plus or minus 10% should be obtained when the PSTG is spiked into a protein base at normal or abnormal levels. The results of stability studies indicated these PSTG's would be commercially useful as controls, calibrators or standards (See Example 2). Also, to be useful, samples must be linear upon dilution, since high concentration human clinical samples are diluted to get within the assayed concentration range for the test. (Example 3.)
Once quantitative recovery and adequate stability was shown for the PSTG when spiked into a protein base, the material was utilized in a number of applications where triglycerides isolated from egg yolk or human or animal blood had been used by other laboratories, namely, to develop materials which could be used as controls for clinical assays for the quantitative and qualitative measurement of triglyceride in human serum (See Examples 4 and 8). These materials are usable not only in human serum, but also in matrices composed of serum from other animals, human or animal albumin or mixtures thereof, urine, spinal fluid, saliva, or other fluids containing protein, or mixtures of any of the aforementioned fluids.
The above describes the best mode contemplated by the inventors for the use of the PSTG materials. However, it is contemplated that the PSTG's could be used in place of triglyceride isolated from egg yolk, or isolated from animal or human blood, in all analytical procedures including, without limitation, radioimmunoassay, ELISA, and other analytical techniques. For example, most immunoassays, for the identification of an antigen, utilize either a labelled antigen or a labelled antibody. PSTG antigen or antibody could be labelled using various established techniques, for example, the addition of a radioactive label, an enzymatic label, a fluorescent label, a chemiluminescent label or other labels which would make the material useful in an immunochemical analytical technique. The label would serve as the reporting groups in the immunoassays. It is also contemplated that PSTG's might be purified and utilized, or perhaps even utilized without purification, in other analytical techniques where triglycerides isolated from egg yolk, or isolated from animal or human blood, might currently be used.
It is further contemplated that the PSTG's could be used as immunogens to develop an antibody. Polyclonal, monoclonal or other antibodies could be raised against the triglyceride substitutes. The technology for production of antibodies (polyclonal or monoclonal) has been well established. (See, for example, Immunology, Second Edition, I. Roitt et al, Gower Medical Publishing, London, 1989, page 82.)
Either the PSTG's or antibody produced therefrom could be immobilized on a solid support. Numerous supports could be used, for example agarose resins (Sepharose etc.), glass beads, etc. An immobilized antibody to triglyceride could act as a rapid and efficient purification tool to obtain pure triglyceride from crude sources. Likewise, pure antibody could be obtained utilizing immobilized PSTG material. These immunoaffinity chromatographic methods are well established in the literature. The preceding illustrates how immobilized ligands can be utilized but should not be construed to limit their usefulness. For example, immobilized triglyceride substitute antibody could be used as a stripping agent to obtain triglyceride free serum.
The following examples describe aspects of the stability and usefulness in various instruments of the PSTG. These materials and the products produced therefrom are also useful in manual techniques. (For a general discussion of procedures for triglyceride, see, for example, "Methods in Clinical Chemistry", A. J. Pesce et al, C. V. Mosby Co., St. Louis, 1987, Chap. 18, pp. 1215-1227.) However, these examples are not intended to limit the usefulness of the PSTG's or techniques for utilization thereof.
EXAMPLE 1
Effect of Time Upon Dissolution:
Using human serum as the matrix of choice, 7.5 mg of PSTG from Karlshamn (Capmul® MCM, lot # 30418-6) was added to 30 mL of serum in a glass bottle, and mixed by tumbling at room temperature. The concentration of Capmul added was 25 mg/dL. No additional solubilizing agents were used. Samples of the solution were periodically taken and assayed for triglyceride concentration using a lipase-containing assay specific for triglyceride on a Ciba Coming Express 550 Clinical Chemistry Analyzer. The following table shows that the material yields a triglyceride concentration with the Express analyzer, that dissolution is complete by 94 minutes and that the concentrations measured remain stable with time. Also, the measured concentration on the Express 550 was 212% of the amount added, demonstrating that PSTG reacts as if it were more potent than endogenous triglyceride. (The variation in the data for concentrations is caused by imprecision of the method of measurement and is well within the precision expected from the Express 550.)
TABLE 1______________________________________ Triglyceride Net PSTGTime concentration Added(minutes) (mg/dL) (mg/dL)______________________________________Endogenous 138 0Triglycerides(baseline)0 191 5394 194 56331 187 491424 189 51______________________________________
EXAMPLE 2
Effect of Time and Temperature on PSTG Activity:
Similar to Example 1 above, 15 mg of PSTG was added to 30 mL of human serum in amber bottles. The solutions were assayed for triglyceride concentration on the Express 550, and separate samples were placed at 5° C., 23° C. and 30° C. The samples were assayed for triglyceride concentration at intervals for up to 12 days. The following table shows the results. All of the concentrations are in mg/dL. The data show that the control materials stored at 5° C. are stable for approximately 3 years, based on extrapolation of the accelerated 30° storage stability studies shown below.
TABLE 2______________________________________Time Storage @ 5° C. Storage @ 23° C. Storage @ 30° C.(days) Control PSTG Control PSTG Control PSTG______________________________________0 140 245 135 243 131 2480.25 128 241 128 243 131 2510.50 128 241 128 242 131 2432 128 243 132 241 135 2484 135 245 137 253 143 2676 136 250 143 262 152 27211 145 256 159 282 176 30112 172 282 191 300 206 322______________________________________
EXAMPLE 3
The Effect of Concentration on PSTG Activity:
To 30 mL of human serum was added 32 mg of PSTG. The mixture was rotated for 60 hours at 5° C., after which aliquots were taken and further diluted with human serum. The triglyceride activity of the final solutions was determined on a DuPont ACA III Clinical Analyzer. The following table presents the data obtained. Units of concentration are mg/dL.
TABLE 3______________________________________ Total PSTG PSTGSerum Conc. Baseline Net Calc.Dilution ACA Conc. Conc. Conc. Ratio______________________________________undiluted 436 130 306 106.7 2.861:2 284 130 154 53.3 2.891:3 234 130 104 35.6 2.921:4 211 130 81 26.7 3.041:5 198 130 68 21.3 3.181:6 181 130 51 17.8 2.87______________________________________
In this table the baseline concentration is the triglyceride activity due to endogenous material in the human serum, and the PSTG calculated concentration is the actual concentration based on the amount of PSTG that was weighed out. It is clear from this table that throughout the concentrations evaluated, the ratio, which is the total concentration minus the baseline concentration divided by the calculated concentration, remains fairly constant at about 2.9. This ratio may be different depending on the analyzer doing the measurement, or the specific PSTG used, but it still remains constant.
That the recovery of measured triglyceride using PSTG is quantitative and reproduceable is shown in Table 3 of Example 3 by the calculation of a ratio which remains constant, at about 2.9. This ratio will likely be different depending upon which PSTG is selected for use, but. for each PSTG, some fixed ratio will be obtained. This then permits the PSTG to be used as a standard or calibration material as well as a control. A calibrator or standard would be prepared as follows: to achieve a calibration value of 200 mg/dL, add to one liter of serum stripped of endogenous triglycerides 689.7 mg of PSTG (specifically in this case Capmul MCM). The calculation is as follows:
689.7 mg/L×2.9×0.1 L/dL=200 mg/dL
To achieve other calibrator values, use proportionately more or less PSTG per liter of stripped serum. For other PSTG's aside from Capmul MCM, or other analytical procedures, the appropriate factor would be used to achieve the desired concentration of "triglyceride".
EXAMPLE 4
PSTG Activity as Measured on the Dupont D-380 Analyzer:
When various types of PSTG are added to a final concentration of 210 mg/dL in human serum, which has an endogenous triglyceride value of about 90 mg/dL, and is mixed for 6 hours at 5° C., they yield stable PSTG values. A sample of these solutions is then stored at 5° C., and assayed for triglyceride activity over time. The following table shows the data for these PSTG's when analyzed on a Dupont D-380 Analyzer.
TABLE 4______________________________________Brands of PSTG MonoTime (days) Control Myverol Tripro Capmul C-8 Tribut______________________________________0 86 237 248 228 256 2342 95 230 265 216 245 2225 95 234 289 221 242 2259 94 234 293 225 248 22227 87 239 306 233 256 234______________________________________
Myverol is a distilled glyceryl monolinoleate, Tripro is glyceryl tripropionate, Capmul is a mixture of mono- and diglycerides of caprylate and caprate, Mono C-8 is monocapryloyl glycerol, and Tribut is glyceryl tributrate.
EXAMPLE 5
PSTG Activity as Measured on the DuPont ACA III:
The samples were mixed as described above in Example 4. The following table shows the data for these PSTG's when analyzed on a DuPont ACA III Analyzer.
TABLE 5______________________________________Brands of PSTG MonoTime (days) Control Myverol Tripro Capmul C-8 Tribut______________________________________0 100 252 269 250 274 2512 97 257 297 250 275 2535 102 258 321 257 275 2539 104 257 326 257 281 257______________________________________
EXAMPLE 6
PSTG Activity as Measured on Ciba Coming's Express 550:
The samples were mixed as described in Example 4 above. The following table shows the data for these PSTG's when analyzed on the Ciba Coming Express 550.
TABLE 6______________________________________Brands of PSTG MonoTime (days) Control Myverol Tripro Capmul C-8 Tribut______________________________________0 86 247 263 244 271 2492 83 246 300 240 272 2405 90 261 321 239 272 2509 90 246 323 240 267 248______________________________________
EXAMPLE 7
PSTG Activity as Measured on Kodak's Ektachem 700OXRC Analyzer:
The samples were mixed as described above in Example 4. The following table shows the data for these PSTG's when analyzed on Kodak's Ektachem 700OXRC Analyzer. Only a single time point is shown here, but serves very well to show that these PSTG's work quite well on this analyzer also.
TABLE 7______________________________________Brands of PSTG MonoTime (days) Control Myverol Tripro Capmul C-8 Tribut______________________________________23 91 268 335 258 287 260______________________________________
EXAMPLE 8
The Use of a PSTG(Capmul) in a Complete Chemistry Control:
Sufficient Capmul MCM (a PSTG) is added to a human serum based complete chemistry control to give a final triglyceride value of about 200 mg/dL when the control is assayed on a DuPont D-380. The chemistry control contains about 50 separate analytes, and shown in the following table are a few representative analytes along with the PSTG acting as most of the triglyceride component. The control material was held at 5° C., and the activity of the various analytes was determined at the time intervals shown.
TABLE 8______________________________________Time (days) ACP ALP Bilirubin CK AST ALT TRIG______________________________________0 3.76 165 7.55 251 222 147 2121 3.86 178 7.46 233 214 142 2182 3.83 181 7.28 227 214 143 2274 3.77 179 7.01 231 218 147 2336 3.74 171 6.79 232 221 144 2179 3.71 171 6.31 218 215 137 238______________________________________
The data in this table clearly show the stability of this PSTG in the presence of numerous other components.
Further variations in the development of control materials comprising triglyceride substitutes will become apparent to those with expertise in the relevant art.
EXAMPLE 9
Use of a Control in the Monitoring of a Triglyceride Assay
The chemistry control as described in example 8 was assayed for triglyceride alongside two unknown human serum samples on a DuPont D-380 clinical analyzer. The triglyceride value in this control was assigned a value of 220 plus or minus 10%. All samples were run in triplicate.
TABLE 9______________________________________ Sample value mg/dl______________________________________Control from example 8 211, 221, 217Patient A 110, 112, 118Patient B 245, 250, 248______________________________________
Since the values obtained on the control were within plus or minus 10% of the assigned value of 220 the clinical chemist would have confidence in the values obtained on patients A and B. | Materials and compositions for making triglyceride controls, calibrators and standards are described. The materials are mono- and di- and tri- glycerides of medium length fatty acids mixed into compositions of human serum or other protein solutions to form stable, miscible solutions suitable for use as controls, calibrators and standards in clinical chemistry for measurement and quality control in assays for triglycerides. The materials described have been used as vehicles for oil-soluble, water-insoluble pharmaceuticals and as facial emollient oils for cosmetics, and as such are safe, functional, stable, rancid-resistant and very inexpensive compared with pure materials synthesized or described previously. | 8 |
This application is a division of application Ser. No. 13/988,742, filed May 21, 2013, which was the U.S. national stage entry of international application Ser. No. PCT/EP2011/070558, filed Nov. 21, 2011.
BACKGROUND OF THE INVENTION
The invention relates to an ultrasonic welding device for welding cables, for example strands. The invention also relates to a mobile ultrasonic welding apparatus.
Cables here are understood to be cables having one or more strands and also individual wires or electrically conductive lines. However, it is possible, in principle, for a cable to be a terminal, i.e. a rigid electrical connection.
In the case of known devices of this type, ultrasonic vibration is introduced parallel to a welding surface, wherein a compacting force is exerted simultaneously in a direction perpendicular thereto, for example via a compacting or abutment surface. A compacting or welding space, in which the welding material is compressed, i.e. compacted, before and during the welding operation, is typically provided here. In particular for welding strands, it is necessary, for the purpose of achieving a durable weld, for the individual wires to be compressed by a comparatively large force during welding. During the welding operation, on account of the compacted welding material moving in relation to one another, the ultrasonic vibration results in the parts being connected, i.e. in welding taking place.
In a large number of industrial applications, in particular in the automobile industry, there is a need for it to be possible for already installed and/or difficult-to-access parts to be connected by means of ultrasonic welding. For example, in the case of the production of cable harnesses for vehicles, these being prefabricated on a board, the individual cables, in some cases, can be raised merely by approximately 4 cm. In particular, there is also increasingly the need to use ultrasonic welding to connect not just copper, but also materials which oxidize to a pronounced extent, for example aluminum. For this purpose, it is necessary for the highest possible level of power to be introduced into the welding region, in order to create a durable welding connection despite the oxide layer.
DE 10 2007 026 707 B3 discloses a device for connecting aluminum strands in an electrically conductive manner. A sonotrode here has a welding surface which is in direct contact with the aluminum strand. The sonotrode, which vibrates in its longitudinal direction, subjects the strands, in the longitudinal direction thereof, to ultrasonic vibration, and therefore the strands are welded to one another. For this purpose, the strands have to be arranged in the longitudinal direction of the sonotrode, which requires a large amount of space and presupposes that the parts which are to be welded allow for a corresponding arrangement in the first place.
EP 0 143 936 B1 proposes, for space-saving welding purposes, that a welding or compacting space of a device should be formed perpendicularly to the longitudinal axis of the sonotrode, and therefore it is also the case that the parts which are to be welded can be arranged perpendicularly to the sonotrode axis. However, the parts here are subjected to the ultrasonic vibration transversely to the compacting space, and thus transversely to their longitudinal direction, as a result of which only a low level of effective power is introduced. It is thus barely possible to effect metal welding of, for example, strands, in particular those made of aluminum.
WO 95/23668 A1 proposes to excite a sonotrode head to perform simultaneous longitudinal and torsional vibrations, wherein the vibration energy is taken off at the circumference. This makes it possible to arrange a compacting space perpendicularly to the sonotrode axis and, nevertheless, for the parts which are to be welded to be subjected to the ultrasonic vibration in their longitudinal direction up to a certain degree. However, it has been found that, on account of the design and excitation of the sonotrode, configuration of the compacting space requires high outlay in design terms and comparatively large tolerances. It is also possible, during the welding of strands, for ultrasonic vibrations introduced transversely to the strand direction to have an adverse effect on the welding since these vibrations disrupt the compacted arrangement of the wires (individual wires “roll”, rather than rub), as a result of which it is also the case that the vibrations can become less effective in the longitudinal direction. Similarly, miniaturizing the sonotrodes is limited by design, since the dimensions of the oblique slots of the converter which are necessary for generating the torsional vibration cannot fall below a certain minimum level. Not least is the design of the slots complex and therefore costly.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to avoid the disadvantages of the prior art and to provide, in particular, a versatile ultrasonic welding device which is of straightforward design and allows space-saving, efficient and durable welding, in particular on a cable harness. The device here should also make it possible, in particular, to weld strands made of copper and of aluminum. It is also an object of the invention to provide a mobile welding apparatus.
The object is achieved according to the invention in that the device for welding metal parts by means of ultrasound comprises a sonotrode with a sonotrode head, which can be excited by a vibration generator to perform torsional vibrations in relation to a torsion axis. A welding surface is arranged circumferentially here on the sonotrode head, as seen in relation to the torsion axis. An anvil with a compacting surface is also present, it being possible for this to be arranged opposite the welding surface of the sonotrode, in a fixed state in relation to the same. In the case of an opposite arrangement, the welding surface and the compacting surface delimit a compacting space, provided for accommodating parts which are to be welded, in a direction perpendicular to the torsion axis. The invention is distinguished in that the sonotrode is designed, and coupled to the vibration generator, such that the sonotrode as a whole can be excited to perform torsional vibration with a negligibly small longitudinal-vibration component. In other words, the vibration generator is designed for generating longitudinal vibrations and is arranged perpendicularly to the torsion axis, wherein the vibration generator is in contact with a torsion vibrator, on which the sonotrode is fitted in a rotationally fixed manner, at a radial distance from the torsion axis, in particular tangentially.
Since, according to the invention, the sonotrode as a whole can be made to perform torsional vibration, the longitudinal-vibration component, which is barely avoidable in practice, can be reduced to a negligibly low level. A negligibly small longitudinal-vibration component is understood here, and herein below, to mean a longitudinal-vibration component which has a longitudinal amplitude which is less than 1% of the torsional operating amplitude, preferably less than 0.5%. It has even been found that, in practice, the device according to the invention achieves amplitudes for the longitudinal-vibration component which are only approximately 0.2% of the operating amplitude.
On the one hand, this results in largely all the vibration energy fed by the vibration generator being available in the torsional vibration of the sonotrode, and therefore optimum power transmission takes place even in the case of welding material being arranged perpendicularly to the torsion axis.
On the other hand, an operating region of the sonotrode, in the present case the sonotrode head with welding surface formed thereon, describes a well-defined rotary movement without any significant deflection in the longitudinal direction. Adjacent fixed or displaceable parts of the device can therefore be respectively installed on, and pushed onto, the sonotrode head with considerably lower tolerances, without account having to be taken of any vibration amplitudes occurring in the longitudinal direction. In particular the compacting or welding space, which is delimited on one side by the welding surface of the sonotrode can be delimited in a comparatively precise manner by it being possible for delimiting elements to be arranged in very close proximity to the sonotrode head even in the direction of the torsion axis. This makes it possible, for example, to prevent the situation where particularly fine wires, during the compacting operation in the compacting space, can enter into gaps between delimiting elements of the compacting space and get caught there.
The vibration generator of the device according to the invention, this generator also being referred to in the art as a converter, is therefore advantageously designed for generating longitudinal vibrations and is arranged perpendicularly to the torsion axis of the sonotrode. Such vibration generators are in widespread use, and it is therefore possible to use cost-effective standard components. Since the vibration generator is arranged perpendicularly and in a laterally offset manner in relation to the torsion axis, it is possible to use suitable, direct or indirect, coupling to the sonotrode to convert the longitudinal vibration of the generator into torsional vibration of the sonotrode as a whole. It is also conceivable for two or more vibration generators to interact with the sonotrode in order to generate the torsional vibration, wherein these generators are then cyclically controlled, for example alternately, depending on their arrangement and/or number.
In order to excite the torsional vibration of the sonotrode, the vibration generator preferably interacts with the sonotrode via a torsional vibrator, which is coupled to the sonotrode in respect of torsional vibration. The torsional vibrator may be designed, for example, as an axial body which is arranged coaxially in relation to the torsion axis and at one end region of which the sonotrode is fastened in a rotationally fixed manner.
For fastening on the torsional generator, the sonotrode is preferably screw-connected thereto. In the case of known screw connections between sonotrodes and torsional vibrators, a blind hole with an internal thread is formed on a respective fastening end side both of the sonotrode and of the torsional vibrator. The sonotrode is screw-connected to the torsional vibrator via a grub screw on either side. The difficulty with such a screw connection, however, is that of aligning the sonotrode in respect of rotation about the longitudinal axis, since it is necessary for the sonotrode to be able to rotate during fastening. In the present case, however, the sonotrode preferably has a one-sided screw connection, in the case of which advantageously a fastening screw is screwed into the torsional vibrator in the direction of the torsion axis so as to be supported on the sonotrode from the sonotrode head. For this purpose, the sonotrode preferably has, in the longitudinal direction, a central countersunk hole which is accessible from the sonotrode head and, in the direction of the fastening end side, has a longitudinally continuous bore on the floor of the countersunk hole. It is thus possible for a screw to be screwed longitudinally through the bore, from the sonotrode head, into the internal thread on the torsional vibrator and for the sonotrode to be fastened on the torsional vibrator. A screw head can be arranged in the countersunk hole and supported on a floor of the countersunk hole. This makes it possible for alignment of the sonotrode in respect of rotation to be straightforwardly predetermined, and fixed by virtue of the screw being tightened. In particular there is no need for the sonotrode to be rotatable in relation to the torsional vibrator during the fastening operation.
It goes without saying that the screw connection can, of course, also take place in the reverse order, i.e. the countersunk hole is formed for access from a rear longitudinal end of the torsional vibrator in the longitudinal direction thereof and the internal thread is formed in the sonotrode. In this case, the screw connection takes place from the torsional vibrator into the internal thread of the sonotrode, wherein the screw head is supported in the countersunk hole on the torsional vibrator. It likewise goes without saying that this fastening principle (screw connection on one side) of the sonotrode on the torsional vibrator is also advantageous as an aspect in its own right and can be used for other sonotrodes.
A region at a longitudinal end of the axial-body-design torsional vibrator which is located opposite the fastening region of the sonotrode may be provided, for example, for contact with the vibration generator. For vibration-isolated mounting on a housing of the device, the axial body can be supported on the housing, for example, in a known manner in a vibration node of the excited vibration mode.
In order to excite the torsional vibration in the torsional vibrator and the sonotrode, which is connected thereto, an activator of the vibration generator is in contact with the torsional vibrator, preferably at a radial distance from the torsion axis. It is particularly straightforward to achieve contact in a region tangential to the cross section of the torsional vibrator. Since the activator is in contact with the torsional vibrator at a radial distance from the torsion axis, the torsional vibrator is subjected to a torque about the torsion axis. It is thus readily possible for the longitudinal vibration, which can be picked up at the activator, to be converted directly into torsional vibration of the torsional vibrator. Since the vibration generator is arranged perpendicularly to the torsion axis, the torsional vibrator is subjected only to a torque about the torsion axis, without any longitudinal force components.
The torsion axis preferably coincides with a longitudinal axis of the sonotrode. It is advantageous here for the sonotrode to be designed in an axis-symmetrical manner in relation to the longitudinal axis, and this therefore means that there is no unbalance in relation to the torsion axis. In the case of a torsional vibrator, the latter is preferably likewise designed in an axis-symmetrical manner in relation to its longitudinal axis, wherein the longitudinal axis coincides with the torsion axis.
In a preferred embodiment, the sonotrode head protrudes in a flange-like manner, transversely to the torsion axis, at a free end of the sonotrode. The flange-like sonotrode head advantageously has, in the longitudinal direction, two plane-parallel surfaces oriented transversely to the torsion axis. A distance between the surfaces in the direction of the torsion axis here defines a thickness of the sonotrode head. It is advantageous here for the welding surface to extend over the entire longitudinal dimension, i.e. the thickness of the sonotrode head. As a result, on the one hand, the welding surface, irrespective of the rest of the design of the sonotrode, may be arranged at largely any desired radial distance from the torsion axis. On the other hand, the entire thickness of the flange can be used for vibration transmission at the welding surface. The flange may therefore be of comparatively thin design.
In a preferred embodiment, the flange-like sonotrode head comprises two lugs which are formed symmetrically in a direction transverse to the torsion axis and of which at least one has the welding surface on the circumference. The vibrating mass of the sonotrode head can thus be reduced further in relation to a completely annular flange. In a modification, it is possible for the two lugs to have a welding surface on the circumference, and therefore, when the one welding surface is worn, the sonotrode can be rotated through 180 degrees in relation to the torsion axis, in order to arrange the other welding surface for use at the compacting or welding space. For this purpose, the sonotrode may have a fastening means which allows it to be fastened on the torsional vibrator in a removable manner and in various positions. It goes without saying that it is also possible, for other designs of the sonotrode head, to provide a plurality of welding surfaces which can be arranged for use at the compacting or welding space by virtue of the sonotrode being fastened in various rotary positions on the torsional vibrator. In a further preferred embodiment, the sonotrode head therefore preferably comprises generally at least two or more, preferably four, welding surfaces formed on the circumference.
The compacting space is delimited preferably by an outer lateral slide and an inner lateral slide in the direction of the torsion axis. The lateral slides therefore define a length of the compacting space in the longitudinal direction, i.e. in the direction of the torsion axis.
The compacting space here is preferably designed to be continuous, and to open outward, in a direction perpendicular to the torsion axis. It is thus possible for the welding material, e.g. one or more cables, to be arranged in the compacting space in a direction transverse to the torsion axis.
It is advantageous, in particular in the case of fixed lateral slides, for the compacting space to be delimited by the lateral slides on either side of the welding surface of the sonotrode, and for the sonotrode head to be arranged, at least in part, in an interspace between the lateral slides. It is preferable here for a distance between the lateral slides in the direction of the torsion axis to correspond to a dimension of the sonotrode head in this direction. The aforementioned dimensional correspondence is understood in the framework of a tolerance which ensures free torsional vibration of the sonotrode head.
Such an arrangement is made possible for the first time by the excited torsional vibration with negligible longitudinal-vibration component of the sonotrode head according to the invention. Otherwise, on account of the longitudinal-vibration amplitude, the lateral slides would have to be spaced apart from the sonotrode head and/or corresponding apertures would have to be present, and these could give rise to possibly undesired free spaces between the sonotrode head and lateral slide.
It is preferred here for the outer lateral slide to be arranged in front of the sonotrode head, as seen in the direction of the torsion axis, and to fully cover over preferably an end side of the sonotrode. Since the outer lateral slide fully covers over the sonotrode head, the latter is outwardly protected against mechanical effects. The outer lateral slide may be of comparatively thin design here, and therefore the compacting space can be moved close up to the welding material in the axial direction.
In particular in the case of an embodiment with longitudinally fixed lateral slides, it is advantageous for the inner lateral slide and the outer lateral slide to be arranged such that they can be jointly displaced in relation to the sonotrode in a direction perpendicular to the torsion axis. For this purpose, for example a longitudinal guide which is oriented transversely to the torsion axis is formed, and the lateral slides can be displaced in a guided manner thereon. It is thus possible for the sonotrode head to be arranged in the interspace between the lateral slides by virtue of the lateral slides being displaced to a more or less pronounced extent.
The inner lateral slide and the outer lateral slide here are advantageously mounted jointly on a carriage, which is guided such that it can be displaced in relation to the sonotrode perpendicularly to the torsion axis, and therefore, during displacement of the carriage, the sonotrode head can be introduced into the interspace between the lateral slides or moved out of the same. It goes without saying that it is also the case that just one of the lateral slides can be mounted on the carriage, while the other is fixed in a direction perpendicular to the torsion axis.
In an embodiment which may possibly be preferred, it is possible for at least one of the lateral slides to be designed such that it can be displaced in the direction of the torsion axis. For this purpose, the lateral slide preferably has an aperture which essentially, i.e. within the framework of a tolerance necessary for the vibration of the sonotrode, leaves free a region of a projection of the sonotrode head in the direction of the torsion axis, in particular in the region of the welding surface. This means that the at least one lateral slide can be displaced into a length region of the sonotrode head and/or the welding surface thereof, wherein a lateral-slide inner surface, which is directed toward the compacting space, follows the welding surface, with the smallest possible gap therebetween. The lateral slide can thus be displaced towards the other lateral slide in the torsion-axis direction and therefore makes it possible to reduce the dimension of the compacting space in the direction of the torsion axis. In particular it is possible, in this case, for the dimension of the compacting space in this direction to be reduced irrespective of the longitudinal dimension of the sonotrode head.
It is preferably the outer lateral slide which can be displaced in the longitudinal direction, while the inner lateral slide is arranged in a longitudinally fixed position. The lateral slide which can be displaced in the longitudinal direction need not be displaceable here in the radial direction in relation to the torsion axis. In this case, it is possible for the anvil to strike longitudinally, for example by way of an end side, against the inner surface of the at least one lateral slide, this inner surface being directed toward the compacting space, in order for the compacting space to be closed off fully in the radially outward direction. When the at least one lateral slide is displaced in the direction of the torsion axis, the anvil can correspondingly be displaced along with it.
It is also conceivable, in principle, for just the inner lateral slide or for the two lateral slides to be configured so as to be displaceable in the direction of the torsion axis. These variants, however, usually involve a higher level of outlay.
It is advantageous for the at least one lateral slide to be mounted directly or indirectly on a device-mounted displacement guide such that it can be displaced in the direction of the torsion axis, wherein preferably an electric drive, in particular with a spindle drive, is present for displacement purposes. The drive can use, for example, a spindle drive to act on a displacement body which is guided on the device-mounted displacement guide, and to which the lateral slide is connected rigidly directly or indirectly. It goes without saying that the displacement can also take place pneumatically, hydraulically or via other drives.
It is advantageous for the anvil to be mounted on the carriage or on one of the lateral slides, in particular on the inner lateral slide, such that the anvil can be displaced transversely to the torsion axis together with said lateral slides, wherein the anvil is arranged such that it can be displaced in the direction of the sonotrode during displacement of the carriage or of the lateral slide.
It is preferable here for the anvil to be arranged such that it can be displaced, in addition, in a direction parallel to the torsion axis, and therefore the anvil can be moved into an extended position, in which it projects beyond the lateral slide and the abutment or compacting surface of the anvil is located opposite the welding surface of the sonotrode. In addition, the anvil is also advantageously displaceable into a retracted position, in which it terminates in the longitudinal direction with the lateral slide, and therefore the compacting space is accessible in order for welding material to be introduced.
It is preferable for the anvil, in the extended position, to close off the compacting space fully outward in a direction perpendicular to the torsion axis. In other words, the anvil, in the extended position, fully spans the distance between the lateral slides, i.e. a length of the compacting space.
The anvil thus forms, together with the lateral slides, a jaw-like unit in respect of displacement in a direction transverse to the torsion axis. In particular, it is thus possible, with the anvil extended, for the volume of the compacting space for compacting the welding material to be uniformly reduced in the radial direction by virtue of the anvil being lowered. In the case of the lateral slide being additionally displaceable in the direction of the torsion axis, it is also possible to reduce a dimension of the compacting space in this direction, in order to achieve the most uniform possible reduction in the volume of the compacting space.
It goes without saying that it is also conceivable to have other variants in which the anvil is mounted, for example, in a pivotable manner or the lateral slides are fixed in relation to the sonotrode and the anvil can be displaced, in the interspace between the lateral slides, in the direction of the welding surface. These variants, however, may have the disadvantage that they involve comparatively high outlay in design terms and/or are difficult to handle in practice.
On account of the welding space being accessible in a space-saving manner, the device according to the invention, in particular all of the embodiments thereof described above, can advantageously be used in mobile welding apparatuses. The invention therefore also covers a mobile welding apparatus which has a device according to the invention.
Such apparatuses are connected to a separate supply unit preferably via a supply line, the separate supply unit preferably comprising a generator for supplying the welding apparatus with electric current or an air-pressure generator for supplying it with compressed air. The supply unit advantageously also comprises a control computer, wherein, for example, an operating panel, also with a screen, is formed on the mobile welding apparatus. In this case, the user can operate the supply unit directly on the mobile welding apparatus. The supply line preferably combines all the necessary connections between the supply unit and the mobile welding apparatus in a single line.
Such mobile welding apparatuses are particularly suitable for use with welding material which, for example, is already installed and/or fixed in some other way and is no longer able to be fed to a stationary welding apparatus. It is precisely in this area that the device supplied according to the invention for space-saving, efficient and durable ultrasonic welding proves to be particularly advantageous.
It is usually the case here that the supply unit is of stationary design, whereas the mobile welding apparatus can be moved largely freely. However, it is also conceivable for the supply unit to be provided on a mobile base, and therefore it can be moved closer to the operating region, in which the mobile welding apparatus can then be used to carry out welding at various locations.
Mobile welding apparatuses are understood to mean, for example, welding tongs or other designs which users can carry and guide up to the welding material. Also conceivable are designs which are retained, for example, on a weight-compensating suspension means and are only guided by the user. Furthermore, it is also possible to have a fastening device or a stand on the mobile welding apparatus, the fastening device or stand allowing the welding apparatus to be respectively temporarily fastened or propped up in an operating region during welding.
In order to be handled by a user, mobile welding apparatuses typically comprise handles formed on the outside of the housing. According to the invention, the compacting/welding space is arranged on the end side in a direction transverse to a longitudinal direction of the device or of the sonotrode. In the case of a mobile welding apparatus according to the invention, it is therefore preferred for a handle to be arranged in a front region, on an upper side of the apparatus, in a direction transverse to the longitudinal axis of the device. This allows reliable handling when the apparatus is moved up to the welding material by way of the front end side, largely in its longitudinal direction. It goes without saying that, depending on the position of the welding material, the apparatus can also be moved up to the welding material in other directions.
In addition, it is advantageous here for a further handle to be provided in a region at a rear longitudinal end of the apparatus. If the converter, which is arranged perpendicularly to the torsion/longitudinal axis, is oriented downward, it is possible for a housing casing of the converter to be designed advantageously as a gun-handle-like grip and thus to form a rear grip.
Further advantageous embodiments and combinations of features of the invention can be gathered from the following detailed description and claims below.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which are used to explain the exemplary embodiment, schematically:
FIG. 1 shows an oblique view, in perspective, of a device according to the invention;
FIG. 2 shows a front view of an operating region of the device along a longitudinal axis;
FIG. 3 a shows a side view of the device in a standby position;
FIG. 3 b shows a side view of the device in a compacting/welding position;
FIG. 4 shows the sonotrode and converter in an arrangement for the device according to the invention;
FIG. 5 shows an oblique view, in perspective, of a further embodiment of a device according to the invention;
FIG. 6 shows a partial outer view of a sonotrode head with an outer lateral slide of the device from FIG. 5 ;
FIG. 7 shows a partial side view of the device according to FIG. 5 ;
FIG. 8 a shows a schematic diagram of the compacting space of the device according to FIG. 1 ;
FIG. 8 b shows a schematic diagram of the compacting space of the device according to FIG. 5 ; and
FIG. 9 shows a partial sectional view of a sonotrode fastening on the torsional vibrator.
It is basically the case in the figures that like parts are provided with like designations.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an oblique view, in perspective, of a device 1 according to the invention.
The device 1 has, at a front longitudinal end 5 , an operating region, at which a compacting or welding space 8 is formed. A vibration generator or converter 9 is arranged in an end region at a rear longitudinal end 6 of the device 1 , and the activator 9 . 1 of the generator or converter is connected to a torsional vibrator 4 of the device 1 . The converter 9 here is oriented perpendicularly to the torsion axis B.
A direction in which the converter 9 extends is referred to here, and herein below, by “upward” and, correspondingly, the opposite direction is referred to by “downward”. It goes without saying that this assignment of terms is selected by way of example in accordance with the embodiment described here. It is, of course, also conceivable to have other embodiments, in which the converter 9 may be oriented, for example, “downward” or “to the side”. A plane C therefore refers, herein below, to a vertical plane, which comprises the longitudinal axis A and the torsion axis B and is oriented in the upward/downward direction. The converter 9 is parallel, and laterally offset in relation, to said plane C.
The torsional vibrator 4 is designed as an elongate axial body, of which the longitudinal axis coincides with a torsion axis B and corresponds to the longitudinal axis A of the device 1 (see also FIG. 4 ). The torsional vibrator 4 is arranged in, and mounted on, a carrier 7 of the device 1 (see FIG. 2 , clamping ring 4 . 1 ). A rear longitudinal end of the torsional vibrator 4 , this end being directed away from the operating region, projects beyond the carrier 7 in the longitudinal direction A. In an end region at the rear longitudinal end of the torsional vibrator, the activator 9 . 1 of the converter 9 is in contact tangentially with the torsional vibrator 4 .
Provided at a front longitudinal end of the carrier 7 , this end being directed toward the operating region, is a carrier plate 11 which is arranged perpendicularly to the longitudinal axis A and on the front side of which is arranged a longitudinal guide 12 , which is provided in the upward/downward direction, perpendicularly to the longitudinal axis A and torsion axis B, and has two parallel rails which are symmetrical in relation to the plane C. Between the rails, the carrier plate 11 contains a through-passage 11 . 1 through which, fastened on the end side of the torsional vibrator 4 , a sonotrode 3 projects forwards into the operating region.
A carriage 13 is mounted on the rails 12 such that it can be guided in a displaceable manner in a direction perpendicular to the torsion axis B (the carriage not being illustrated in FIG. 1 ; see, for example, FIG. 2 ). On an underside of the carrier 7 , two linearly acting activators 14 . 1 and 14 . 2 are arranged perpendicularly to the longitudinal axis A and are supported on the carrier 7 via carrier elements 7 . 1 and 7 . 2 . The activators 14 . 1 and 14 . 2 can each expand in their longitudinal direction, (e.g. by being subjected to the action of compressed air) and can thus each exert a force in a direction perpendicular to the longitudinal axis A. Arranged between the activators 14 . 1 and 14 . 2 is a driver element 15 , which projects forward through the aperture 11 . 1 in the carrier plate 11 and engages with coupling action in the carriage 13 . If the upper activator 14 . 1 , which is arranged closer to the carrier 7 , is actuated, this results in the driver element 15 being subjected to a downward force, as a result of which the carriage 13 is also displaced downward. Conversely, the carriage 13 is subjected to an upward force via the driver element 15 if the lower activator 14 . 2 is actuated.
The carriage 13 here has an aperture 13 . 1 , through which the sonotrode 3 can pass without obstruction in any displacement position of the carriage 13 (see FIG. 2 ). A head 3 . 1 of the sonotrode 3 is arranged in front of the carriage 13 , as seen in the longitudinal direction. The carriage 13 has arranged on it, above the sonotrode 3 , an inner lateral slide 16 , which has a through-passage 16 . 1 in the longitudinal direction A directly above the sonotrode head 13 . 1 . The through-passage 16 . 1 contains an anvil 18 which, guided in a longitudinal guide 10 , can be extended and retracted through the through-passage 16 . 1 via an actuator 19 , which acts in the longitudinal direction A. On a side which is directed toward the sonotrode head 3 . 1 , the anvil 18 has an abutment surface or compacting surface 18 . 1 . Both the actuator 19 and the longitudinal guide 10 , as well as the anvil 18 , are mounted on the carriage 13 and are also displaced when the carriage 13 is displaced.
Likewise mounted on the carriage 13 is an outer lateral slide 17 , which is fastened on the carriage 13 via two carrying bolts 17 . 1 and 17 . 2 , which project in the direction of the carrier 7 . The outer lateral slide 17 here is arranged in front of the sonotrode head 3 . 1 , as seen in the longitudinal direction A, and is spaced apart from the inner lateral slide 16 in the longitudinal direction 1 . The outer lateral slide 17 fully covers over the sonotrode head 3 . 1 on the end side.
The sonotrode head 3 . 1 has two wings 3 . 2 and 3 . 3 , which protrude in a flange-like manner and extend upward ( 3 . 2 ) and downward ( 3 . 3 ). The upwardly projecting wing 3 . 2 here is arranged between the outer lateral slide 17 and the inner lateral slide 16 , wherein a welding surface 3 . 4 is formed circumferentially on an upper side of the wing 3 . 2 . Along with the welding surface 3 . 4 of the sonotrode head 3 . 1 , regions of the mutually facing inner surfaces of the lateral slides 16 and 17 which are arranged by the welding surface 3 . 4 delimit three sides of the compacting space 8 . The anvil 18 is arranged in a displaceable manner on the inner lateral slide 16 such that, in the extended state, it is adjacent to the outer lateral slide 17 , wherein the compacting surface 18 . 1 is located opposite the welding surface 3 . 4 of the sonotrode 3 . With the anvil 18 extended, the compacting space 8 is thus annularly enclosed in the plane C. In the direction perpendicular to the plane C, the compacting space 8 is open on either side, and therefore welding material can pass transversely through the compacting space 8 .
FIG. 2 shows a front view of the operating region 5 of the device 1 along the longitudinal axis A. For the sake of priority, the illustration does not include the outer lateral slide 17 , in order to give a free view of the sonotrode head 13 . 1 .
The sonotrode head 13 . 1 is of largely lozenge-shaped design in plan view, this giving rise to the upwardly and downwardly projecting wings 3 . 2 and 3 . 3 , respectively. The sonotrode head 3 . 1 is designed symmetrically in relation to the torsion axis B, and this therefore avoids any unbalance in relation to torsional vibration.
An upper end of the sonotrode head 3 . 1 , i.e. the upwardly projecting wing 3 . 2 , is flattened (cropped lozenge shape) and formed into the welding surface 3 . 4 , which is arranged circumferentially in relation to the torsion axis B. The downwardly projecting wing 3 . 3 is flattened correspondingly, wherein, depending on the embodiment of the device 1 , a second (replacement) welding surface 3 . 5 may be formed. In the arrangement illustrated, this latter welding surface is not in a functional position, but, for example in the case of the sonotrode 3 being fitted in a rotatable manner on the torsional vibrator 4 , can be rotated into the position of the welding surface 3 . 4 . This may be expedient, in particular, when the welding surfaces are subjected to rapid wear and have to be exchanged.
Above the welding surface 3 . 4 , the inner lateral slide 16 is designed as a crossbar-like element arranged largely perpendicularly to the plane C. The lateral slide 16 here is fastened in a groove which is formed correspondingly on the carriage 13 . The anvil 18 , arranged in the longitudinal guide 10 , can be seen on the lateral slide 16 , through the through-passage 16 . 1 . The abutment or compacting surface 18 . 1 is formed on an underside of the anvil 18 , said underside being directed toward the welding surface 3 . 4 .
Two further apertures 13 . 2 and 13 . 3 are formed on the carriage 13 level with the torsion axis B or the longitudinal axis A of the device 1 , these further apertures being provided for accommodating, and retaining, the carrying bolts 17 . 1 and 17 . 2 of the outer lateral slide 17 .
FIG. 2 further shows the converter 9 being arranged laterally, in a manner in which it is offset in relation to the plane C and which allows the activator 9 . 1 to be in tangential contact with the torsional vibrator 4 in order to excite the torsional vibration.
FIG. 3 a shows a side view of the device 1 , wherein, for the sake of clarity, the carrier 7 has been omitted from the illustration.
The illustration of FIG. 3 a shows the device 1 in a standby state. The lower actuator 14 . 2 has been expanded and the upper actuator 14 . 1 has been collapsed, and therefore the driver element 15 , arranged therebetween, has been displaced upward. The coupling to the carriage 13 means that the latter has been carried along by the driver element 15 and has likewise been displaced upward.
The anvil 18 is fully retracted into the through-passage 16 . 1 , and therefore an end surface of the anvil 18 terminates with the inner surface of the inner lateral slide 16 , said inner surface being directed toward the outer lateral slide 17 . The compacting space 8 is thus open in the upward direction, as a result of which welding material, for example strands or other cables, can be introduced into the compacting space 8 and arranged on the welding surface 3 . 4 of the sonotrode 3 .
FIG. 3 b corresponds to the illustration of FIG. 3 a , although the device 1 is in a compacting/welding position.
The anvil 18 has been extended forward, out of the through-passage, in the longitudinal direction A, and therefore its end side strikes against an inner surface of the outer lateral slide 17 , said inner surface being directed toward the inner lateral slide 16 . The compacting surface 18 . 1 of the anvil 18 is arranged opposite the welding surface of the sonotrode head 3 . 4 . The compacting space 8 is thus fully closed off in the upward direction by the anvil 18 .
In the welding position, in addition, the carriage 13 has been displaced downward. This is achieved by the upper actuator 14 . 1 having been expanded and the lower actuator 14 . 2 having been collapsed. The driver element 15 is thus moved downward, away from the carrier 7 , and carries along the carriage 13 , which is displaced downward in the longitudinal guide 12 .
Together with the carriage 13 , it is also the case that the lateral slides 16 , 17 , fitted thereon, and the anvil 18 (as well as the actuator 19 and longitudinal guide 10 ) are lowered downward in relation to the carrier 7 . The sonotrode 3 , mounted on the carrier 7 , and the torsional vibrator 4 remain in a fixed location in relation to the carrier 7 . This gives rise to the carriage 13 , with components fitted thereon, being displaced relative to the sonotrode 3 .
The lateral slides 16 and 17 and anvil 18 here form a U-shaped compacting jaw, which at least partially encloses the sonotrode head 3 . 1 and is displaced in relation to the same during transfer into the welding position. The sonotrode head 3 . 1 , or the wing 3 . 2 of the sonotrode head 3 . 1 , enters into the interior space enclosed by the U shape. The interior space of the U shape and the wing 3 . 2 of the sonotrode head 3 . 1 are dimensioned here such that the wing 3 . 2 virtually completely fills the interior space in the longitudinal direction A. It goes without saying that a tolerance which allows for free torsional vibration of the sonotrode head 3 . 1 is provided here.
During transfer into the welding position, in particular also the compacting surface 18 . 1 of the anvil 18 is displaced in the direction of the welding surface 3 . 4 . The welding material (not illustrated), which is present in the compacting space 8 , is compacted between the compacting surface 18 . 1 and welding surface 3 . 4 and, depending on the force exerted by the actuator 14 . 2 , pressed against the welding surface 3 . 4 . The torsional vibration of the sonotrode 3 can thus be introduced into the welding material via the welding surface 3 . 4 of the sonotrode head 3 . 1 . The welding material is preferably compacted by a first force prior to the excitation of the torsional vibration in the sonotrode 3 . When the welding operation is initiated, i.e. when the torsional vibration of the sonotrode is excited, the welding material may thus continue to be subjected to the action of the first force or be subjected to the action of a second, e.g. greater force.
For removal of the welding material, the device 1 is moved back into the standby state, i.e. the carriage 13 is displaced upward again and the anvil 18 is retracted, as a result of which the compacting space is open once again in the upward direction.
FIG. 4 shows the sonotrode 3 , the torsional vibrator 4 and the converter 9 in an arrangement for the device according to the invention.
A front end side of the sonotrode 3 is terminated by the sonotrode head 3 . 1 . Along the torsion axis B or longitudinal axis of the sonotrode 3 , the sonotrode extends rearward to a region 3 . 6 , in which it is connected to the torsional vibrator 4 . The torsional vibrator 4 here is designed as an elongate axial body, of which the longitudinal axis coincides with the longitudinal axis of the sonotrode 3 and with the torsion axis B.
The torsional vibrator 4 , at a longitudinal position behind the sonotrode 3 , is enclosed by the clamping ring 4 . 1 , which forms a bearing for the torsional vibrator, at which the torsional vibrator is supported on the carrier 7 . The clamping ring 4 . 1 here is typically arranged in a vibration node of the excited torsional-vibration mode, in order to avoid transmission of vibrations to the carrier 7 and thus also to other components of the device 1 .
Behind the clamping ring 4 . 1 , i.e. at a longitudinal position of the torsional vibrator 4 which is located opposite the sonotrode 3 , as seen in relation to the clamping ring 4 . 1 , the actuator 9 . 1 of the laterally offset converter 9 is in contact with the torsional vibrator 4 tangentially to a circumference of the torsional vibrator 4 and perpendicularly to the longitudinal axis or to the torsion axis B.
FIG. 5 shows a further embodiment of the device 1 ′ according to the invention. In a manner similar to the device 1 , a compacting or welding space 8 ′ is formed at a front longitudinal end 5 ′. Two converters 9 a and 9 b are present at a rear longitudinal end 6 ′, each being in contact, on opposite sides, with an axial-body-design torsional vibrator 4 ′ and by way of an activator 9 a . 1 and 9 b . 1 . The converters 9 a and 9 b here are arranged perpendicularly to a torsion axis B′, which is defined by the torsional vibrator 4 ′. A longitudinal axis A′ of the device 1 ′ coincides here with the torsion axis B′.
A sonotrode 3 ′ (not visible in FIG. 5 ; see, for example, FIG. 6 ) is fastened on the torsional vibrator 4 ′ in the direction of the front longitudinal end 5 ′. A sonotrode head 3 . 1 ′ of the sonotrode 3 ′ is arranged in the longitudinal region of the compacting space 8 ′ and delimits the latter radially, in the direction of the torsion axis B′, by way of a lateral welding surface 3 . 4 ′.
A gun-like handle 30 is formed on an underside of the device 1 ′ and allows a user to hold the device 1 ′. The handle 30 has an actuating element 30 . 1 , by means of which a welding operation can be initiated.
The compacting space 8 ′ is delimited on the end side by an outer lateral slide 17 . 2 ′, which is part of a lateral-slide unit 17 ′ (see FIG. 7 ), which is mounted in the device 1 ′ such that it can be displaced in the direction B′. The lateral-slide unit 17 ′, furthermore, comprises a slide carrier 17 . 1 ′, to which the outer lateral slide 17 . 2 ′ is fixed. The slide carrier 17 . 1 ′ is arranged in front of the sonotrode head 3 . 1 ′, as seen in the direction of the torsion axis B′, and extends in the direction perpendicular to B′.
The compacting space 8 ′ is delimited on the inside in relation to B′, i.e. in the direction of the longitudinal end 6 ′, by an inner lateral slide 16 ′, on which an anvil 18 ′ is mounted such that it can be displaced in the direction B′.
FIG. 6 shows a partial view of the device 1 ′ in the region of the sonotrode head 3 . 1 ′, wherein, for the sake of clarity, the slide carrier 17 . 1 ′ has not been included in the illustration. The sonotrode head 3 . 1 ′ has four wings 3 . 2 ′ protruding radially in a flange-like manner. The wings 3 . 2 ′ here are arranged in a crosswise manner at right angles in relation to one another. The welding surface 3 . 4 ′ which delimits the compacting space 8 ′ is formed laterally on an upwardly projecting wing 3 . 2 ′ which is directed toward the compacting space 8 ′. The welding surface 3 . 4 ′ here has channels which are oriented parallel to the torsion axis B and ensure good transmission of the sonotrode vibrations to the welding material compacted in a compacting space 8 ′. The rest of the wings 3 . 2 each bear an identical welding surface 3 . 5 ′. Depending on the rotary position of the sonotrode 3 ′ on the torsional vibrator 4 ′, it is optionally possible for any of the welding surfaces 3 . 5 ′ to be assigned to the compacting space 8 ′.
The inner lateral slide 16 ′ is arranged behind the welding surface 3 . 4 ′, as seen in the direction of the torsion axis B′, and delimits the compacting space 8 ′ in the rearward direction. The outer lateral slide 17 . 1 ′ is arranged opposite the inner lateral slide 16 ′, as seen in the direction B′. The lateral slide 17 . 1 ′ has an aperture 17 . 3 ′ which, as seen in the direction of the torsion axis B′, corresponds to a projection of the wing 3 . 2 ′ which bears the welding surface 3 . 4 ′-wing 3 . 2 ′ with welding surface 3 . 4 ′ is thus essentially aligned with the aperture 17 . 3 ′.
The aperture 17 . 3 ′ allows the lateral slide 17 . 2 ′ to be displaced in the direction of the lateral slide 16 ′ for the purpose of compacting the welding material in the compacting space 8 ′, in the direction of the torsion axis B′ via the welding surface 3 . 4 ′. The aperture 17 . 3 ′ here is dimensioned such that there is sufficient space for the torsional vibration of the sonotrode 3 ′ if the wing 3 . 2 ′ with the welding surface 3 . 4 ′ is arranged, at least in part, in the aperture 17 . 3 ′. The aperture 17 . 3 ′, in addition, has longitudinal ribbing which complements the welding surface 3 . 4 ′. The small vibration amplitudes thus make it possible for the lateral slide 17 . 2 ′ to extend comparatively closely to, with just a small gap from, the welding surface 3 . 4 ′. As can be seen from (the bottom of) FIG. 7 , the lateral slide 17 . 2 ′ is connected rigidly, via the slide carrier 17 . 1 ′, to a slide carriage 17 . 5 ′, which is mounted on a displacement guide 25 of the device 1 ′, beneath the sonotrode 3 ′. The displacement guide 25 here comprises device-mounted guide elements 25 . 1 , on which a rail 25 . 2 , which is fixed to the slide carriage 17 . 5 ′, is mounted such that it can be guided in a displaceable manner in the direction of the torsion axis B′, or in the present case also in the longitudinal direction A′. The slide carrier 17 . 1 ′, which is not illustrated in FIG. 6 , extends from the slide carriage 17 . 5 ′ in the direction of the lateral slide 17 . 2 ′, in doing so spanning the sonotrode head 3 . 1 ′ on the end side (see FIG. 7 ).
FIG. 7 shows the device 1 ′ in a side view in which some concealing elements have been removed. For reasons of clarity, FIG. 7 does not illustrate a central carrier body of the device 1 ′, the components of the device 1 ′ such as, for example, the torsional vibrator 4 ′ being fastened and/or mounted on said carrier body directly or indirectly via a clamping ring 4 . 1 ′. Screws designated by X serve for anchoring the corresponding component on the carrier body. Such components anchored on the carrier body are also referred to as being “device-mounted”.
The guide elements 25 . 1 , which are arranged largely beneath the sonotrode 3 ′, as seen in relation to B′, are anchored on the carrier body via the screws X. The guide rail 25 . 2 is mounted in the guide elements 25 . 1 such that it can be displaced in the direction of the torsion axis B′. The slide carriage 17 . 5 ′ is fastened rigidly on the rail 25 . 3 . A motor 21 is mounted on the device via screws X essentially behind the slide carriage 17 . 5 ′, as seen in direction B′. Via a spindle 21 . 1 , the slide carriage 17 . 5 ′ can be displaced in the displacement guide, in direction B′, by the motor 21 .
The slide carrier 17 . 1 ′ is fastened rigidly on the end side of the slide carriage 17 . 5 ′. In front of the sonotrode head 3 . 1 ′, as seen in direction B′, the slide carrier 17 . 1 ′ extends into a region by the compacting space 8 ′, where the outer lateral slide 17 . 2 ′ is fastened rigidly on the slide carrier 17 . 1 ′. It is thus possible for the motor 21 to displace the lateral slide 17 . 2 ′ in direction B′ toward the inner lateral slide 16 ′ or away from the same. It is therefore possible for a longitudinal dimension of the compacting space 8 ′ to be reduced for compacting purposes (or increased for the purpose of freeing the welding material).
The anvil 18 ′ is designed such that, in the extended state, it follows a displacement of the lateral slide 17 . 2 ′. This ensures that, during the compacting operation, the compacting space 8 ′ is closed off fully in the radially outward direction in any displacement position of the lateral slide 17 . 2 ′.
The lateral slide 16 ′ is mounted on a carriage 13 ′ such that it can be displaced in a direction perpendicular to the torsion axis B′, and therefore it can be displaced radially in the direction of the torsion axis B′ or away from the same. Actuators 14 . 1 ′ and 14 . 2 ′ for displacing the carriage 13 ′ are arranged beneath the sonotrode 3 ′ (i.e. largely opposite the lateral slide 16 ′, as seen in relation to B′) and are fixed to the carrier body by screws X.
In contrast to the end-side longitudinal guide 12 of the device 1 for the carriage 13 , the functionally largely corresponding longitudinal guide 12 ′ for guiding the carriage 13 ′ is arranged on either side of the sonotrode 3 ′, as seen in relation to B′. The carriage 13 ′ comprises, on either side, an outer plate 13 . 1 ′, which operatively connects the lateral slide 16 ′, via screws Y, to a driver element 15 ′ arranged between the actuators 14 . 1 ′ and 14 . 2 ′. The plates 13 . 1 ′ are each fastened rigidly on runners 12 . 1 ′ of the longitudinal guide 12 ′. The runners 12 . 1 ′ are guided in a displaceable manner on guide rails 12 . 2 ′, which are arranged perpendicularly to B′ and are mounted on the device via screws X (in FIG. 7 , elements of the longitudinal guide 12 ′ are illustrated only on the side which is hidden from view.
During the compacting operation, the actuators 14 . 1 ′ and 14 . 2 ′ act on the driver element 15 ′ such that the carriage 13 ′, and thus also the lateral slide 16 ′, is displaced downward in the direction of the sonotrode 3 ′. A compacting surface 18 . 1 ′ of the extended anvil 18 ′ is moved here in the direction of the welding surface 3 . 4 ′. The inner lateral slide 16 ′ and the anvil 18 ′, which is mounted thereon, thus essentially corresponding, in functional terms, to the corresponding elements of the device 1 .
FIGS. 8 a and 8 b show a schematic sectional view of the compacting space 8 or 8 ′, respectively, of the devices 1 and 1 ′, respectively.
FIG. 8 a shows the compacting space 8 of the device 1 . The compacting space 8 is delimited by the lateral slides 16 and 17 in the direction of the torsion axis B. Said slides are spaced apart from one another, in the direction of B, in a fixed longitudinal position such that there is just enough space for the sonotrode head 3 . 1 in between. The two lateral slides 16 and 17 are arranged rigidly on the carriage 13 , which can be displaced relative to the sonotrode head 3 . 1 in a direction perpendicular to B. During the compacting operation, the two lateral slides 16 and 17 , at a fixed longitudinal distance apart, are jointly lowered in the direction of the torsion axis B, wherein the extended anvil 18 is lowered, by way of its compacting surface 18 . 1 , onto the welding surface 3 . 4 . During the compacting operation, there is therefore a reduction only in the dimension of the compacting space 8 in a direction perpendicular to B. A longitudinal dimension in the direction of B is predetermined by the sonotrode head 3 . 1 .
FIG. 8 b shows the compacting space 8 ′ of the device 1 ′. The compacting space 8 ′ is delimited by the lateral slides 16 ′ and 17 . 2 ′ in the direction of the torsion axis B. Whereas the lateral slide 16 ′ is arranged in the fixed longitudinal position, as seen in the direction of B′, adjacent to the welding surface 3 . 4 ′ of the sonotrode head 3 . 1 ′, the lateral slide 17 . 2 ′ can be displaced in the direction of B′, above the welding surface 3 . 4 ′, toward the lateral slide 16 ′. The lateral slide 16 ′ here is arranged rigidly on the carriage 13 ′, which can be displaced relative to the sonotrode head 3 . 1 ′ in a direction perpendicular to B′. During the compacting operation, the lateral slide 16 ′ is lowered in the direction of the torsion axis B′, wherein the extended anvil 18 ′, which is mounted on the lateral slide 16 , is lowered, by way of its compacting surface 18 . 1 ′, onto the welding surface 3 . 4 ′. During the compacting operation, in addition, the lateral slide 17 . 2 ′ is displaced in the direction of the lateral slide 16 ′. This can take place at the same time as, or sequentially in relation to, the operation of lowering the lateral slide 16 ′. The anvil 18 ′ here is displaced along in the direction B′ and can thus close off the compacting space 8 ′ fully in the upward direction. During the compacting operation, there is therefore a reduction in the dimension of the compacting space 8 ′ both in a direction perpendicular to B′ and in the direction of B′, in particular irrespective of a corresponding dimension of the sonotrode head 3 . 1 ′.
FIG. 9 shows, schematically, a partial cross-sectional view along the torsion axis B (or B′) through the sonotrode 3 (or 3 ′) and the torsional vibrator 4 (or 4 ′).
The sonotrode 3 here from the direction of the sonotrode head 3 . 1 , has a countersunk hole 3 . 6 , which extends in the direction B essentially over the entire length of the sonotrode 3 . At a fastening end 3 . 7 of the sonotrode 3 , the countersunk hole 3 . 6 is terminated by a floor 3 . 8 . The floor 3 . 8 contains a continuous bore 3 . 9 , which runs in direction B and is open on an end-side fastening surface 3 . 10 .
The sonotrode 3 butts, by way of the fastening surface 3 . 10 , against a complementary fastening surface 4 . 2 on the torsional vibrator 4 . The torsional vibrator 4 has an internal thread 4 . 4 in an inner bore 4 . 3 .
The sonotrode 3 is fastened on the torsional vibrator 4 by way of a screw 26 , which is arranged in the countersunk hole 3 . 6 . The screw 26 extends through the bore 3 . 9 and is screwed into the internal thread 4 . 4 by way of an external thread 26 . 1 . A screw head 26 . 2 here is supported on the floor 3 . 8 of the countersunk hole 3 . 6 . This gives rise to a particularly straightforward, front-access means of fastening the sonotrode 3 on the torsional vibrator 4 or, possibly, directly on a converter, wherein the sonotrode 3 can be straightforwardly aligned in respect of rotation about B and can then be fixed in this position. | A device for ultrasonically welding metal parts includes a sonotrode whose head can be excited by a vibration generator to produce vibrations. The sonotrode is connected to the vibrator with a screw connection provided on one side of the sonotrode. The sonotrode head may have at least one welding surface relative to the torsion axis on the circumference side. An anvil having a counter/compacting surface may be arranged opposite the welding surface of the sonotrode in a stationary position. The welding surface and the compacting surface may delimit a compaction space to receive parts to be welded. The entire sonotrode may be excited to produce torsional oscillation with a negligibly small longitudinal vibration component. | 1 |
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/796,167, filed Apr. 28, 2006, the content of which is hereby incorporated by reference in its entirety into this disclosure.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to supporting of printed matter. In particular, the present invention relates to the support of various reading and/or viewing printed material including books, brochures, catalogs and the like.
[0004] 2. Background of the Invention
[0005] As the volume of literature increases, additional costs are associated with the manufacture of printed material, including books, brochures, catalogs, magazines, and the like. Some of this printed matter becomes very large or heavy, particularly because of their tremendous volume or size. Despite the advancement of literature and information, conventional methods of manufacture in the art of bookbinding has been relatively constant and has essentially been limited to (i) case binding and (ii) perfect binding. Traditional Smyth sewn books require a series of arranging, sewing, and gluing steps to adhere signatures (sections of the entire book) to the cover spine. Typically, textbooks and other large-mass books employ the Smyth sewn binding technique.
[0006] Perfect bound books mainly require an adhesive binding between the book block and the cover. After the technological booms following World War II, perfect binding became an economical option for many publishers, making it a common practice in contemporary times. Nearly all paperback books, telephone books, and other small-mass books are bound using the perfect binding technique.
[0007] Large-mass books are typically perfect bound or bound using the Smyth sewn technique. Many of these large-mass books are published in the form of textbooks or trade books for school students. Such large and heavy books take their toll on those who have to carry these books on a daily or regular basis, typically students. The American Chiropractic Association (ACA) and the American Occupational Therapy Association (AOTA) states that children should not carry more than 10% of their bodyweight. Researchers have found, however, that children are carrying 22% of their bodyweight in studies conducted in the United States.
[0008] The National Safety Council states that according to the US Consumer Product Safety Commission there were more than 21,000 backpack related injuries that ended up being treated in emergency rooms, clinics and doctors' offices in 2003. The range of these injuries was widespread from contusions, to sprains, and even fractures.
[0009] Some subject matters require new versions of texts in order to account for changes that took place after the initial publication of the book. Using bookbinding methods of the art, the entire text is replaced when revisions are made to a sufficient number of sections. Some fields, such as legal texts, use “pocket parts,” which are smaller independent sections showing only the changes; but the main body of text is unchanged, and both the main body of text and the pocket part must be referenced in order to read the actual updated text. Using existing techniques of the art, there is no other way to replace merely a section of the book.
[0010] Thus, there is a need in the art for a more effective technique for manufacturing printed matter such that portions of the printed matter may be carried independently of the other portions, and allowed to be changed, revised or replaced without having to do so for the entire volume in which such portion is a part. The technique should be simple to understand, use and manufacture so that it provides an efficient and less costly alternative to constant volume changes and/or provides an efficient method of carrying just one portion of a large size or volume printed matter.
SUMMARY OF THE INVENTION
[0011] The present invention provides a unique technique of manufacturing printed matter such that such matter may be easily taken apart into defined portions and each portion carried or reviewed independently of the other. Each such portion can also be independently updated or revised without affecting the other portions of the matter that have not been changed. The present invention overcomes many problems associated with conventional bookbinding and manufacturing techniques by using a novel and simple technique of combining interlocking components that comprise sections of a reading material, such as a book. Book users need not transport the entirety of a book when they only desire to focus on one chapter or section of the book. With the present invention, the book user can select the portion(s) of the book they would like to carry with her. Likewise, book publishers need not reprint the entirety of a book when they only desire to alter select chapters or sections of the book. With the present invention, the book publisher can select portion(s) of the book that they would like to update, reprint, and sell. Such technique is more advantageous to the publisher because only certain portions of a textbook are revised, the cost of printing is only limited to those particular portions, such as a chapter. That individual portion can then be sold at a substantially reduced rate than having to re-publish and sell the entire textbook. Such high costs of having to re-publish an entire book also prevent many buyers from buying new versions because of the lack of substantial difference from older versions of the same textbook. Thus, with the present technique, the publishers can realize higher sales of only relevant portions of a textbook because consumers are more apt to purchase only portions of a textbook that are updated rather than an entire new textbook.
[0012] Using techniques presented herein and according to the present invention, portions or sections of a book will be individually bound, such as but not limited to a perfect binding method. These smaller sections of the whole textbook could be gathered under a book cover. The force used for attraction between the sections and the book cover would be strong enough to keep the entire book block together, when this is the desired use. The sections can also be detached from the book cover and carried separately. A few examples of forces used for attaching the detachable sections include magnetic and mechanical techniques.
[0013] For sake of simplicity, exemplary techniques that may be used in conjunction with the present invention have been presented in various groups of embodiments. Also, for sake of simplicity, the various embodiments are presented with use of a “book” for sake of simplicity. However, the present invention and techniques are equally applicable to other forms of printed and bound matter, including but not limited to, magazines, directories, newspapers, brochures, photographic albums, and the like. One of ordinary skill in the art would be cognizant of these and other type of printed or photographic matter that could be used by the techniques presented in the present disclosure. All such uses are within the scope of the present invention.
[0014] In a magnetic group of embodiments, devices according to the present invention can include complementary, magnetically-adhering members used in the section covers and book cover. These materials attract each other, permitting the sections to be retained in the book. In some of these embodiments, other products can compliment the embodiment, such as larger head and foot bands. These bands serve as an additional ways by which to secure the book sections are retained within the book cover.
[0015] The sections (such as chapters) of a sectional book constructed under the magnetic technique can be magnetically-adhered to the book cover, so that each section may also be separated from the entire book block. Thus, the sections of the book can be individually bound, including a section cover with a magnetically-adhering member. Each section can attach to the book cover (usually along the spine), which can also contain a magnetically adhering member.
[0016] In a mechanical group of embodiments, the devices according to the present invention provide mechanical methods for fastening the sections to the book cover. Examples of mechanically-attaching mechanisms include but are not limited to paper fasteners, clips, binders, rods, rivets, and hook and loop fasteners, including Velcro and others. Many other mechanical binding devices may be used and such other devices are apparent to one having ordinary skill in the art and thereby within the scope of the present invention.
[0017] The sections (or chapters) of a sectional book constructed using the mechanical method can be mechanically-adhered to the book cover, so that each section may be separated from the entire book block. Thus, sections of the book can be individually bound, and the book cover can include at least one mechanically-attaching member.
[0018] The present invention has many uses and advantages as would be apparent to one having ordinary skill in the art after consideration of the present disclosure. Exemplary non-limiting uses and advantages over conventional techniques include, but are not limited to: providing a convenient way for users to select which portions of a book to carry with them; providing a reduction in overall weight carried by the user in the forms of books; providing a way for reducing back-related injuries due to carrying heavy books; providing book publishers a way to update portions of the book without need to reprint the entire book; providing book publishers a way to reduce their overall cost of production for new and/or updated versions of books.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side elevated, exploded view of an exemplary embodiment of the present invention illustrating components that make up a preferred embodiment.
[0020] FIG. 2 is an exploded view of one technique of incorporating a magnet or metal as the magnetically-adhering cover member into a book cover, according to an exemplary embodiment of the present invention.
[0021] FIG. 3 is an exploded view of one method of incorporating a magnet or metal as the magnetically-adhering cover member into a book cover, according to an exemplary embodiment of the present invention.
[0022] FIG. 4 shows magnetically-adhering members of varying sizes and shapes, according to an exemplary embodiment of the present invention.
[0023] FIG. 5 shows magnetically-adhering and mechanically-attaching members of varying sizes and shapes, according to an exemplary embodiment of the present invention.
[0024] FIG. 6 is a perspective view of a book with interlocking book sections and book cover, according to an exemplary embodiment of the present invention.
[0025] FIG. 7A is a perspective view of an alternative version of interlocking book sections and book cover, with convexities along the book section's spine and complimentary concavities in the book cover, according to an exemplary embodiment of the present invention.
[0026] FIG. 7B is an alternative view of FIG. 7A .
[0027] FIG. 8A is a perspective view of an alternative version of interlocking book sections and book cover, with concavities along the book section's spine and complimentary convexities in the book cover, according to an exemplary embodiment of the present invention.
[0028] FIG. 8B is an alternative view of FIG. 8A .
[0029] FIG. 9A is a perspective view of book section with openings in its spine and a book cover with complimentary rivets as the mechanically-attaching book member, according to an exemplary embodiment of the present invention.
[0030] FIG. 9B is an alternative view of FIG. 9A .
[0031] FIG. 9C is an exploded view of FIG. 9A .
[0032] FIG. 10 is a perspective view of book sections and a book cover with complimentary hook and loop pieces along their spines, according to an exemplary embodiment of the present invention.
[0033] FIG. 11A is a perspective view of a book cover incorporating clips along the interior of its spine, according to an exemplary embodiment of the present invention.
[0034] FIG. 11B is an exploded view of FIG. 11A .
[0035] FIG. 12 is a perspective view of a book cover incorporating a clamping mechanism along the interior of its spine, according to an exemplary embodiment of the present invention.
[0036] FIG. 13 is a perspective view of a mechanically-attaching embodiment using a book section with flexible, durable rods along the spine of book section and a void along the width of book cover, according to an exemplary embodiment of the present invention.
[0037] FIG. 14 is a perspective view of a mechanically-attaching embodiment using a book cover with flexible, durable rods along the interior spine of the book cover, according to an exemplary embodiment of the present invention.
[0038] FIG. 15 is an exploded view of a book cover with a spine of variable width, employing a friction mechanism between the back book cover and the pocket formed by the front inner and outer covers, according to an exemplary embodiment of the present invention.
[0039] FIG. 16 is a view of a book cover with a spine of variable width, employing an interlocking mechanism between the back book cover and the pocket formed by the front inner and outer covers, according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] As disclosed in the present description and accompanying drawings, the present invention provides for manufacture, sale, and use of a printed matter incorporating reversibly detachable sections.
[0041] To assist in the consideration of the present disclosure and accompanying drawings, the following labels have been used and are generally presented here and described in more detail below:
[0042] 1 A, B, C: Rectangular magnetically-attractive members
[0043] 2 A, B, C: Cubical magnetically-attractive members
[0044] 3 A, B, C: Cylindrical magnetically-attractive members
[0045] 4 A, B, C: Rectangular magnetically-attractive members (metal)
[0046] 5 : Flexible, durable rod
[0047] 6 A, B: Metal rod
[0048] 7 : Alternative rectangular magnetically-attractive strip (magnet)
[0049] 10 A: Book cover
[0050] 10 B: Alternative book cover
[0051] 11 A, B: Openings in cover layers
[0052] 11 C, D: Openings in cover boards
[0053] 12 A, B, E, F: Alternative openings in cover layers
[0054] 12 C, D: Alternative openings in cover boards
[0055] 13 A: Inner book cover layer
[0056] 13 B: Alternative inner book cover layer
[0057] 14 A: Outer book cover layer
[0058] 14 B: Alternative outer book cover layer
[0059] 15 A: Spine region of book cover
[0060] 15 B: Alternative spine region of book cover with variable width
[0061] 16 A, B, C: Book cover boards
[0062] 16 D: Alternative inner support structure for book cover
[0063] 17 : Magnetically-adhering cover member
[0064] 18 A, B: Book cover's complimentary interlocking convex elements
[0065] 18 C, D: Book cover's complimentary concave elements
[0066] 18 E, F: Alternative book cover's complimentary convex elements
[0067] 19 A: Book section's interlocking convex element
[0068] 19 B, C: Book section's complimentary convex elements
[0069] 19 D, E: Alternative book cover's complimentary concave element
[0070] 20 A, B: Rivets
[0071] 21 A, B: Openings in spine region of book section
[0072] 22 : Hook and loop material
[0073] 23 : Complimentary hook and loop material
[0074] 24 A, B: Heads of rivets
[0075] 25 A, B: Clips
[0076] 26 A, B: Levers on clips
[0077] 27 : Lever
[0078] 28 A, B: Durable Rods
[0079] 29 : Void in spine of book cover
[0080] 30 A: Book section
[0081] 30 B: Alternative book section
[0082] 35 A, B, C: Spine region of book section
[0083] 35 D: Alternative spine region of book section
[0084] 37 A, B, C: Magnetically-adhering section member
[0085] 41 A, B: Rubber ends
[0086] 43 A, B: Interlocking members
[0087] 45 A, B, C, D, E, F, G, H, I, J: Openings within these common axes
[0088] Several general classes of embodiments are presented herein and grouped together only for sake of simplicity. In the magnetic group of embodiments, at least one of the magnetically-adhering members of either the book cover or the section will include a magnet of sufficient strength to attach and retain the sections to the book cover. Combinations of attaching the book section and book cover include (i) magnet-metal, (ii) metal-magnet, and (iii) magnet-magnet.
[0089] FIG. 1 depicts an exemplary embodiment of the present invention incorporating the magnetic embodiments. In this drawing, three book sections 30 A, 30 B, and 30 C are encompassed within a book cover 10 A. In this embodiment, a magnetically adhering cover member 17 is located along the spine of the book cover 15 A and will engage the complimentary magnetically-adhering section member 37 A, 37 B, and 37 C, which is located along the spine region of each book section 35 A, 35 B, and 35 C.
[0090] FIG. 4 shows examples of magnetically-adhering of varying sizes and shapes. These magnetically-adhering members may be placed along the spine of the book cover 15 A and/or the spines of the book sections 35 A, 35 B, and 35 C as the magnetically-adhering members 17 or 37 A, 37 B, and 37 C, respectively, for the following magnetic embodiments. The variety of the magnetically-adhering members include cylindrical, disc, cube, and rectangular shapes of materials with magnetic properties.
[0091] FIG. 5 shows additional magnetically-adhering members of varying sizes and shapes. These magnetically-adhering members may be placed along the spine of the book cover 15 A and/or the spines of the book sections 35 A, 35 B, and 35 C as the magnetically-adhering members 17 or 37 A, 37 B, and 37 C, respectively, for the following magnetic embodiments. The variety of the magnetically-adhering members include rectangular, rod, and strip shapes of materials with magnetic and/or metallic properties.
[0092] FIG. 3 is a perspective view of one method of incorporating a magnetically-adhering section member 37 A into a book section 30 A along its spine 35 A. A magnetically-adhering cover member 37 A is affixed to the spine region 35 A of a book section 30 A by a variety of techniques, such as gluing, sewing, or crimping.
[0093] The magnetically-adhering section member 37 A described in FIG. 3 serves as a placeholder for a material or variety of materials that can fill this area as a magnetically-adhering cover member, such as those depicted in FIG. 4 and FIG. 5 . The following are examples of materials that can be used to fill the area.
[0094] Metal section member—I. In one embodiment, a natural or synthetic adhesive includes metal additives, such as fine powder. The metal additives or powder have properties which cause the adhesive mixture to be attracted to magnetic material. This composition base of the adhesive may include but is not limited to a polyvinyl acetate (PVA), resin, ground animal, ground hide, liquid hide, or caoutchouc (raw rubber). The adhesive with metal additives may be used in the binding of the book sections 30 A, 30 B, and 30 C, serving as the magnetically-adhering members 37 A, 37 B, and 37 C, respectively.
[0095] Metal section member—II. In an additional embodiment, a metal material (or plurality therein), may be incorporated into the composition of a tape. This tape with metallic parts would likely help to bind the book sections 30 A, 30 B, and 30 C and would serve as the magnetically-adhering members 37 A, 37 B, and 37 C, respectively.
[0096] Metal section member—III. In another embodiment, a metal section member may be manufactured by incorporating a material with metallic properties (or plurality therein) into the spine region of the book section. The form of the metal material may include but is not limited to a rod, block, strip or sheet structure, or a plurality therein. The metal material can be incorporated by various methods, such as gluing, sewing, or crimping the material over the book section.
[0097] Magnetic section member—I. A fourth embodiment of the section member uses a natural or synthetic adhesive with materials with magnetic properties. These magnetic materials may include fine magnets such as powder or a material that can be altered to be attracted to a magnetic force. This composition base of the adhesive may include but is not limited to a polyvinyl acetate (PVA), resin, ground animal, ground hide, liquid hide, or caoutchouc (raw rubber). The adhesive with magnetic additives may be used in the binding of the book sections 30 A, 30 B, and 30 C, serving as the magnetically-adhering members 37 A, 37 B, and 37 C, respectively.
[0098] Magnetic section member—II. In an additional embodiment, a magnetic material (or plurality therein) may be incorporated into the composition of a tape. This tape with magnetic parts would likely help to bind the book sections 30 A, 30 B, and 30 C and would serve as the magnetically-adhering members 37 A, 37 B, and 37 C, respectively.
[0099] Magnetic section member—III. In yet another embodiment, a material with magnetic properties.(or plurality therein) of sufficient strength, width, and flexibility is adhered to the spine of the book section. Although other ways to adhere the magnet to the section members 30 A, 30 B, and 30 C can be used, an example would be to attach the magnet to the book section in an adhesive fashion. This magnet spine would serve as the magnetically-adhering members 37 A, 37 B, and 37 C, respectively.
[0100] FIG. 2 is an exploded view of one method of incorporating a magnetically-adhering cover member 17 into a book cover 10 A. A magnetically-adhering cover member 17 is enclosed into the spine region of a book cover 10 A by the cover inner layer 13 A, for example a paper stock, and the cover outer layer 14 A, such as a leather-like material. In this example, the cover is strengthened by the relatively thick cover boards 16 A, 16 B, and 16 C, which are also enclosed into the cover by the outer 14 A and inner 13 A cover layers. The support for the book cover's spine region 16 C is optional and can be made of a different weight stock than the other cover board(s).
[0101] The magnetically-adhering cover member 17 described in FIG. 2 serves as a placeholder for a material or variety of materials that can fill this area as a magnetically-adhering cover member, such as those depicted in FIG. 4 and FIG. 5 . The below presents examples of materials that can be used to fill the area.
[0102] Metal book member—I. In one embodiment, a natural or synthetic adhesive includes metal additives, such as fine powder. The metal additives or powder have properties which cause the adhesive mixture to be attracted to magnetic material. This composition base of the adhesive may include but is not limited to a polyvinyl acetate (PVA), resin, ground animal, ground hide, liquid hide, or caoutchouc (raw rubber). The adhesive with metal additives may be used in the manufacture of the book cover, serving as the magnetically-adhering member 17 of the book cover 10 A.
[0103] Metal book member—II. In an additional embodiment, a metal material (or plurality therein) may be incorporated into the composition of a paper-based material. The board with metallic parts would be used at least in part for the book cover board and would serve as the magnetically-adhering member 17 for the book cover 10 A.
[0104] Metal book member—III. In another embodiment, a metal section member may be manufactured by incorporating a material with metal properties (or plurality therein) into the spine region of the book cover. The form of the metal material may include but is not limited to a rod, block, or sheet structure, or a plurality therein. The metal material can be incorporated by various methods, such as gluing, sewing, or crimping the material over the book cover. This metal material would serve as the magnetically-adhering member 17 for the book cover 10 A.
[0105] Magnetic book member—I. A third embodiment of the book cover uses a natural or synthetic adhesive with materials with magnetic properties. The magnetic materials may include fine magnets such as powder or a material that can be altered to be attracted to a magnetic force. This composition base of the adhesive may include but is not limited to a polyvinyl acetate (PVA), resin, ground animal, ground hide, liquid hide, or caoutchouc (raw rubber). The adhesive with magnetic additives may be used in the manufacture of the book cover, serving as the magnetically-adhering member 17 of the book cover 10 A.
[0106] Magnetic book member—II. In an additional embodiment, a magnetic material (or plurality therein) may be incorporated into the composition of a paper-based material. The board with magnetic parts would be used at least in part for the book cover board and would serve as the magnetically-adhering member 17 for the book cover 10 A.
[0107] Magnetic book member—III. In yet another embodiment, a material with magnetic properties (or plurality therein) of sufficient strength, width, and flexibility is adhered to the spine of the book cover. Although other ways to adhere the magnet to the section member can be used, an example would be to attach the magnet to the book section in an adhesive fashion. This magnet material would serve as the magnetically-adhering member 17 for the book cover 10 A.
[0108] The following is a list of mechanical embodiments of the present invention. The book sections 30 A, 30 B, and 30 C can be attached to the book cover 10 A through adjoining members. Combinations of attaching the book section 30 A, 30 B, and 30 C and book cover 10 A by adjoining members include but are not limited to (i) concavity-convexity interlocking parts, (ii) convexity-concavity interlocking parts, (iii) opening-rivet, (iv) hook-and-loop, (v) clamping, and (vi) clipping mechanisms.
[0109] Interlocking section member. In one embodiment, the section member would be independently bound. The spine region of the section member may then be manipulated or further molded so that it will have a concavity and/or convexity (or plurality therein) that fits into a complimentary part of the book cover.
[0110] Interocking book member. As a compliment to the section member described in the interlocking section member embodiment, the book cover would be fashioned to include a concavity and/or convexity (or plurality therein) that fits into a complimentary part of the book section.
[0111] FIG. 6 depicts an interlocking mechanism between a book cover 10 A and book section 30 A. In this embodiment, there is a unique convexity 19 A along the exterior of the spine region 35 A of the book section 30 A. Complimentary convexities 18 A and 18 B are placed along the interior of the spine region 15 A of the book cover 10 A. This arrangement of convexities will allow the book section 30 A to attach and be retained by the book cover 10 A.
[0112] FIGS. 7A and 7B depict another mechanical embodiment using interlocking convexity and concavity members. In these drawings, unique convexities 19 B and 19 C are placed along the exterior of the spine region 35 A of the book section 30 A. Complimentary convexities 18 C and 18 D are placed along the interior of the spine region 15 A of the book cover 10 A. This arrangement of convexities will allow the book section 30 A to attach and be retained by the book cover 10 A.
[0113] FIGS. 8A and 8B depict another mechanical embodiment using interlocking convexity and concavity members. In these drawings, unique concavities 19 D and 19 E are placed along the exterior of the spine region 35 A of the book section 30 A. Complimentary convexities 18 E and 18 F are placed along the interior of the spine region 15 A of the book cover 10 A. This arrangement of convexities will allow the book section 30 A to attach and be retained by the book cover 10 A.
[0114] Rivet section member. In another mechanical embodiment, section members 30 A, 30 B, and 30 C would be bound and include an opening (or plurality therein) in or near their spine regions 35 A, 35 B, and 35 C. An exemplary fashion in which these section members are bound is through saddle stitching method, which employs staples to attach the pages of these book sections to each other. Openings, such as holes, would be punched in or around the spine regions 35 A, 35 B, and 35 C. The opening(s) would allow a member of the book cover 10 A to be attached by in a way other than a binder apparatus, which is widely used for business and school use already.
[0115] Rivet book member. As a compliment to the section member described in the rivet section member embodiment, the book cover 10 A would include an adjoining member that would attach the book sections 30 A, 30 B, and 30 C to the book cover 10 A through the opening(s) in the book sections 30 A, 30 B, and 30 C. Examples of the adjoining member include rivets, clips (such as paper clips), and/or other materials which are flexible and durable enough to bend and attach the book section to the book cover.
[0116] FIGS. 9A and 9B shows book section 30 A with small openings 21 A and 21 B along its spine of the book section 35 A. There are rivets along the interior of the spine of the book cover 15 A. The arms of these rivets 20 A and 20 B will connect to the openings 21 A and 21 B within the spine of the book section 35 A.
[0117] An exemplary construction of this embodiment is depicted in FIG. 9C and encloses the heads of the rivets 24 A and 24 B within the spine of the book cover 15 A. This embodiment may be manufactured by including small openings along the spine region 15 A of the inner cover layer 13 A of the book cover 10 A through which the arms of these rivets 20 A and 20 B may extend. To create additional strength, the heads of these rivets 24 A and 24 B may be enclosed behind the support for the spine region of the book cover 16 C. In this case, small openings through which the arms of these rivets 20 A and 20 B may extend also need to be included along the support for the spine region of the book cover 16 C.
[0118] Hook and loop book section and book cover members. Using this embodiment, complimentary hook and loop material would be affixed to the book section and the book cover. The hook and loop material can be incorporated by various methods, such as gluing or sewing the material over the book section and the book cover.
[0119] FIG. 10 depicts a hook and loop system of attaching the book section 30 A to the book cover 10 A. A hook and loop piece 23 is placed along the exterior of the spine region of the book section 35 A. A complimentary hook and loop piece 22 is placed along the interior of the spine region of the book cover 15 A. These hook and loop pieces may be applied in multiplicity along the spine region of the book section 35 A and the spine of the book cover 15 A as well. It is contemplated that an ideal form of attaching the these hook and loop (such as Velcro) pieces to the spine region of the book section 35 A and the spine region of the book cover 15 A will be in an adhesive fashion.
[0120] Clamp book member—I. In another mechanical embodiment, a clamp or series of clamps would bind the section members 30 A, 30 B, and 30 C to the book cover 10 A. The clamping mechanism would be placed along the interior of the spine region of the book cover 15 A. These clamps may be composed of Acco® clips that have the opening of the clip towards the interior of the book cover and the clamping mechanism along the exterior of the book cover.
[0121] FIG. 11A shows the use of clamps to attach the book section 30 A to the book cover 10 A. A series of clamps 25 A and 25 B are placed along the interior of the spine region of the book cover 15 A. The user can capture and release the book section 30 A by applying and releasing pressure on the lever-ends of the clamps 26 A and 26 B, which can be accessed on the exterior of the book cover ( 10 ).
[0122] An exemplary construction of this embodiment is depicted in FIG. 11B and exposes the lever-ends of the clamps 26 A and 26 B on the exterior of the spine region of the book cover 15 A. This embodiment may be manufactured by including small openings along the spine region 15 A of the inner cover layer 13 A of the book cover 10 A through which the clamps 25 A and 25 B may extend. To access the lever-ends of the clamps 26 A and 26 B, additional openings must be created along the support 16 C for the spine region of the book cover 15 A as well as the outer cover layer 14 A of the book cover 10 A.
[0123] Clamp book member—II. In another mechanical embodiment, a clamp or series of clamps would bind the section members to the book cover. The clamping mechanism would be enclosed along the interior of the spine of the book cover. This clamping mechanism would include a lever and a series of rods that would raise and lower, according to the movement of the lever. The clamping mechanism would serve as the adjoining member of the book cover and would capture and retain the book sections.
[0124] FIG. 12 depicts a clamping mechanism that uses a lever 27 to raise and lower a series of durable rods 28 A and 28 B. As the user manipulates lever 27 and the rods 28 A and 28 B raise, the book section 30 A will be captured and retained by the book cover 10 A. When the lever 27 is moved in an alternative direction, the rods 28 A and 28 B lower and release pressure on the book section 30 A, allowing the book section 30 A to be removed from the book cover 10 A. The clamping mechanism may be attached to the interior of the spine of the book cover 15 A in a sewing, clamping, clipping, and/or adhesive fashion.
[0125] Clip book member—I. In an additional mechanical embodiment, a rod (or plurality therein) would bend and clip the book sections to the book cover. The materials used in this embodiment include a flexible and durable rods (such as those made of a plastic and/or rubber and/or metal materials), which would be attached to the book cover. The rods may be attached in a variety of ways, such as gluing, sewing, or crimping. The rods may be placed in a variety of regions throughout the spine of the book section, such as along the head and foot of the book cover or in and around the middle of the book cover.
[0126] FIG. 13 shows a flexible, durable rod 5 attached to the spine of the book section 35 A. This rod 5 bends and attaches to the exterior the book cover 10 A or through the opening 29 along the width of the spine region of the book cover 15 A. Although this drawing shows the rod 5 extending the entire length of the spine region of the book section 35 A, a rod may be placed along the head and/or foot of the spine region of the book section 35 A and have the same effect. The rod 5 may be attached along the interior or exterior of the spine region of the book section 35 A by a variety of ways, including but not limited to gluing, taping, sewing, clamping, or crimping. The ideal construction for this embodiment is contemplated to have one rod 5 that extends beyond the head and foot of the spine region of book section 35 A and that attached to the interior of the spine region of the book section 35 A. The adhesive that binds the section's book block to the cover of the book section may also help to keep the rod 5 in place and add extra strength to its design.
[0127] Clip book member—II. In a different mechanical embodiment, a rod (or plurality therein) would bend and clip the book sections to the book cover. The materials used in this embodiment include a flexible and durable rods (such as those made of a plastic and/or rubber and/or metal materials), which would be attached to the book cover. The rods may be attached in a variety of ways, such as gluing, sewing, or crimping. The rods may be placed in a variety of regions throughout the spine of the book cover, such as along the head and foot of the book cover or in and around the middle of the book cover.
[0128] FIG. 14 shows a flexible, durable rod 5 attached to the spine of the book cover 15 A. This rod 5 bends and attaches the book cover 10 A to the book section 30 A. This rod 5 would attach in between the pages of the book section 30 A, preferably towards the middle of the section's book block. Although this drawing shows the rod 5 extending the entire length of the spine region of the book cover 15 A, a rod may be placed along the head and/or foot of the spine of the book cover 15 A and have the same effect. The rod 5 may be attached along the interior, exterior, or within the layers of the spine of the book cover 15 A by a variety of ways, including but not limited to gluing, taping, sewing, clamping, or crimping. The ideal construction for this embodiment is contemplated to have one rod 5 that attaches along the spine region of book cover 15 A and extends beyond the head and foot of the spine region of book cover 15 A. The rod 5 would be mostly enclosed within the layers of book cover 10 A. The adhesive that binds the layers of the book cover 10 A may also help to keep the rod 5 in place and add extra strength to its design.
[0129] One of the many uses of the present invention is for books that are traditionally bulky and heavy, and which may require updates and additional versions to be reprinted in an effort to contain the most current information. Sections of the book may be republished with the most up-to-date material. Users of the book may also choose to separate sections of the text from the whole by detaching the sections from the book cover. The sections may be removed by unclipping, unclamping, sliding, and/or pulling the individually-bound section members from the book cover.
[0130] As previously mentioned in the present disclosure, variations in the above embodiments includes a plurality of the adjoining members described for each embodiment.
[0131] In FIG. 15 , a book cover 10 B with a spine of variable width 15 B is illustrated. The contemplated embodiments of the present invention would work in the same or similar fashion using this book cover as with a book cover used in traditional case binding. The inner cover layer 13 B of the book cover described in FIG. 15 is attached to the outer cover layer 14 B of this book cover along three of its sides, such as by an adhesive, sewing, or interlocking mechanism. The open pocket along the fourth side allows room for the extended back cover 16 D to be at least partially included in the opening. One version of this embodiment includes members that provide friction between the extended back cover 16 D and the open pocket created by the inner cover layer 13 B and the outer cover layer 14 B. These friction members 41 A and 41 B may be made of a material such as but not limited to rubber. As the extended back cover 16 D is pulled out its spine 15 B increases. An ideal version of this embodiment would use scoring or some other ways of marking and sectioning the parts of the spine 15 B.
[0132] Another exemplary version of this embodiment would include a locking mechanism along the parallel sides of the pocket which is created by joining the inner cover layer 13 B and the outer cover layer 14 B. This embodiment is depicted in FIG. 16 , with interlocking members 43 A and 43 B attached along two edges of back cover 16 D. Complimentary openings 45 A, 45 B, 45 C, 45 D, 45 E, 45 F, 45 G, 45 H, 451 , and 45 J are placed along the common axes between back cover 16 D and the axes of the pocket formed from inner cover layer 13 B and the outer cover layer 14 B.
[0133] The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
[0134] Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. | A book block is contemplated to be bound in its individual sections through various techniques. These sections will be attached to the book cover by a magnetic or mechanical way. The user of the book will then be allowed to select and detach individual sections of the book without destroying the integrity of the entire book block. Likewise, publishers of the book are now able to update and/or replace sections of an entire book block without needing to reprint and republish the whole book. | 1 |
This is a U.S. National Phase Application under 35 U.S.C. §371 of International Application PCT/FR2008/000783, filed on Jun. 9, 2008, which claims priority to French Application No. FR 07 04096, filed on Jun. 8, 2007. The International Application was published in French on Jan. 15, 2009 as WO 2009/007530 under PCT article 21 (2).
The present invention relates to a method and to a system for estimating the angular velocity of a moving body.
The technical field of the invention is that of fabricating autopilot systems on board aircraft.
The present invention relates in particular to a method and to a system of autopilot sensors that combine data resulting from measurements delivered by a plurality of sensors. In the meaning of the present application, unless specified explicitly to the contrary, the terms “measurement”, “data”, “signal”, and their derivatives are considered as being equivalent, and likewise the terms “combined”, “hybridized”, and their derivatives, are considered as being equivalent.
BACKGROUND
The invention relates to inertial reference systems (IRS) and to attitude and heading reference systems (AHRS), in particular those based on rate gyros using microelectromechanical systems (MEMS) technology.
Controlling a moving body (e.g. an aircraft) requires inertial measurements to be taken relating to the six degrees of freedom of the moving body. As a general rule, these are usually firstly measurements of the three components of the angular velocity vector, and secondly of the three components of the angular acceleration vector.
Historically, angular measurements were initially made by means of free gyros, and subsequently they have been made by means of rate gyros that measure the angular velocity (rotation) components of the carrier directly.
Rate gyros include in particular so-called “strap-down” gyros (i.e. their axes of rotation are constrained to remain parallel to the axis of the carrier, with the applied force being proportional to angular velocity), laser gyros, optical fiber laser gyros, and resonating structure gyros.
In a resonating structure gyro, a mechanical resonator (such as a tuning fork) is caused to vibrate and its oscillations are sustained, with the movements thereof perpendicular to the excitation plane being measured. Coriolis forces tend to keep the vibration plane fixed in an inertial frame of reference, so such perpendicular components appear only in the presence of angular velocity and they are proportional to the amplitude thereof. That type of resonator can be miniaturized down to a scale of a MEMS made of silicon and located in an integrated circuit, thereby making it possible to fabricate a gyro at low cost.
Nevertheless, in such a gyro, since the resonating mass is extremely small, measurement noise is high. In a precision inertial unit, use is generally made of laser gyros having an intrinsic noise level that is of the order of 100th the noise level of a microsensor (of the MEMS type). It is known to incorporate angular accelerometers in a strap-down inertial unit in order to attempt to correct its deterministic errors (improperly referred to as “high frequency noise”) as constituted by the cone and sculling effects that appear during dynamic stages of flight and in the event of computations being performed at too slow a rate or of the gyros having too narrow a passband. The amplitude of these errors is troublesome in navigation grade inertial units, but not for autopilot sensors, particularly since there is no longer a computation rate limitation given the power of modern computers.
These navigation grade gyros are laser rings of large size or possibly fiber optic gyros (FOGS), likewise of large size. Navigation applications are not accessible to MEMS inertial sensors. Rate gyros are essential sensors for an aircraft autopilot (below “AP”). It is possible to model a system including an aircraft 20 and it AP as shown in FIG. 2 .
The main purpose of an AP is to stabilize the aircraft when faced with disturbances caused by turbulence in the mass of air. One way of modeling the effect of such turbulence is to represent it as a term 21 that is added to the movements of the flight control actuators 22 .
The diagram of FIG. 2 serves to establish the following transfer function (where w is the actual angular velocity, P is the disturbance, B is the noise of the gyro 24 , C is the gain of a correcting filter 23 for correcting gyro measurements, and where the transfer functions of the aircraft, of the actuator, and of the gyro are taken to be unity):
ω
=
(
1
1
+
C
C
1
+
C
)
(
P
B
)
Given the simplifications that are adopted, the corrector reduces to an integrator:
C = 2 π f 0 p = 1 τ p
where f 0 is the closed loop resonant frequency of the airplane with its autopilot. The transfer function then takes the form:
ω
=
(
τ
p
1
+
τ
p
1
1
+
τ
p
)
(
P
B
)
It can be seen that the system is complementary. It applies a highpass filter to the disturbances and a lowpass filter to the angular velocity measurement noise, using the same cutoff frequency. If the resonant frequency (i.e. the open loop gain) is increased to reject disturbances, then the bandwidth of the lowpass filter is increased in equal manner, thereby transmitting the sensor noise to the entire airplane.
When developing a helicopter AP fitted with FOGs that nevertheless present low measurement noise, the limiting factor on increasing the gain of the corrector is measurement noise, which is manifested by the appearance of broadband vibration felt by the crew. It is therefore measurement noise, even in high quality gyros, that limits the overall performance of the loop. Most present autopilots take advantage of the low noise of FOGs, in spite of their expense.
The graph of FIG. 1 shows variations in spectral power density (PSD)—in degrees per second per square root of hertz (°/s/√Hz)—of the angular measurement noise respectively of a FOG, of a closed loop (CL) type MEMS, and of an open loop (OL) type MEMS, plotted up the ordinate as a function of frequency, plotted along the abscissa.
Given that the frequency band for an autopilot extends well beyond 1 hertz (Hz) (where the typical passband of a helicopter AP gyro is 10 Hz), and given the noise level of a FOG is the limiting criterion on improving an AP in terms of its response to turbulence, a MEMS gyro, even one of the closed loop type, presents a noise level that is excessive.
Furthermore, an “f” noise profile (i.e. a profile that increases in proportion to frequency) makes gain adjustment more sensitive: unlike a FOG in which noise amplitude increases with the square root of the passband, the noise level transmitted by the MEMS increases directly with frequency.
SUMMARY OF THE INVENTION
An aspect of the present invention is to reduce the “high frequency” measurement noise of a gyro (in particular at frequencies greater than one hertz).
The document “A compensator to advance gyro-free INS precision”, Chao-Yu Hung et al., “International Journal of Control, Automation, and Systems”, Vol. 4, No. 3, pp. 351-358, June 2006, proposes a gyro-free inertial navigation system having six linear accelerometers (axial accelerometers) oriented along and disposed on the edges of a regular tetrahedron (not constructed in full); purely and simply eliminating the gyros, with them being replaced by integrating angular acceleration measurements would require the linear accelerometers to present very great accuracy because of the way error in angular velocity estimated by integration diverges.
In an aircraft inertial unit, gyros are necessary to guarantee long-term stability (i.e. non-divergence) in the measured/estimated angular velocity. U.S. Pat. No. 3,824,386 and U.S. Pat. No. 4,254,465 propose using angular accerolometers to determine the angular velocity of the carrier.
Known angular accerolometers are constituted by a flywheel mounted on a shaft presenting elasticity in torsion. The torsion deflection is measured in order to deduce the angular acceleration therefrom. Such sensors are bulky and they are not suitable for being positioned in an aircraft. Miniature sensors (MEMS) used for regulating the speed of computer hard disk platters present sensitivity that is too small.
Patents EP 0 170 314 and U.S. Pat. No. 4,629,729 describe a device for determining angular position, which device includes an angular accelerometer serving to determine the high frequency components of a signal corresponding to the angle to be measured, together with an electrolytic sensor serving to determine the low frequency components of the signal.
Patents FR-2 552 222 and U.S. Pat. No. 4,601,206 describe using accelerometers to correct cone and sculling errors; proposals are made to use broadband accelerometers or to combine low frequency accelerometers with high frequency accelerometers.
The invention is defined by the claims.
An aspect of the invention is to propose an autopilot inertial system mounted, or suitable for mounting, on board an aircraft that is improved and/or that remedies the shortcomings or drawbacks of systems of that type, at least in part.
According to an embodiment of the invention, it is proposed to make use of miniature linear accelerometers, to combine and then integrate signals obtained from said accelerometers in order to produce calculated angular velocity signals, and to use complementary filtering in the frequency domain to combine the calculated angular velocity signals with angular velocity signals measured by gyros in order to obtain (estimated) hybrid angular velocity signals.
According to another embodiment of the invention, there is provided a method of determining the angular velocity of an aircraft, wherein the following steps are performed:
measuring the angular velocity by means of gyros delivering measured angular velocity signals m ; measuring the angular acceleration of the aircraft by accelerometers delivering signals m representative of the angular acceleration of the aircraft; and using filtering that is complementary in the frequency domain to combine the measured angular velocity signals and the measured angular acceleration signals so as to obtain hybrid angular velocity signals .
In preferred implementations of the method of the invention:
the high frequencies of the measured angular velocity signals m are attenuated as are the low frequencies of the angular velocity signals obtained by integrating the angular acceleration; in order to measure the angular acceleration of the aircraft, a cluster of at least six linear accelerometers is used (preferably single-axis or two-axis accelerometers), and three components of the angular acceleration of the aircraft are calculated as a function of at least six scalar acceleration measurements as delivered respectively by the linear accelerometers; an excess (redundant) number of accelerometers is used and proper operation of the measurement and hybridizing system is monitored by comparing the innovation m − with at least one reference value; it should be observed that in the vocabulary commonly used in the field of Kalman filters, the term “innovation” designates a difference such that m − here designates an angular velocity difference; and a failure detection signal is produced when the reference value is exceeded for a plurality of successive cycles.
The invention can be implemented by a processor of a computer on board, or suitable for mounting on board, an aircraft, executing a program including instructions corresponding to the signal processing steps, including the filtering and the combining of the signals from the accelerometers and from the gyros.
Thus, a program including code usable by an aircraft computer for determining the angular velocity of the aircraft includes:
a first code segment for determining measured angular velocity data m of the aircraft from signals delivered by the gyro; a second code segment for determining angular acceleration data m of the aircraft from signals delivered by the accelerometers; and a third code segment for hybridizing the measured angular velocity data and the measured angular acceleration data, and for obtaining estimated angular velocity data .
In another embodiment of the invention, there is provided a system for determining the angular velocity of an aircraft, the system comprising gyros that deliver measured angular velocity signals m , and further comprising:
accelerometers delivering signals m representative of the angular acceleration of the aircraft; and a hybridizing module coupled to the gyros and to the accelerometers to perform filtering that is complementary in the frequency domain, to combine the measured angular velocity signals and the measured angular acceleration signals and to obtain hybrid angular velocity signals .
In preferred embodiments of the system of the invention:
the gyros present noise of power spectrum density that is substantially uniform at least in a frequency band going from about 0.1 Hz to about 10 Hz, or else noise of power spectrum density that is substantially proportional to the frequency, at least in a frequency band going from about 1 Hz to about 10 Hz; the accelerometers present noise of power spectrum density that is substantially uniform, at least in a frequency band going from about 0.1 Hz to about 10 Hz; the system includes at least six linear accelerometers that are rigidly secured to one another in a configuration presenting central symmetry, in particular at least six single-axis linear accelerometers spaced and oriented in a configuration in which the respective sensitive points of the accelerometers are located at the respective centers of the edges of a regular tetrahedron, and the respective sensitivity axes of the accelerometers are oriented along said edges; in a variant, the system includes at least four two-axis linear accelerometers disposed at the vertices of a regular tetrahedron; in another variant, the system includes at least three linear accelerometers placed in a trihedron and three angular accelerometers placed in a trihedron; the gyros and/or accelerometers are essentially constituted by microelectromechanical systems; the hybridizing module comprises a filter presenting proportional gain 1/τ, integral gain 1/τi that is low, i.e. τ<<τi, and a cutoff frequency of less than 1 Hz, in particular of the order of a few millihertz; the hybridizing module includes a comparator arranged to compare the innovation m − with a threshold, and failure confirmation logic connected to the comparator.
By means of the invention, the stochastic (non-deterministic) noise that is not correlated to the movements of the carrier and that affects the measurements of the gyros is reduced or eliminated by replacing the high frequency components of the gyro measurements by measurements taken from the angular accelerometers.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, characteristics, and advantages of the invention appear from the following description which reference to the accompanying drawings that illustrate preferred embodiments of the invention without any limiting character.
FIG. 1 is a diagram showing the appearance of the variation, as a function of frequency, in the PSD of the noise in three respective types of gyro.
FIG. 2 is a diagram of the angular velocity stabilization loop of an aircraft.
FIG. 3 is a block diagram of a hybridizing filter of a system of the invention.
FIG. 4 is a diagram showing the appearance of the variation, as a function of frequency, in the PSD of the noise in two respective types of gyro, and also the time integral of an angular accelerometer, together with the noise that results from hybridizing the measurement, for each of the two gyros.
FIG. 5 is a block diagram of an embodiment of a system of the invention.
FIG. 6 is a diagram showing the architecture of an angular accelerometer made of six single-axis linear gyros associated in a regular tetrahedron configuration.
FIG. 7 is a block diagram of another embodiment of a system of the invention.
FIG. 8 is a diagram showing the appearance of the variation, as a function of frequency, in the PSD of the noise respectively in a gyro and in the time integral of the signal from an angular accelerometer, together with the noise that results from hybridizing the measurements from these two sensors.
FIG. 9 is a diagram showing the appearance of the variation, as a function of frequency, in the PSD of the noise respectively in a servo-controlled gyro and in the integral of an accelerometer signal.
FIG. 10 is a diagram showing the variation, as a function of frequency, of the weighting of the signals coming respectively from a gyro and from the time integral of an accelerometer by means of a third-order filter in a hybridizing system of the invention.
FIG. 11 is a diagram showing the appearance of the variation, as a function of frequency, in the PSD of the noise respectively in a gyro and in the integral of an accelerometer, together with the noise that results from hybridizing the measurements from these two sensors by the filter having the characteristics shown in FIG. 10 .
FIG. 12 is a block diagram of another embodiment of a hybridizing filter of the system of the invention.
FIG. 13 is a diagram showing the architecture of an angular accelerometer made up of four two-axis linear accelerometers in another regular configuration based on a tetrahedron.
FIG. 14 is a block diagram of a hybridizing system of the invention incorporating failure surveillance means.
DETAILED DESCRIPTION
In accordance with an aspect of the invention, in order to reduce the high frequency noise that is troublesome for the autopilot system of an aircraft, the high frequency components of gyro measurements are attenuated, and the dynamic range lost in this way is restored by accelerometers that measure the derivative of the magnitude of interest, i.e. the angular velocity of the aircraft.
For this purpose, and as shown in FIG. 3 , a hybridizing filter 25 is used comprising:
a subtractor 26 receiving as input the angular velocity measurement signal m delivered by the gyro, and also the hybrid/estimated angular velocity ; a filter 27 connected to the subtractor 26 , receiving as input the innovation m − produced by the subtractor 26 , and outputting a bias correction, presenting characteristics that are described in detail; a summing circuit 28 connected to the filter 27 and receiving as input the signal output by the filter together with the angular acceleration measurement m as delivered by the angular accelerometer; and an integrator 29 connected to the summing circuit 28 , receiving as its input the sum produced thereby, and delivering as its output the estimated angular velocity .
When the angular accelerometer presents noise with uniform PSD (i.e. white noise), the angular velocity estimate that comes therefrom (by time integration) presents a so-called “1/f” noise spectrum distribution, which intersects the noise PSD of the gyro (which is “white” or “f”). It thus suffices to adjust the form and the cutoff frequency of the filter, i.e. the structure and the values of the coefficients of the filter H(p) shown in FIG. 3 so that it “selects” for each frequency band the better source: the accelerometer or the gyro.
FIG. 4 plots the noise spectra respectively of an OL-MEMS gyro (reference 37 ), of the integral (reference 38 ) of a signal delivered an angular accelerometer, and also the noise spectrum 39 of the hybrid measurement that results from this first combination; the figure also shows the noise spectrum 43 of a CL-MEMS gyro and the noise spectrum 46 of the hybrid measurement that results from combining it with the accelerometer.
It is preferable to select an angular accelerometer presenting a noise level that is low enough for the intersection between the spectra to be located at as low a frequency as possible, so as to remove a maximum amount of noise from the gyro.
Alternatively, it is possible to use accelerometers having high noise levels by increasing the position difference between the sensors so as to increase the lever arm of the sensors relative to the center of rotation.
To measure all three components of the angular acceleration, it is possible in particular to make use of six single-axis linear accelerometers, or else four two-axis linear accelerometers, each combining two axial accelerometers.
Typically, an AHRS type inertial sensor contains three gyros mounted as a trihedron, such as those referenced 31 in FIG. 5 , and three linear accelerometers, likewise mounted as a trihedron.
In one embodiment, an inertial sensor of the invention may be constituted essentially by a conventional AHRS together with three linear accelerometers for measuring angular acceleration (giving a total of nine accelerometers); in another embodiment, the sensor of the invention may have three gyros mounted in a trihedron and six linear accelerometers disposed in a symmetrical configuration such as that shown in FIG. 6 .
A cluster 30 (as shown in FIGS. 5 and 6 ) of six linear accelerometers serves not only to measure the three components of angular acceleration m , but also the three components of linear acceleration {right arrow over (γ)} m ; this data is output from a matrix calculation module 32 that receives as input the signals from the six linear accelerometers; this module also receiving the previously-estimated angular velocity in order to correct the linear acceleration of centripetal interfering terms.
This data is applied as input to a calculation module 33 that calculates the roll, pitch, and heading angles, and also the altitude and the speed of the aircraft (delivered as outputs 35 , cf. FIG. 5 ) on the basis of a virtual strap-down platform algorithm and as a function of said data, of velocity and altitude assistance signals 34 , and of signals taken from a magnetometer.
The (measured) linear acceleration components {right arrow over (γ)} m , (measured) angular acceleration components m , and (estimated) angular velocity components are delivered to the autopilot. The hybridizing module 25 also outputs a signal 36 representing detection of a sensor failure, and as described in detail below.
A system of the invention thus makes it possible to reduce the noise level in the angular velocity measurement, and to provide two additional functions: it outputs an angular acceleration measurement as such (which may be used as such as an input to the AP), and it monitors proper operation of certain components of the system: by segregating acquisition and processing firstly of the accelerometer cluster and secondly of the three gyros, two distinct sources are made available for measuring the same angular movements. They can therefore be used to perform mutual surveillance, thereby significantly reducing the rate at which failures occur without being detected.
In a preferred embodiment of the invention, six single-axis linear accelerometers are used that are rigidly associated with one another, being disposed and oriented in a first configuration as shown in FIG. 6 , in which:
the sensing point—represented by small disks—of the respective accelerometers referenced 1 to 6 are located at the respective centers of the edges of a regular tetrahedron; and the sensing axes—represented by arrows starting from the disks—of the respective accelerometers referenced 1 to 6 point along said edges.
As described in the above-referenced document “A compensator to advance gyro-free INS precision”, in this particular configuration of accelerometers, the relationship between the three angular acceleration components and the six linear acceleration measurements γ 1 , γ 2 , . . . γ 6 can be written in the following forms:
ω
→
.
=
1
2
2
ρ
[
1
-
1
0
0
1
-
1
-
1
0
1
-
1
0
-
1
0
1
-
1
-
1
1
0
]
[
γ
1
γ
2
γ
3
γ
4
γ
5
γ
6
]
In this form, ρ is the length of the edge of a cube in which the tetrahedron is inscribed, the edges of the tetrahedron corresponding respectively to the diagonals of the faces of the cube.
Thus, for the cluster of six accelerometers mounted as a regular tetrahedron, one angular acceleration component is the sum of four linear accelerations divided by 2√2ρ. If the linear acceleration noise is {tilde over (γ)}, then the angular acceleration noise is given by:
ω
.
~
=
4
γ
~
2
2
ρ
=
1
2
ρ
γ
~
MEMS accelerometers generally present noise that is white (i.e. substantially constant PSD for the frequencies used). The angular acceleration noise is therefore likewise white.
In contrast, the angular velocity noise PSD affecting a MEMS gyro depends on the technology used. Open-loop sensors present white noise, whereas servo-controlled sensors present PSD that is proportional to frequency.
With a miniature gyro presenting white noise, writing for the spectrum density of the angular acceleration measurement noise and for the spectrum density of the angular velocity noise coming from the gyro, the frequency corresponding to the point of intersection of the noise density spectra respectively from the “gyro” angular velocities and the “accelerometer” angular velocities is given by:
f
i
=
1
2
π
ω
.
~
ω
~
The order of magnitude of this frequency may be a few millihertz. Assuming that these two kinds of white noise are the only sources of error, the optimum filter is a first-order filter; the transfer function H(p) of FIG. 3 is no more than a mere gain K=1/t.
The overall transfer function of the filter and hybridizing system shown in FIG. 3 is given by:
ω
→
^
=
(
τ
p
1
+
τ
p
1
1
+
τ
p
)
(
ω
→
.
p
ω
→
)
=
τ
ω
→
.
+
ω
→
1
+
τ
p
It is easy to verify that the optimum value for τ, i.e. the value that minimizes the amplitude of the noise affecting the hybrid angular velocity can be determined using the following formula:
τ
=
ω
~
ω
.
~
The optimum cutoff frequency for the hybridizing filter (f=½πτ) coincides with the frequency at which the noise spectra intersect.
FIG. 8 shows in greater detail, in superposition, the respective noise spectra of the two inputs and of the outputs of the filter: the noise 37 of an OL-MEMS gyro, the integral 38 of the noise of a MEMS angular accelerometer, and the resulting hybrid noise 39 .
If it is desired to give precedence to high frequencies (to the detriment of flow frequencies), then it is possible to adopt a lower cutoff frequency, so that the asymptote of the high frequency noise approaches that of the integrated angular accelerometer; with an optimum adjustment it is situated 3 decibels (dB) higher (reference 40 ).
For a servo-controlled miniature gyro presenting “f” noise, i.e. presenting a noise spectrum that increases substantially proportionally with frequency (possibly from a determined frequency that is generally much lower than 1 Hz), the gyro noise is white noise filtered by a second-order bandpass filter presenting a high Q factor. The noise spectrum 43 presents a peak (maximum) at the resonant frequency 42 of the gyro, as shown in FIG. 9 .
In the frequency range 41 of interest, in particular for frequencies less than or equal to 100 Hz, it can be considered that the noise from the gyro is constituted by white noise {tilde over (θ)} “colored” by a differentiating filter.
In the useful frequency range, in particular in the frequency range about 0.01 Hz to about 10 Hz, the noise present therefore comprises uniform angular acceleration noise (white noise) together with “f” gyro noise. The hybridizing filter therefore needs to behave like a first second-order lowpass filter for the gyro, so that it presents decreasing “1/f” residual high frequency noise, and as a second-order highpass filter for the angular accelerometer, so that it presents “f” residual low frequency noise tending to 0.
These two requirements that can be achieved by means of a third-order filter corresponding to the following transfer function:
ω
→
^
=
(
bp
2
+
cp
3
1
+
ap
+
bp
2
+
cp
3
1
+
ap
1
+
ap
+
bp
2
+
cp
3
)
(
ω
→
.
p
ω
→
)
FIGS. 10 and 11 show the characteristics and the performance of such filters drawn up for values of a, b, and c such that the common denominator in the two terms of the transfer function is of the second-order Butterworth type, of the form (1+τρ) 3 , with τ=½πf c and with f c =1 Hz.
FIG. 10 shows the weighting curves corresponding to the moduluses of the two transfer functions 44 and 45 respectively of said first and second filters that stop respectively low frequencies and high frequencies (like second-order filters).
FIG. 11 shows in greater detail the spectra 38 and 43 of the two noise sources (integrated angular accelerometer and gyro) together with the spectrum 46 of the hybrid noise that results from the filtering.
It can be seen in FIG. 11 that the hybrid noise density is 6 dB above that of the integral of the angular accelerometer.
Since most linear accelerometers are affected by bias, the measured angular acceleration is likewise biased, thereby disturbing the estimated angular velocity when using the above-described first-order filter. It is therefore desirable under such circumstances to add an integral effect in the feedback loop, as shown in FIG. 12 .
The filter 27 then comprises a first branch comprising an amplifier 50 of gain equal to 1/τ, and a second branch comprising an integrator 51 , 52 with integral gain equal to 1/τi. These two branches are connected in parallel between the output from the subtractor 26 for calculating the innovation, and the input to a summing circuit 53 whose output is connected to the input of the summing circuit 28 .
It is generally possible to conserve the above-defined gain value 1/τ. It is preferable to select an integral gain (1/τi) having a value that is small (τi>>τ), but sufficient to track slow fluctuations in accelerometer bias. In other words, it is necessary to adopt a high damping coefficient in this second-order loop.
The above-described third-order filter behaves like a second-order highpass filter for the integrated angular acceleration. The combination of the second order and the operation of integration produces first-order low frequency behavior for angular acceleration measurements. The bias is thus rejected by this filter.
An advantage of the invention is that it makes two independent sources available for measuring angular movements. Monitoring consistency between these two sources thus makes it possible to detect a failure of one of them, and to reduce considerably the rate at which dangerous failures occur.
Thus, it is possible to provide an autopilot that has only one AHRS in accordance with the invention, with this mere detection of failure (i.e. without locating it) making it possible at least to passivate the failure (i.e. freeze the actuators) and warn the pilot of the aircraft. Such a system is therefore passive after a failure (“fail passive”), whereas conventional systems require a second inertial sensor.
In a dual system having two AHRSes in accordance with the invention, there is no need to have a third source in order to be able, in the event of a failure, to determine which one of the two has failed, since each of the two AHRSes itself detects it own failures. It is then possible to devise a system that continues to be operational after a failure (fail operative) based on only two AHRSes in accordance with the invention whereas conventional systems require a third inertial sensor.
In order to detect failure, it is preferable to use a surveillance technique that processes the “innovation” (i.e. the signal representing the difference between the estimate and the measurement). In the absence of a failure, this signal is close to white noise with a zero mean value. In the presence of a failure, a bias is seen to appear (either instantaneous if the failure relates to a gyro and appears as an error step change, or progressively if the failure relates to an accelerometer).
Since the amplitude of the white noise that is expected in the absence of a failure is known (it is a characteristic of the gyro), it is possible to compare the innovation with a threshold (in fact two symmetrical thresholds, one positive and the other negative), and to indicate that a failure has occurred when the threshold is crossed.
This processing can be performed by a module 60 that calculates the absolute value of the innovation monitored at the outlet from the subtractor 26 of the filter 25 , and delivering the absolute value as an input to a comparator 61 having its second input connected to a reference value 62 corresponding to the detection threshold, as shown in FIG. 14 .
In order to optimize the compromise between accuracy of surveillance and the rate at which false detections occur, it is possible to act on the following two parameters:
i) threshold adjustment: for a determined expected standard deviation, setting the threshold, e.g. to six times the standard deviation, leads to a false detection rate of the order of 3×10 −9 , i.e. three false detections per billion samples; and
ii) confirming the failure over a plurality of samples: a sequential logic system is inserted between the output from the threshold comparator and the signal indicating the failure. The logic system is designed so that the failure is not considered as being confirmed unless the threshold has been exceeded for several successive cycles. For example, the threshold may be set to four times the standard deviation, leading to a probability of 10 −4 of the threshold being exceeded on each sample, and then to a probability of it being exceeded during three successive cycles of 10-12.
The hybridizing filter of a device in accordance with the invention is thus advantageously associated with a threshold comparator and with a logic circuit 63 for confirming failure, thus making it possible to increase the coverage ratio of the incorporated test, as shown in FIG. 14 .
Most gyros are included in an inertial measurement unit (IMU) that measures the three components of the rotation vector, and also the three components of the acceleration vector. When the angular accelerometer is made using a cluster of linear accelerometers, it is also possible to provide an estimate of the linear acceleration at a point.
In the embodiment where the redundant cluster is configured as a tetrahedron, the linear acceleration at the center of the tetrahedron can be calculated in the manner described in the above-mentioned document “A compensator to advance gyro-free INS precision”:
γ
→
0
=
1
2
2
[
1
1
0
0
-
1
-
1
1
0
1
-
1
0
1
0
1
1
1
1
0
]
[
γ
1
γ
2
γ
3
γ
4
γ
5
γ
6
]
+
ρ
[
ω
y
ω
z
ω
z
ω
x
ω
x
ω
y
]
By ignoring centripetal acceleration terms, the system of equations is overdetermined (six linear accelerometers for measuring three acceleration components), and it can be solved simply by a least-squares method, corresponding to the left-hand term of the above expression. Because of the excess number of accelerometers, it is possible to detect an accelerometer failure, e.g. by comparing the least squares residue with a threshold.
The right-hand term of the above expression corrects the effects of centripetal acceleration that appear as a result of the accelerometers not all coinciding at a single point. To minimize noise, the angular velocity components used may advantageously be the hybrid estimates. For an embodiment of small size (ρ close to 10 centimeters (cm), for example), this term may possibly be ignored.
By using an angular accelerometer that presents white noise, it is thus possible, for any noise profile of the gyro, to obtain a high frequency asymptote for “1/f” hybrid noise. Whatever the shape of the PSD at low frequencies, it can be bounded by a function of the “first-order lowpass type”:
ω
~
0
2
1
+
(
f
f
0
)
2
Unlike white noise, or a fortiori “f” noise, such noise presents “finite power” that is completely localized in low frequencies. Above a certain threshold, increasing the resonant frequency of the “AP+aircraft” loop has no more influence on the amplitude of the sensor noise transmitted to the aircraft. In an autopilot system in accordance with the invention, it is therefore possible to envisage an open loop gain that is as high as desired, and that is limited only by closed loop stability problems.
The advantage of high frequency lowpass filtering of noise by means of an angular accelerometer presenting white noise is particularly important for MEMS gyros, those of the type having a resonant structure to which the invention is easily applied. The invention can also be used with other types of gyros, such as FOGs, even if their intrinsic noise is low, thereby further reducing high frequency noise and enabling the gain of the piloting loop to be further increased, and thus improving the quality of the autopilot.
With reference to FIG. 7 in particular, in another embodiment of the invention, the system comprises three MEMS angular accelerometers disposed in a trihedron 70 that measure the angular acceleration of the carrier directly, three gyros 31 , and three linear accelerometers 71 in a trihedron; the signals delivered by these sensors are input to the hybridizing modules 25 and to the virtual platform calculation module 33 .
In the variant embodiment shown in FIG. 13 , four identical MEMS accelerometers 81 to 84 are secured to one another at the vertices of a regular tetrahedron in a configuration presenting central symmetry; each accelerometer presents two mutually orthogonal sensitivity axes (such as those referenced x and y), and it delivers two corresponding (axial) linear acceleration signals.
A simple matrix product enables the three angular acceleration components to be calculated as a function of the eight “scalar” measurements of acceleration as delivered by these four two-axis sensors. | A method of determining an angular velocity of an aircraft includes measuring the angular velocity using at least one gyro delivering a measured angular velocity signal affected by stochastic noise; measuring the angular acceleration of the aircraft using at least one accelerometer delivering a signal representing the angular acceleration of the aircraft; and using a filtering complementary in a frequency domain to combine a sum of the measured angular velocity signal and the angular acceleration signal so as to obtain a hybrid estimated angular velocity signal with reduced stochastic noise. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a recycle heat exchanger and a fluidized bed combustion system and method incorporating same, and, more particularly, to such a heat exchanger, system and method in which solids from a combustor are recycled through the heat exchanger and back to the combustor.
According to prior art fluidized bed combustion systems and methods, air is passed through a bed of particulate material, including a fossil fuel, such as coal, and a sorbent for the oxides of sulfur generated as a result of combustion of the coal, to fluidize the bed and to promote the combustion at a relatively low temperature. These types of systems are often used in steam generators in which water is passed in a heat exchange relationship to the fluidized bed to generate steam and permit high combustion efficiency, fuel flexibility, high sulfur adsorption and low nitrogen oxides emissions. These types of systems often utilize a "circulating" fluidized bed in which the entrained solid particles of fuel and sorbent (hereinafter referred to as "solids") from the furnace are separated from the mixture of fluidizing air and combustion gases (hereinafter referred to as "flue gases") and are recycled back to the furnace.
In these circulating beds, the fluidized bed density is relatively low when compared to other types of fluidized beds, the fluidizing air velocity is relatively high, and the flue gases passing through the bed entrain a substantial amount of the fine solids to the extent that they are substantially saturated therewith.
The relative high solids recycling is achieved by disposing a cyclone separator at the furnace section outlet to receive the flue gases, and the solids entrained thereby, from the fluidized bed. The solids are separated from the flue gases in the separator and the flue gases are passed to a heat recovery area while the solids are recycled back to the furnace. This recycling improves the efficiency of the separator, and the resulting increase in the efficient use of sulfur adsorbent and fuel residence times reduces the adsorbent and fuel consumption. Also, the relatively high internal and external solids recycling makes the circulating bed relatively insensitive to fuel heat release patterns, thus minimizing temperature variations and, therefore stabilizing the sulfur emissions at a low level.
When the circulating fluidized bed combustors are utilized in a steam generating system, the combustor is usually in the form of a conventional, water-cooled enclosure formed by a welded tube and membrane construction so that water and steam can be circulated through the wall tubes to remove heat from the combustor. However, in order to achieve optimum fuel burn-up and emissions control, additional heat must be removed from the system. This heat removal has been achieved in the past by several techniques. For example, the height of the furnace has been increased or heat exchange surfaces have been provided in the upper furnace to cool the entrained solids before they are removed from the furnace, separated from the flue gases and returned to the furnace. However these techniques are expensive and the heat exchange surfaces are wear-prone. Other techniques involve the deployment of an additional, separate heat exchanger between the outlet of the separator and the recycle inlet of the furnace. Although heat can be removed from the recycled solids in this separate heat exchanger before the solids are passed back into the furnace, these type of arrangements are not without problems. For example, it is difficult to precisely control the heat transfer rates in the recycle heat exchanger. Also, during start-up or load low conditions, it is often difficult to bypass the heat exchange surfaces in the recycle heat exchanger. Further, in situations when the recycle heat exchanger is formed integrally with the furnace, there is often an increase in boiler plan area which adds to the cost of the system.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a recycle heat exchanger and a fluidized bed combustion system and method incorporating same in which the recycle heat exchanger selectively removes heat from the recycled solids.
It is a further object of the present invention to provide a heat exchanger, system and method of the above type in which the amount of heat removed from the recycled solids can be precisely controlled.
Towards the fulfillment of these and other objects, according to the present invention a fluidized bed of fuel particles is established in a furnace and the flue gases produced as a result of combustion of the fuel particles entrain a portion of the particles. The entrained particles are separated from the flue gases and a heat exchanger is provided for receiving the separated particles. The heat exchanger includes an inlet compartment for receiving the separated particles, at least one heat exchange compartment for cooling the particles and two or more outlet compartments for discharging the particles back to the furnace. The particles in the compartments are selectively fluidized so that they pass from the inlet compartment through one of the outlet compartments and back to the furnace, or from the inlet compartment, through both of the outlet compartments and back to the furnace.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and summary, as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of the presently preferred, but nevertheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic representation depicting the combustion system and the recycle heat exchanger of the present invention;
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 1; and
FIGS. 3, 4 and 5 are cross-sectional views taken along the lines 3--3, 4--4 and 5--5, respectively, of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings depict the fluidized bed combustion system of the present invention used for the generation of steam and including an upright pressure vessel 10 in which is disposed a water-cooled furnace enclosure, referred to in general by the reference numeral 12. The furnace enclosure 12 includes a front wall 14, a rear wall 15 and two sidewalls 16a and 16b (FIG. 3). As shown in FIG. 1, the lower portions 14a and 15a of the walls 14 and 15, respectively, converge inwardly for reasons to be explained. The upper portion of the enclosure 12 is enclosed by a roof 18a and a floor 18b defines the lower boundary of the enclosure. It is understood that an air inlet duct (not shown) connects to the lower portion of the pressure vessel 10 for introducing pressurized air from an external source, such as a compressor driven by a gas turbine, or the like.
A plurality of air distributor nozzles 20 are mounted in corresponding openings formed in a horizontal plate 22 extending across the lower portion of the enclosure 12. The plate 22 is spaced from the floor 18 to define an air plenum 24 which is adapted to receive air contained in the vessel 10 and selectively distribute the air through the plate 22 and to portions of the enclosure 12, as will be described.
It is understood that a fuel feeder system (not shown) is provided for introducing particulate material including fuel into the enclosure. The particulate material is fluidized by the air from the plenum 24 as it passes upwardly through the plate 22. The air promotes combustion of the fuel and the flue gases thus formed rise in the enclosure 12 by forced convection and entrain a portion of the solids to form a column of decreasing solids density in the enclosure to a given elevation, above which the density remains substantially constant.
A cyclone separator 26 extends adjacent the enclosure 12 inside the vessel 10 and is connected to the enclosure by a duct 28 extending from an outlet provided in the rear wall 15 of the enclosure to an inlet provided through the separator wall. The separator 26 receives the flue gases and the entrained particulate material from the enclosure in a manner to be described and operates in a conventional manner to disengage the particulate material from the flue gases due to the centrifugal forces created in the separator.
The separated flue gases, which are substantially free of solids enter a duct 30 projecting upwardly through the upper portion of the separator 26 and the vessel 10 for passage into a hot gas clean-up and a heat recovery section (not shown) for further treatment. The lower portion of the separator includes a hopper 26a which is connected to a conventional "J-valve" 32 by a dip leg 34.
The heat exchanger 38 of the present invention is located adjacent the enclosure 12 and within the vessel 10, and is connected to the outlet of the J-valve 32 by a duct 39. The heat exchanger 38 includes an enclosure 40 formed by two front wall portions 42a and 42b, a rear wall 43, two sidewalls 44a and 44b (FIG. 2), a roof 46a and a floor 46b. As shown in FIGS. 1, 3, and 4, a large portion of the sidewalls 44c and 44b are formed by extension of the sidewalls 16a and 16b of the furnace enclosure 12. Also, as shown in FIG. 1, the front wall portions 42a and 42b form lower extensions of corresponding portions of the rear enclosure wall 15 that extends just above the converging portion 15a. As shown in FIGS. 1 and 5, the plate 22 extends to the wall 42 to form a solids outlet compartment 50 defined above the latter extension and between the converging portion 15a of the enclosure rear wall 15 and the front wall portions 42a and 42b of the enclosure 40.
Two horizontal, vertically-spaced, plates 54 and 56 (FIGS. 1, 2 and 5) are disposed in the enclosure 40 and receive two groups of air distributor nozzles 58a and 58b, respectively. A third horizontal plate 60 is disposed in the enclosure 40 and extends between the plates 54 and 56 to generally divide the enclosure into an upper portion and a lower portion. As shown in FIG. 2, a plenum section 61 is defined between the plates 54 and 60 for supplying air to the nozzles 58a, and a plenum section 62 is defined between the plate 56 and the floor 46b for supplying air to the nozzles 58b.
As shown in FIGS. 2 and 3, a pair of spaced, parallel vertical plates 64 and 66 extend between the rear wall 43 of the enclosure 40 and the wall 15 (and the wall 42) in a spaced parallel relationship to the sidewalls 44a and 44b. The plates 64 and 66 thus divide the upper portion of enclosure 40 into two heat exchange sections 68 and 70, respectively extending to the sides of a inlet/bypass section 72 (FIGS. 2 and 3). The plates 64 and 66 also divide the lower portion of the enclosure 40 into two heat exchange sections 74 and 76 respectively extending to the sides of a transfer section 78 (FIGS. 2 and 4). As shown in FIG. 2, three openings 64a, 64b, and 64c are formed in the plate 64 and three openings 66a, 66b and 66c are formed in the plate 66 to permit the flow of solids between the upper sections 68, 70, and 72, as well as between the lower sections 74, 76 and 78 as will be described.
As shown in FIG. 2, the plates 64 and 66 also divide the plenum 61 into three sections respectively extending below the sections 74, 76, and 78 and, in addition, divide the plenum 62 into three sections respectively extending below the sections 74, 76, and 78.
It is understood that pressurized air from the vessel 10 is selectively introduced into the aforementioned plenum sections at varying velocities in a conventional manner, for reasons to be described.
A vertical partition 80 (FIGS. 3 and 5) extends from the horizontal plate 60 to the roof 46a and divides the inlet/bypass compartment 72 into two sections 72a and 72b. An opening 80a is provided in the upper portion of the partition 80 to communicate the compartment section 72a with the section 72b. The portion of the plate 54 that defines the compartment 72a, as well as the corresponding portion of the plate 60, each terminates at the partition 80 and thus does not extend to the wall 15. Thus the compartment section 72b communicates with the section 78 for reasons that will be described.
With reference to FIG. 4, the lower portions of the walls 64 and 66 extend past the front wall portions 42a and 42b and to the wall portion 15a. This divides the outlet compartment into two spaced sections 50a and 50b and an intermediate section 50c extending between the spaced sections and forming an extension of the lower bypass section 78. Openings 64d and 66d extend through the respective extended portions of the walls 64 and 66 for reasons to be described.
Four bundles 82a, 82b, 82c, and 82d of heat exchange tubes (FIGS. 2-4) are disposed in the heat exchange sections 68, 70, 74, and 76, respectively and are connected in a conventional manner to a fluid flow circuit (not shown) to circulate cooling fluid through the tubes to remove heat from the solids in the sections, in a conventional manner.
As shown in FIG. 4, two spaced openings 15b and 15c are provided in the lower, vertical wall portion 15a and two openings 42c and 42d are formed through the wall portions 42a and 42b, respectively.
It is understood that all of the foregoing walls, plates and partitions are formed of a conventional welded membrane and tube construction shown and described in U.S. Pat. No. 5,069,171 assigned to the assignee of the present application, the disclosure of which is incorporated by reference. It is also understood that a steam drum is provided adjacent the vessel and a plurality of headers, downcomers and the like are provided to establish a fluid flow circuit including the foregoing tubed walls. Thus, water is passed in a predetermined sequence through this flow circuitry to convert the water to steam by the heat generated by the combustion of the fuel solids in the furnace enclosure 12.
In operation, the solids are introduced into the furnace enclosure 12 in any conventional manner where they accumulate on the plate 20. Air is introduced into the pressure vessel 10 and passes into the plenum 24 and through the plate 20 before being discharged by the nozzles 22 into the solids on the plate 20, with the air being at sufficient velocity and quantity to fluidize the solids.
A lightoff burner (not shown), or the like, is provided to ignite the fuel material in the solids, and thereafter the fuel portions of the solids is self-combusted by the heat in the furnace enclosure 12. The flue gases pass upwardly through the furnace enclosure 12 and entrain, or elutriate, a quantity of the solids. The quantity of the air introduced, via the plenum 24, through the nozzles 22 and into the interior of the enclosure 12 is established in accordance with the size of the solids so that a circulating fluidized bed is formed, i.e., the solids are fluidized to an extent that substantial entrainment or elutriation thereof is achieved. Thus, the flue gases passing into the upper portion of the furnace enclosure are substantially saturated with the solids and the arrangement is such that the density of the bed is relatively high in the lower portion of the furnace enclosure 12, decreases with height throughout the length of this enclosure and is substantially constant and relatively low in the upper portion of the enclosure.
The saturated flue gases in the upper portion of the furnace enclosure 12 exit into the duct 28 and pass into the cyclone separator 26. The solids are separated from the flue gases in the separator 26 in a conventional manner, and the clean gases exit the separator and the vessel 10 via the duct 30 for passage to hot-gas clean-up and heat recovery apparatus (not shown) for further treatment as described in the above-cited patent.
The separated solids in the separator 26 fall into the hopper 26a and exit the latter, via the dip leg 34 before passing through the J-valve 32 and, via the duct 39, into the enclosure 40 of the heat exchanger 38.
The separated solids from the duct 39 enter the inlet/bypass compartment section 72a of the enclosure 40 as shown by the flow arrow A in FIG. 3. In normal operation, air is introduced at a relatively high rate into the sections of the plenum 61 extending below the heat exchange sections 68 and 70 while air at a relatively low rate is introduced into the section of the plenum extending below the section 72a. As a result, the solids from the section 72a flow through the openings 64b and 66b (FIG. 2) in the partitions 64 and 66, respectively, and into the sections 68 and 70, as shown by the flow arrows B1 and B2 in FIGS. 2 and 3. The solids flow under and up through the heat exchange tube bundles 82a and 82b in the sections 68 and 70, as shown by the arrows C1 and C2 in FIGS. 2 and 3.
The solids thus build up in the sections 68 and 70 and spill through the openings 64a and 66a in the partitions 64 and 66 respectively, into the inlet/bypass compartment section 72b, as shown by the flow arrows D1 and D2 in FIGS. 2 and 3. The solids then fall, by gravity through the openings in the plates 54 and 60, respectively, and into the lower section 78, as shown by the flow arrows E in FIGS. 2 and 5.
Air at a relatively high rate is introduced into the sections of the lower plenum 62 extending below the lower heat exchange sections 74 and 76 while air at a relatively low rate is introduced into the section of the plenum 62 extending below the section 78. This promotes the flow of the solids from the section 78, through the openings 64c and 66c in the partitions 64 and 66, and into the heat exchange sections 74 and 76, as shown by the flow arrows F1 and F2, respectively, in FIGS. 2 and 4. The solids thus flow up through the tube bundles 82c and 82d in the sections 74 and 76, respectively, to transfer heat to the fluid flowing through the latter tubes. As shown in FIG. 4 by the flow arrows H1 and H2, the solids exit the sections 74 and 76 via openings 42c and 42d, respectively, in the wall 42 portions 42a and 42b, respectively, and pass into the sections 50a and 50b, respectively, of the outlet compartment 50 where they mix before passing, via the openings 15b and 15c, respectively, in the wall 15, back into the furnace enclosure 12. The fluidizing air from all of the heat exchange sections 68, 70, 74 and 76 also flows into the furnace enclosure 12 through the openings 42c, 42d, 15b, and 15c.
Feed water is introduced into, and circulated through, the flow circuit described above including the water wall tubes and the steam drum described above in a predetermined sequence to convert the water to steam and to superheat and reheat (if applicable) the steam.
During low loads, emergency shutdown conditions or start-up, a bypass operation is possible by terminating all air flow into the sections of the plenums 61 and 62 extending below the sections 68, 70, 74 and 76 and thus allowing the solids to build up in the inlet section 72a until their level reaches that of the weir port 80a in the partition 80, as shown in FIG. 5. Thus, the solids spill over into the section 72b of the inlet/bypass compartment 72 and fall down into the section 78. The solids thus build up in the section 78 and pass into the section 50c of the outlet compartment 50 until their level reaches that of the openings 64d and 66d of the extended portions of the walls 64 and 66d and into the sections 50a and 50b, respectively, of the outlet compartment 50. The solids then pass from the outlet compartment sections 50a and 50b through the openings 15b and 15c in the wall 15 and back into the furnace enclosure 12 at substantially the same temperature as when the solids entered the heat exchanger 38.
By selective control of the respective velocities of the air discharging into the heat exchange sections 68, 70, 74 and 76, the respective heat exchange with the fluid passing through the walls and partitions of the enclosure 40 can be precisely regulated and varied as needed. For example, in the bypass operation described above, instead of completely defluidizing the sections 68, 70, 74 and 76 and thus allowing all of the solids to bypass through the sections 72b, 78 and 50c as described above, the sections 68, 70, 72a, 74 and 76 can be partially fluidized so that only a portion of the solids bypass directly through the sections 72b, 78 and 50c, and thus pass directly into the enclosure 12. The remaining portion of the solids would thus pass in the standard manner through one or more of the sections 68, 70, 74 and 76 to remove heat therefrom, as described above, resulting in less heat removal from the solids when compared to the standard operation described above in which all of the solids pass through the sections 68, 70, 74 and 76.
Also, the fluidization could be varied so that the solids bypass one of the sections 68 and 70 as described in the bypass operation, above, and pass through the other as well as bypass one of the sections 74 and 76 and pass through the other. Moreover, during the standard operation, the fluidization, and the resulting heat removal, can be varied between the sections 68 and 70 and between the section 74 and 76, especially if these sections perform different functions (such as superheat, reheat, and the like). For example, the respective fluidization can be controlled so that 70% of the solids pass through the section 68 and 30% pass through the section 70 and so that 60% of the solids pass through the section 74 and 40% pass through the section 76, with these percentages being variable in accordance with particular design requirements.
In addition to providing the flexibility of operation discussed above, the present invention enjoys several other advantages. For example, a significant amount of heat can be removed from the solids circulating through the recycle heat exchanger 38 to maintain the desired temperature within the furnace for optimum fuel burn-up and emissions control. Also, the aforementioned selective fluidization, including the bypass modes, is done utilizing non-mechanical techniques. Moreover, the use of a pressurized system enables the separator to be relatively small, thus making room for the stacked heat exchange sections in the enclosure 40 to minimize the pressure vessel diameter.
It is understood that several variations can be made in the foregoing without departing from the scope of the invention. For example, an optional opening 15d (FIG. 5) can be provided in the wall 15a which permits the fluidizing air from all of the heat exchange sections 68, 70, 74 and 76 to be vented into the furnace enclosure instead of through the openings 15b and 15c along with the solids. This venting of the air in this manner through the opening 15d would enable the air to enter the furnace at a higher level and function as secondary air. In this arrangement, the solids would still be returned to the enclosure 12 through the openings 15b and 15c but would be allowed to build up to a sufficient level to balance the pressure difference between the openings 15b, 15c, and 15d.
It is also understood that the number and location of the various other openings in the walls of the enclosures 12 and 40 can be varied, and more than one separator can be utilized. Further, although the present invention has been described in connection with a pressurized fluidized bed boiler, it is understood that it is equally applicable to an atmospheric fluidized bed boiler. Examples of the latter are fully disclosed in U.S. Pat. No. 5,133,943 and No. 5,140,950, both assigned to the assignee of the present invention. Further, although a J-valve 32 was utilized in the preferred embodiment described above, it is understood that it could be replaced with another type of pressure sealing device within the scope of the invention. Examples of pressure sealing devices that would be applicable in this context are an L-valve, a seal pot, an N-valve or any other non-mechanical sealing device. Finally, although the preferred embodiment described above utilized two upper heat exchange sections 68 and 70 and two lower heat exchange sections 74 and 76, it is within the scope of the present invention to vary the number of these sections. Thus, in smaller systems one upper and/or lower heat exchange section can be used while larger systems may employ three or more.
Other variations in the present invention are contemplated and in some instances, some features of the invention can be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly in a manner consistent with the scope of the invention. | A heat exchanger and a fluidized bed combustion system and method utilizing same in which the heat exchanger includes a plurality of stacked sections. The sections include an inlet section for receiving the particles and a plurality of stacked sections and are arranged in such a manner that the particles are introduced into an upper level of the sections and pass through these sections to a lower level of sections before returning to the furnace. A portion of the stacked sections contain heat exchange surfaces for removing heat from the particles, and a multi-sectioned outlet compartment is provided to receive the separated particles from the heat exchange sections and directly from the inlet section and pass the particles back to the furnace. | 5 |
This is a continuation of application Ser. No. 07/724,532 filed on Jun. 28, 1991, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method for treating or preventing breast and endometrial cancer, bone loss, and for treating endometriosis in susceptible warm-blooded animals including humans involving administration of a compound possessing androgenic activity, and to kits containing active ingredients to be used in the therapy.
Various investigators have been studying hormonal therapy for breast and endometrial cancer as well as for the prevention and treatment of bone loss and for treatment of endometriosis. The main approaches for the treatment of already developed breast cancer are related to the inhibition of estrogen action and/or formation. The role of estrogens in promoting the growth of estrogensensitive breast cancer is well recognized (Lippman, Semin. Oncol. 10 (suppl. 4): 11-19, 1983; Sledge and McGuire, Cancer Res. 38: 61-75, 1984; Wittliff, Cancer 53: 630-643, 1984; Poulin and Labrie, Cancer Res. 46: 4933-4937, 1986).
Estrogens are also known to promote the proliferation of normal endometrium. Chronic exposure to estrogens unopposed by progesterone can lead to the development of endometrial hyperplasia which predisposes to endometrial carcinoma (Lucas, Obstet. Gynecol. Surv. 29: 507-528, 1974). The incidence of endometrial cancer increases after menopause, especially in women receiving estrogen therapy without simultaneous treatment with progestins (Smith et al., N. Engl. J. Med. 293: 1164-1167, 1975; Mack et al., N. Engl. J. Med. 294: 1262-1267, 1976).
Various investigators have been studying hormone-dependent breast and endometrial cancer. A known form of endocrine therapy in premenopausal women is castration most commonly performed by surgery or irradiation, two procedures giving irreversible castration. Recently, a reversible form of castration has been achieved by utilizing Luteinizing Hormone-Releasing Hormone Agonists (LHRH agonists) which, following inhibition of secretion of bioactive Luteinizing Hormone (LH) by the pituitary gland, decrease serum estrogens to castrated levels (Nicholson et al., Brit. J. Cancer 39: 268-273, 1979).
Several studies show that treatment of premenopausal breast cancer patients with LHRH agonists induces responses comparable to those achieved with other forms of castration (Klijn et al., J. Steroid Biochem. 20: 1381, 1984; Manni et al., Endocr. Rev. 7: 89=94, 1986). Beneficial effects of treatment with LHRH agonists have also been observed in postmenopausal women (Nicholson et al., J. Steroid Biochem. 23: 843-848, 1985).
U.S. Pat. No. 4,071,622 relates to the use of certain LHRH agonists against DMBA-induced mammary carcinoma in rats.
U.S. Pat. No. 4,775,660 relates to the treatment of female breast cancer by use of a combination therapy comprising administering an antiandrogen and an antiestrogen to a female after the hormone output of her ovaries has been blocked by chemical or surgical means.
U.S. Pat. No. 4,775,661 relates to the treatment of female breast cancer by use of a therapy comprising administering to a female, after the hormone output of her ovaries has been blocked by chemical or surgical means, an antiandrogen and optionally certain inhibitors of sex steroid biosynthesis.
U.S. Pat. No. 4,760,053 describes a treatment of selected sex steroid dependent cancers which includes various specified combinations of compounds selected from LHRH agonists, antiandrogens, antiestrogens and certain inhibitors of sex steroid biosynthesis.
In U.S. Pat. No. 4,472,382 relates to treatment of prostatic adenocarcinoma, benign prostatic hypertrophy and hormone-dependent mammary tumors with specified pharmaceuticals or combinations. Various LHRH agonists and antiandrogens are discussed.
International Patent Application PCT/W086/01105, discloses a method of treating sex steroid dependent cancers in warm-blooded animals which comprises administering specific pharmaceuticals and combinations. Antiandrogens, antiestrogens, certain inhibitors of sex steroid biosynthesis and blocking of hormonal output are discussed.
The inventor's co-pending U.S. patent application Ser. No. 07/321926 filed Mar. 10, 1989, relates to a method of treatment of breast and endometrial cancer in susceptible warm-blooded animals which may include inhibition of ovarian hormonal secretion by surgical means (ovariectomy) or chemical means (use of an LHRH agonist, e.g. [D-Trp 6 , des-Gly-NH 2 10 ]LHRH ethylamide, or antagonists) as part of a combination therapy. Antiestrogens, androgens, progestins, inhibitors of sex steroid formation (especially of 17β-hydroxysteroid dehydrogenase- or aromatase-catalyzed production of sex steroids), inhibitors of prolactin secretion and of growth hormone secretion and ACTH secretion are discussed.
Androgen receptors have been shown to be present in normal (Witliff, In: Bush, H. (Ed.), Methods in Cancer Res., Vol. 11, Acad. Press, New York, 1975, pp. 298-304; Allegra et al., Cancer Res. 39: 1447-1454, 1979) and neoplastic (Allegra et al., Cancer Res. 39: 1147-1454, 1979; Engelsman et al., Brit. J. Cancer 30: 177-181, 1975; Moss et al., J. Ster. Biochem. 6: 743-749, 1975; Miller et al., Eur. J. Cancer Clin. Oncol. 2: 539-542, 1985; Lippman et al., Cancer 38: 868-874, 1976; Allegra et al., Cancer Res. 39: 1447-1454, 1979; Miller et al., Eur. J. Clin. Oncol. 21: 539-542, 1985; Lea et al., Cancer Res. 49: 7162-7167, 1989) as well as in several established breast cancer cell lines (Lippman et al., Cancer Res. 36: 4610-4618, 1976; Horwitz et al., Cancer Res. 38: 2434-2439, 1978; Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988). Androgen receptors are also present in dimethylbenz(a)anthracene (DMBA)-induced mammary tumors in the rat (Asselin et al., Cancer Res. 40: 1612-1622, 1980).
Androgen receptors have also been described in human endometrium (MacLaughlin and Richardson, J. Steroid Biochem. 10: 371-377, 1979; Muechler and Kohler, Gynecol. Invest. 8: 104, 1988). The growth inhibitory effects of the androgen methyltrienolone (R1881), on endometrial carcinoma in vitro have been described (Centola, Cancer Res. 45: 6264-6267, 1985).
Recent reports have indicated that androgen receptors may add to the selective power of estrogen receptors or even supplant estrogen receptors as best predicting response to endocrine therapy (Teulings et al., Cancer Res. 40: 2557-2561, 1980; Bryan et al., Cancer 54: 2436-2440, 1984).
The first androgen successfully used in the treatment of advanced breast cancer is testosterone propionate (Nathanson, Rec. Prog. Horm. Res. 1: 261-291, 1947). Many studies subsequently confirmed the beneficial effect of androgens on breast cancer (Alan and Herrman, Ann. Surg. 123: 1023-1035; Adair, Surg. Gynecol. Obstet. 84: 719-722, 1947; Adair et al., JAMA 140: 1193-2000, 1949). These initial results stimulated cooperative studies on the effect of testosterone propionate and DES which were both found to be effective in producing objective remissions. (Subcommittee on Steroid and Cancer of the Committee on Research of the Council on Pharmacy and Chemistry of the Am. Med. Association followed by the Cooperative Breast Cancer Group under the Cancer Chemotherapy National Service Center of the NCI who found that testosterone propionate improved remission rate and duration, quality of life and survival (Cooperative Breast Cancer Group, JAMA 188, 1069-1072, 1964)).
A response rate of 48% (13 of 27 patients) was observed in postmenopausal women who received the long-acting androgen methonolone enanthate (Kennedy et al., Cancer 21: 197-201, 1967). The median duration of survival was four times longer in the responders as compared to the non-responder group (27 versus 7.5 months). A large number of studies have demonstrated that androgens induce remission in 20 to 40% of women with metastatic breast cancer (Kennedy, Hormone Therapy in Cancer. Geriatrics 25: 106-112, 1970; Goldenberg et al., JAMA 223: 1267-1268, 1973).
A response rate of 39% with an average duration of 11 months has recently been observed in a group of 33 postmenopausal women who previously failed or did not respond to Tamoxifen (Manni et al., Cancer 48: 2507-2509, 1981) upon treatment with Fluoxymesterone (Halostatin) (10 mg, b.i.d.). Of these women, 17 had also undergone hypophysectomy. There was no difference in the response rate to Fluoxymesterone in patients who had previously responded to Tamoxifen and in those who had failed. Of the 17 patients who had failed to both Tamoxifen and hypophysectomy, 7 responded to Fluoxymesterone for an average duration of 10 months. Among these, two had not responded to either Tamoxifen or hypophysectomy.
The combination Fluoxymesterone and Tamoxifen has been shown to be superior to Tamoxifen alone. In fact, complete responses (CR) were seen only in the combination arm while 32% showed partial response (PR) in the combination arm versus only 15% in the monotherapy arm. In addition, there were only 25% of non-responders in the combination therapy arm versus 50% in the patients who received TAM alone (Tormey et al., Ann. Int. Med. 98: 139-144, 1983). Moreover, the median time from onset of therapy to treatment failure was longer with Fluoxymesterone+Tamoxifen (180 days) compared to the Tamoxifen arm alone (64 days). There was a tendency for improved survival in the combination therapy arm (380 versus 330 days).
The independent beneficial effect of an androgen combined with an antiestrogen is suggested by the report that patients who did not respond to Tamoxifen could respond to Fluoxymesterone and vice versa. Moreover, patients treated with Tamoxifen and crossing over to Fluoxymesterone survived longer that those treated with the reverse regimen (Tormey et al., Ann. Int. Med. 98: 139-144, 1983).
Since testosterone propionate had beneficial effects in both pre- and postmenopausal women (Adair et al., J. Am. Med. Ass. 15: 1193-1200, 1949), it indicates that in addition to inhibiting gonadotropin secretion, the androgen exerts a direct inhibitory effect on cancer growth.
Recent in vitro studies describe the relative antiproliferative activities of an androgen on the growth of the estrogen-sensitive human mammary carcinoma cell line ZR-75-1 (Poulin et al. "Androgens inhibit basal and estrogen-induced cell proliferation in the ZR-75-1 human breast cancer cell line", Breast Cancer Res. Treatm. 12: 213-225, 1989). As mentioned above, Poulin et al. (Breast Cancer Res. Treatm. 12: 213-225, 1989) have found that the growth of ZR-75-1 human breast carcinoma cells is inhibited by androgens, the inhibitory effect of androgens being additive to that of an antiestrogen. The inhibitory effect of androgens on the growth of human breast carcinoma cells ZR-75-1 has also been observed in vivo in nude mice (Dauvois and Labrie, unpublished data).
As a possible mechanism of androgen action in breast cancer, it has recently been shown that androgens strongly suppress estrogen (ER) and progesterone (PgR) receptor contents in ZR-75-1 human breast cancer cells as measured by radioligand binding and anti-ER monoclonal antibodies. Similar inhibitory effects were observed on the levels of ER mRNA measured by ribonuclease protection assay. The androgenic effect is measured at subnanomolar concentrations of the non-aromatizable androgen 5α-adihydrotestosterone, regardless of the presence of estrogens, and is competitively reversed by the antiandrogen hydroxyflutamide (Poulin et al., Endocrinology 125: 392-399, 1989). Such data on estrogen receptor expression provide an explanation for at least part of the antiestrogenic effects of androgens on breast cancer cell growth and moreover suggest that the specific inhibitory effects of androgen therapy could be additive to the standard treatment limited to blockade of estrogens by antiestrogens.
Dauvois et al. (Breast Cancer Res. Treatm. 14: 299-306, 1989) have shown that constant release of the androgen 5α-dihydrotestosterone (DHT) in ovariectomized rats bearing DMBA-induced mammary carcinoma caused a marked inhibition of tumor growth induced by 17β-estradiol (E 2 ). That DHT acts through interaction with the androgen receptor is supported by the finding that simultaneous treatment with the antiandrogen Flutamide completely prevented DHT action. Particularly illustrative of the potent inhibitory effect of the androgen DHT on tumor growth are the decrease by DHT of the number of progressing tumors from 69.2% to 29.2% in E 2 -treated animals and the increase by the androgen of the number of complete responses (disappearance of palpable tumors) from 11.5% to 33.3% in the same groups of animals. The number of new tumors appearing during the 28-day observation period in E 2 -treated animals decreased from 1.5±0.3 to 0.7±0.2 per rat during treatment with the androgen DHT, an effect which was also reversed by the antiandrogen Flutamide. Such data demonstrate, for the first time, that androgens are potent inhibitors of DMBA-induced mammary carcinoma growth by an action independent from inhibition of gonadotropin secretion and suggest an action exerted directly at the tumor level, thus further supporting the in vitro data obtained with human ZR-75-1 breast cancer cells (Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988).
The natural androgens testosterone (TESTO) and dihydrotestosterone (DHT) are formed from conversion of androstenedione into TESTO by 17β-hydroxysteroid dehydrogenase and then TESTO into DHT by the action of the enzyme 5α-reductase. The adrenal precursor 5-androst-5-ene-3 β,17β-diol can also be converted into TESTO by action of the enzyme 3β-hydroxysteroid dehydrogenase/Δ 5 Δ 4 isomerase (3β-HSD).
Since the natural androgens TESTO and DHT have strong masculinizing effects, numerous derivatives of TESTO as well as progesterone have been synthesized in order to obtain useful compounds having fewer undesirable masculinizing side effects (body hair growth, loss of scalp hair, acne, seborrhea and loud voice).
Medroxyprogesterone acetate (MPA) is one of the most widely used compounds in the endocrine therapy of advanced breast cancer in women (Mattsson, Breast Cancer Res. Treatm. 3: 231-235, 1983; Blumenschein, Semin. Oncol. 10: 7-10, 1983; Hortobagyi et al., Breast Cancer Res. Treatm. 5: 321-326, 1985; Haller and Glick, Semin. Oncol. 13: 2-8, 1986; Horwitz, J. Steroid Biochem. 27: 447-457, 1987). The overall clinical response rate of high doses of this synthetic progestin averages 40% in unselected breast cancer patients (Horwitz, J. Steroid Biochem. 27: 447-457, 1987), an efficacy comparable to that of the nonsteroidal antiestrogen tamoxifen (Lippman, Semin. Oncol. 10 (Suppl.): 11-19, 1983). Its more general use, however, is for breast cancer relapsing after other endocrine therapeutic modalities. The maximal inhibitory action of medroxyprogesterone acetate (MPA) on human breast cancer cell growth in vitro may be achieved at concentration as low as 1 nM while an approximately 1000-fold higher dose is often required for glucocorticoid action (Poulin et al., Breast Cancer Res. Treatm. 13: 161-172, 1989).
Until recently, the mechanisms underlying the antitumor activity of MPA were poorly understood and have been attributed to interaction with the progesterone receptor. This steroid, however, presents a high affinity for progesterone (PgR) as well as for androgen (AR) and glucocorticoid receptors (GR) in various animal tissues (Perez-Palacios et al., J. Steroid Biochem. 19: 1729-1735, 1983; Janne and Bardin, Pharmacol. Rev. 36: 35S-42S, 1984; Pridjian et al., J. Steroid Biochem. 26: 313-319, 1987; Ojasso et al., J. Steroid Biochem. 27: 255-269, 1987) as well as in human mammary tumors (Young et al., Am. J. Obstet. Gynecol. 137: 284-292, 1980), a property shared with other synthetic progesterone derivatives (Bullock et al., Endocrinology 103: 1768-1782, 1978; Janne and Bardin, Pharmacol. Rev. 36: 35S-42S, 1984; Ojasso et al., J. Steroid Biochem. 27: 255-269, 1987). It is known that in addition to progesterone receptors (PgR), most synthetic progestational agents bind with significant affinity to androgen (AR) as well as glucocorticoid (GR) receptors, and induce biological actions specifically determined by these individual receptor systems (Labrie et al., Fertil. Steril. 28: 1104-1112, 1977; Engel et al., Cancer Res. 38: 3352-3364, 1978; Raynaud et al., In: Mechanisms of Steroid Action (G. P. Lewis, M. Grisburg, eds), MacMiland Press, London, pp. 145-158, 1981; Rochefort and Chalbos, Mol. Cell. Endocrinol. 36: 3-10, 1984; Janne and Bardin, Pharmacol. Rev. 36: 35S-42S, 1984; Poyet and Labrie, Mol. Cell. Endocrinol. 42: 283-288, 1985; Poulin et al., Breast Cancer Res. Treatm. 13: 161-172, 1989). Accordingly, several side effects other than progestational have been noted in patients treated with MPA.
The most easily explained adverse side effects of MPA are related to its glucocorticoid-like action with Cushingoid syndrome, euphoria and subjective pain relief (Mattsson, Breast Cancer Res. Treatm. 3: 231-235, 1983; Blossey et al., Cancer 54: 1208-1215, 1984; Hortobagyi et al., Breast Cancer Res. Treatm. 5: 321-326, 1985; Van Veelen et al., Cancer Chemother. Pharmacol. 15: 167-170, 1985). Suppression of adrenal function by MPA is believed to be caused both by an inhibitory action on ACTH secretion at the pituitary level and by direct inhibition of steroidogenesis at the adrenal level (Blossey et al., Cancer 54: 1208-1215, 1984; Van Veelen et al., Cancer Chemother. Pharmacol. 15: 167-170, 1985; Van Veelen et al., Cancer Treat. Rep. 69: 977-983, 1985).
Despite its high affinity for AR, MPA seldom causes significant virilizing symptoms (acne, hirsutism, etc.) (Haller and Glick, Semin. Oncol. 13: 2-8, 1986). Moreover, its inhibitory effect on gonadotropin secretion is clearly exerted through its direct interaction with pituitary AR in the rat (Labrie et al., Fertil. Steril. 28: 1104-1112, 1977; Perez-Palacios et al., J. Steroid Biochem. 19: 1729-1735, 1983) and human (Perez-Palacios et al., J. Steroid Biochem. 15: 125-130, 1981). In addition, MPA exhibits androgenic activity in the mouse kidney (Janne and Bardin, Pharmacol. Rev. 36: 35S-42S, 1980) and in the rat ventral prostate (Labrie, C. et al., J. Steroid Biochem. 28: 379-384, 1987; Labrie C. et al., Mol. Cell. Endocrinol. 68: 169-179, 1990).
Poulin et al. "Androgen and glucocorticoid receptor-mediated inhibition of cell proliferation by medroxyprogesterone acetate in ZR-75-1 human breast cancer cells", Breast Cancer Res. Treatm. 13: 161-172, 1989) have recently found that the inhibitory effect of medroxyprogesterone acetate (MPA) on the growth of the human ZR-75-1 breast cancer cells is mainly due to the androgenic properties of the compound. The androgenic properties of MPA have been demonstrated in other systems (Labrie C. et al., J. Steroid Biochem. 28: 379-384, 1987; Luthy et al., J. Steroid Biochem. 31: 845-852, 1988; Plante et al., J. Steroid Biochem. 31: 61-64, 1988; Labrie C. et al., Mol. Cell. Endocrinol. 58: 169-179, 1990). Other synthetic progestins have also been shown to possess, in addition to their progesterone-like activity, various degrees of androgenic activity (Labrie et al., Fertil. Steril. 31: 29-34, 1979; Poyet and Labrie, The Prostate 9: 237-246, 1986; Labrie C. et al., J. Steroid Biochem. 28: 379-384, 1987; Luthy et al., J. Steroid Biochem. 31: 845-852, 1988; Plante et al., J. Steroid Biochem. 31: 61-64, 1989).
High dose MPA as first treatment of breast cancer has shown similar effects as Tamoxifen (Van Veelen et al., Cancer 58: 7-13, 1986). High dose progestins, especially medroxyprogesterone acetate and megestrol acetate have also been successfully used for the treatment of endometrial cancer (Tatman et al., Eur. J. Cancer Clin. Oncol. 25: 1619-1621, 1989; Podratz et al., Obstet. Gynecol. 66: 106-110, 1985; Ehrlich et al., Am. J. Obstet. Gynecol. 158: 797-807, 1988). High dose MPA is being used with a success similar to that of Tamoxifen for the treatment of endometrial carcinoma (Rendina et al., Europ. J. Obstet. Gynecol. Reprod. Biol. 17: 285-291, 1984).
In a randomized clinical trial, high dose MPA administered for 6 months has been shown to induce resolution of the disease in 50% of the patients and a partial resolution in 13% of subjects compared to 12% and 6%, respectively, in patients who received placebo (Telimaa et al., Gynecol. Endocrinol. 1: 13, 1987).
The androgen methyltestosterone has been shown to relieve the symptoms of endometriosis (Hamblen, South Med. J. 50: 743, 1987; Preston, Obstet, Gynecol. 2: 152, 1965). Androgenic and masculinizing side effects (sometimes irreversible) are however important with potent androgenic compounds such as testosterone.
In analogy with the androgen-induced decrease in estrogen receptors in human breast cancer ZR-75-1 cells (Poulin et al., Endocrinology 125: 392-399, 1989), oral administration of MPA to women during the follicular phase caused a decrease in the level of estrogen binding in the endometrium (Tseng and Gurpide, J. Clin. Endocrinol. Metab. 41, 402-404, 1975).
Studies in animals have shown that androgen deficiency leads to osteopenia while testosterone administration increases the overall quantity of bone (Silberberg and Silberberg, 1971; see Finkelstein et al., Ann. Int. Med. 106: 354-361, 1987). Orchiectomy in rats can cause osteoporosis detectable within 2 months (Winks and Felts, Calcif. Tissue Res. 32: 77-82, 1980; Verhas et al., California Tissue Res. 39: 74-77, 1986).
While hirsute oligomenorrheic and amenorrheic women having low circulating E 2 levels would be expected to have reduced bone mass, these women with high androgen (but low estrogen) levels are at reduced risk of developing osteoporosis (Dixon et al., Clinical Endocrinology 30: 271-277, 1989).
Adrenal androgen levels have been found to be reduced in osteoporosis (Nordin et al., J. Clin. Endocr. Metab. 60: 651, 1985). Moreover, elevated androgens in postmenopausal women have been shown to protect against accelerated bone loss (Deutsch et al., Int. J. Gynecol. Obstet. 25: 217-222, 1987; Aloia et al., Arch. Int. Med. 143: 1700-1704, 1983). In agreement with such a role of androgens, urinary levels of androgen metabolites are lower in postmenopausal symptomatic menopausis than in matched controls and a significant decrease in conjugated dehydroepiandrosterone (DHEA) was found in the plasma of osteoporotic patients (Hollo and Feher, Acta Med. Hung. 20: 133, 1964; Urist and Vincent, J. Clin. Orthop. 18: 199, 1961; Hollo et al., Acta Med. Hung. 27: 155, 1970). It has even been suggested that postmenopausal osteoporosis results from both hypoestrogenism and hypoandrogenism (Hollo et al., Lancet 1357, 1976).
As a mechanism for the above-suggested role of both estrogens and androgens in osteoporosis, the presence of estrogen (Komm et al., Science 241: 81-84, 1988; Eriksen et al., Science 241: 84-86, 1988) as well as androgen (Colvard et al., Proc. Natl. Acad. Sci. 86: 854-857, 1989) receptors in osteoblasts could explain increased bone resorption observed after estrogen and androgen depletion.
In boys, during normal puberty, an increase in serum testosterone levels procedes an increase in alkaline phosphate activity (marker of osteoblastic activity) which itself precedes increased bone density (Krabbe et al., Arch. Dis. Child. 54: 950-953, 1979; Krabbe et al., Arch. Pediat. Scand. 73: 750-755, 1984; Riis et al., California Tissue Res. 37: 213-217, 1985).
While, in women, there is a rapid bone loss starting at menopause, bone loss in males can be recognized at about 65 years of age (Riggs et al., J. Clin. Invest. 67: 328-335, 1987). A significant bone loss is seen in men at about 80 years of age, with the accompanying occurrence of hip, spine and wrist fractures. Several studies indicate that osteoporosis is a clinical manifestation of androgen deficiency in men (Baran et al., Calcif. Tissue Res. 26: 103-106, 1978; Odell and Swerdloff, West. J. Med. 124: 446-475, 1976; Smith and Walker, California Tissue Res. 22 (Suppl.): 225-228, 1976).
Although less frequent than in women osteoporosis can cause significant morbidity in men (Seeman et al., Am. J. Med. 75: 977-983, 1983). In fact, androgen deficiency is a major risk for spinal compression in men (Seeman et al., Am. J. Med. 75: 977-983, 1983). Decreased radial and spinal bone density accompanies hypogonadism associated with hyperprolactinemia (Greespan et al., Ann. Int. Med. 104: 777-782, 1986) or anaorexia nervosa (Rigotti et al., JAMA 256: 385-288, 1986). However, in these cases, the role of hyperprolactinemia and loss in body weight is uncertain.
Hypogonadism in the male is a well-recognized cause of osteoporotic fracture (Albright and Reinfenstein, 1948; Saville, Clin. End. Metab. 2: 177-185, 1973). Bone density is in fact reduced in both primary and secondary hypogonadism (Velentzas and Karras. Nouv. Presse Medicale 10: 2520, 1981).
Severe osteopenia as revealed by decreased cortical and trabecular bone density was reported in 23 hypogonadotropic hypogonadal men (Finkelstein et al., Ann. Int. Med. 106: 354-361, 1987; Foresta et al., Horm. Metab. Res. 15: 56-57, 1983). Osteopenia has also been reported in men with Klinefelter's syndrome (Foresta et al., Horm. Metab. Res. 15: 206-207, 1983; Foresta et al., Horm. Metab. Res. 15: 56-57, 1983; Smith and Walker, California Tissue Res. 22: 225-228, 1977).
Androgenic-reversible decreased sensitivity to calcitonin has been described in rats after castration (Ogata et al., Endocrinology 87: 421, 1970; Hollo et al., Lancet 1: 1205, 1971; Hollo et al., Lancet 1: 1357, 1976). In addition, serum calcitonin has been found to be reduced in hypogonadal men (Foresta et al., Horm. Metab. Res. 15: 206-207, 1983) and testosterone therapy in castrated rats increases the hypocalcemic effect of calcitonin (McDermatt and Kidd, End. Rev. 8: 377-390, 1987).
Albright and Ruferstein (1948) originally suggested that androgens increase the synthesis of bone matrix. Androgens have also been shown to increase osteoid synthesis and mineralization in chicken (Puche and Rosmano, California Tissue Res. 4: 39-47, 1969). Androgen therapy in hypogonadal men increases skeletal growth and maturation (Webster and Hogkins, Proc. Soc. Exp. Biol. Med. 45: 72-75, 1940). In addition, testosterone therapy in man has been shown to cause positive nitrogen, calcium and phosphate balance (Albright, F., Reifeinstein, E. C. In: The parathyroid glands and metabolic bone disease. Williams and Williams Co.: Baltimore, pp. 145-204, 1948). As studied by bone histomorphometry, testosterone therapy in hypogonadal males resulted in increases in relative osteoid volume, total osteoid surface, linear extend of bone formation and bone mineralization (Barau et al., Calcif. Tissue Res. 26: 103-106, 1978).
Treatment with testosterone has been shown to increase osteoid surfaces and beam width with unchanged or reduced oppositional rates, thus indicating and increase in total bone mineralization rate (Peacock et al., Bone 7: 261-268, 1986). There was also a decrease in plasma phosphate probably due to an effect on renal tubular reabsorption of phosphates (Selby et al., Clin. Sci. 69: 265-271, 1985).
Cortical bone density increases in hyperprolactinemic men with hypogonadism when testicular function is normalized (Greenspan et al., Ann. Int. Med. 104: 777-782, 1986; Greenspan et al., Ann. Int. Med. 110: 526-531, 1989). Testosterone therapy increases bone formation in men with primary hypogonadism (Baron et al., Calcif. Tissue Res. 26: 103-106, 1978; Frands et al., Bone 7: 261-268, 1986).
In 21 hypogonadal men with isolated GnRH deficiency, normalization of serum testosterone for more than 12 months increased bone density (Kinkelstein et al., J. Clin. Endocr. Metab. 69: 776-783, 1989). In men with already fused epiphyses, however, there was a significant increase in cortical bone density while no significant change was observed on trabecular bone density, thus supporting previous suggestions of variable sensitivity of cortical and trabecular bone to steroid therapy.
Previous studies with anabolic steroids in small numbers of patients have suggested positive effects on bone (Lafferty et al., Ann. J. Med. 36: 514-528, 1964; Riggs et al., J. Clin. Invest. 51: 2659-2663, 1972; Harrison et al., Metabolism 20: 1107-1118, 1971). More recently, using total body calcium measurements by neutron activation as parameter, the anabolic steroid methandrostenolone has shown positive and relatively long-term (24-26 months) effects in a doubleblind study in postmenopausal osteoporosis (Chessnut et al., Metabolism 26: 267-277, 1977; Aloia et al., Metabolism 30: 1076-1079, 1981).
The anabolic steroid nandrolone decanoate reduced bone resorption in osteoporotic women (Dequeker ancl Geusens, Acta Endocrinol. 271 (Suppl.): 45-52, 1985) in agreement with the results observed during estrogen therapy (Dequeker and Ferin, 1976, see Dequeker and Geusens). Such data confirm experimental data in rabbits and dogs when nandrolone decanoate reduced bone resorption (Ohem et al., Curr. Med. Res. Opin. 6: 606-613, 1980). Moreover, in osteoporotic women (Dequeker and Geusens, Acta Endocrinol. (Suppl.) 271: 45-52, 1985) the anabolic steroid not only reduced bone loss but also increased bone mass. Vitamin D treatment, on the other hand, only reduced bone resorption.
Therapy of postmenopausal women with nandrolone increased cortical bone mineral content (Clin. Orthop. 225: 273-277). Androgenic side effects, however, were recorded in 50% of patients. Such data are of interest since while most therapies are limited to an arrest of bone loss, an increased in bone mass was found with the use of the anabolic steroid nandrolone. A similar stimulation of bone formation by androgens has been suggested in a hypogonadal male (Baran et al., Calcif. Tissue Res. 26: 103, 1978). The problem with regimens which inhibit bone resorption with calcium, calcitriol or hormones is that they almost certainly lead to suppression of bone formation (Need et al., Mineral. Electrolyte Metabolism 11: 35, 1985). Although, Albright and Reiferestein (1948) (See Need, Clin. Orthop. 225: 273, 1987) suggested that osteoporosis is related to decreased bone formation and will respond to testosterone therapy, the virilizing effects of androgens have made them unsuitable for the treatment of postmenopausal women. Anabolic steroids, compounds having fewer virilizing effects, were subsequently developed. Although, minimal effects have been reported by some (WiIson and Griffin, Metabolism 28: 1278, 1980) more positive results have been reported (Chessnut et al., Metabolism 32: 571-580, 1983; Chessnut et al., Metabolism 26: 267, 1988; Dequeker and Geusens, Acta Endocrinol. (Suppl. 110) 271: 452, 1985). A randomized study in postmenopausal women has been shown an increase in total bone mass during treatment with the anabolic steroid stanazolol although side effects were recorded in the majority of patients (Chessnut et al., Metabolism 32: 571-580, 1983).
As mentioned above, the doses of "progestins" (for example medroxyprogesterone acetate) used for the standard therapy of breast cancer are accompanied by undesirable important side effects (especially those related to interaction of the steroid with the glucocorticoid receptor, especially Cushingoid syndrome, euphoria) (Mattsson, Breast Cancer Res. Treatm. 3: 231-235, 1983; Blossey et al., Cancer 54: 1208-1215, 1984; Hortobagyi et al., Breast Cancer Res. Treatm. 5: 321-326, 1985; Von Veelen et al., Cancer Chemother. Pharmacol. 15: 167-170, 1985).
The term "progestin" refers to derivatives of progesterone and testosterone. Such progestins have, at times, been synthesized with the aim of developing compounds acting as analogs of progesterone on the progesterone receptors, especially for the control of fertility. With the availability of new and more precise tests, however, it became evident that such compounds, originally made to interact exclusively with the progesterone receptor, do also interact, frequently with high affinity, with the androgen receptor (Labrie et al., Fertil. Steril. 28: 1104-1112, 1977; Labrie et al., Fertil. Steril. 31: 29-34, 1979; Labrie, C. et al., J. Steroid Biochem. 28: 379-384, 1987; Labrie C. et al., Mol. Cell. Endocrinol. 68: 169-179, 1990). Sometimes, the androgenic activity of these compounds, especially at low concentrations, becomes more important than the true progestin activity. This is the case, for example, for medroxyprogesterone acetate (Poulin et al., Breast Cancer Res. Treatm. 13: 161-172, 1989).
A problem with prior-art treatments of breast and endometrial cancer with synthetic progestins is the side effects observed with such treatments. The blockade of estrogens, another common treatment for breast cancer, would have undesirable deleterious effects on bone mass in women. Similarly, blockade of estrogens, a common treatment for endometriosis, has similar undesirable deleterious effects on bone mass in women.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for prevention and treatment of breast cancer, endometrial cancer, osteoporosis and endometriosis, while substantially avoiding undesirable side effects.
It is another object of the invention to provide a method for prevention of cancer having more specific effectiveness in delaying tumor growth.
It is another object of the invention to provide a method for prevention of breast and endometrial cancer having significantly reduced frequency of unwanted side effects.
It is another object of the invention to provide a method for prevention of bone loss in men and women having a reduced frequency of unwanted side effects.
It is another object of the invention to provide a method for prevention of bone loss in women where estrogen formation and/or action is blocked in order to treat various estrogen-sensitive diseases, including cancer.
It is another object of the invention to provide a method for prevention of bone loss in women already exposed to low estrogens following menopause.
It is a further object of the invention to provide kits and pharmaceutical compositions for use in the methods described herein.
These and other objects are achieved by practicing the methods disclosed herein and/or by utilizing the pharmaceutical compositions and kits disclosed herein.
In one embodiment, a method is provided for activating androgen receptors in a warm blooded animal, including a human, comprising administering to said animal at least one androgenic steroid having a Ki value of less than 2×10 -8 M for the androgen receptor, an androgen receptormediated inhibitory effect on the growth of human breast cancer ZR-75-1 cells which reaches half-maximal value at a concentration below 3.0 nanomoles per liter, and no visible masculinizing activity at blood serum concentrations below 50 nM, wherein every such androgenic steroid is administered at a dosage sufficiently low to maintain a cumulative serum concentration below 50 nanomoles per liter.
The methods of said androgenic steroid described herein are particularly useful for the treatment of human breast or endometrial cancer, osteoporosis or endometriosis. It is believed that the methods are also suitable for all purposes which are enhanced by administering androgens or otherwise activating androgen receptors. Both treatment and prevention of the diseases and disorders discussed herein are contemplated within the scope of the invention. It is believed that the methods of the invention are suitable for both prophylactic and therapeutic use.
The compounds utilized have the special property of possessing potent androgenic activity at low blood concentration (e.g. less than 50 nM) while exhibiting very little glucocorticoid receptor activity at those concentrations. They are also characterized by the absence of physical masculinizing activity in females at the concentration range at which they are used. This is to be distinguished from natural androgens produced in gonadal or peripheral tissues such as testosterone and dihydrotestosterone which exhibit considerable masculinizing activity even at low blood concentrations. Synthetic progestins, e.g. progesterone derivatives are useful for this invention, as are some anabolic steroids.
The androgens of the invention on average do not cause physically detectable increase in masculinizing effects such as increased hair growth in females, acne, seborrhea or hair loss. These masculinizing effects have been quantified in the literature. See, for example, Ferriman and Gallwey, J. P. Clin. Endocrinol. Metab. 21: 1440-1447, 1961 (regarding hair growth); Cremoncini et al., Acta. Eur. Fertil. 7: 248-314, 1976 (acne, seborrhea and hair loss). See also Cusan et al., J. Am. Acad. Dermatol. 23: 462-469, 1990. Tables 1 and 2 below set forth a quantification.
TABLE 1______________________________________Definition of hair grading at each of 11 sites(Grade 0 at all sites indicates absence of terminal hair)Site Grade Definition______________________________________ 1. Upper lip 1 A few hairs at outer margin 2 A small moustache at outer margin 3 A moustache extending halfway from outer margin 4 A moustache extending to mid-line 2. Chin 1 A few scattered hairs 2 Scattered hairs with small concentrations 3 & 4 Complete cover, light and heavy 3. Chest 1 Circumareolar hairs 2 With mid-line hair in addition 3 Fusion of these areas, with three- quarter cover 4 Complete cover 4. Upper back 1 A few scattered hairs 2 Rather more, still scattered 3 & 4 Complete cover, light and heavy 5. Lower back 1 A sacral tuft of hair 2 With some lateral extension 3 Three-quarter cover 4 Complete cover 6. Upper 1 A few mid-line hairsabdomen 2 Rather more, still mid-line 3 & 4 Half and full cover 7. Lower 1 A few mid-line hairsabdomen 2 A mid-line streak of hair 3 A mid-line band of hair 4 An inverted V-shaped growth 8. Arm 1 Sparse growth affecting not more than a quarter of the limb surface 2 More than this; cover still incomplete 3 & 4 Complete cover, light and heavy 9. Forearm 1, 2, 3, 4 Complete cover of dorsal surface; 2 grades of light and 2 of heavy growth10. Thigh 1, 2, 3, 4 As for arm11. Leg 1, 2, 3, 4 As for arm______________________________________
TABLE 2______________________________________Grading of Acne, Seborrhea and Hair Loss______________________________________Acne1. Isolated pustules, up to 10 in number2. More than 10 isolated pustules3. Clusters of pustules4. Confluent pustulesSeborrhea1. Mild2. Moderate3. SevereHair Loss1. Mild2. Obvious thinning3. Very obvious thinning4. Baldness______________________________________
Preferred compounds for use in the invention include synthetic progestins, anabolic steroids and other steroidal compounds having a Ki value of less than 2×10 -8 M for the androgen receptor, an androgen receptormediated inhibitory effect on the growth of human breast cancer ZR-75-1 cells reaching half-maximal value at a concentration below 3.0 nanomoles per liter, and lacking the masculinizing activity discussed above. Preferred androgens of the invention would cause no significant increase in the average masculinizing effect (e.g. a significant increase in any of the numerical grades set forth in Tables 1 or 2 above) observed in females following treatment for three months with blood concentrations of the androgen maintained at the top of the claimed concentration range (e.g. 50 nanomoles per liter). For most female patients for whom no masculinizing effects were visible prior to treatment, or a total score of 10 or less for all 11 sites indicated in Table 1 prior to treatment, the same score would normally be maintained during treatment in accordance with the present invention. That is, there would be no visible masculinizing effects after three months of treatment. For female patients displaying some masculinizing effects prior to treatment, it would be expected that those effects would not be increased by treatment.
To determine whether the Ki values are below 2×10 -8 M, Ki values may be determined by the following method for measuring the affinity of various compounds for the androgen receptor.
Preparation of Prostatic Tissue
Ventral prostates are from Sprague-Dawley rats (Crl:CD(SD)Br) (obtained from Charles River, St-Constant, Quebec) weighing 200-250 g and castrated 24 h before sacrifice. Immediately after removal, prostates are kept on ice and used for the androgen binding assays.
Preparation of Cytosol
Prostatic tissues are finely minced with scissors (fresh tissue) or pulverized with a Thermovac system (frozen tissue) before homogenization in buffer A (Tris, 0.025M; monothioglycerol, 20 mM; glycerol, 10% (v/v); EDTA, 1.5 mM and sodium molybdate, 10 mM, pH 7.4) in a 1:5 ratio (w/v) using a Polytron PT-10 homogenizer. These and all the following procedures are performed at 0°-4° C. The homogenate is centrifuged at 105000×g for 1 h in order to obtain the cytosolic fraction in the supernatant.
Cytosolic Androgen Receptor Assay
Aliquots of 100 μl are incubated at 0°-4° C. for 18 h with 100 μl of 3 nM [ 3 H] T or [ 3 H] R1881 in the presence or absence of increasing concentrations of the non-labeled androgenic compound to be tested. At the end of the incubation, free and bound T or R1881 are separated by the addition of 200 μl dextran-coated charcoal (1% charcoal, 0.1% dextran T-70, 0.1% gelatin, 1.5 mM EDTA and 50 mM Tris (pH 7.4)) for 15 min before centrifugation at 2300×g for another 15 min at 0°-4° C. Aliquots (350 μl) of the supernatant are transferred to scintillation vials with 10 ml of an aqueous counting solution (Formula 963, New England Nuclear) before counting in a Beckman LS 330 counter (30% efficiency for tritium).
Ki Calculation
Apparent inhibition constant "Ki" values are calculated according to the equation Ki=IC 50 /(1+S/K) (Cheng and Prusoff, Biochem. Pharmacol. 22: 3099-3108, 1973). In this equation, S represents the concentration of [ 3 H]T or [ 3 H]R1881, K is the dissociation constant (KD) of T or R1881 and IC 50 is the concentration of unlabeled compounds giving a 50% inhibition of T or R1881 binding. For numerous compounds, Ki values are reported in the literature. See, for example, Ojasso et al., J. Ster. Biochem. 27: 255-269, 1987; Asselin et al., Cancer Res. 40: 1612-1622, 1980; Toth and Zakar J. Steroid Biochem. 17: 653-660, 1982. A method giving similar results is described in Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988.
In order to determine the concentration at which a given compound reaches half-maximal androgen receptor-mediated inhibitory effect on the growth of human breast cancer ZR-75-1 cells, the following technique is utilized as described in detail in Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988.
Maintenance of Stock Cultures
The ZR-75-1 human breast cancer cell line can be obtained from the American Type Culture Collection (Rockville, Md.). The cells are routinely cultured in phenol red-free RPMI 1640 medium supplemented with 10 mM E 2 , 15 mM Hepes, 2 mM L-glutamine, 1 mM sodium pyruvate, 100 IU penicillin per ml, 100 μg streptomycin sulfate per ml, and 10% (v/v) fetal bovine serum (FBS), in a water-saturated atmosphere of 95% air: 5% CO 2 at 37° C.
Stock cultures in their logarithmic growth phase are harvested with 0.05% trypsin/0.02% EDTA (w/v) in Hanks' balanced salts solution and resuspended in E 2 - and phenol red-free RPMI 1640 medium containing 5% (v/v) dextrancoated charcoal (DCC)-treated FBS and 500 ng of bovine insulin per ml, but otherwise supplemented as described above for maintenance of stock cultures. Cells were plated in 24-well Linbro culture plates (Flow Laboratories) at a final density of 0.5-4.0×10 4 cells/well.
Fourty-eight hours after plating, fresh SD medium containing the appropriate concentrations of steroids are added. The final concentration of ethanol used for the addition of test substances does not exceed 0.12% (v/v) and has no significant effect on cell growth and morphology. The incubation media are replaced every other day and cells are harvested by trypsinization after 12 days of treatment, unless otherwise indicated. Cell number can be determined with a Coulter Counter.
Calculations and Statistical Analyses
Apparent IC 50 values are calculated using an iterative least squares regression (Rodbard, Endocrinology 94: 1427-1437, 1974), while apparent inhibition constants (Ki values) are calculated according to Cheng and Prusoff (Biochem. Pharmacol. 22: 3099-3108, 1973).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a comparative graph over time of the number of tumors observed in a group of rats protected by a method in accordance with the invention following administration of dimethylbenz(a)anthracene (DMBA) versus an unprotected control group.
FIG. 2 is a comparative graph of estradiol-stimulated growth of tumors in ovariectomized rats treated in accordance with the invention versus an untreated control group.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A better understanding of the multiple endocrine activity of synthetic progestins is required not only for their more rational use in the prevention and therapy of breast and endometrial cancers as well as endometriois and bone loss but also to avoid side effects caused by interaction with steroid receptors unnecessary for the desired beneficial effect.
Precise analysis of the biological actions of synthetic "progestins" having affinity for many steroidal receptors would ideally require the selection of in vitro models possessing functional receptors for all major classes of steroids. For this purpose, we have chosen the ZR-75-1 human breast cancer cell line, which possesses functional receptors for estrogens, androgens, progesterone and glucocorticoids (Vignon et al., J. Clin. Endocrinol. Metab. 56: 1124-1130, 1983) in order to compare the relative contribution of the different steroid receptor systems in the control of cell proliferation by synthetic progestins. While estrogens are strongly mitogenic in ZR-75-1 cells (Poulin and Labrie, Cancer Res. 46: 4933-4937, 1986) and specifically regulate the expression and/or the secretion of several proteins (Dickson and Lippman, Endocr. Rev. 8: 29-43, 1987), androgens (Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988), as well as progestins (Poulin et al., Breast Cancer Res. Treatm. 13: 161-172, 1989) inhibit their proliferation through specific interactions with their respective receptors.
Many progestins have been used in the treatment of breast cancer, including MPA (Blossey et al., Cancer 54: 1208-1215, 1984; Hortobayyi et al., Breast Cancer Res. Treatm. 5: 321-326, 1985), MGA (Johnson et al., Semin. Oncol. 13 (Suppl.): 15-19, 1986; Tchekmedyan et al., Semin. Oncol. 13 (Suppl.): 20-25, 1986) and norethindrone (Clavel et al., Eur. J. Cancer Clin. Oncol. 18: 821-826, 1982; Earl et al., Clin. Oncol. 10: 103-109, 1984). Using the in vitro system of human breast cancer ZR-75-1 cells, I have found that the synthetic progestins or anabolic steroids, Nor-testosterone, R1881, dromostanolone, fluoxymesterone, ethisterone, methandrostanolone, oxandrolone, danazol, stanozolol, calusterone, oxymetholone, cyproterone acetate, chlormadinone acetate and norgestrel, possess androgenic activity at low concentrations. In addition to inhibition of cell growth, the secretion of two glycoproteins, namely gross cystic disease fluid protein-15 (GCDFP-15) and GCDFP-24 is markedly stimulated by androgens (Simard et al., Mol. Endocrinol. 3: 694-702, 1989; Simard et al., Endocrinology 126: 3223-3231, 1990). Measurements of GCDFP-25 or GCDFP-24 secretion can thus be used as sensitive parameter or marker of androgen action in these cells. In fact, changes in GCDFP- 15 and GCDFP-24 secretion are opposite to the changes in cell growth under all experimental conditions examined. All the synthetic progestins or anabolic steroids that I have studied exhibit androgenic activity on ZR-75-1 breast cancer growth and secretion of GCDFP-15 and GCDFP-24.
Identification of the receptors (estrogen, androgen, progesterone and glucocorticoid) responsible for the action of the compounds is essential in order to assess the potential actions (including adverse effects) of such compounds. It is thus especially important to assess the specific interaction at low concentrations with the androgen receptor since such low concentrations do not interact with the glucocorticoid receptor, thus avoiding or minimizing secondary side effects.
One method for inhibiting growth of breast and endometrial cells is activation of the androgen receptor with an effective compound having an affinity for the receptor site such that is binds to the androgen receptor at low concentrations while not significantly activating other classes of steroid receptors linked to potential side effects. It is important to select compounds having maximal affinity for the androgen receptor which have minimal or no virilizing effects in women. In order to minimize interaction of such compounds with the glucocorticoid and estrogen receptors, it is important to use low dose of the compounds. It is also important to choose steroids having androgenic activity at low concentrations which are not metabolized into estrogens under in vivo conditions which, at the low concentrations used, will not lead to significant activation of receptors other than the androgen receptors.
My research has shown that the compounds used in the invention, particularly anabolic steroids and synthetic progestins, vary markedly, over different concentrations, in their ability to activate different classes of steroidal receptors. Hence, by carefully controlling concentration, it is possible to selectively cause activation of desired receptors while not causing significant activation of undesired receptors. For example, at the low concentrations specified herein, MPA can be utilized to desirably activate androgen receptors while substantially avoiding side effects associated with glucocorticoid activation which have plagued prior art treatments.
Thus, this invention provides a novel method for prevention and therapy of breast and endometrial cancer as well as other diseases responsive to activation of the androgen receptor, e.g. bone loss and endometriosis. In this invention, the amount of the androgenic compounds administered is much lower than previously used in art for the treatment of breast and endometrial cancer.
Monitoring Blood Concentration of Androgens of the Invention
To help in determining the potential effects of the treatment, blood concentrations of the compound can be measured. For example, measurements of plasma medroxyprogesterone acetate (MPA) levels can be made by radioimmunoassay following extraction as follows:
Antibody Preparation
Antibody 144A was raised in rabbits against 17-hydroxyprogesterone-3-0-carboxymethyloxime-BSA. The labeled steroid used in the radioimmunoassay (RIA) was methyl-17α-hydroxyprogesterone acetate, 6α-[1,2- 3 H(N)]- obtained from NEN (CAT NO: NET 480) while the reference preparation was medroxyprogesterone acetate (MPA) obtained from Steraloids. The assay buffer used was 0.1% gelatin in 0.1M sodium phosphate, 0.15M sodium chloride, 0.1% sodium azide, pH 7.2. The extraction solvent mixture was ethyl etheracetone (9:1, v:v) [EEA] while the LH-20 chromatography solvent mixture was iso-octane: toluene: methanol (90:5:5;v:v:v) [IOTH].
Extraction Procedure
One ml of plasma was extracted twice with 5 ml of EEA. The extracts were evaporated to dryness with nitrogen and the remaining residue was dissolved in one ml of IOTH. The extracts were then subjected to LH-20 chromatography on 10×30 cm columns (Corning CAT NO: 05 722A) filled with 2 g of LH-20 (Pharmacia). The gel was washed with 30 ml of IOTH before addition of one ml of sample and elution with IOTH. The first 6 ml were discarded. The following 10, 16.5 and 27.5 ml of eluent were fraction I (progesterone), II (MPA) and III (17-LH-progesterone), respectively. Fraction II was evaporated to dryness and reconstituted in 1.5 ml of assay buffer.
Radioimmunoassay
To each 12×75 mm borosilicate test tube was added: 0.2 ml containing 25,000 DPM of tritiated steroid, 0.5 ml of reference preparation ranging from 5 to 5000 pg/tube or 0.5 ml of extracted sample fraction II, 0.2 ml of antiserum 144A diluted 1/5000 or 0.2 ml of assay buffer to account for non specific binding. The tubes were then incubated overnight at 4° C. Then, 0.2 ml 2% charcoal Norit-A, 0.2% Dextran T-70 diluted in water was added. The tubes were then shaken gently and, after 10 min, they were centrifuged at 2000×g for 10 min. The supernatant was mixed with 8 ml of Formula-989 (NEN: NEF-989) and the radioactivity was counted in a β-counter.
The lower and upper limits of detection of MPA are 10 and 10000 pg/ml, respectively, while the slope (LOGIT-LOG) is -2.2 and the ED 50 value is 315 pg/ml. Non-specific and net binding are 1.5 and 45%, respectively. Antibody 144A is highly specific for MPA since cross-reactivity with progesterone, 20α-OH-Prog, pregnenolone, 17-OH-pregnenolone, DHT, androstenedione, testosterone, 3α-diol, estrone, estradiol and cortisol is less than 0.1%.
Calculations and Statistics
RIA data were analyzed using a program based on model II of Roadbard and Lewald (In: 2nd Karolinska Symposium, Geneva, 1970, pp. 79-103). Plasma MPA levels are usually shown as the means ±SEM (standard error of the mean) of duplicate measurements of individual samples. Statistical significance is measured according to the multiple-range test of Duncan-Kramer (Kramer, C. Y., Biometrics 12: 307-310, 1956).
A Test Compound's Relative Effect On Various Receptors
To assist in determining the activity of the potential compounds on the various steroid receptors, androgen, glucocorticoid, progesterone and estrogen-receptor-mediated activities of synthetic progestins and anabolic steroids can be measured in ZR-75-1 human breast cancer cells using cell growth as well as GCDFP-15 and GCDFP-24 release as parameters of response (Poulin and Labrie, Cancer Res. 46: 4933-4937, 1986; Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988; Poulin et al., Breast Cancer Res. Treatm. 13: 161-172, 1989; Poulin et al., Breast Cancer Res. Treatm. 13: 265-276, 1989; Simard et al., Mol. Endocrinol. 3: 694-702, 1989; Simard et al., Endocrinology 126: 3223-3231, 1990).
The following properties permit measurement of progesterone receptor (PgR) activity: 1) the addition of insulin completely reverses the inhibition due to the interaction of the progestin R5020 with the PgR in ZR-75-1 cells; and 2) the antiproliferative effect of R5020 is observed only under EH 1 -stimulated conditions. These two characteristics of ZR-75-1 cell growth permit study of the extent to which a tested compound's effects on ZR-75-1 cells are attributated to its interaction with PgR by evaluating the effect of insulin and/or estrogen addition on the growth response measured at the end of a 15-day incubation of ZR-75-1 cells with the test compounds.
The contribution of the estrogen receptor (ER), on the other hand, can be directly measured by incubating ZR-75-1 cells in the presence or absence of estrogen in the medium.
In order to analyze the interactions of synthetic progestins or anabolic steroids with the androgen receptor (AR) and glucocorticoid receptor (GR) in their inhibitory action on cell growth, one takes advantage of the additivity of the anti-proliferative effects of androgens and glucocorticoids in this cell line (Poulin et al., Breast Cancer Res. Treatm. 12: 213-225, 1988. Thus, one can saturate AR with 5α-dihydrotestosterone (DHT) and then measure the effect on cell proliferation resulting from the addition of a putative glucocorticoid. On the other hand, the effect of a putative androgen can similarly be measured following saturation of GR by dexamethasone (DEX). The specificity of the growth-inhibitory activity thus observed with the test compound can also be further assessed by its reversibility using the appropriate antagonist (i.e. antiglucocorticoid or antiandrogen). Thus, in the presence of excess androgen (1 μM DHT) in the presence of E 2 and insulin, glucocorticoid effects can be assessed with precision and with no interference by the other receptors. The same applies to study of the role of AR when the cells are incubated in the presence of excess glucocorticoid (3 μM DEX), in the presence of E 2 and insulin. As demonstrated by detailed kinetic studies, 1 μM DHT and 3 μM DEX exert maximal inhibitory effects on the AR and GR, respectively.
In addition, the possible antagonistic activities of "progestins" mediated through the AR and GR can be determined by saturating both receptor systems with DHT and DEX with one ligand being in far greater excess than the other in order to allow reversal through a single chosen receptor at a time. All experiments are performed with ZR-75-1 cells grown in E 2 -supplemented media containing insulin in order to prevent the PgR-mediated effect of "progestins" on cell growth.
Using the foregoing techniques, I have found that numerous androgenic compounds which also activate other receptors (e.g. glucocorticoid or progesterone receptors) vary in their relative effects on different receptors as a function of concentration. By staying within concentration ranges defined herein, compounds of the invention may beneficially affect androgen receptors without substantial undesirable effects on other receptors.
Selection of Patients Who May Benefit From the Method's Described Herein
The appearance of breast cancer is usually detected by self breast examination and/or mammography. Endometrial cancer, on the other hand, is usually diagnosed by endometrial biopsy. Both cancers can be diagnosed and evaluated by standard physical methods well known to those skilled in the art, e.g. bone scan, chest X-Ray, skeletal survey, ultrasonography of the liver and liver scan (if needed), CAT scan, MRI and physical examination. Endometriosis can be diagnosed following pains or symptoms associated with menstruations in women while definitive diagnosis can be obtained by laparascopy and, sometimes, biopsy.
Bone density, on the other hand, can be measured by standard methods well known to those skilled in the art, e.g. QDR (Quantitative Digital Radiography), dual photon absorptiometry and computerized tomography. Plasma and urinary calcium and phosphate levels, plasma alkaline phosphatase, calcitonin and parathormone concentrations, as well as urinary hydroxyproline and calcium/creatinine ratios.
Breast or endometrial cancer, osteoporosis or otherwise insufficient bone mass, and other diseases treatable by activating androgen receptor may be treated in accordance with the present invention or prophylactically prevented in accordance herewith.
Typically suitable androgenic compounds include 6-alpha-methyl,17-alpha-acetoxy progesterone or medroxyprogesterone acetate available, for exemple, from Upjohn and Farmitalia Carlo Erba, S.p.A. under the trade names Provera, DepoProvera or Farlutal, and the acronym MPA.
Other suitable androgenic compounds include those described in Labrie et al. (Fertil. Steril. 31: 29-34, 1979) as well as anabolic steroids or progestins (Raynaud and Ojasso, In: Innovative Approaches in Drug Research, Elsevier Sci. Publishers, Amsterdam, pp. 47-72, 1986; Sandberg and Kirdoni, Pharmac. Ther. 36: 263-307, 1988; and Vincens, Simard and De Lignieres, Les Androgenes. In: Pharmacologie Clinique, Base de Therapeutique, 2ieme Edition, Expansion Scientifique (Paris), pp. 2139-2158, 1988), as well as Calusterone (7β,17α-dimethyltestosterone), anabolic steroids (Lam, Am. J. Sports Medicine 12, 31-38, 1984; Hilf, R., Anabolic-androgenic steroids and experimental tumors. In: (Kochachian, C. D., eds.), Handbook of Experimental Pharmacology, vol. 43, Anabolic-Androgenic Steroids, Springer-Verlag, Berlin, 725 pp, 1976), fluoxymesterone (9α-fluoro-11β-hydroxy-17α-methyltestosterone), testosterone 17β-cypionate, 17α-methyltestosterone, Pantestone (testosterone undecanoate), Δ 1 -testololactone and Andractim.
Other typical suitable androgenic compounds are cyproterone acetate (Androcur) available from Shering AG, 6-alpha-methyl, 17-alpha-acetoxy progesterone or medroxyprogesterone acetate (MPA) available from, among others, Upjohn and Farmitalia, Calbo ERba, Gestodene available from Shering, megestrol acetate (17α-acetoxy-6-methyl-pregna-4,6-diene-3,20-dione) available from Mead Johnson & Co., Evanswille, Ind., under the trade name of Megace. Other synthetic progestins include Levonorgestrel, Norgestimate, desogestrel, 3-ketodesogestrel, norethindrone, norethisterone, 13α-ethyl-17-hydroxy-18,19-dinor-17β-pregna-4,9,11-triene-20-yn-3-one (R2323, gestrinone), demegestone, norgestrienone, gastrinone and others described in Raynaud and Ojasso, J. Steroid Biochem. 25: 811-833, 1986; Raynaud et al., J. Steroid Biochem. 25: 811-833, 1986; Raynaud et al., J. Steroid Biochem. 12: 143-157, 1980; Raynaud, Ojasoo and Labrie, Steroid Hormones, Agonists and Antagonists, In: Mechanisms of Steroid Action (G. P. Lewis and M. Ginsburg, eds), McMillan Press, London pp. 145-158 (1981). Any other progestin derivative having the above-described characteristics could also be useful for the invention.
The androgenic compound is preferably administered as a pharmaceutical composition via topical, parenteral or oral means. The compound can be administered parenterally, i.e. intramuscularly or subcutaneously by injection of infusion by nasal drops, by suppository, or where applicable intravaginally or transdermally using a gel, a patch or other suitable means. The androgenic compound may also be microencapsulated in or attached to a biocompatible, biodegradable polymer, e.g. poly(d1,1-lactide-co-glycolide) and subcutaneously or intramuscularly injected by a technique called subcutaneous or intramuscular depot to provide continuous, slow release of the compound over a period of 30 days or longer. In addition to the oral route, a preferred route of administration of the compound is subcutaneous depot injection. DepoProvera can be released at a relatively constant rate for approximately 3 months after intramuscular administration of an aqueous suppression.
The amount of each compound administered is determined by the attending clinician taking into consideration the patient's condition and age, the potency of each component and other factors. In the prevention of breast and endometrial cancer, as well as bone loss, according to this invention, the following dosage ranges are suitable.
The androgenic composition is preferably administered in a daily dosage which delivers less than 25 mg of active androgenic steroid per 50 kg of body weight.
A dosage of 1-10 mg per 50 kg of body weight, especially 3-7 mg (e.g. 5 mg) is preferred. The dosage selected preferably maintains serum concentration below 50 nanomoles per liter, preferably between 1.0 nanomoles per liter and 10, 15 or 25 nanomoles per liter depending on patient's response. The dosage needed to maintain these levels may vary from patient to patient. It is advisable for the attending clinicial to monitor levels by the techniques described herein and optimize dosage accordingly. For prophylactic purposes, administration of the androgen is preferably started in the perimenopausal period for the prevention of breast and endometrial cancer and bone loss in normal women. The androgen may be associated with an accepted dose of an estrogen used to prevent other signs and symptoms of menopause. In women, when estrogen formation and/or action has been blocked for treatment of endometriosis, leiomyomata, breast cancer, uterine cancer, ovarian cancer or other estrogen-sensitive disease, administration of the androgen can be started at any time, preferably at the same time as blockade of estrogens.
The androgen for intramuscular or subcutaneous depot injection may be microencapsulated in a biocompatible, biodegradable polymer, e.g., poly(d,1-lactide-co-glycolide) by, among other techniques, a phase separation process or formed into a pellet or rod. The microspheres may then be suspended in a carrier to provide an injectable preparation or the depot may be injected in the form of a pellet or rod. See also European patent application EPA No. 58,481 published Aug. 25, 1982 for solid compositions for subdermal injection or implantation or liquid formulations for intramuscular or subcutaneous injections containing biocompatible, biodegradable polymers such as lactideglycolide copolymer and active compounds. These formulations permit controlled release of the compound.
The androgens useful in the present invention can be typically formulated with conventional pharmaceutical excipients, e.g., spray dried lactose and magnesium stearate into tablets or capsules for oral administration.
The active substance can be worked into tablets or dragee cores by being mixed with solid, pulverulent carrier substances, such as sodium citrate, calcium carbonate or dicalcium phosphate, and binders such as polyvinyl pyrrolidone, gelatin or cellulose derivatives, possibly by adding also lubricants such as magnesium stearate, sodium lauryl sulfate, "Carbowax" or polyethylene glycol. Of course, taste-improving substances can be added in the case of oral administration forms.
As further forms, one can use plug capsules, e.g., of hard gelatin, as well as closed soft-gelatin capsules comprising a softener or plasticizer, e.g. glycerine. The plus capsules contain the active substance preferably in the form of granulate, e.g., in mixture with fillers, such as lactose, saccharose, mannitol, starches, such as potato starch or amylopectin, cellulose derivatives or highly dispersed silicic acids. In soft-gelatin capsules, the active substance is preferably dissolved or suspended in suitable liquids, such as vegetable oils or liquid polyethylene glycols.
In place of oral administration, the active compound may be administered parenterally. In such case, one can use a solution of the active substance, e.g., in sesame oil or olive oil. The active substance can be microencapsulated in or attached to a biocompatible, biodegradable polymer, e.g. poly(d,1-lactide-coglycolide) and subcutaneously or intramuscularly injected by a technique called subcutaneous or intramuscular depot to provide continuous slow release of the compound(s) for a period of 2 weeks or longer.
The invention also includes kits or single packages containing the pharmaceutical composition active ingredients or means for administering the same for use in the prevention and treatment of breast and endometrial cancer as well as bone loss and treatment of endometriosis as discussed above. The kits or packages may also contain instructions on how to use the pharmaceutical compositions in accordance with the present invention.
Following the above therapy using the described regimen, tumor growth of breast and endometrial cancer as well as bone loss and endometriosis can be relieved while minimizing adverse side effects. The use of the described regimen can also prevent appearance of the same diseases.
EXAMPLE 1
Prevention of Mammary Carcinoma Induced by Dimethylbenz(a)anthracene (DMBA) in the Rat, By Low Dose Medroxyprogesterone Acetete ("MPA").
To illustrate the efficacy of the present invention in reducing the incidence of mammary carcinoma, FIG. 1 illustrates the effect of a single subcutaneous injection of Depo-Provera (Medroxyprogesterone Acetate (MPA) (30 mg)) one week before inducing carcinoma with dimethylbenz(a)anthracene. FIG. 1 shows the period from 30 to 85 days following administration of DMBA. One curve in FIG. 1 shows the average number of tumors per animal in the group protected by Depo-Provera while the other curve shows the average number of tumors per animal in the unprotected group. It is estimated that the 30 mg. injection of Depo-Provera would release approximately 0.17 mg. of active medroxyprogesterone acetate per day over a six-month period. As may be seen by comparing the two graphs in FIG. 1, the Depo-Provera-treated group showed much greater resistance to the development of tumors than did the unprotected group. After 85 days an average of 1.89 tumors per rat was observed in the unprotected group, while only 0.30 tumor per rat was observed in the Depo-Provera protected group. Tumor number and size measured with calipers were determined weekly.
EXAMPLE 2
Treatment of Mammary Carcinoma Induced By Dimethylbenz(a)anthracene in the Rat, By Low Dose Medroxyprogesterone Acetate.
FIG. 2 illustrates the inhibition of mammary carcinoma growth which may be achieved in accordance with the methods of the invention. Tumors were induced in ovariectomized rats using dimethylbenz(a)anthracene. Estradiol was used to stimulate growth in both a treatment and control group of rats. Each animal in the treatment group received a single subcutaneous administration of 30 mg of Depo-Provera (which is estimated to release approximately 0.17 mg. per day of active medroxyprogesterone acetate for a period of about six months). This figure illustrates the average estradiolstimulated change in total tumor area in each group following treatment. As may be seen in FIG. 2, the group treated with Depo-Provera exhibited significantly less tumor growth than the untreated group.
The terms and descriptions used herein are preferred embodiments set forth by way of illustration only, and are not intended as limitations on the many variations which those of skill in the art will recognize to be possible in practicing the present invention as defined by patent claims based thereon. | A method of treatment or prevention of breast and endometrial cancer, osteoporosis and endometriosis in susceptible warm-blooded animals comprising administering a low dose of a progestin or other steroid derivative having androgenic activity and low masculinizing activity. Pharmaceutical compositions useful for such treatment and pharmaceutical kits containing such compositions are disclosed. An in vitro assay permitting specific measurements of androgenic activity of potentially useful compounds is also disclosed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an additive block which may be coupled to a circuit breaker.
2. Description of the Prior Art
Such additive blocks are generally used as residual differential current protective devices, shunt releases or trips, voltage minima trips or trips of any other kind capable of causing opening of the circuit breaker from a given signal. They may also be used as auxiliary signalling devices signalling on the spot or at a distance tripping of the circuit breaker.
As is known, a circuit breaker generally comprises at least two separable contacts and a tripping mechanism comprising a storage spring and a tripping shaft, this mechanism being controlled to separate the contacts by a thermal release and/or a magnetic release capable of acting more especially in the case of a short circuit or an over current; it also comprises a manual or motorized means for resetting the tripping mechanism.
In known additive tripping blocks, the trip generally comprises a release electromagnet and a mechanical energy storage spring held under tension by a catch mechanism; the release electromagnet only therefore requires low power for releasing the mechanism. The mechanical energy released causes breaking of the circuit by acting on the release shaft of the circuit breaker through an appropriate connection mechanism. After each tripping operation, it is again obviously necessary to reset the catch mechanism of the additive block manually for example by means of a lever.
The circuit breaker and the additive block have a means accessible from the outside and allowing mechanical transmission of the tripping action, either in the additive block-circuit breaker direction with a trip addition or in the circuit breaker-additive block direction with a signalling addition.
Known embodiments of such additive blocks therefore require resetting which is either independent or dependent on resetting of the circuit breaker.
In the first case, it is necessary to design a free tripping mechanism independent of the resetting lever of the additive block so as not to temporarily cancel out the action of the trip during this operation when the circuit breaker has been previously reengaged. This design has the drawback of leading to an expensive construction.
In the second case, the distinction between a contact opening action caused by the tripping additive block and such an action proper to the circuit breaker is not correctly displayed for the user. Correlatively, this solution excludes the use of circuit breakers with automatic reset which would have the disadvantage of not allowing the user to question himself about the causes of the fault detected by the additive block.
The purpose of the present invention is more especially to overcome the above-mentioned drawbacks of known apparatus by creating an additive block which may be coupled to a circuit breaker and which only allows the circuit breaker to be reset by a conscious and voluntary action on the part of the user.
SUMMARY OF THE INVENTION
According to the invention, in an additive block for a circuit breaker of the type described comprising in a case an auxiliary tripping and/or signalling member, and a connecting mechanism with, on the one hand, the mechanism for tripping the circuit breaker and, on the other hand, the auxiliary member for communicating a control movement to the first one in response to tripping of the second or vice versa, as well as a manual resetting member able to cooperate with the connecting mechanism for returning to its original position the active part of said mechanism associated with the auxiliary member after tripping of the circuit breaker; the connecting mechanism has a locking piece capable of assuming a first position and a second position corresponding respectively to engagement and disengagement of the circuit breaker, the locking piece cooperating in its first position with a manual resetting member for preventing manual actuation thereof and being retracted in its second position so as to allow actuation of a resetting member.
Inhibition of the manual resetting member, as long as the circuit breaker is engaged, is therefore provided using very simple mechanical means provided by the additive block of the invention in interdependence with the circuit breaker.
Preferably, the manual resetting member and the locking piece have stop means cooperating in the second position of this piece during manual actuation of the member so as to prevent temporarily resetting of the circuit breaker.
This simple arrangement provides a veritable interlocking between the resetting members of the circuit breaker and the additive block and increases the safety during use of the additive block-circuit breaker pair, since it compels the user first of all to reset the additive block which caused or signalled tripping of the circuit breaker and to question himself about the causes of the fault and to remedy them if necessary. The utility of this priority attributed to resetting of the additive block is evident when an automatic reset circuit breaker is used.
When the auxiliary member is a tripping member, the connection mechanism may comprise a pivotable transmitting lever urged by spring and supporting an indicating element; this lever is coupled to the tripping mechanism of the circuit breaker and cooperates through catch elements with a pivoting lever intermediate between said transmitting lever and the auxiliary member; the transmitting lever and the intermediate lever may have associated bearing elements for causing return of the intermediate lever at the end of the tripping stroke and pushing back with, if required, resetting of the auxiliary member. When this latter is a relay biased by a permanent magnet, its magnet circuit can thus be readily closed again.
When the auxiliary member is a signalling member, the connection mechanism may comprise a receiving lever supporting an indicator element and coupled to the tripping mechanism of the circuit breaker and operable by this mechanism, and cooperating by means of catch elements with an intermediate pivoting lever between said receiving lever and the auxiliary member.
The additive block may advantageously comprise a single spring urging, on the one hand, the transmitting or receiving lever and, on the other hand, the manual resetting member and, if included, a differential current test push-button.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be clear from the following description with reference to the accompanying drawings in which:
FIG. 1 shows a schematical side view in section of a first embodiment of a tripping additive block in accordance with the invention in the set position,
FIGS. 2 and 3 are similar views showing the additive block in its respective tripped and reset positions,
FIG. 4 shows in schematical cross section a second embodiment of a tripping additive block according to the invention in the set position,
FIG. 5 shows similarly a third embodiment of a tripping additive block,
FIGS. 6, 7 and 8 show a fourth embodiment of an additive block according to the invention with signalling function in the respective set, signalling and reset positions, and
FIGS. 9 and 10 show very schematically one method of mounting the additive blocks of FIGS. 1 to 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The additive block 10 of FIGS. 1 to 3, comprises in a molded casing 11 an auxiliary tripping member 12 having a push or pull piece 13, this piece being in the present case formed by a pusher and acting in the direction of arrow F in response to a voltage or current signal, for example a differential current appearing at the terminals of the auxiliary member 12 connected to the main circuit of the circuit breaker through conductors 14, 15.
Block 10 further comprises an intermediate lever 20. Lever 20 is mounted for rotation on a pin or on pivots 21 and it comprises a first arm 22 whose end 22a cooperates with the pusher 13 and a second arm 23 opposite the first one with respect to pin 21 and whose end 23a has a role which will be explained further on. Below pin 21, lever 20 has a nose 24. Lever 20 is subjected in a clockwise direction to a torque produced for example by the force of a spring shown schematically by the arrow F1 exerted on the arm 22 or by any other equivalent means.
A lever 30 for transmitting the tripping signal to the circuit breaker is mounted for rotation on a pin or on pivots 31 and it has on the same arm or on slightly divergent arms, on the one hand, a hook 32 adapted for engagement with the nose 24 of the intermediate lever 20 and, on the other hand, a ramp 33 adapted for engagement with end 23a of arm 23 so as to push this latter back in a clockwise direction and to return pusher 13 to its starting position as will be explained further on.
Lever 30 comprises above pin 31 and indicator element 34 visible in the tripped position (FIG. 2) through a window 16 in the case; lever 30 is further urged in an anticlockwise direction by a force represented at F2 and produced by a spring or any other equivalent means.
A manual resetting member 40 formed by a key, a lever or a push button is disposed on the front face of the case so as to be able to rotate about a pin 41 or pivots in an anticlockwise direction during a resetting operation (FIG. 3). It comprises at its left hand end a nose or stop 42 turned upwardly and intended to engage with a shoulder 17 provided on a face of the case as well as a finger, boss or other equivalent bearing element 43 turned downwardly and intended to push lever 30 back in a clockwise direction.
The resetting key 40 further comprises a concave shoulder 44 having an integral edge or nose 45. Shoulder 44 is adapted for engaging with locking lever 50, possibly provided with a cam. Lever 50 comprises a convex bearing surface 52 having a profile complementary to that of shoulder 44 and it is capable of rotating about a pin or pivots 51 so as to pivot in an anticlockwise direction when the circuit breaker is tripped (FIG. 2), and in a clockwise direction during resetting of the circuit breaker. Lever 50 has a lateral face 53 serving as a stop for nose 45 of key 40 during the resetting of the additive block (FIG. 3).
It should be noted that the pin 31 of lever 30 is coupled to a shaft or lever of the circuit breaker so as to deliver thereto the "outward" tripping information in the case of a tripping additive block or to receive the tripping information in the case of a signalling additive block, whereas pin 51 of locking lever 50 is coupled to a shaft or to a lever of the circuit breaker which sends to the additive block the "inward" tripping information of the circuit breaker.
The mechanical and kinematic arrangements described may of course be modified. In particular, while keeping the same direction of rotation for the intermediate lever 20, a lever 30 may be provided which pivots in a clockwise direction during tripping of the additive block.
The corresponding embodiment is shown in FIG. 4.
An intermediate lever 60 corresponding to lever 20 of FIG. 1 is shown pivoting about a pin 61 and has an arm 62 whose end 62a cooperates with the tripping pusher 13, a lower arm 63 whose end 63a cooperates at the end of tripping with a main lever 70 and a nose 64 provided for engagement with a nose of the main lever.
The main lever 70 may pivot about a pin 71 coupled to a shaft or to a lever of the circuit breaker so as to transmit thereto the tripping information from the additive block by clockwise rotation.
Lever 70 has an arm 72 with a bearing face 73 provided for engagement with the end 63a of the intermediate lever 60; it comprises on the same arm a hook 74 for engagement with the nose 64. A circular slit 75 is formed in arm 72 for limiting the angular travel of the lever 70 in a clockwise direction by abutment of pin 61 against the bottom of the slit. A torsion spring 76 bears on the one hand on a shoulder 46 of the resetting key 40 and, on the other hand, on arm 72 of lever 70; this latter finally has an arm 77 supporting an indicating element 78 adapted so as to appear opposite window 16 of case 11 in the tripped position of the additive block.
Operation of the embodiment shown in FIGS. 1 to 3 will now be described; operation of the variant shown in FIG. 4 only differs therefrom by the direction of rotation of lever 70.
In the state shown in FIG. 1, the additive block is set: the lever 50 occupies a position indicating that the circuit breaker is engaged and locks the resetting key 40. When the auxiliary control member 12, for example a measurement relay, is actuated in response to a current or fault detected on conductors 14, 15 pusher 13 moves in the direction of an arrow F and causes the intermediate lever to pivot in an anticlockwise direction about pin 21 against the torque determined by the spring exerting a small force F 1 . Thus, nose 24 is freed from hook 32 and lever 30 pivots in the anticlockwise direction about axis 31 under the effect of the force spring F 2 . The result is that the lever 30 transmits a tripping order to the tripping mechanism of the circuit breaker via the rotary pin 31 and the tripping indicator 34 becomes visible through window 16 of case 11 of the additive block (FIG. 2).
The tripping mechanism of the circuit breaker opens the separable contacts thereof and in return causes the cam lever 50 to rotate in an anticlockwise direction so as to bring it to the position shown in FIG. 2, with consequently unlocking of the resetting key 40.
In addition, at the end of travel, ramp 33 of lever 30 is applied against the end 23a of arm 23 and causes this latter to rotate in a clockwise direction so as to bring the pusher back in the reverse direction of arrow F; this allows the relay 12 to be reset, for example so as to avoid leaving its magnetic circuit open when it is a relay biased by a premanent magnet.
For resetting the circuit breaker, the user is forced to reset the additive block first of all for, otherwise, pin 31 remains in the position shown in FIG. 2.
Resetting of the additive block is then carried out as shown in FIG. 3 by manually rocking key 40 about its pin 41. Boss 43 is applied to lever 30 and drives it in a clockwise direction until the nose 24 of the intermediate lever slides over hook 32 and is held in the hook, whereas the indicator 34 disappears from window 16.
It will be noted that, during this resetting operation, nose 45 of key 40 is opposite the lateral face 53 of the locking lever 50 and prevents the circuit breaker from being engaged.
As soon as key 40 has come back to the position shown in FIGS. 1 and 2 under the effect of a resilient return means, the cam lever 50 may be brought back in its position for locking the key in response to resetting of the circuit breaker by the user.
In the embodiment shown in FIG. 5, the additive block 10 has the function of detecting a residual differential current--by means of the measurement relay 12 with pusher 13--and also the function of tripping the circuit breaker following this detection. For this the block comprises a test push-button 80 having an abutment element 81 which may be applied against a shoulder 18 of case 11 under the effect of a spring. A lever 82 has, on each side of a fulcrum point 83, a first arm 84 bearing at a 1 on the pusher 80 and a second arm 85 bearing at a 2 on a projection 47 of key 40. The ends 84a, 85a of arms 84, 85 may slide in slides 86, 87 having an appropriate radius of curvature, substantially equal to the distance "d" between ends 84a, 85a.
A torsion spring 88 wound round a pin 89 comprises on one side of the pin a first arm 90 applied against a lower bearing point 35 on lever 30 and a second arm 91 applied against the bearing point 83 on lever 82. Spring 88 exerts respectively at 35 and 83 forces F' 2 and F' 1 , force F' 1 being broken down into two forces F 3 , F 4 urging respectively the resetting key 40 and the test push-button 80.
Operation of the additive block described in connection with FIG. 5 is substantially identical to that of the embodiments shown in FIGS. 1 to 4 as far as levers 20, 30, 40 and 50 are concerned.
However, during the operation for resetting the additive block, the projection 47 of key 40 moves down during pivoting of the key about its pin 41. Projection 47 causes a downward movement of the bearing point a 2 in slide 87 and, since bearing point a 1 remains fixed by abutment of element 81 of push button 80 against shoulder 18, causes a slight pivoting of lever 82 about a 1 in the anticlockwise direction; this movement of lever 82 is effected against force F' 1 of the torsion spring 88, one of whose functions is, as can be seen, to provide return of the key.
Actuation of the test push-button 80 causes the bearing point a 1 to move down in slide 86 and lever 82 to pivot about bearing point a 2 which remains applied against the projection 47 of key 40 following engagement of stop 42 against shoulder 17 of the case.
In another way, levers 20, 30, 40 and 50 may be disposed in a half case and push button 80, lever 82 and spring 88 housed in an adjacent half case, the two half cases forming the additive block.
In the embodiment shown in FIGS. 6 to 8, the additive block no longer communicates a tripping order to the circuit breaker but receives therefrom the tripping information. Thus, this information is signalled, for example on the additive block and resetting of the circuit breaker is dependent on manual resetting of the additive block.
Case 10 of the additive block comprises key 40 and the interlocking lever 50 already described, as well as an auxiliary signalling assembly 100, an intermediate lever 110 and a receiving lever 120, coupled to the circuit breaker.
The signalling assembly 100 comprises a pusher 101 urged upwardly (FIG. 6) by a spring 102 and having two arms 103, 104, carrying contacts 105, 106 fastened to return means and movable along the axis of the pusher. Contacts 105, 106 are disposed respectively on conductors 107, 108.
The intermediate lever 110 is mounted for pivoting on a pin 111, as previously lever 20 on its pin 21, and it has an arm 112 with a nose 113 and a guide member 114 such as a ramp, slide, fork or other similar element. Element 114 has thereover a bearing face 115 provided for engagement with boss 43 of key 40.
The receiving lever 120 is mounted on a pin 121 and comprises a hook 122 which cooperates with nose 113, a finger 123 which cooperates with the guide fork 114 and an indicating element 124 adapted to appear opposite window 16 in case 11.
Pin 121 of lever 120 is coupled to a shaft or lever of the circuit breaker so as to rotate during tripping thereof in order, on the one hand, to make indicator 124 visible through window 16 and, on the other hand, actuate the contacts. In FIG. 6, the additive block is illustrated in its set position corresponding to the engaged state of the circuit breaker. The intermediate lever 110 is engaged on lever 120 and it is subjected to a holding force F 6 produced by the reaction of the springs of the auxiliary contact assembly 100. Contacts 105 are open and contacts 106 are closed, whereas indicator 124 is retracted.
Automatic or manual tripping of the circuit breaker causes lever 120 (FIG. 7) to pivot immediately in a clockwise direction, which frees hook 113 from nose 122; the springs associated with pusher 101 cause this latter to rise, which in its turn causes an anticlockwise rotation of lever 110 and reversal of the contacts of the signalling assembly 100, that is to say closure of contacts 105 and opening of contacts 106. Furthermore, the intermediate lever 110 confirms the movement of the receiving lever 120 by rotating while continuing to drive this latter through the guide fork 14 of finger 123.
Simultaneously, the cam lever 50, also coupled to the circuit breaker, is brought by the connection shaft thereof to the position illustrated in FIG. 7 so as to unlock the resetting key.
By pressing this key (FIG. 8), the intermediate lever 110, the receiving lever 120 and the signalling assembly 100 are reset in their original position shown in FIG. 6, through its boss 43. It should be noted that, during resetting of the additive block and as in all the preceding embodiments, edge 45 of shoulder 44 of key 40 prevents lever 50 from pivoting in an anticlockwise direction and consequently temporarily prevents resetting of the circuit breaker.
When an automatic reset circuit breaker trips, the user is therefore alerted of the effective tripping by the electric circuit which controls the signalling assembly 100 and he must reset the additive block by a conscious and voluntary action, which conditions the automatic resetting of the circuit breaker.
One example of coupling an additive block BA 1 such as shown in FIGS. 1 to 5 to a three pole circuit breaker D 1 has been shown in FIG. 9, whereas an example of coupling an additive block BA 2 such as shown in FIGS. 6 to 8 to a twin pole circuit breaker D 2 has been illustrated in FIG. 10. The direction of transmitting tripping information between the additive block and the circuit breaker has been shown in both cases by arrows.
A means for locking the resetting lever, which may be secured by a seal or a padlock if required, may be provided for preventing any unauthorized person from resetting the additive block and/or serving as locking device for the circuit breaker; this locking means may be formed by a drawer, a needle, a pin or any other similar member.
Furthermore, in the case where the additive block is a voltage failure or transmitting tripping block, a self break contact of the relay of said block may be advantageously associated with the transmitting lever 30 inside the additive block.
It goes without saying that other modifications may be made to the additive block described without departing from the scope and spirit of the invention.
In the embodiment of FIG. 5, a member locking resetting lever 40 may be advantageously provided, this member also maintaining test pusher 80 in its locking position, this being facilitated by the immediate neighborhood of lever 40 and pusher 80. | An additive block is provided which may be coupled to a circuit breaker comprising two separable contacts and a resettable tripping mechanism controlled by a thermal trip and/or a magnetic trip. It comprises an auxiliary tripping and/or signalling member, a connecting mechanism between the tripping mechanism of the circuit breaker and the auxiliary member and a manual resetting member cooperating with the connecting mechanism for resetting the active part of the mechanism associated with said auxiliary member in its original position after tripping of the circuit breaker. The connecting mechanism has an interlocking piece which may assume two positions corresponding to engagement and disengagement of the circuit breaker and cooperating in its first position with the resetting member for preventing manual actuation thereof. | 7 |
CROSS-REFERENCE
The present application is a continuation of U.S. patent application Ser. No. 10/766,858 filed on Jan. 30, 2004 (now allowed), now U.S. Pat. No. 7,054,884 which is a continuation of U.S. patent application Ser. No. 09/500,488 filed on Feb. 9, 2000 (now U.S. Pat. No. 6,789,072 B1), issued Sep. 7, 2004) for which priority is claimed under 35 U.S.C. §120; and the present application claims priority of Patent Application No. 1999-04467 filed in Republic of Korea on Feb. 9, 1999 and Patent Application No. 2000-00715 filed in Republic of Korea on Jan. 7, 2000, under 35 U.S.C. §119. The entire contents of each of these applications are herein fully incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for creating and recording time information for searching digital data streams to be recorded on a recording medium and a method and apparatus for searching for requested data using the created time information.
2. Description of the Related Art
In the conventional analog television broadcast, video signals are transmitted over the air or through cables after being AM or FM modulated. With the recent advance of digital technologies such as digital image compression or digital modulation/demodulation, standardization for digital television broadcast is in rapid progress. Based upon the Moving Picture Experts Group (MPEG) format, satellite and cable broadcast industry also moves towards the digital broadcast.
The digital broadcast offers several advantages that its analog counterpart cannot provide. For example, the digital broadcast is capable of providing services with far more improved video/audio quality, transmitting several different programs within a fixed bandwidth, and offering enhanced compatibility with digital communication media or digital storage media.
In the digital broadcast, a plurality of programs encoded based upon the MPEG format are multiplexed into a single transport stream before transmitted. The transmitted transport stream is received by a set top box at the receiver and demultiplexed into original programs. If a program is chosen from among the demultiplexed programs, the chosen program is decoded by a decoder in the set top box and original audio and video signals are retrieved. The retrieved audio and video signals can be presented by an A/V output apparatus such as a TV.
It is also possible to record the received digital broadcast signals on a storage medium instead of directly outputting the received broadcast signals to A/V output devices. The stored digital broadcast signals can be edited and retrieved afterwards. For example, a digital data stream received by the set top box can be transmitted to a streamer such as a digital video disk (DVD) recording apparatus through communication interfaces like an IEEE-1394 serial bus and stored on a recording medium by the streamer. The recorded digital data stream can be edited and transmitted back to the set top box so that the digital audio and video data can be presented.
When recording the digital data stream of a single program on a recording medium in a streamer, the basic recording unit is a stream object (SOB) comprising a series of stream object units (SOBUs). To record received digital data streams on a recording medium and to reproduce the recorded data afterwards, it is necessary to explore how to group and record stream objects (SOBs) and stream object units (SOBUs) and how to create search information for managing and searching for the recorded stream objects (SOBs) and stream object units (SOBUs). Also, it is required to investigate how to search a specific data stream corresponding to a search time requested by a user.
A conventional method for recording digital data streams and creating and recording navigation information will now be explained with reference to the accompanying drawings.
FIG. 1 depicts a block diagram of an apparatus in which the conventional method for creating and recording the navigation information for recorded digital data streams can be employed. FIG. 2 depicts the process of recording digital data streams and creating the navigation information in the system shown in FIG. 1 . The system comprises a set top box 100 , a communication interface (IEEE-1394), and a streamer 200 . The set top box 100 receives transport streams encoded by system encoders and broadcast by a plurality of broadcast stations and demultiplexes the received transport streams. After a decoder 120 decodes the transport stream of a program tuned by a tuning unit 110 , a control unit 140 outputs the decoded transport stream to an A/V output apparatus or to the streamer 200 through the IEEE-1394 communication interface 130 and 210 so that the transmitted program can be recorded on a recording medium 230 by the streamer 200 , depending upon a user's choice. When requested by a user, the streamer 200 retrieves the recorded program and transmits the retrieved program through the IEEE-1394 communication interface back to the set top box 100 . In the set top box 100 , the received program is decoded by the decoder 120 and then outputted to an A/V output apparatus so that the recorded program can be presented.
A control unit 250 of the streamer 200 controls a stream recording unit 220 to record the data stream transmitted from the set top box 100 on the recording medium 230 , as shown in FIG. 2 . The received data stream composed of transport stream packets is recorded on the recording medium along with the packet arrival time (PAT) of each transport stream packet. The transport stream packets with packet arrival times are organized in sectors on the recording medium, with each sector having a predetermined size. A predetermined number of sectors, for example 32 sectors, are grouped into a stream object unit (SOBU). If the recording process is stopped or suspended by a user, the recorded stream object units (SOBUs) are grouped into a stream object (SOB). Additionally, navigation data such as the stream start application packet arrival time (S_S_APAT) and incremental application packet arrival time (IAPAT) for managing and searching for the stream object (SOB) and stream object units (SOBUs) is recorded together with the transport stream packets on the recording medium. A stream reproducing unit 240 reproduces the data recorder with recording medium 230 .
FIG. 3 shows the way the received digital data stream is recorded on the recording medium 230 . An application packet and its packet arrival time (PAT or time stamp) constitute a transport stream packet (TSP). A plurality of transport stream packets (TSPs) and header information are organized into a sector and a predetermined number of sectors, for example 32 sectors, constitute a stream object unit (SOBU). A series of stream object units (SOBUs) constitutes a stream object (SOB). Meanwhile, the stream object information (SOBI), which is the navigation data for managing and searching the recorded stream object (SOB), comprises stream object general information (SOB_GI) and a mapping list (MAPL) for managing stream object units (SOBUs) contained in the stream object (SOB), as shown in FIGS. 4 and 5 . The stream object general information (SOB_GI) includes the stream start application packet arrival time (S_S_APAT) indicative of the start time of the associated stream object (SOB). As shown in FIG. 2 , the incremental application packet arrival time (IAPAT), which is a count value counted at constant time intervals (x) between two consecutive stream object units (SOBUs), is included in the mapping list (MAPL) and used as information for searching for the associated stream object units (SOBUs).
The stream start application packet arrival time (S_S_APAT) contained in the stream object general information (SOB_GI) is recorded as a 6-byte packet arrival time (PAT) comprising a 9-bit packet arrival time extension (PAT_ext) and a 39-bit packet arrival time base (PAT_base), as shown in FIG. 6( a ). The packet arrival time extension (PAT_ext) is a modulo- 300 counter that is incremented at a rate of 27 MHz, whereas the packet arrival time base (PAT_base) is incremented at a rate of 90 kHz. Unlike the stream start application packet arrival time (S_S_APAT), the time stamp recorded along with the application packet shown in FIG. 3 is recorded as a 4-byte packet arrival time (PAT) as shown in FIG. 6( b ) that is incremented at a rate of 27 MHz and thus can represent from 0 s up to 159 s (=232/27 MHz). As discussed above, the PAT of the transport stream packet as shown in FIG. 6( b ) is a time stamp recorded along with an application packet, and is part of a SOB as shown in FIG. 3 where the SOB is part of user data (actual presentation data) recorded on the recording medium 230 .
The method for searching for a transport stream packet corresponding to requested search time using the navigation and time information regarding the stream object (SOB), stream object units (SOBUs) will be explained in detail with reference to an example.
Suppose that the position (s) of a transport stream packet corresponding to the search time (ST) requested by a user is to be searched for, as shown in FIG. 2 . First, the stream start application packet arrival time (S_S_APAT) contained in the stream object general information (SOB_GI) of each stream object (SOB) is compared with the requested search time (ST) and a stream start application packet arrival time (S_S_APAT) that is closest to but does not exceed the request search time (ST) is detected. Referring to the mapping list (MAPL) of the stream object SOB # 1 containing the detected stream start application packet arrival time (S_S_APAT), the incremental application packet arrival time (IAPAT 1 ˜ 4 ) contained in the mapping list (MAPL) are summed up. The sum value is multiplied by the unit time (x) and added to the detected stream start application packet arrival time (S_S_APAT). The procedure is repeated until the calculated value (S_S_APAT+x×ΣIAPAT) approaches the requested search time (ST) without exceeding it. In FIG. 2 , the summation and multiplication is repeated to include IAPAT 4 because the calculated value exceeds the search time (ST) if the calculation continues to IAPAT 5 . Then, the entry in the mapping list (MAPL) corresponding to the calculated time (S_S_APAT+x×ΣIAPAT) is located and the index of the entry is multiplied by the number of sectors constituting a stream object unit (for example, 32 sectors) to locate the desired stream object unit SOBU 5 .
From the start position A′ of the searched stream object SOBU 5 , the 4-byte packet arrival time (PAT), which is the time stamp of the transport stream packet, is detected. Recall that the stream start application packet arrival time (S_S_APAT) and the packet arrival time (PAT) of a transport stream packet have different formats and therefore the two values cannot be directly compared. For this reason, the difference between the detected packet arrival time (PAT) and the packet arrival time of the first transport stream packet of the stream object unit SOBU 5 is compared with the difference between the requested search time (ST) and the calculated value (S_S_APAT+x×ΣIAPAT) for fine search of the transport stream packet corresponding to the requested search time (ST).
The position A searched based upon the time information (S_S_APAT+x×ΣIAPAT) calculated using the incremental application packet arrival times (IAPATs), however, does not coincide with the actual start position A′ of the stream object unit SOBU 5 , as shown in FIG. 2 . Therefore, the offset between the transport stream packet position A detected by the fine search operation and the actual position A′ results in a delay in the search operation.
As a result, additional information indicative of the offset value between A′ and A (Offset_SZ in FIG. 2 ) is necessary for precisely searching for the position (s) of the transport stream packet corresponding to the requested search time (ST). It is not desirable, however, to add the additional information to every stream object unit (SOBU), which dramatically lowers the recording efficiency of the recording medium.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a recording medium, a method and an apparatus for recording time information associated with digital data streams, which overcome the limitations and disadvantages of the related art.
It is another object of the present invention to provide a method and apparatus for creating search information for recorded digital data streams and a method and apparatus for searching digital data streams using the search information.
According to an aspect of the present invention, the time information for management and search of recorded digital data streams has the same time base as the time information used in navigation data for digital data streams and thus no information on the position offset is required. The overflow of the packet arrival time due to insufficient length of the packet arrival time data is detected and correction of time data is performed to prevent search error resulting from the overflow.
According to an aspect of the present invention, there is provided a method of recording time information associated with digital data streams, the method comprising the steps of: (a) recording first time information on a recording medium, the first time information being part of management data for managing presentation data; and (b) recording second time information on the recording medium, the second time information being time information of the presentation data, wherein a format of the first time information coincides with a format of the second time information.
According to an aspect of the present invention, there is provided an apparatus for recording time information associated with digital data streams, the apparatus comprising a recording unit for recording first time information and second time information on a recording medium, the first time information being part of management data for managing presentation data, the second time information being time information of the presentation data, wherein a format of the first time information coincides with a format of the second time information.
According to an aspect of the present invention, there is provided a recording medium for recording time information associated with digital data streams, the recording medium comprising: a recording layer; first time information stored on the recording layer, the first time information being part of management data for managing presentation data; and second time information stored on the recording layer, the second time information being time information of the presentation data, wherein a format of the first time information coincides with a format of the second time information.
These and other objects of the present application will become more readily apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modification 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
The accompanying drawings, which are included to provide a further understanding of the invention, illustrate the preferred embodiments of the invention, and together with the description, serve to explain the principles of the present invention.
In the drawings:
FIG. 1 is a block diagram of an apparatus in which a general method for creating and recording the navigation information for digital data streams and for searching recorded digital data streams using the navigation information can be employed;
FIG. 2 is a pictorial representation of a general process for creating and recording the navigation information;
FIG. 3 is a pictorial representation showing the general hierarchical structure of a recorded digital data stream;
FIG. 4 is a table showing the general navigation information for a recorded data stream;
FIG. 5 is a table detailing a part of the general navigation information of a recorded data stream;
FIG. 6 is a table showing the general time information for a recorded data stream, wherein FIG. 6( a ) shows 6-byte stream start application packet arrival time (S_S_APAT) contained in a stream object general information (SOB_GI) and FIG. 6( b ) shows 4-byte packet arrival time (PAT) which is time stamp recorded with an application packet;
FIG. 7 is a table showing the time information for a recorded data stream according to an embodiment of the present invention, wherein FIG. 7( a ) shows 6-byte stream start application packet arrival time (S_S_APAT) contained in a stream object general information (SOB_GI) and FIG. 7( b ) shows 4-byte packet arrival time (PAT) which is time stamp recorded with an application packet;
FIG. 8 is a pictorial representation of the reset indication information according to an embodiment of the present invention;
FIG. 9 is a pictorial representation of the relation between a stream object unit and the time information according to an embodiment of the present invention;
FIG. 10 is a pictorial representation of the packet arrival time of transport stream packets recorded as 4-byte data; and
FIG. 11 is a pictorial representation showing the case where the arrival time information obtained in FIG. 10 differs from the actual packet arrival time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order that the invention may be fully understood, preferred embodiments thereof will now be described with reference to the accompanying drawings. It is understood that the methods of the present invention can be implemented in the apparatus of FIG. 1 or other apparatuses or systems. For the sake of easy understanding, the present invention will be discussed referring to the elements of FIG. 1 .
FIGS. 7 and 8 depict the data format of the stream start application packet arrival time (S_S_APAT) and the packet arrival time (PAT) of a transport stream packet in accordance with an embodiment of the invention. When the control unit 250 of the streamer 200 records the stream start application packet arrival time (S_S_APAT) contained in the stream object general information (SOB_GI) on the recording medium 230 , the stream start application packet arrival time (S_S_APAT) is recorded as 6-byte data as shown in FIG. 7( a ) comprising a 9-bit packet arrival time extension (PAT_ext) and a 39-bit packet arrival time base (PAT_base) in accordance with the MPEG format. The stream start application packet arrival time (S_S_APAT) is part of navigation/management data.
In the stream start application packet arrival time (S_S_APAT), the packet arrival time extension (PAT_ext) is a modulo- 300 counter that is incremented at a rate of 27 MHz, whereas the packet arrival time base (PAT_base) is incremented at a rate of 90 kHz. On the other hand, the packet arrival time (PAT) of a transport stream packet received through the communication interface 210 is 4-byte data as shown in FIG. 7( b ) comprising a 9-bit packet arrival time extension (PAT_ext) and 23-bit packet arrival time base (PAT_base). Like the stream start application packet arrival time (S_S_APAT) in FIG. 7( a ), the packet arrival time extension (PAT_ext) in FIG. 7( b ) is a modulo- 300 counter that is incremented at a rate of 27 MHz and the packet arrival time base (PAT_base) is incremented at a rate of 90 kHz. The PAT of the transport stream packet shown in FIG. 7( b ) is a time stamp recorded along with an application packet, and is part of a SOB as shown in FIG. 3 .
In consequence, as shown in FIGS. 7( a ) and 7 ( b ), the 4-byte packet arrival time (PAT) of the transport stream packet has the same format as the lower 4 bytes of the 6-byte stream start application packet arrival time (S_S_APAT). Thus, according to the present invention, the lower 4-byte data of a stream start application packet arrival time (S_S_APAT) always coincides with one of the recorded 4-byte packet arrival times (PATs). Also, there is certainly a packet arrival time (PAT) coinciding with the lower 4-byte data of the search time (ST) requested by a user, the 6-byte search time (ST) comprising a packet arrival time base (PAT_base) and a packet arrival time extension (PAT_ext) specified by the MPEG format.
The 4-byte packet arrival time (PAT) of a transport stream packet can represent up to 93.2 s (93.2=223/90 kHz) since its packet arrival time base (PAT_base) is 23-bit data that is incremented at a rate of 90 kHz. The packet arrival time (PAT) is reset to zero whenever the value reaches the limit. The control unit 250 keeps examining occurrence of reset. If reset occurs, the control unit 250 controls the stream recording unit 220 to record information indicative of the occurrence of reset (PAT_carry) in the header information area pertaining to a sector comprising a plurality of transport stream packets (TSPs) and header information, as explained before with reference to FIG. 3 .
The reset indication information is used in the case of data search. The reset indication information (PAT_carry) as shown in FIG. 8 may be recorded as 1-bit data in the application header extension area, one of header information contained in the associated sector.
FIG. 9 shows the way the packet arrival time (PAT) of each transport stream packet is created when a digital data stream received by the set top box 100 is recorded by the streamer 200 . It is assumed that a stream object unit (SOBU) is made up of 32 sectors with each sector having 2048 bytes and the transfer rate of the data stream is not higher than 10 kbps. Hence, the time needed to record a stream object unit (SOBU) is 52.4 s (52.4=32 sectors×2048 byte/10 kbps) and the packet arrival time (PAT) is reset at 93.2 s intervals.
In other words, a stream object unit is created every 52.4 s (S 1 , S 2 , . . . ), and the packet arrival time (PAT) is reset every 93.2 s (R 1 , R 2 , . . . ) and so the reset indication information (PAT_carry) is also created every 93.2 s (C 1 , C 2 , . . . ). As a result, the packet arrival times (PATs) of all transport stream packets belonging to a stream object unit (SOBU) have mutually exclusive values as long as the transfer rate of the digital data stream exceeds 10 kbps.
The method for searching for the position (s) of a transport stream packet corresponding to the search time (ST) requested by a user from the data stream recorded as shown in FIG. 9 will be explained with reference to FIG. 2 . First, the stream start application packet arrival time (S_S_APAT) contained in the stream object general information (SOB_GI) of each stream object (SOB) is compared with the requested search time (ST) and a stream start application packet arrival time (S_S_APAT) that is closest to but does not exceed the request search time (ST) is detected. Referring to the mapping list (MAPL) of the stream object SOB # 1 containing the detected stream start application packet arrival time (S_S_APAT), the incremental application packet arrival time (IAPAT 1 ˜ 4 ) contained in the mapping list (MAPL) are summed up. The sum value is multiplied by the unit time (x) and added to the stream start application packet arrival time (S_S_APAT). The procedure is repeated until the calculated value (S_S_APAT+x(ΣIAPAT)) approaches the requested search time (ST) without exceeding it. In FIG. 2 , the summation and multiplication is repeated to include IAPAT 4 because the calculated value (S_S_APAT+x(ΣIAPAT)) exceeds the search time (ST) if the calculation continues to IAPAT 5 . The stream object corresponding to the calculated value is SOBU 5 , which corresponds to the upper 2-byte data of the search time (ST) requested by the user.
From the start position A′ of the searched stream object SOBU 5 , the 4-byte packet arrival time (PAT) of each transport stream packet is detected. The detected packet arrival time (PAT) is compared with the lower 2-byte data of the search time (ST) requested by the user to find the transport stream packet (TS) the packet arrival time (PAT) of which coincides with the lower 2-byte data of the search time (ST).
In summary, using the stream start application packet arrival time (S_S_APAT) and incremental application packet arrival time (IAPAT) contained in the mapping list, the stream object unit SOBU 5 corresponding to the upper-unit time data of the requested search time (ST) is detected and then a transport stream packet the packet arrival time of which coincides with the lower-unit time data of the search time (ST) is detected. As a result, the position of the detected transport stream packet coincides with the requested search time (ST).
In this case, however, if the 4-byte packet arrival time added to each transport stream packet overflows after the start of the associated stream object unit (SOBU) and before certain unit time elapses, the actual packet arrival time may become different from the arrival time of the first transport stream packet calculated based on the incremental application packet arrival time in the mapping list. This case will be explained in detail with reference to FIG. 10 .
FIG. 10 depicts an example where the packet arrival time of each transport stream packet being received is recorded as 4-byte data. In this case, it is assumed that the unit time of the incremental application packet arrival time (IAPAT) corresponds to the bit 3 of the 4th byte of the packet arrival time (the bit shaded in FIG. 10 ). Therefore, whenever the unit time elapses, the bit 3 of the 4th byte is toggled.
In FIG. 10 , the packet arrival time reference information ((a) in FIG. 10 ) of the first transport stream packet of the nth stream object unit (SOBU #n) is FFFEDEFB (16) and the packet arrival time reference information ((b) in FIG. 10 ) of the third transport stream packet is FFFFFEFF (16) . Because the unit time elapses after the third transport stream packet arrives, the lower 4 bytes of the 6 bytes indicative of the packet arrival time are reset after the third transport stream packet arrives and before the unit time elapses and a carry is propagated to the upper 2 bytes. Accordingly, the fifth transport stream packet, for example, has the arrival time reference information of 00007EEFh, which is less than the previous value.
The upper 2 bytes of the actual packet arrival time of the first transport stream packet are 6EBE (16) but the value is not recorded on the recording medium. In the case of data search, therefore, the upper 2 bytes are calculated based on the incremental application packet arrival time (IAPAT) information. However, because a carry already exists before the first time duration of the unit time of the incremental application packet arrival time (IAPAT) elapses within the associated stream object unit (SOBU), the value of the upper 2 bytes obtained based on the incremental application packet arrival time (IAPAT) information is greater than that of the upper 2 bytes of the actual packet arrival time by 1. For this reason, in the case of data search, the upper 2 bytes calculated base on the incremental application packet arrival time (IAPAT) information should be not regarded as the upper 2 bytes prefixed to the 4-byte arrival time reference information detected from the transport stream packet.
FIG. 11 depicts the case where a carry is generated as explained before. It is shown that the actual packet arrival time ((d) in FIG. 11 ) differs from the 6-byte packet arrival time ((c) in FIG. 11 ) comprising the upper 2 bytes ((b) in FIG. 11 ) calculated based on the incremental application packet arrival time (IAPAT) information and the 4 byte arrival time reference information ((a) in FIG. 11 ) detected from the first transport stream packet.
In FIG. 11 , the time information corresponding to a stream object unit (SOBU) calculated based on the incremental application packet arrival time (IAPAT) information is expressed by the upper 3 bytes and upper 6 bits of the forth byte. This is because the unit time of the incremental application packet arrival time (IAPAT) does not have time resolution lower than 218 bits.
In order to compensate for the error in the calculated packet arrival time, therefore, it is inevitable to check whether the 4-byte packet arrival time reference information generated a carry after the first packet of an arbitrary stream object unit (SOBU) arrives and before the unit time of the incremental application packet arrival time (IAPAT) elapses.
To this end, the control unit 250 compares the lower 14 bits of the 30-bit time information calculated based on the incremental application packet arrival time (IAPAT) information with the upper 14 bits of the 4-byte arrival time reference information of the first transport stream packet of the current stream object unit (SOBU) and concludes that a carry is generated if the latter is greater than the former. If so, the control unit 250 subtracts the least significant bit of the upper 2-bytes from the 30 bits calculated based on the incremental application packet arrival time (IAPAT) information, takes the 2-byte result as the upper 2 bytes of the packet arrival time of the first transport stream packet of the associated stream object unit, and compares the packet arrival time with the requested search time.
In the example shown in FIG. 11 , the number 11011110111110 (2) is greater than the number 00000000000000 (2) and thus the upper 2 bytes of the arrival time of the first transport stream packet is obtained by subtracting 000100000000 (16) from 6EBFXXXXXXXX (16) and taking the upper 2 bytes from the result. As a result, the time information comprising the 2-byte data and the 4-byte packet arrival time detected from the transport stream packet is used in the case of data search.
The existence of carry may be checked in a different manner. For example, the control unit 250 retrieves all data of the sectors constituting the associated stream object unit and checks the reset indication information (PAT_carry) recorded in the header information in each sector. If any of the reset indication information indicates carry, the packet arrival time can be corrected by the aforementioned method. Otherwise, the upper 2 bytes of the value calculated based on the incremental application packet arrival time information can be used as the upper 2 bytes of the packet arrival time.
As one skilled in the art would readily recognize, the recording medium 230 can be, e.g., a DVD.
The invention may be embodied in other specific forms without departing from the sprit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A method and apparatus for recording time information for received digital data streams are provided. The method includes recording first time information and second time information on a recording medium. The first time information is part of management data for managing presentation data and the second time information is time information of the presentation data. The format of the first time information coincides with the format of the second time information. | 8 |
This application is a continuation of U.S. application Ser. No. 08/159,287 filed Nov. 30, 1993, now abandoned.
FIELD OF THE INVENTION
This invention relates to an information processing apparatus for combining a plurality of data signals received from different media such as sound, image, etc. The data is combined into one multimedia representation of the data signals, with the reproduction times of the corresponding parts of the plurality of data signals coinciding to each other.
BACKGROUND OF THE INVENTION
In recent years, with the development of technologies for processing data signals for various media such as sound, image, etc., it has become desirable to develop technology to produce multimedia representations without difficulty.
Hereinafter, media is defined as each elementary means to carry sound or images, for example, which when combined form a multimedia representation.
One prior art method for producing multimedia representations was to combine a plurality of media such as sound, image, etc. using an editor. An editing person would edit the individual media manually so the reproducing times of the corresponding parts of the media coincided to each other. However, because of the complex relationship between the times of different media, it was difficult work for the editor.
In the Japanese Patent Provisional Publication No. Hei 5-3561, a method to produce a multimedia representation is disclosed which makes the reproducing times of image and sound coincide, when they are different, by extending or reducing the times of image and sound. However, this method extends or reduces the reproducing time of each media to the mean values of the media without any consideration for the characteristics of the sound and images. Sometimes this results in unnatural or incomplete reproduction, especially when the media whose reproducing time is extended or reduced is an image. For example, a scene of a man walking too fast or too slow will be notably unnatural.
SUMMARY OF THE INVENTION
The present invention relates to an information processing apparatus and method which easily generates automatically or at an editor's will and without any manual editing work, a multimedia representation with natural feeling and coinciding reproducing times for the different media without the omission of necessary information.
An information processing apparatus related to the present invention comprises: database means for storing a plurality of media signals which have corresponding reference signals, determining means for determining one processing method from among a plurality of processing methods obtained by combining attribute characteristics, and an information processing part which, based on the determined processing method, extends or reduces the reproduction time for each individual media signal, or discontinues an individual media signal as necessary.
The attribute characteristics include, with regard to the media signals, data giving reproducing times and the degree of yes or no for omitting or interrupting the media signals. The attribute characteristics may also include, if necessary, data specifying the quantity of the media signals when a plurality of media signals are transferred to the information processing part. In addition, data identifying the relationship between the plurality of media signals or the reproduction order of the media signals can be provided.
The reference signals may be constructed with the attribute characteristics specifying that media signals of the same kind of media have some relationship to each other and specifying the order the related media signals are to be reproduced.
The apparatus may also include a document processing part which, upon receiving a sentence input, extracts reference data therefrom, and inputs the reference data into the processing-method-determining part.
The information processing apparatus related to the present invention thus constructed, determines a processing method from among a plurality of processing methods obtained from the attribute characteristics of the plurality of individual media signals. The individual media signals which correspond to each reference signal are retrieved from the database, based upon the attribute characteristics of the individual media signals. It then extends or reduces the reproduction times of the plurality of media or interrupts the reproduction as necessary. Thus, a multimedia representation which has a plurality of media signals with coinciding reproduction times can be easily accomplished.
Thus, according to the apparatus as defined above, any labor for coinciding the reproduction times of various media is saved, and a multimedia representation with natural feeling and with coinciding reproduction times of individual media without omission of necessary information is generated, easily and automatically, as directed by the editor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the overall structure of the first exemplary embodiment of the information processing apparatus according to the present invention.
FIG. 2 is a block diagram showing the structure of the second exemplary embodiment of the information processing apparatus according to the present invention.
FIG. 3 is an example of the data stored in the database part of the first exemplary embodiment of the information processing apparatus according to the present invention.
FIG. 4 is a first example of different media signals being combined according to the first exemplary embodiment of the information processing apparatus according to the present invention.
FIG. 5 is a second example of different media signals being combined according to the first exemplary embodiment of the information processing apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, exemplary embodiments of the information processing apparatus according to the present invention are explained.
Referring to FIG. 1, an information processing apparatus according to the first exemplary embodiment of the present invention comprises a database part 1, a processing-method-determining part 2, and an information processing part 3.
FIG. 3 shows an example of data stored in the database part. For one media signal stored in the database part, there would also be stored in the database part attribute characteristics and reference signals. For example, for media signal a(a1) stored in the database part, there would also be stored in the database part reference signal c(a1) and attribute characteristics b(a1).
The database part 1 stores a plurality of media signals, for example audio signal a(a), and video signal a(v), and attribute characteristics b of each individual media signal. The attribute characteristics consists of three elements; kind (e.g., type, such as audio or video), length of time, and "yes or no" for interruption of the single-medium. For example, attribute characteristics of audio signals b(a) and attribute characteristics of video signals b(v). Referring to the "yes or no" for interruption, if interruption of an individual signal a(a) results in the loss of the exact content of the signal, such as an audio signal containing news commentary, which will result in essential parts of the news being lost, then the interruption is treated as "no". If, on the other hand, interruption of an individual signal a(a), as in the case of an audio signal consisting of background music, results only in the loss of unimportant content, then the interruption is treated as a "yes".
The processing-method-determining part 2 selects and determines one processing method from among a plurality of processing methods. For example, if two different reference signals c(a) and c(v) referring to audio signal a(a) and video signal a(v) are inputted, the processing-method-determining part 2 retrieves out from the database part 1 attribute characteristics b(a) of audio signal a(a) corresponding to the reference signal c(a). It also reads out attribute characteristics b(v) of video signal a(v) corresponding to the reference signal c(v). Then the processing-method-determining part 2 selects and determines one processing method automatically or at the editor's will from among a plurality of plural processing methods d obtained by combining the attribute characteristics b(a) and b(v) as shown in the Table below.
The information processing part 3 produces a multimedia representation e, by combining the audio signals a(a) with reproduction time in its current state, reduced or extended, and visual media signals a(v) with reproduction speed unchanged.
When the processing-method-determining part 2 receives two reference signals c(a) and c(v) referring individually to audio signal a(a) and video signal a(v) which are desired to be combined, the processing-method-determining part 2 retrieves attribute characteristics b(a) and b(v) of audio signal a(a)
TABLE______________________________________Attribute Soundinformation Interruption: No Interruption: Yes______________________________________ Sound reproducing > Image reproducing time time ImageInterruption Image: Standard Image: StandardNo reproduction reproduction Sound: Speed changed Sound: Fade out (reduce)Interruption Image: Standard Image: StandardYes reproduction reproduction Sound: Speed changed Sound: Fade out (reduce) Sound reproducing < Image reproducing time timeInterruption Image: Standard Image: StandardNo reproduction reproduction Sound: Speed changed Sound: Speed changed (Extend) (Extend)Interruption Image: Reproduction Image: ReproductionYes interrupted interrupted Sound: Standard Sound: Standard reproduction reproduction______________________________________
and video signal a(v) corresponding to the reference signals c(a) and c(v) from the many attribute characteristics b(a) and b(v) stored in the database part 1. The processing-method-determining part 2 then determines, automatically or at the editor's will, one processing method d from a plurality of processing methods d which are obtained by combining these attribute characteristics b (a) and b (v) .
Then, the information processing part 3 edits the two individual media signals a(a) and a(v) which were retrieved from the database part 1, based on the processing method determined in the processing-method-determining part 2. The information processing part 3 produces a multimedia representation consisting of the two media signals, in this case audio signal a(a) and video signal a(v) with coinciding reproduction times.
For example, as shown in FIG. 4, if the attribute characteristics b (a1) and b (v1) of the media signals a(a1) and a(v1) corresponding to the two reference signals c(a1) and c(v1) inputted into the processing-method-determining part 2 are "Sound, 10 seconds, Interruption No" and "Image, 15 seconds, Interruption Yes", the processing-method-determining part 2 determines a method d using this attribute characteristics. The method d chosen from the preceding table is that the sound is reproduced using standard reproduction and the image is interrupted. Method d is chosen from the preceding table by combining these attribute characteristics b(a1) and b(v1).
Then, the information processing part 3, based on the processing method d that the sound is reproduced using standard reproduction and the image is interrupted, edits so that the attribute characteristic b(a1) standard-reproduces the audio signal a(a1) consisting of "Sound, 10 seconds, Interruption No". It also reproduces the video signal a(v1) using the attribute characteristics b(v1) interrupting the video signal a(v1) consisting of "Image, 15 seconds, Interruption Yes", when 10 seconds, which is the reproduction time of the audio signal a(a1), has elapsed. Thus, a multimedia representation e with the same reproduction times for the audio signal a(a1) and the video signal a(v1) is produced.
As shown in FIG. 5, if the attribute characteristics b(a1) and b(v2) for each individual media signal corresponding to the two reference signals c(a1) and c(v2) inputted into the processing-method-determining part 2 are "Sound, 10 seconds, Interruption No" and "Image, 7 seconds, Interruption No", the information processing part 2 determines the processing method d that sound is compressed by speed conversion, and image is standard-reproduced by combining the attribute characteristics b(a1) and attribute characteristics b(v2) .
Then the information processing part 3, based on the processing method d that the sound is compressed by speed conversion, and image is standard-reproduced, compress-reproduces the audio signal a(a1) whose attribute information is "Sound, 10 seconds, Interruption No" by converting the speed thereof so that the reproducing time thereof is 7 seconds. This is the reproduction time for the video signal a(v2). A multimedia representation e is thus formed with the reproducing time coinciding to the video signal a(v2) with attribute characteristics b(v2) "Image, 7 seconds, Interruption No".
The determination of the processing method d accomplished by combining the attribute characteristics b(a1) for the audio signal a(a1) and the attribute characteristics b(v2) for the video signal a(v2) is based on the consideration of whether interruption is possible so that omission of necessary information for the audio signal a(a1) or the video signal a(v2) is prevented.
Thus, according to the first exemplary embodiment of the present invention, it is determined whether the reproduction time of the audio signal is kept, compressed, or expanded, and the reproduction time of the video signal is kept or interrupted, by combining the attribute characteristics b(a) for the audio signal a(a) and the attribute characteristics b(v) for the video signal a(v). These correspond to the two reference signals c(a) and c(v) respectively.
If the quantity of data contained in the audio signal a(a) and video signal a(v) is large, especially the latter, the transferring of media signals a(a) and a(v) from the database part 1 to the information processing part 3 takes a long time. As a result, times for the audio signal a (a) and video signal a(v) to be combined may not coincide. In this case, the quantities of the audio signal a(a) and video signal a(v) are specified in the attribute characteristics b(a) and b(v). Then the processing method d for transferring from the processing-method-determining part 2 to the information processing part 3 is determined, and the effect of time delay caused while the media signals a(a) and a(v) are transferred from the database part 1 to the information processing part 3 is alleviated or absorbed by the information processing part 3, resulting in coinciding times.
The above explanation used as an example two media signals, audio and video. However, other media, for example computer graphic and computer data, can be treated in a similar manner. Also, instead of the attribute characteristics consisting of three elements, kind, time length, and "yes or no" of interruption as explained, any elements showing the characteristic of the media can be used. Thus, by increasing the kinds of media signals a and the elements of the attribute characteristics b, the processing methods for the media signals are increased, resulting in a more detailed editing process.
Now referring to FIG. 2, another information processing apparatus of the second exemplary embodiment of the present invention comprises, in addition to a database part 1, a processing-method-determining part 2, and an information processing part 3, which act in the same manner as the first exemplary embodiment, further includes a document-processing-part 4. The document-processing-part 4 converts an input text f to the reference signal c which refers to the media signals stored in the database part 1. The document-processing part 4 outputs the reference signal c to the processing-method-determining part 2. According to the information processing apparatus of the second exemplary embodiment so structured, an input of a sentence generates reference signals from which a multimedia information e is produced, more easily.
In the above exemplary embodiment, media signals of a multimedia representation generated by combining a plurality of media signals is not necessarily confined to one kind of media signal. For example, combination of video signal and audio signals is not limited to video of one scene and a speech of one paragraph, but may include video signals of one scene and a plurality of audio signals, for example, two separate speeches, may be assembled to make a multimedia representation. Alternately, a speech may be combined with video signals of two scenes related to the speech.
For the one scene, two speech case, when the reference signals c(a1), c(a2) and c(v1) are inputted, the attribute characteristics b(a1) and b(a2) for the same type of media include data values specifying that media signals of the same kind are to be combined , and data values prescribing the order of reproduction of the two audio signals. For the latter example, the attribute characteristics b(v) of the two video signals include data values specifying that the same kind of media is to be combined and data values providing the reproduction order of the video signals. Similarly, a plurality of video signals and a plurality of audio signals can be combined.
When individual media signals of the same kind of media are to be used and combined as one, they may be temporarily stored, taking the accessing time into consideration, in the memory included in the information processing part 3, and synthesized applying compression or expansion if necessary.
In addition, instead of giving the attribute characteristics b necessary for assembling the plurality of individual signals of one media, the reference signals c may be given the same function. Namely, it can be instructed with a reference signal c(a3) that an attribute characteristic b(a1) of an individual signal of the same kind of media and an attribute characteristic b(a2) of another individual signal of the same kind of media are to be combined as one and reproduced in a certain order.
As illustrated in the table above of the preferred embodiment, "Yes" or "No" of interruption for standard reproduction is provided as an alternative for processing the video signals. Further, the inclusion of the attribute characteristics "Yes" or "No" for compression or extension of video signals, provides another alternative for processing, slow or fast reproduction, of the video signals.
Although illustrated and described herein with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. | An information processing apparatus and method for the same, comprising a database part, a processing-method-determining part, and an information-processing-part. The processing-method-determining part extracts from the data base part attribute characteristics corresponding to the individual media signals which correspond to the reference signals. The processing-method-determining part selects one processing method from among methods by combining the attribute characteristics. The informations processing part, based on the selected processing method, extends or reduces the reproduction time of the media signals to be combined, or discontinues an individual media signal, wherein a multimedia representation consisting of different media signals is produced with reproducing times that satisfactorily coincide. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation patent application of its parent patent application, Ser. No. 926,493, filed Aug. 7, 1992, now abandoned, which, in turn, is a divisional patent application of its parent patent application, Ser. No. 732,533, filed Jul. 18, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a new method of making a plurality of toothed belt constructions and to a new set of such belt constructions.
2. Prior Art Statement
It is known to provide a method of making a plurality of toothed belt means comprising the steps of disposing tubular sleeves of stretchable fabric material respectively onto a plurality of toothed mold members having different diameters, and forcing mold material against the outside surfaces of the sleeves to tend to stretch the fabric material into the grooves of the toothed mold members as the mold material enters the grooves of the mold members so that the resulting toothed belt means will have the fabric material thereof carried in certain positions relative to the respective teeth thereof. For example, see the U.S. Pat. Nos. to Breher, 4,443,396 and to Valerio et al, 3,419,449.
It is also known to have fabric material disposed in each tooth of a toothed belt construction between the root and tip thereof. For example, see the U.S. Pat. No. to Skura et al, 4,392,842.
SUMMARY OF THE INVENTION
It is one feature of this invention to provide a new method of making a plurality of toothed belt means respectively having different diameters and still being formed from sleeves of the same fabric material and having the same diameters in the nonstretched conditions thereof so that the fabric material will be carried in certain positions relative to the respective teeth thereof.
In particular, it is well known to dispose a tubular sleeve of stretchable fabric material onto a tooth mold member and then forcing mold material against the outside surface of the sleeve to tend to stretch the fabric material into the grooves of the toothed mold member as the mold material enters the grooves of the mold member so that the resulting toothed belt means will have the fabric material thereof carried in a certain position relative to the respective teeth thereof. For example, see the aforementioned U.S. Pat. Nos. to Breher, 4,443,396, and the aforementioned to Valerio et al, 3,419,449, whereby these two U.S. patents are being incorporated into this disclosure by this reference thereto.
While the toothed belt constructions being made by the methods set forth in the aforementioned two U.S. Pat. Nos. 4,443,396 and 3,419,449, have the sleeves of fabric material thereof lining the exterior peripheral surface means of the teeth of the resulting toothed belt constructions thereof, it was found according to the teachings of this invention that the sleeve of fabric material could be disposed anywhere from the root of each tooth to the outer periphery or tip of the tooth and will still provide an improved belt life over belts produced without such fabric material.
Therefore, it was further found according to the teachings of this invention that the same sized sleeve of the same fabric material can be utilized to produce belt constructions having various diameters so that the resulting method will be less costly than using sleeves of fabric material which must be formed so that each only makes a tooth face as in the prior mentioned U.S. Pat. Nos. 4,443,396 and 3,419,449.
For example, one embodiment of this invention provides a method of making a plurality of toothed belt means comprising the steps of disposing tubular sleeves of stretchable fabric material respectively onto a plurality of toothed mold members having different diameters, forcing mold material against the outside surfaces of the sleeves to tend to stretch the fabric material into the grooves of the toothed mold members as the mold material enters the grooves of the mold members so that the resulting toothed belt means will have the fabric material thereof carried in certain positions relative to the respective teeth thereof, and forming the sleeves from the same fabric material and with the same diameters in the nonstretched conditions thereof.
Accordingly, it is an object of this invention to provide a new method of making a plurality of toothed belt means, the method of this invention having one or more of the novel features of this invention as set forth above or hereinafter shown or described.
Another object of this invention is to provide a new set of a plurality of toothed belt constructions, the new set of this invention having one or more of the novel features of this invention as set forth above or hereinafter shown or described.
Other objects, uses and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawings forming a part thereof and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view partially in cross section illustrating the toothed belt construction of this invention formed by the apparatus of FIG. 5.
FIG. 2 is a view similar to FIG. 1 and illustrates another toothed belt construction of this invention that is formed by the apparatus of FIG. 6.
FIG. 3 is a view similar to FIG. 1 and illustrates another toothed belt construction of this invention that is formed by the method illustrated in FIG. 7.
FIG. 4 is a perspective view illustrating one of the steps in the method of this invention for forming one of the toothed belt constructions of this invention.
FIG. 5 is a cross-sectional view illustrating the apparatus utilized to make the toothed belt construction of this invention that is illustrated in FIG. 1.
FIG. 6 is a view similar to FIG. 5 and illustrates the apparatus for forming the toothed belt construction of this invention that is illustrated in FIG. 2 and that has a larger diameter than the diameter of the toothed belt construction of FIG. 1.
FIG. 7 is a view similar to FIG. 5 and illustrates the apparatus for forming the toothed belt construction of this invention that is illustrated in FIG. 3 and that has a larger diameter than the diameters of the toothed belt constructions of FIGS. 2 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the various features of this invention are hereinafter illustrated and described as being particularly adapted to provide belt constructions that have load carrying cord means, it is to be understood that the various features of this invention can be utilized singly or in various combinations thereof to provide toothed belt constructions having other types of load carrying means as desired.
Therefore, this invention is not to be limited to only the embodiment illustrated in the drawings, because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention.
Referring now to FIG. 1, a new endless toothed belt construction of this invention is generally indicated by the reference numeral 20 and comprises an outer peripheral surface means 21, an inner peripheral surface means 22 defined by a plurality of radially inwardly directed teeth 23, a reinforcing cord means 24, and a teeth reinforcing fabric means 25 lining the teeth 23 whereby it can be see that the toothed belt construction 20 of this invention has a configuration that is well known in the art, such as set forth in the aforementioned U.S. Pat. Nos. to Breher, No. 4,443,396, and to Valerio et al, No. 3,419,449.
Another endless toothed belt construction of this invention is generally indicated by the reference numeral 20A in FIG. 2 and parts thereof similar to the belt construction 20 previously described are indicated by like reference numerals followed by the reference letter "A".
As illustrated in FIG. 2, the belt construction 20A is substantially identical to the belt construction 20 previously described except that the diameter of the belt construction 20A is larger than the diameter of the belt construction 20 as will be apparent hereinafter and has the fabric material 25A thereof embedded in the teeth 23A intermediate the roots 26 thereof and the tips 27 thereof as illustrated in FIG. 2.
Another endless toothed belt construction of this invention is generally indicated by the reference numeral 20B in FIG. 3 and parts thereof similar to the belt constructions 20 and 20A previously described are indicated by like reference numerals followed by the reference letter "B".
As illustrated in FIG. 3, the belt construction 20B is substantially the same as the belt constructions 20 and 20A previously described except that the diameter of the belt construction 20B is larger than the diameters of the belt constructions 20 and 20A as will be apparent hereinafter and the fabric material 258 thereof is located at the roots 26B of the teeth 23B as illustrated in FIG. 3.
Therefore, it can be seen that it is a feature of this invention to provide a set of a plurality of toothed belt constructions wherein the fabric material for the teeth thereof is located at the outer tips thereof so as to line the teeth thereof, is disposed at the roots of the teeth or is embedded in the teeth anywhere between the roots thereof and the tips thereof as it has been found according to the teachings of this invention that merely providing the fabric material so as to be in any position relative to the teeth thereof improves the belt life over a similar belt construction which does not utilize any fabric material in connection with the teeth thereof.
It has been further found according to the teachings of this invention that the fabric material for forming the belt constructions of this invention can be disposed in a seamless sleeve form, be the same fabric material and have the same diameters in the nonstretched conditions thereof so as to respectively form a plurality or set of toothed belt constructions having different diameters with each belt construction having the sleeve of fabric material thereof disposed somewhere relative to the teeth thereof to reinforce such teeth.
In one working embodiment of this invention, the fabric material comprises a knitted seamless nylon stocking that has a circumferential length in the nonstretched condition thereof of approximately 6.0 inches and has a circumferential length of approximately 14.0 inches when fully stretched so that no residual stretch characteristic remains therein. Such a sleeve of fabric material has been utilized to form a toothed belt construction wherein the pitch length thereof is approximately 7.5072 inches, the thickness thereof is approximately 0.045 of an inch and the number of teeth is ninety-two whereby the outside diameter of the toothed belt construction is approximately 21/4 inches.
It is to be understood that while certain dimensions, etc., have been set forth above for one working embodiment of this invention, such dimensions, etc., are not to be a limitation on this invention as other dimensions, etc., can be utilized, as desired.
The belt constructions 20, 20A and 20B of this invention can be respectively formed by the apparatus 30, 30A and 30B illustrated respectively in FIGS. 5, 6 and 7 wherein it can be seen that the apparatus 30, 30A and 30B are substantially identical except that the apparatus 30A is larger in diameter than the apparatus 30 and the apparatus 30B is larger in diameter than the apparatus 30A whereby only the details of the structure and method of making the belt construction 20 with the apparatus 30 of FIG. 5 will now be described with the understanding that such description equally applies to the method of using the apparatus 30A and 30B for forming the belt constructions 20A and 20B.
As illustrated in FIGS. 4 and 5, the apparatus 30 includes a substantially cylindrical toothed mold member 31 having an outer peripheral surface means 32 provided with a plurality of longitudinally disposed and equally spaced apart grooves 33 which will form the teeth 23 of the belt construction 20 of this invention, the mold member 31 being formed of any suitable material, such as the metallic material illustrated in the drawings.
A stretchable sleeve 34 of seamless knitted fabric material is axially disposed on the mold member 31 by causing relative movement between the mold member 31 and the sleeve 34 so that the sleeve 34 is actually in a stretched condition on the mold member 31 but has a sufficient residual stretch characteristic therein so that the sleeve 34 will stretch fully into the grooves 33 of the mold member 31 to line the same in the manner illustrated in FIG. 5 when mold material 35 is injected into the apparatus 30 between the mold member 31 and an outer surrounding cylindrical casing 36 so as to engage against the outside surface 37 of the sleeve 34 and force the sleeve 34 into the grooves 33 of the mold member 31 to line the grooves 33 and, thus, line the resulting teeth 23 of the toothed belt construction 20 being formed in the apparatus 30 in the manner fully set forth in the aforementioned U.S. Pat. No. to Breher, 4,443,396.
However, before the mold member 31 is disposed in the outer surrounding casing 36 of the apparatus 30, a suitable tensile cord means 24 is wrapped in a helical manner on the outer peripheral surface 37 of the sleeve 34 in the manner illustrated in FIG. 4 so that the mold material 35 will exude through the spacings between the coils of the cord means 24 to form the teeth 23 in the manner previously set forth.
Once the mold material 35 has been exuded into the apparatus 30 in the manner illustrated in FIG. 5 to complete the configuration of the endless toothed belt construction 20, the material 35 can be solidified in the apparatus 30 in a manner well known in the art, the mold material 35 comprising any suitable polymeric material normally utilized to form toothed belt constructions.
The resulting toothed belt construction 20 is removed from the apparatus 30 in a manner well known in the art and comprises a relatively wide belt sleeve means whereby individual narrower toothed belts can be cut from the belt sleeve also in a manner well known in the art and as illustrated in FIG. 1. For example see the aforementioned U.S. Pat. No. to Valerio, 3,419,449.
Thus, it can be seen that when forming the belt construction 20A with the apparatus 30A of FIG. 6, the same belt sleeve 34 is being utilized with the mold member 31A whereby the sleeve 34 must be in a greater stretched condition when initially disposed onto the mold member 31A than when disposed on the mold member 31 previously described so that the resulting residual stretch characteristic of the sleeve 34 is less than the residual stretch characteristic of the sleeve 34 when on the mold member 31. Thus, when the mold material 35A is disposed in the apparatus 30A, the mold material 35A will exude against the fabric material 25A and carry the same along therewith into the grooves 33A of the mold member 31A and will exude through the fabric material 25A once the remaining stretch characteristic thereof has been used up so that the material 35A exudes beyond the material 25A in each groove 33A as illustrated in FIG. 6 and FIG. 2.
Likewise, since the mold member 31B of the apparatus 30B of FIG. 7 has a greater diameter than the diameter of the mold member 31A of FIG. 6, and since the same sleeve 34 of fabric material is being utilized to initially be disposed thereon as in the apparatus 30 and 30A, it may be found that the entire stretch characteristic of the sleeve 34 is used up in merely placing the sleeve 34 onto the mold member 31B so that when the mold material 35B is subsequently disposed into the apparatus 30B, the mold material 35B will exude through the material 25B without carrying the same into the grooves 33B so that the fabric material 25B will merely be disposed at the roots 26B of the resulting teeth 23B as illustrated in FIGS. 3 and 7.
Therefore, it can be seen that it is a unique feature of this invention to utilize the same sleeve of fabric material for forming belt constructions that have different diameters as such sleeve of fabric material improves the belt life of the resulting toothed belt construction regardless of where the fabric material ends up in the teeth thereof as the fabric material may be disposed at the outer tips of the teeth so as to line the teeth, be disposed at the roots thereof or be disposed in the teeth anywhere between the tips and the roots thereof and still perform a belt life increasing function as previously set forth.
Therefore, it can be seen that this invention not only provides a new method of making a plurality of toothed belt constructions, but also this invention provides a new set of a plurality of toothed belt constructions.
While the forms and methods of this invention now preferred have been illustrated and described as required by the Patent Statute, it is to be understood that other forms and method steps can be utilized and still fall within the scope of the appended claims wherein each claim sets forth what is believed to be known in each claim prior to this invention in the portion of each claim that is disposed before the terms "the improvement" and sets forth what is believed to be new in each claim according to this invention in the portion of each claim that is disposed after the terms "the improvement" whereby it is believed that each claim sets forth a novel, useful and unobvious invention within the purview of the Patent Statute. | A method of making a plurality of toothed belt constructions and a set of such belt constructions are provided, the method including the steps of disposing tubular sleeves of stretchable fabric material respectively onto a plurality of toothed mold members having different diameters, forcing mold material against the outside surfaces of the sleeves to tend to stretch the fabric material into the grooves of the toothed mold members as the mold material enters the grooves of the mold members so that the resulting toothed belt constructions will have the fabric material thereof carried in certain positions relative to the respective teeth thereof, and forming the sleeves from the same fabric material and with the same diameters in the nonstretched condition thereof. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a divisional of U.S. application Ser. No. 13/604,713 filed Sep. 6, 2012, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to advanced vertical cavity surface-emitting lasers (VCSEL) devices for the pumping of solid state lasers. More particularly, the present invention improves the thermal management of high power VCSEL arrays used for pumping solid state lasers and amplifiers.
BRIEF DESCRIPTION OF PRIOR DEVELOPMENTS
[0003] Solid state lasers are commonly used in many applications, such as directed energy technologies. In these applications, the lasers are often limited by the performances of the pump source and, more particularly, its thermal management (the optical power of the pump source, such as a laser diode or a VCSEL array, is primarily limited by the thermal load of the device). For instance, current GaAs/AGaAs distributed Bragg reflectors (DBRs) have a low thermal conductivity of approximately 0.2 W/cmK. Additionally, the emission wavelength of the device is strongly linked to its operating temperature. The DBR structure currently used in high power VCSEL devices is the main limitation in the thermal management of a device due to its low thermal conductivity.
[0004] A need, therefore exists, for a VCSEL system with improved thermal management and heat dissipation.
SUMMARY OF THE INVENTION
[0005] The present invention uses hyperbolic metamaterials in a layered structure to replace the conventional DBRs that are commonly used in VCSEL design and construction. This enables improved thermal management of high power VCSEL arrays for pumping solid state lasers and amplifiers. In the proposed approach, the metamaterial structure is expected to provide 100 times better thermal conductivity than that of DBRs, which would enable significant improvement in the VCSEL array performance and reliability. This is due to the broadband divergence of photonic density of states and greatly benefits the solid state lasers and amplifiers pumped by such VCSEL arrays.
[0006] Compared to laser diodes, VCSEL arrays provide several benefits relating to pumping applications. For example, the low wavelength dependence with temperature, power scalability with geometry and low beam divergence have proved useful in improving the reliability of solid state lasers while reducing its weight and complexity. Another benefit of this approach over traditional methods is that the heat spreader is as close as possible to the heat source, in this case the active region of the VCSEL.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention is further described with reference to the accompanying drawings wherein:
[0008] FIG. 1 shows the typical geometry of a prior art distributed Bragg mirror.
[0009] FIG. 2 shows the geometry of layered hyperbolic metamaterial.
[0010] FIGS. 3A and 3B show the heat transfer for a metal/dielectric and a hyperbolic medium, respectively.
[0011] FIG. 4 shows the positive dielectric function of ZnSe as a function of wavelength.
[0012] FIG. 5 shows the negative dielectric function of SiN and CaF 2 as a function of wavelength.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] In the present invention hyperbolic metamaterials are implemented in a layered structure in VCSEL design and construction. These materials are extremely anisotropic, being metallic (ε<0) in one direction, while dielectric (ε>0) in the orthogonal direction—such anisotropy leading to the opening of the photonic density of sates (DOS), and the surface of constant frequency becomes open in a select space k. The wave equation describing a hyperbolic metamaterial is as follows:
[0000]
-
ω
2
c
2
ϕ
ω
=
∂
2
ϕ
ω
ɛ
1
∂
z
2
+
1
ɛ
2
(
∂
2
ϕ
ω
∂
x
2
+
∂
2
ϕ
ω
∂
y
2
)
[0000] where ε 1 and ε 2 have opposite signs, reducing to
[0000]
ω
2
c
2
=
k
z
2
ɛ
1
+
k
xy
2
ɛ
2
[0014] The layered hyperbolic metamaterial essentially replaces the commonly used DBR structure. The hyperbolic metamaterial functions similar to the way a DBR structure does, and acts as a highly efficient heat spreader. This is partly because of the geometric similarity in a DBR structure and a layered metamaterial. FIG. 1 depicts the geometry of a distributed Bragg mirror and quantum well structures found in a typical oxide-confined VCSEL 10 . Layers 12 are comprised of either AlAs or AlGaAs. These layers 12 are typically 100 nm to less than 10 μm thick. The VCSEL 10 is supported by a substrate 14 such as an n-GaAs substrate.
[0015] The DBR is formed of alternating layers with respectively high and low indexes of refraction, while the metamaterial structure in FIG. 2 is formed of alternating layers with respectively positive 22 and negative 24 dielectric constants ε in the long wave infrared range (LWIR). For both structures, the layers are of comparable thickness. The thickness 26 of the layers is less than 10 μm. These layered hyperbolic metamaterials may act as a DBR in the visible range, while having broadband hyperbolic behavior in the LWIR range. The comparable thickness of the two structures creates the possibility of a design with a combination of materials for each layer so that the structure works as a DBR for a specific wavelength and as a metamaterial structure with efficient heat transfer properties.
[0016] FIG. 3A shows the heat transfer of an ordinary metal/dielectric (“elliptic” material) 30 heat source 32 to a heat sink 34 . As seen in the Figure, heat transfer is dominated by the electrons 38 and the phonons 40 . Very little, if any, heat transfer is made by the photons 42 . FIG. 3B , on the other hand, shows a hyperbolic metamaterial medium in which the heat transfer is dominated by the photons. However, FIG. 3B shows the heat transfer 50 from a heat source 52 , through hyperbolic metamaterial 54 , to a heat sink 56 . Here, in addition to the heat transfer made by the electrons 58 and phonons 60 , the heat transfer is dominated by the photons 62 .
[0017] A reason for the novel phenomena of hyperbolic metamaterials is the broadband singular behavior of their density of photonic states. For instance, the broadband divergence of the photonic density of states leads to a substantial increase in radiative heat transfer compared to the Stefan-Boltzmann law observed in a vacuum and in dielectric materials. This radiative thermal “hyper-conductivity” may approach or even exceed heat conductivity via electrons and phonons, with the additional advantage of radiative heat transfer being much faster. This key characteristic is essential to the present invention. The enhanced photonic density of states in the hyperbolic metamaterials originates from the waves with high wave numbers that are supported by the system. These propagating modes do not have an equivalent in conventional dielectrics. As each of these waves can be thermally excited, a hyperbolic metamaterial will therefore show a dramatic enhancement in the radiative transfer rates (i.e. transfer of energy in the form of electromagnetic radiation). This mechanism results in an infinite value of the density of states for every frequency where different components of the dielectric permittivity have opposite signs. The unit cell size in the metamaterials runs from approximately 10 nm (for semiconductor and metal-dielectric layered structures) to approximately 100 nm (for nanowire composites), and also depends on the fabrication method used.
[0018] The materials selected for the dual DBR/heat spreader structure should meet the requirement of the metamaterial structure (materials with positive and negative dielectric constant in the LWIR), but also the requirements of the DBR for the VCSEL device (materials transparent at the emission wavelength of the VCSEL). As seen in FIG. 4 , ZnSe is a favorable optical material in the LWIR range, which means that it has a positive dielectric constant ε. FIG. 4 illustrates the dielectric function as a function of wavelength for ZnSe. As seen in FIG. 5 , CaF 2 is a favorable broadband having a negative ε material in the LWIR due to the Reststrahlen effect. That is, the dielectric constant is less than zero and is seen as a function of wavelength in FIG. 5 .
[0019] Using different materials, the same approach can be applied to form a DBR and heat spreader structures that are tuned for VCSEL emitting at other wavelengths such as 808 nm or 880 nm. Preliminary electromagnetic simulations verify the propagation of LWIR photons through this structure in the form of coupled surface waves, which live on the positive and negative interfaces. A preliminary calculation of the thermal conductivity of the structure is given by the following formula:
[0000]
K
=
1
3
C
v
cL
=
1
3
(
∂
u
hyp
T
)
cL
=
ck
2
K
max
3
C
*
(
ω
)
LT
108
h
≈
27
W
cmK
Wherein:
[0000]
K max is defined by the metamaterial structure scale: K max ˜2π/<d>, where <d> is the average layer thickness (42 nm in the above equation);
C*˜λ/2 πc, where λ˜10 μm;
L is the free propagation length of photons (˜100 μm);
T is the temperature.
[0024] For this architecture, the projected average conductivity is more than 100 times larger than a conventional DBR structure and nearly the same as that of diamond. However, unlike diamond, the projected thermal conductivity of metamaterial increases with temperature. Additionally, the thermal conductivity is temperature dependent. That is, it will increase with the temperature of the device, thereby allowing the VCSEL to operate at higher temperature and/or in high ambient temperature environment. This enhancement of thermal conductivity greatly improves the performance of the VCSEL. First, the output power of the VCSEL is proportional to the square root of the thermal impedance distanced away from the threshold. Thus, if the thermal conductivity of the DBR improves 100-fold, the output power should improve˜10-fold. With this improvement, VCSEL arrays would prove far superior to laser diodes regarding the efficiency, brightness, reliability, and operating temperature in a laser pumping application. In addition, for a solid state laser pumped by this type of VCSEL array, numerous benefits are expected depending on the laser operation. Moreover, new concepts that reduce cost, weight, and complexity while improving efficiency and reliability can be readily envisioned. Also, as wall-plug efficiency rises, significant savings in size and weight can be achieved due to reduction in the required logistic equipment needed to operate the laser, particularly power supply and the cooling system.
[0025] While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating there from. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | Implementing a layered hyperbolic metamaterial in a vertical cavity surface emitting laser (VCSEL) to improve thermal conductivity and thermal dissipation thereby stabilizing optical performance. Improvement in the thermal management and power is expected by replacing the distributed Bragg reflector (DBR) mirrors in the VCSEL. The layered metamaterial structure performs the dual function of the DBR and the heat spreader at the same time. | 1 |
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