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The present application claims priority from German patent application number 10 2010 049 404.6 filed Oct. 26, 2010, which application is hereby incorporated herein by reference for all purposes.
The present invention relates to an apparatus and a method of producing plastics material containers. Apparatus and methods of this general type have long been known from the prior art. In this case plastics material pre-forms are usually first heated in a furnace and are then shaped to form plastics material containers by means of a blow molding device, such as for example a stretch blow molding machine. Problems arise for example if problems arise in a unit, such as for example a labelling machine, arranged downstream of the shaping device, and if the shaping procedure has to be interrupted. An interruption of the conveying of the plastics material pre-forms by the heating device can lead to individual plastics material pre-forms becoming overheated and being destroyed in this way. In addition, plastics material pre-forms once heated in the heating device cannot be cooled again and heated a further time, and so these plastics material pre-forms go to waste.
A pre-treatment of plastics material pre-forms before a blow molding procedure is known from EP 0 736 367 B1. In this case a pre-conditioning unit is provided which is traversed by the plastics material pre-forms and which is arranged in such a way that exactly the same heat is introduced into each plastics material pre-form. In this case, during the conveying, the plastics material pre-forms are put in groups of three in each case onto conveying units and are conveyed through the pre-conditioning unit with these conveying units. In this way it can be made possible in a very short time for the plastics material pre-forms to be at substantially the same temperature.
Nevertheless, the apparatus described in EP 0 736 367 B1 is relatively complicated technically and, in particular, the conveying system is relatively expensive.
DE 10 2008 014 215 A1 describes an apparatus for heating plastics material pre-forms. In this case the plastics material pre-forms are first pre-heated in order to be subsequently heated again in a more energy-efficient manner with a microwave heating device.
A magazine for pre-forms is known from DE 30 20 150 C2. This magazine has a closed housing with vertical lateral walls, and openings for the introduction of hot air kept at a constant temperature by means of a temperature regulating device in order to pre-heat the plastics material pre-forms in a heating zone of the magazine.
The object of the present invention is to make available a facility for the conditioning of plastics material pre-forms, which also permits a uniform heating or conditioning of the plastics material pre-forms even at the most widely varying starting temperatures of the latter.
In addition, it should be possible for this conditioning to be carried out irrespectively of whether the plastics material pre-forms arrive at the conditioning device starting from a production device or starting from very low or very different initial temperatures.
SUMMARY OF THE INVENTION
An apparatus according to the invention for the conditioning, in particular the thermal conditioning, of plastics material pre-forms has a tempering space for receiving a plurality of plastics material pre-forms as well as a supply device in order to supply the plastics material pre-forms to the tempering space. In addition, the apparatus has a removal device in order to move the plastics material pre-forms out of the tempering space, as well as a conveying device which conveys the plastics material pre-forms from the supply device to the removal device in such a way that each plastics material pre-form remains in the tempering space for a pre-set duration of the dwell period.
According to the invention a temperature of the plastics material pre-forms leaving the removal device is substantially constant irrespective of a duration of the dwell period of the plastics material pre-forms in the tempering space and the conveying device is designed in such a way that each plastics material pre-form remains in the tempering space for a period of time of at least 5 minutes.
Whereas reference is made in EP 0 736 367 B1 mentioned above to the fact that the plastics material pre-forms are conditioned only over a relatively short period of time such as from one and a half to two minutes, it is proposed in the scope of the present invention that this period of time should be extended to at least 5 minutes. It is advantageous for the plastics material pre-forms to remain inside the tempering space for a period of time of at least 7 minutes, in an exemplary manner of at least 10 minutes, in a particularly exemplary manner of at least 12 minutes, and in a still more particularly exemplary manner of at least 15 minutes.
On account of this period of time, which is considerably increased as compared with the prior art, it is made possible for the pre-forms leaving the apparatus to be at the same temperature in each case, irrespectively of how long they have remained individually inside the tempering space and also at which initial temperature they were supplied to the tempering space. This is true even if the initial temperatures are considerably different. In addition, it is possible in this way for the apparatus for conditioning also to be used as a buffer for the plastics material pre-forms since no further damage to the plastics material pre-forms occurs even in the case of considerably longer times of the duration of the dwell period.
In this way, it is desirable for the apparatus for conditioning, as described here, also to allow an injection molding machine for producing plastics material pre-forms to be coupled to a stretch blow molding machine, in which case the apparatus according to the invention performs four tasks to this end, namely firstly to bridge the path between the injection molding machine and the stretch blow molding machine, in addition to rectify clock-timed to continuous running, in addition to maintain an energy and heat level and finally possibly also to decouple in the event of failure of one of the two machines.
To this end the apparatus according to the invention mentioned above advantageously has a tempered conveying system or a conveying device which in a particularly exemplary manner has a separation means and a supply channel. These plastics material pre-forms can be supplied by way of the supply device and the tempered plastics material pre-forms can be removed by way of the removal device.
In addition, a feedback unit can also be provided which feeds superfluous plastics material pre-forms for example back into an inlet again. In this way, as mentioned above, the system is designed in such a way that the plastics material pre-forms have a long duration of the dwell period in the tempering space or in the tempering region, which in constant operation is at least 5 minutes, or at least 6 minutes, or at least 8 minutes, and in a particularly exemplary manner at least from 10 to 15 minutes, in which case the duration of the dwell period can be dependent upon a dimension and/or a throughput of the tempering region. This has the consequence that, independently of the temperature at which the plastics material pre-forms arrive in the tempering space and irrespective of how long they are in it, they can be delivered at always approximately the same temperature and thus enter always at the same temperature a blow molding machine arranged downstream.
In this case the deviation from the nominal temperature depends upon the duration of the dwell period and the flow speed in the tempering space, as well as, in addition, the entry and exit temperatures. The apparatus is designed in such a way (in particular with respect to the dimension and the conveying speed of the conveying device) that the duration of the dwell period is at least so long that even in the event of a pronounced fluctuation of the entry temperature there is only a slight deviation at the outlet. A deviation in the range of +/−0 degrees would be ideal, but this would theoretically involve a residence time of infinite length in the tempering space.
For a deviation in the range of +/−2 degrees, depending upon the marginal conditions a duration of the dwell period of from 10 to 25 minutes is necessary (in this case a hot air throughput of at least 500 m 3 /h, or between 800 and 2,000 m 3 /h is taken as a basis and as high a flow speed as possible (of the air to be heated or tempered) of up to 15 m/s.
In the case of an exemplary embodiment the temperature of the plastics material pre-forms leaving the removal device is substantially independent of a temperature of the plastics material pre-forms supplied to the tempering space by way of the supply device. This too, as mentioned above, is attained by way of the relatively long duration of the dwell period of the plastics material pre-forms. In this case “substantially independent” is to be understood as being that the temperatures of the individual plastics material pre-forms differ from one another by not more than 6K, or by not more than 5K, or by not more than 4K, or by not more than 3K, and in a particularly exemplary manner by not more than 2K.
In the case of an advantageous embodiment the conveying device conveys the plastics material pre-forms non-sorted at least locally through the tempering space. This is to be understood as being that the plastics material pre-forms are conveyed for example in bulk through the tempering space. It is desirable, however, for the conveying to be carried out in such a way that the longitudinal directions of the plastics material pre-forms conveyed non-sorted are orientated in more than one direction and in an exemplary embodiment are distributed in a substantially statistical manner. As a result, a considerable simplification of the apparatus is achieved and, in addition, the apparatus can also act as a buffer store for the plastics material pre-forms in this way.
In the case of a further advantageous embodiment the apparatus has a flow generation device which in the tempering space generates an air flow with which it is possible to act upon the plastics material pre-forms. This flow generation device can be for example fans and the like which generate a directed flow of the air or in general a gaseous medium inside the apparatus according to the invention. It would also be possible for sterile air or even a sterilization gas, which not only thermally conditions but also sterilizes the plastics material pre-forms, to be used instead of conventional air.
The time required for the thermal conditioning is reduced by the generation of the air flow.
In the case of a further advantageous embodiment the apparatus has a sensor device for determining a temperature inside the tempering space. In particular, in this case the sensor device determines a temperature of the air situated in the tempering space. In addition, a regulating device can be provided which also permits a setting of this temperature inside the tempering space.
In the case of a further advantageous embodiment the apparatus has conveying regions extending adjacent to one another. In this way, it is possible for the apparatus according to the invention or the tempering space respectively to be made comparatively small. In this case these conveying regions can be made laterally adjacent to one another and/or offset vertically or even in a spiral shape. In this way it would be possible for a plurality of conveyor belts to be arranged inside the tempering space and for the plastics material pre-forms to drop or move in some other way from one conveyor belt to the next conveyor belt. In particular, the conveying device does not extend along a straight line inside the tempering space.
In the case of a further advantageous embodiment the conveying device has a conveyor belt on which the plastics material pre-forms are conveyed through the tempering space. In addition, a plurality of conveyor belts can also be provided, for example conveyor belts—in particular thermally insulated—which are arranged one above the other and which are acted upon with hot air in a regulated manner. In this case these conveyor belts can be designed in such a way that it is also possible for the plastics material pre-forms to be acted upon with hot air from below. It is possible for all the conveying units or only individual conveying units of the conveying device to be fed with one or more tempering devices. This can be carried out for example in a manner dependent upon an initial temperature of the plastics material pre-forms on the supply device.
The present invention further relates to a plant for the treatment of plastics material pre-forms with an apparatus of the type described above, as well as an apparatus—arranged downstream of this apparatus in a conveying direction of the plastics material pre-forms—for shaping the plastics material pre-forms to form plastics material containers. In this case a first heating device for heating the plastics material pre-forms is arranged between the apparatus for shaping the plastics material pre-forms and the apparatus for the conditioning as described above.
This heating device can be for example a furnace which heats the plastics material pre-forms to a temperature which is suitable for shaping the plastics material pre-forms. In contrast, the temperature which is reached in the apparatus for the conditioning according to the invention is for example considerably below this temperature, i.e. a temperature which is for example in the range of between 30° and 70°, or between 40° and 60°, and in a particularly exemplary manner between 45° and 55°. It is desirable that the temperature to be below the glass transition temperature of the material of the plastics material pre-form and desirably at least 5° below the glass transition temperature. In this way, it is possible, even if the plastics material pre-forms are not subsequently shaped to form plastics material containers after leaving the apparatus for the conditioning, for them to be capable of being used again.
In the case of an advantageous embodiment the apparatus has a connecting line which conveys heated air from the heating device and/or the apparatus for shaping the plastics material pre-forms to form plastics material containers to the apparatus according to the invention. In this case in this embodiment the apparatus according to the invention is advantageously operated with the waste air of at least one of the two plants named above.
In the case of a further advantageous embodiment the plant according to the invention has a production device for producing the plastics material pre-forms. This can be for example an injection molding machine which produces the plastics material pre-forms from a raw mass. In this case it is advantageous for this apparatus for producing plastics material pre-forms to be arranged immediately upstream of the apparatus according to the invention. It is desirable for the conditioning apparatus according to the invention to be capable of being optionally equipped by the production device or by a reservoir with plastics material pre-forms. If the plastics material pre-forms, starting from a production device, arrive at the apparatus according to the invention, they are generally at a higher temperature than is present in the tempering space mentioned above. In this case the apparatus according to the invention is used as a cooling device for the plastics material pre-forms.
It would additionally be possible for a further heating device, through which the plastics material pre-forms are likewise conveyed and in which the plastics material pre-forms are tempered to a precise uniform temperature, to be provided between the apparatus for conditioning according to the invention and the heating device mentioned above.
The present invention further relates to a method of producing plastics material containers, in which plastics material pre-forms are heated and are then shaped in a shaping device to form plastics material containers and in which the plastics material pre-forms are conditioned thermally before the heating. In this case the plastics material pre-forms are conveyed by means of a conveying device through a tempering space to the apparatus for the conditioning. According to the invention the plastics material pre-forms are present in the tempering space for a period of at least 5 minutes. It is thus also proposed with respect to the method that the plastics material pre-forms should remain in the tempering space for a specified time (a minimum of 5 minutes) in order to leave it at a substantially constant equal temperature in this way.
It is desirable for the tempering space to have air flow through it. In this case the through-flow can take place in the conveying direction of the plastics material containers, in a direction opposed thereto, or even in other directions. It is advantageous for the plastics material pre-forms to be conveyed non-sorted at least locally through the tempering space and, in a particularly exemplary manner, on at least one conveyor belt.
In the case of a further advantageous embodiment the apparatus is acted upon with waste air from a heating device which is situated upstream of the shaping device and/or with waste air from the shaping device itself.
It is advantageous for a position of the plastics material pre-forms to be altered at least for a time with respect to an air flow for tempering purposes. This can be carried out for example by the plastics material pre-forms passing or dropping from a first conveying device onto a second conveying device or even by being moved in a direction opposed to their conveying device in a purposeful manner by turning devices and/or shaking devices inside the apparatus for the conditioning.
It is advantageous for the plastics material pre-forms to be conveyed in a variable geometrical position with respect to one another. In the case of a further advantageous embodiment the plastics material pre-forms are heated once more after leaving the apparatus for the conditioning. In the case of a further advantageous embodiment the plastics material pre-forms are heated once more before they arrive in the apparatus for the conditioning. It would also be possible, however, for the plastics material pre-forms to arrive in the apparatus for the conditioning immediately after they have been finished or produced.
DESCRIPTION OF THE DRAWING
Further advantageous embodiments are evident from a drawing in several figures, of which:
FIG. 1 is an illustration in the manner of a block diagram of a plant according to the invention for the treatment of containers;
FIG. 2 is a diagrammatic illustration of an apparatus according to the invention for the conditioning of plastics material pre-forms;
FIG. 3 is a diagrammatic illustration of a guide system for plastics material pre-forms;
FIG. 4 shows a possible distribution for the plastics material pre-forms inside the tempering space;
FIG. 5 is a further illustration for conveying the plastics material pre-forms through the tempering space;
FIGS. 6 a -6 c are three diagrams to illustrate a temperature pattern of the plastics material pre-forms, and
FIGS. 7 a -7 b are two illustrations to explain the air tempering for an apparatus according to the invention.
DETAILED DESCRIPTION
FIG. 1 is an illustration in the manner of a block diagram of a plant 40 for the treatment of plastics material containers. In this case an injection molding machine 42 is provided here which produces the plastics material pre-forms and delivers them first of all to a first cooling device 44 . If the plastics material pre-forms produced are not to be immediately further processed, they can be delivered to a magazine or store 48 of plastics material pre-forms by way of a second cooling device 46 . If the plastics material pre-forms are to be formed into plastics material containers immediately after that, they are first transferred to an apparatus for the conditioning 1 according to the invention or are conveyed through this apparatus.
Inside the apparatus 1 the plastics material pre-forms are acted upon with heated air which is supplied in the direction of the arrow P 1 and is removed in the direction of the arrow P 2 . It would also be possible, however, for the flow to be guided in the opposite direction, so that the air flows from the interior of the apparatus 1 in a direction opposed to the conveying direction P of the plastics material pre-forms. The apparatus 1 is adjoined by a tempered separating device 56 in which the plastics material pre-forms are separated on the one hand and are brought to an equal temperature level on the other hand. After that, the heated plastics material pre-forms are supplied to a shaping device 20 such as for example a stretch blow molding machine. In this case this stretch blow molding machine has in turn a heating device 58 in which the plastics material pre-forms are brought to a temperature which is suitable for the shaping procedure.
Alternatively, it would also be possible for the plastics material pre-forms to be supplied from a magazine or a plastics material store 52 , optionally by way of a pre-heating unit 54 , to the apparatus 1 according to the invention. The first cooling device 44 , i.e. the after-cooling station, is usually a component part of the injection molding machine 42 and cools the plastics material pre-forms to a temperature of approximately 70°, so that they are not damaged or deformed during the following conveying.
In the apparatus 1 according to the invention or in the tempering space the plastics material pre-forms advantageously lie non-sorted in the manner of bulk material on a conveyor belt or a similar conveying system and they are cooled or heated with a defined air flow (which can be directed optionally in or contrary to the conveying movement of the plastics material pre-forms). On account of the long duration of the dwell period the temperatures of the plastics material pre-forms approach a controlled circulation temperature in an asymptotic manner. In this case the system can comprise for example one or more thermally insulated conveyor belts which are acted upon in a regulated manner with heated air. Reference number T relates to a conveying direction of the plastic preforms 10 .
The reference number 36 relates to a line by which waste air can be conveyed out of the shaping device 20 to the apparatus 1 , and the reference number 38 relates to a line by which waste air can be conveyed out of the heating device 58 to the apparatus 1 . In this case it would also be possible for the lines 36 and 38 to open into a common collecting line and for a mixing device to be provided which by the respective mixing ratios regulates the temperature of the air flowing into the apparatus 1 .
FIG. 2 shows a possible embodiment of a conditioning apparatus 1 according to the invention. In this case the plastics material pre-forms are conveyed along a spiral path from a supply device 4 through a tempering space 2 and are removed from the tempering space 2 again by way of a removal device 6 . The reference number 12 relates to a guide rail along which the plastics material pre-forms slide through the tempering space 2 also under the action of gravity. In this case it is also possible for the conveying path inside the tempering space 2 to be designed in the form of an accumulation path, so that the tempering space 2 or the apparatus 1 can also act as a buffer.
In addition, it would also be possible for the tempering path discussed above to be formed from a plurality of conveying units which are arranged one above the other or adjacent to one another and which are connected to one another. In this case it is desirable for all the portions or only individual portions to be fed by a tempering unit. The apparatus shown in FIG. 2 can also, however, act as an ascending conveyor.
In this case it is advantageous for the system to be designed to be as compact as possible and, in addition, also for the outer faces 3 to be insulated in order to keep the energy requirement to a minimum. It is desirable for the air tempered in a controlled manner to be conveyed in a circuit in the interior of the tempering space 2 or to be fed back again into the flow line by way of a circulating air heat exchanger described in detail below or a circulating air mixer, in order to lose as little energy as possible to the environment.
In this way, it would be possible for the tempering space 2 to be fed with waste heat from the furnace, a microwave heating means, a compressor, a compression cooler or the like. The reference number 16 designates roughly diagrammatically a sensor device which detects a temperature inside the tempering space 2 , or expressed in more precise terms, a temperature of the air in the tempering space 2 . It would also be possible for a plurality of sensor devices 16 of this type to be provided. In addition, a control device or regulating device can also be provided (not shown) which carries out a control or regulation of the temperature inside the tempering space 2 in reaction to measured temperatures.
FIG. 3 is an illustration to explain the conveying of the pre-forms. In the case of this embodiment the plastics material pre-forms in a guide rail 18 are gripped below their support ring 10 b and are conveyed in this way. In addition, it would also be possible for the region 19 to be acted upon with cooler air so as to treat a thread 10 a of the plastics material pre-forms still more gently in this way.
FIG. 4 shows two possible designs of the conveying or the structured arrangement of the plastics material pre-forms 10 inside the tempering space. In this case the arrows w relate to the supply of heated air. In the case of the left-hand design the plastics material pre-forms are situated in alignment with one another and in the case of the right-hand design they are offset one behind the other.
FIG. 5 shows a further arrangement of an apparatus according to the invention. In this case the plastics material pre-forms are conveyed from one path 32 for example to three paths 34 a , 34 b and 34 c or more and are conveyed on these three paths through the tempering space 2 .
It is possible for the plastics material pre-forms to be supplied separately, but a conventional supply can also be used which is enclosed and is kept at the nominal temperature of the plastics material pre-forms. In the case of this design the plastics material pre-form should no longer be heated or cooled, but should only keep its temperature.
The shaping device 20 shown in FIG. 1 can, as mentioned above, manage with a smaller profiling furnace as compared with the prior art, since significantly less energy is used for heating the plastics material pre-forms.
The second cooling device 46 ( FIG. 1 ) can also be used, in the event of a prolonged disruption at the blow molding machine or in the event that other plastics material pre-forms are produced on the injection molding machine 42 than are required on the shaping device 20 , in order to cool the plastics material pre-forms to a sufficiently low temperature for the plastics material pre-forms to be capable of being transferred into the store 48 without problems. In the store 48 the plastics material pre-forms can be stored in crates or the like, but so-called pre-form silos would also be possible.
The conveying device 54 is used in particular in the event of a failure of the injection molding machine 42 or in the event that other plastics material pre-forms are processed on the shaping device than are produced just on the injection molding machine 42 . In this case the plastics material pre-forms can, if necessary, be taken from a store 52 of plastics material pre-forms and can be pre-heated. In addition, it would also be possible for the pre-heating unit 54 to be incorporated in the apparatus 1 according to the invention. It is also possible for cold plastics material pre-forms from octabins or the like to be supplied, if necessary, from the store 52 .
In the event of a disruption the conveying device 12 remains in the tempering space 2 . On account of the fact that the plastics material pre-forms are brought to the ambient temperature in an asymptotic manner in the tempering space 2 , they cannot overheat but at most adopt the temperature of the surrounding air which is tempered in a controlled manner.
In addition, it is possible for the plastics material pre-forms in the tempering space 2 and/or in the supply to be arranged in a structured manner as shown in FIG. 4 on a conveying device. In this case the distance s 1 of the plastics material pre-forms as shown in FIG. 4 should advantageously be kept as small as possible and the distance s 2 should be set for example to lengths in the range of between 30 and 60 mm, or between 40 and 50 mm, in a particularly exemplary manner in the range of 44 mm. The deviation from the nominal temperature and the duration of the dwell period and thus the overall energy consumption can be reduced in this way. In addition, it would be possible, in the case of a structured arrangement, for the openings to be separated off, as shown in FIG. 3 , in order to prevent unnecessary heat input.
It would also be possible for a tempering in the tempering space 2 to be used only in order to equalize the starting conditions of normal plastics material pre-forms of for example 0 degrees from outside in winter and 40 degrees adjacent to the furnace and to bring them to a constant starting temperature of 45 degrees.
FIGS. 6 a to 6 c show possible temperature patterns of the plastics material pre-forms with a wall thickness of 4 mm over the duration of the heating of the outer wall. FIG. 6 a shows an example of forced convection. It is evident that a temperature difference of 70 K (curve K 1 ) or an increase in temperature of from 20° C. to 90° C. is substantially achieved in a time frame of approximately 10 minutes. If, as indicated by the curve K 2 , a temperature difference of 47 K is to be achieved, this is also possible in a time period of approximately 10 minutes. FIG. 6 b shows the same procedure in the case of free convection. It is evident that in this case substantially longer periods of time are necessary in order to achieve a heating to the ambient temperature of 45° C. As is evident from the curve K, a temperature in the range of 45° C. is achieved only after approximately 3 h.
FIG. 6 c shows three possible temperature patterns, in which it is evident that the temperatures of the plastics material pre-forms have converged with one another very closely essentially independently of the starting temperature at a specified time T 1 , in which case the fluctuations still existing can also be accepted for the processes to be pursued.
It would also be possible for the apparatus according to the invention to be used only in order to improve the overall energy balance of a stretch blow molding plant. In this case the injection molding plant can be omitted completely and instead the operation is carried out with the “pre-form store supply”, as described above, with plastics material pre-forms injection molded at another location at room temperature. Although no residual heat is used from the preceding process in this case, the heating of the tempering path is possible with substantially less outlay and also with less energy input, since more time is available for the introduction of the energy. The convective heat input by way of hot air and the thermal conduction is considerably better in terms of efficiency than the introduction of energy by means of infrared radiation on a short path. In this way, the overall efficiency of the plant is improved and the less efficient infrared heating path can be shortened with respect to a standard stretch blow molding plant.
The deviation of the nominal temperature is lowered to a minimum after tempering in the pre-heating path by tempering and insulation of the separating means and supply rail to the blow molding device. The temperature distribution in and between the plastics material pre-forms is subsequently homogenized by a structured arrangement of the plastics material pre-forms in the supply to the blow molding device.
In order to reduce the deviation of the nominal temperature further it is expedient to mix the plastics material pre-forms during the conveying through the tempering path in a permanent manner or at diverse time intervals in order to change the position of the individual plastics material pre-forms in the hot air flow. This can take place for example by way of a stirring unit or even by way of a shaking apparatus or even a shifting during the conveying between a plurality of conveyor belts.
FIGS. 7 a and 7 b are two illustrations to explain the heat recovery. In this case it is possible for example for outside air AU to be supplied to a heat exchanger 28 , this heat exchanger 28 also being integrated in the heat circuit with the apparatus 1 according to the invention. The reference number 22 designates a fan unit which, in the same way as a further fan unit 24 supplies heated air to the apparatus 1 or the tempering space 2 and also removes it again. In addition, a pre-heating means 26 for pre-heating the air supplied to the apparatus 1 can be provided. This pre-heating means 26 can also be a water/air/heat exchanger and the fan units 22 , 24 can also be axial fans. On account of a recovery of the heat content of the waste air AB it is possible to achieve a considerable reduction of the energy consumption. In this case this waste air AB is supplied to the heat exchanger 28 mentioned above. The reference ZU relates to the supply air.
In this way, in the case of the variant shown in FIG. 7 a , a recovery of heat takes place by way of the circulating air heat exchanger 28 .
FIG. 7 b shows a further variant, in which the recovery of heat takes place by way of an admixture of circulating air. For this purpose a mixing unit 50 is provided in place of the heat exchanger 28 . In the mixing chamber of this mixing unit a certain amount of discharge air FO is admixed with the outside air in order to reduce the energy consumption of the after-heating means as a result, in order to save energy in this way. The reference U relates in this case to circulating air and the reference M relates to mixed air.
Whereas the pre-heating output is 69 or 67 KW during the procedure shown in FIGS. 7 a and 7 b , without this recovery of heat 102 kW of pre-heating output are required.
LIST OF REFERENCES
1 apparatus
2 tempering space
3 outer face
4 supply device
6 removal device
10 plastics material pre-form
10 a thread
10 b support ring
12 conveying device
16 sensor device
18 guide rail
19 region
20 shaping device
22 , 24 fan units
26 pre-heating means
28 heat exchanger
32 path
34 a , 34 b , 34 c paths
36 line to the waste air supply from the shaping device
38 line to the waste air supply from the heating device
40 plant
42 injection molding machine
44 first cooling device
46 second cooling device
48 store of plastics material pre-forms
50 mixing unit
52 store of plastics material pre-forms
54 pre-heating unit
56 separating device
58 heating device
K, K 1 , K 2 curves
T 1 temperature
AB waste air
ZU supply air
FO discharge air
U circulating air
M mixed air
T conveying direction
P 1 , P 2 arrows
w air flow
s 1 , s 2 distance | An apparatus for the conditioning of plastics material pre-forms with a tempering space for receiving a plurality of plastics material pre-forms, with a supply device a removal device, and a conveying device which conveys the plastics material pre-forms from the supply device to the removal device in such a way that each plastics material pre-form remains in the tempering space for a preset duration of the dwell period. The temperature of the plastics material pre-forms upon leaving the removal device is substantially constant irrespective of a duration of the dwell period of the plastics material pre-forms in the tempering space and the conveying device is designed in such a way that each plastics material perform remains in the tempering space for a period of time of at least five minutes. | 8 |
RELATED APPLICATIONS
[0001] This application is a Continuation-in-Part of U.S. patent application Ser. No. 12/217,916 entitled TOWER AND WIND TURBINE SUPPORTING STRUCTURES AND METHOD FOR MOUNTING THE LATTER, FILED Jul. 9, 2008, invented by Russel H. Marvin et al,
[0000] U.S. patent application Ser. No. 12006024 entitled IMPROVED INLET PASSAGEWAY AND SEALING IN A TURBINE WIND POWER GENERATING SYSTEM filed Dec. 28, 2007, invented by Russel H. Marvin, hereby incorporated herein by reference, and
U.S. patent application Ser. No. 12077556 entitled ACCELERATOR FOR USE IN A WIND POWER ELECTRICAL GENERATING SYSTEM, filed Mar. 28, 2008 invented by Russel H. Marvin, also incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The construction of wind turbines and associated apparatus on supporting towers at elevations reaching hundreds of feet is a difficult, dangerous and very expensive proposition. Further, the massive foundations required for the exceptionally high towers are also a major component of the overall cost of wind turbine generation of electrical power.
[0003] Accordingly, it is a general object of the present invention to provide a tower and wind turbine supporting structure configuration and a method of mounting wind turbines and their supporting structures on the tower which dramatically reduces the overall cost of construction of a wind turbine electrical generating system.
[0004] A further object of the invention resides in the provision of an improved foundation system which can be installed employing a relatively simple process involving a minimum number of steps at substantial economic advantage and which is yet highly efficient and efficient in operation.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention and in fulfillment of the foregoing object a tower is provided for mounting wind turbines and their supporting structures which at least partially envelop the tower at elevated positions for enhanced wind velocities. The tower comprises a plurality of horizontally spaced apart vertically extending narrow elongated and lightweight main members and a plurality of shorter narrow lightweight interconnecting cross members extending between the vertical members and cooperating therewith to form a massive monolithic structure having a vertical dimension of at least thirty (30) feet. In the illustrative embodiment of the invention shown and described herein below a tower of two hundred (200) feet in height is provided and the exterior cross sectional configuration and dimensions of the tower from its base to the area of attachment of the wind turbine supporting structures is substantially uniform. A power operated lifting device is provided at the base or the top of the tower as shown and has at least one (1) connected lift line, two (2) shown. Adjacent the base of the tower a plurality of diagonally extending outriggers are also provided for attachment to the tower after the turbines and their supporting structures have been positioned adjacent the tower at its base, raised by the power lifting device, and secured in place at their respective operating positions.
[0006] The outriggers are spaced apart horizontally about the tower and each is of narrow elongated and lightweight but rigid construction longitudinally providing support against both tension and compression loading. Each outrigger has its upper end portion connected to the tower in supporting relationship therewith and its lower end portion is disposed in horizontally spaced relationship with the tower at least approximately at ground level.
[0007] Finally, a foundation system is provided and supports each vertical member of the tower and each outrigger individually at its lower end portion. More particularly, the foundation system preferably comprises an individual foundation for each tower and outrigger member supported thereby, each foundation system including a member of narrow elongated configuration and of composite metallic and concrete construction. The elongated foundation members extend downwardly from their supported members into the earth a substantial distance and provide effective resistance against both compression and tension forces Micro piles are presently preferred.
[0008] In another embodiment of the invention, the vertical members of the tower and the outriggers may be supported by micro piles extending from their supported members to anchors in bedrock which is reasonably close to the surface.
[0009] In an alternative embodiment of the invention three (3) micro piles are provided for each main structural member of the tower and each outrigger and have associated manifolds which receive the inner members of the micro piles through openings and maintain the same in a desired “splayed” configuration. The manifolds also serve as guides during drilling and other activity occurring in formation of the foundations with the inner members of the micro piles passing through their openings and properly aligned and guided thereby.
[0010] Preferably, the wind turbine and support structures carry a pair of turbines on opposite sides of the support structure with a pair of wind accelerating surfaces or passageways respectively capturing and accelerating a flow of wind to the turbines. A wide variety of wind turbine and supporting structures may be employed but the turbine and support structure or “accelerator” design of the aforementioned patents is presently preferred. In this embodiment a cylindrical supporting structure completely surrounds the tower and the tower is of substantially uniform cross section throughout its height. In other embodiments of the invention when the tower may for example have a rectangular cross section with wind turbine supporting structures of generally U-shaped or parti-circular cross section, the relationship between the tower and the supporting structures is established such that the tower exterior dimensions are less than those of the supporting structures at least in the areas where they reside in adjacent relationship during raising and assembly. Thus, for example the fourth exposed side of a rectangular tower may take a completely irregular configuration.
[0011] In accordance with a method of the invention a tower of the desired height and substantially uniform cross section from its base to the desired area of attachment of the wind turbines and their supporting structures is first constructed. At least one wind turbine and its assembled supporting structure is then positioned on the ground adjacent the base of the tower. The wind turbine and support structure is thereafter raised to its desired point of attachment and secured in place. At least three diagonal outriggers and their respective foundations are then provided and the upper end portions of the outriggers are connected to the tower in spaced relationship thereabout, the lower end portions of the outriggers being attached to their respective foundations.
[0012] When each wind turbine and supporting structure comprises a pair of turbines arranged on opposite sides thereof the turbines are spaced apart between 150 and 210 degrees and are approximately one hundred and seventy (170) degrees apart in the presently preferred embodiment of the invention. Each supporting structure at least partially envelops the tower and provides at least one surface to capture the wind and accelerate flow to the turbines. Further, when a plurality of wind turbines and supporting structures are provided, the wind turbines and supporting structures are disposed sequentially adjacent the base of the tower, raised sequentially to their desired positions and attached proceeding from the uppermost wind turbine and supporting structure downwardly to the lowermost.
[0013] As will be apparent, the method of the invention accommodates the construction of the wind turbines and their supporting structures on the ground and thus avoids the excessive labor and/or crane costs encountered with construction at high elevations.
[0014] Optionally, the wind turbines and supporting structures may be manufactured completely on site or manufactured in sections off-site, transported to the site and thereafter assembled sequentially adjacent the tower base.
DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a somewhat schematic elevation showing a tower without outriggers during practice of the method of the invention, a wind turbine and its supporting structure being shown at the base of the tower and a power lifting device at the top of the tower.
[0016] FIG. 2 is a view in elevation similar to FIG. 1 but showing the tower, wind turbines and supporting structures mounted thereon, outriggers in place about the base of the tower with foundation members supporting the tower and outriggers, and
[0017] FIG. 3 is a fragmentary view in elevation showing a lower portion of the tower and outriggers in greater detail.
[0018] FIG. 4 is an enlarged fragmentary perspective view showing a manifold and lower end portions of an outrigger comprising three (3) tubular members with a three member foundation, and
[0019] FIG. 5 is an enlarged fragmentary perspective showing a manifold and a connecting bracket associated with a three member foundation and main structural member of a tower, and
[0020] FIG. 6 is a fragmentary sectional view showing a guide and manifold with associated foundation members during drilling and formation of the micro pile.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Referring in particular to FIGS. 1 and 2 , a tower for mounting wind turbines and their supporting structures is indicated generally at 10 with the tower proper at 12 , supporting structures at 14 , 14 and turbines at 16 , 16 . The illustrative tower 12 shown has a height A of approximately two hundred (200) feet. As best illustrated in FIG. 3 , the tower 12 includes a plurality of narrow elongated vertically extending main longitudinal members 18 , 18 , preferably tubular, and a plurality of shorter narrow interconnecting cross members 20 , 20 . The cross members 20 , 20 may be tubular or triangular in cross section in a truss structure. The members 20 , 20 extend between the members 18 , 18 and cooperate therewith to form a massive monolithic structure having a vertical dimension of at least fifty (50) feet, 200 feet as shown and mentioned above. The cross sectional configuration and other structural characteristics of the tower may vary but in all cases the cross sectional dimensions and configuration of the tower from its base to the area of connection with the wind turbine supporting structures must be at least partially uniform to permit raising of the wind turbines and their supporting structures thereabout. The tower 12 is of a presently preferred triangular vertically uniform cross sectional configuration with the short cross members 20 , 20 extending diagonally between the vertical members 18 , 18 .
[0022] Mounted at or near the top of the tower is a power operated lifting device 21 which is shown with a pair of depending lift lines 23 , 23 respectively on opposite sides of the tower 12 and connected with a wind turbine supporting structure 14 at the base of the tower.
[0023] The wind turbines 16 , 16 and their supporting structures 14 , 14 may vary widely in construction but as mentioned above are preferably of the cylindrical type disclosed in the aforementioned patents and completely surround the tower 12 . It should also be noted that the supporting structures are mounted for incremental rotation about the tower in adjusting the position of the turbines for optimum performance in response to changes in the direction of wind flow.
[0024] As best illustrated in FIG. 3 , a plurality of longitudinally rigid outriggers are provided for support in both tension and compression. As shown, three (3) outriggers 22 , 22 are provided and each outrigger 22 is of tubular metallic construction with three (3) longitudinally extending elongated tubular members 24 , 24 in a triangular configuration and with a plurality of shorter tubular members 26 , 26 interconnecting the longitudinal members. The outriggers 22 , 22 have their upper end portions connected in supporting relationship with the vertical longitudinally members of the tower; three (3) outriggers being provided for the triangular tower 12 . Preferably, the connection of the outriggers with the tower is effected at the point where at least one cross member 20 also connects with a vertical member 18 . The outriggers have a length B in the range twenty (20} to one hundred (100) feet and, in the illustrative embodiment shown, the outriggers have a length B of approximately fifty (50) feet. The outriggers are at an angle with the vertical in the range of thirty (30) to eighty (80) degrees, the preferred angle being approximately sixty (60) degrees.
[0025] At lower end portions the outriggers 22 , 22 are preferably provided with separate foundation members in the form of elongated members 28 , 28 of composite metallic and concrete construction. As shown, the foundation members 28 , 28 take the form of micro piles of the type sold and installed by CON-TECH K SYSTEMS LTD. of 8150 River Road, Delta, B.C. Canada V4G 1B5 under the trademarks SCHEBECK and TITAN and extend downwardly into the earth at angles substantially the same as that of the members which they support. The length of the micro pile members should be in the range of twenty (20) to fifty (50) feet and in the illustrative embodiment shown, the outrigger foundation members 28 . 28 are approximately thirty (30) feet long.
[0026] When bedrock is reasonably close to the surface, the foundation members 28 , 28 may be supported by anchors 19 embedded in the bedrock, one shown on the right hand member 28 in FIG. 2 .
[0027] Foundation members 30 , 30 for the vertical members 18 , 18 of the tower 12 are preferably the same as those for the outriggers with the length of the members falling in the range of twenty (20) to fifty (50) feet. In the illustrative embodiment shown the length of the members 30 , 30 is approximately thirty (30) feet and the members extend vertically, downwardly from the vertical members which they support.
[0028] In accordance with the method of the invention, and as mentioned above, a tower at least partially uniform in cross section is provided and the wind turbines and their supporting structures are positioned at the base of the tower, raised to the area of attachment, and secured in place. When twin turbines are provided, the supporting structures at least partially envelope the base of the tower and may be manufactured off-site in sections and assembled around the tower base, or they may be manufactured on site about the tower base. Thereafter, when all of the wind turbine and supporting structures have been raised and secured in place, the outriggers may be assembled with the tower and their foundations to complete the installation.
[0029] FIG. 4 et sequa illustrate an alternative embodiment of the invention with improved foundation systems providing a higher degree of structural integrity and superior stability for the tower and its wind turbines even in hurricane conditions. Referring particularly to FIG. 4 , lower end portions 40 , 40 of three (3) elongated tubular members forming an outrigger are shown connected by flanges 42 , 42 with short tubular connecting tubes 44 , 44 . The connecting tubes are open at their lower ends and receive upper end portions of tubular metallic inner members 46 , 46 of micro piles 48 , 48 . External nuts 50 , 50 , one shown, cooperate with nuts internally of the connecting tubes together with bearing plates in affecting connections between the outriggers 40 , 40 and the tubular inner members 46 , 46 of the micro piles.
[0030] A manifold 52 , which is preferably of precast concrete, has three (3) openings 54 , 54 for receiving the inner members 46 , 46 of the micro piles. A hardenable medium 56 fills the gaps between the walls of the openings 54 , 54 and the tubular micro pile members 46 , 46 , the former being somewhat larger in diameter than the latter.
[0031] As will be apparent from the forgoing, the upper end portions of the tubular members 46 , 46 of the micro piles are maintained in desired pre-determined positions by means of the manifold 52 , and as will be described herein below, the manifold 52 also serves as a guide during the formation of the micro piles whereby to establish desired predetermined angular relationships of the micro piles.
[0032] In FIG. 5 , a manifold 58 is shown for establishing connection of tubular upper end portions 60 , 60 of micro piles 62 , 62 . The manifold 58 is also constructed of precast concrete in presently preferred form and has three through openings 64 , 64 , two shown, for receiving the tubular inner members 60 , 60 of the micro piles. A hardenable medium 66 , 66 fills gaps between the tubular members 60 , 60 and the walls of the openings 64 , 64 . At upper end portions, the members 60 , 60 are connected with a manifold type bracket 68 which has three (3) flanges 70 , 70 , two shown. The flanges 70 , 70 have openings for receiving the members 60 , 60 and associated upper and lower nuts 72 , 74 secure the members 60 , 60 in the openings in the flanges 70 , 70 . At its upper end, the manifold type bracket 68 carries a large flange 76 for connection with a main vertical structural member of a wind turbine tower. An associated truss member may be connected with the bracket 78 .
[0033] The micro piles 48 , 48 and 62 , 62 extend a substantial distance downwardly into the earth and are between 20 and 50 feet in length, preferably approximately 30 feet long for both the outriggers and the main structural members of the tower. Further, the micro plies extend in a “splayed” relationship with each other, FIG. 6 , for maximum effectiveness in both compression and tension. The angular relationship of the micro piles with respect to the centerlines of their supported members may vary but it is preferred to maintain a displacement of approximately 3 degrees from the centerlines of the outriggers and a displacement of approximately 10 degrees from the centerlines of the structural members of the towers.
[0034] Referring now to FIG. 6 , the template function of the manifolds 52 , 58 is illustrated subsequent to the drilling operation and the injection of concrete through a tube such as 60 a . The tube 60 a may be entered in an opening 54 a and maintained in position on completion of drilling and concrete injection by means one or more small inserts 80 , 80 positioned in the opening 54 a . A first insert 80 is shown in the opening 54 a in FIG. 6 and a second insert 80 is shown above the upper end of the tube 60 a . As will be apparent, the inserts 80 , 80 will serve to maintain the tubular member 60 a in a desired angular position when drilling and formation of the micro pile is complete with the concrete remaining in an unhardened condition. The inserts 80 , 80 are retained in the opening 54 a during grouting of the opening 54 a with hardenable medium and insure precise final positioning of the upper ends of the members 60 a , 60 a for connection with their respective supported members.
[0035] As will be apparent from the forgoing, both an improved tower and an improved foundation system have been provided with substantial savings achieved particularly in the foundation system.
[0036] The erection method of the invention also provides for substantial savings in avoidance of the excessive cost of labor and large cranes for assembly or repair of the wind turbines and supporting structures at high elevations. | A tower and wind turbine supporting structure which at least partially envelops the tower. The tower is of uniform cross sectional configuration throughout and has a plurality of outriggers. The outriggers are connected with the tower after the wind turbines and their supporting structure have been positioned at the base of the tower, raised to their point of attachment and secured in place. Individual foundation members for each vertical tower member and for each outrigger are in the form of micro piles and may include a plurality of micro piles and a manifold for maintaining upper end portions thereof in desired positions. Another aspect of the method of the invention involves providing a tower of uniform cross section, positioning wind turbines and their supporting structures sequentially at the base of the tower, raising them and mounting them on the tower sequentially, and thereafter providing a plurality of outriggers and their foundations and attaching them to the tower. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to bed frames and more particularly pertains to a new multiple configuration bed frame system for allowing a single or multiple bed frames to be configured in many different ways to accommodate available space and the creativity of the user.
2. Description of the Prior Art
The use of bed frames is known in the prior art. U.S. Pat. No. 6,314,595 issued to Price describes an interlocking bed frame with an integrated ladder and safety rail. The Price device has a number of individual bars and rails that interconnect and are held in place by pins extending through the corner posts.
Another type of bed frame is U.S. Pat. No. 2,945,241 issued to Sideroff. The Sideroff patent discloses a convertible bed that is expandable from a configuration having the appearance of a single bed to a configuration having multiple beds or bunks. U.S. Pat. No. 4,788,727 issued to Liu discloses a collapsible base frame for supporting a bed, particularly a water-filled mattress. U.S. Pat. No. 3,967,327 issued to Severson discloses a foldable bed assembly having multiple cot-like frames positionable in a bunk like configuration. U.S. Pat. No. 5,655,234 issued to Randleas discloses a static frame having a lower bed and a vertically movable bunk. U.S. Pat. No. 5,911,245 issued to Kurz discloses a joint structure for a hinged frame positionable for supporting a person in a prone position. U.S. Pat. No. 1,724,852 issued to Scott discloses a hinged or collapsible bed structure. U.S. Pat. No. 4,179,763 issued to Echavarren discloses another collapsible double bunk bed structure. U.S. Pat. No. 895,898 issued to Scheer discloses a bunk bed structure using bars and posts to be easily assembled and lightweight. U.S. Pat. No. 1,389,697 issued to Phipps discloses a very simple and easily assembled double bunk bed structure. U.S. Pat. No. 1,624,950 issued to Hoard discloses a multi-function support structure for use as a slumber bed, cooling board, and casket support. U.S. Pat. No. 3,747,134 issued to Montiague discloses a sofa convertible into a double bunk bed structure. U.S. Pat. No. 5,865,128 issued to Tarnay discloses a folding leg mechanism for supporting a planar structure such as a table or mattress support. The published U.S. patent application No. 2002/0092445 of Glover et al. discloses a collapsible and folding banquet table.
While these devices fulfill their respective, particular objectives and requirements, the need remains for a system that provides even greater flexibility in the possible configurations and superior storage potential of unused component parts.
SUMMARY OF THE INVENTION
The present invention meets the needs presented above by providing a bed frame system having component bed frames, leg and rail structures, and storage options for compactly storing unused components. The components of each bed frame unit will interlock with another bed frame unit to permit multiple configurations having multiple bed spaces.
An object of the present invention is to provide a new multiple configuration bed frame system that has storage options for unused components to prevent loss of component parts.
Another object of the present invention is to provide a new multiple configuration bed frame system that provides myriad configuration possibilities to permit users having traditionally few furniture options, such as college dorm residents, to exercise creativity in configuring necessary furniture.
Still another object of the present invention is to provide a new multiple configuration bed frame system that efficiently utilizes available space.
Even another object of the present invention is to provide a new multiple configuration bed frame system that allows compact positioning of multiple bed spaces within a small area.
Yet another object of the present invention is to provide a new multiple configuration bed frame system that is easily assembled and disassembled to permit efficient reconfiguration of the bed structure.
Still even another object of the present invention is to provide a new multiple configuration bed frame system that is durable, sturdy and stable.
To this end, the present invention generally comprises at least one main frame member, an optional rail member, raised bed leg members, and short leg members that also serve as frame connectors for joining two or more main frame members. A plurality of receivers are coupled to the main frame member and positioned to permit joining of the components of the invention to form various configurations.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
The objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a new multiple configuration bed frame system according to the present invention.
FIG. 2 is a perspective view of the present invention in an end to end configuration.
FIG. 3 is a perspective view of the present invention in a spaced end to end configuration.
FIG. 4 is a top view of the present invention in an L-shaped configuration.
FIG. 5 is a bottom view of the main frame member of the present invention.
FIG. 6 is a side view of the main frame member of the present invention.
FIG. 7 is a side view of the attachment means of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 7 thereof, a new multiple configuration bed frame system embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
As best illustrated in FIGS. 1 through 7 , the multiple configuration bed frame system 10 in the simplest form generally comprises a main frame member 20 and a plurality of leg members 40 . A plurality of leg connection members 22 are coupled to the main frame member 20 for attaching the leg members 40 to the main frame member 20 to support the main frame member 20 . The main frame member 20 includes cross members for supporting a mattress. The plurality of leg members 40 includes short leg members 42 and elevated leg members 44 . The elevated leg members 44 each include a pair of outer side members 46 and cross members 48 extending between the outer side members 46 . The cross members 48 form a ladder 50 for facilitating access to the main frame member 20 when the main frame member 20 is supported by the elevated leg members 44 . The elevated leg members 44 have a length greater than the short leg members 42 for supporting the main frame member 20 at a higher elevation than the short leg members 42 . Thus, by selecting either the short or elevated leg members, the main frame member is positionable at different elevations.
Leg locking means 52 are provided for securely coupling each of the leg members 40 to a selectable one of the leg connection members 22 . The typical leg locking means 52 comprises each leg member having a biased protrusion extending through an aperture adjacent to the inserted end of the leg member. The protrusion is pushed into the leg member to permit insertion of the leg member into the leg connection member. Each leg connection member includes an aperture for receiving the protrusion, thus locking the leg member in place. Removal is achieved by pressing on the protrusion directly when the leg connection member has an aperture that exposes the protrusion.
The leg connection members 22 include end leg connection members 23 that are pitched outwardly such that lower ends 45 of the elevated legs 44 are spaced when the elevated leg members 44 are coupled to the end leg connection members 23 . The outward pitching and length of the elevated leg members 44 permits positioning of a second main frame member 20 beneath a main frame member 20 supported by elevated leg members 44 when the second main frame member is supported by short leg members 42 . The depth of the leg receivers is preferably not greater than the depth of the main frame member to prevent the leg receivers from protruding downwardly from the main frame member. However, additional support for the leg members may be obtained by utilizing leg receivers having greater depth.
In an embodiment, a rail member 30 is couplable to the main frame member 20 . A pair of rail collars 32 are coupled to the main frame member 20 and positioned on an underside of the main frame member 20 . The rail collars 32 are positioned to hold the rail member 30 in a storage position extending along the underside of the main frame member 20 .
For connection of the rail member 30 to the main frame member 20 , the main frame member 20 includes a pair of recesses 34 positioned in spaced relationship along one long side 21 of the main frame member 20 . The rail member has a pair of opposite ends 31 insertable into the recesses 34 such that the rail member 30 extends up from the long side 21 of the main frame member 20 .
Rail locking means 36 are provided for releasably securing the opposite ends 31 of the rail member 30 in the recesses 34 . The rail locking means also employs a biased protrusion similar to the leg locking means 52 except the biased protrusion is rigidly attached to a button portion remote from the protrusion such that pushing on the button portion will retract the protrusion into the rail member to permit removal of the rail member from the depression in the main frame member. It is to be understood that the rail member may be attached to a collar extending from the main frame member and utilizing a locking means similar in structure to the leg locking means 52 . Conversely, the leg connection members may restrict direct access to the biased protrusion of locking means 52 in which case a locking means similar to rail locking means 36 may be employed.
The main frame member 20 further has a plurality of interconnection receivers 24 for facilitating interconnection of multiple main frame members. Each of the interconnection receivers 24 is structured to receive a selectable one of the leg members 40 , typically one of the short leg members 42 , such that leg member 40 is partially inserted into the main frame member 20 and extends outwardly from the main frame member 20 . The extending portion of the leg member 40 is then insertable into a selectable interconnection receiver 24 of a second main frame member 20 to couple the main frame members together. Leg members 42 have locking means 52 on each end for securely interconnection the main frames.
The interconnection receivers 24 of each frame member includes a pair of end connection receivers 28 . Thus, first and second main frame members 20 are couplable to each other by alignment of the main frame members and insertion of leg members 40 into the end connection receivers 28 to form an end to end configuration as seen in FIG. 2 .
In an embodiment, each of the main frame members 20 has a respective side leg receiver 25 positioned in spaced relationship to an end of the main frame member 20 . The side leg receivers 25 are for receiving a respective one of the outer side members 46 of one of the elevated leg members 44 when the main frame members 20 are in the end to end configuration. Thus, an elevated leg member 44 is positioned along a side of the end to end positioned main frame members 20 . However, the strength of materials used is preferably sufficient to make use of the elevated leg member 44 along a side of the end to end configuration optional.
The interconnection receivers 24 of the main frame members 20 also include a pair of side connection receivers 29 . The side connection receivers 29 are spaced to conform to the spacing of the end connection receivers 28 . Thus, first and second main frame members 20 are couplable to each other to form an L-shaped configuration as seen in FIG. 4 .
Support members 66 are insertable into the interconnection receivers 24 for coupling main frame members 20 together in spaced relationship to each other. The support members 66 have a length longer than the short leg member 42 to permit ample support of the main frame members and the desired spacing. The side leg receivers 25 are positioned appropriately from the ends of the main frame members to permit coupling of the elevated leg members 44 to extend along the side and between the spaced end to end main frame members. When in the spaced end to end configuration, the cross members 48 of the elevated leg member 44 positioned between the main frame members forms a ladder for facilitating access to the main frame members through an opening 68 formed between the main frame members and the support members.
It is to be understood that the inventive system may include main frame members having a limited number of specifically positioned interconnection receivers to permit only specific configurations between given main frame members. However, full functionality and creativity is provided by each main frame member having the full compliment of interconnection members to permit the maximum number of possible configurations.
A plurality of leg storage receivers 60 are coupled to the main frame member 20 for facilitating storage of unused leg members 40 . Typically, the leg storage receivers 60 are coupled to the underside of the main frame member and pitched slightly downward to prevent interference between the stored rail member and a stored elevated leg member attached to the leg storage receivers 60 .
The elevated leg members 44 also include storage collars 49 . The storage collars 49 are positioned and spaced such that the elevated leg members 44 are nestable in series for storing a plurality of elevated leg members 44 coupled to the main frame member 20 as shown in FIG. 7 . Due to the uniform sizing of the leg members and various receivers and collars, the short leg members 42 are also couplable to either the leg storage receivers 60 or the storage collars 49 . Further, the positioning of the storage collars 49 aligns below at least one of the cross members of the main frame to provide potential support to the main frame in the event the locking means of the elevated leg member fails and the upper end of the elevated leg member begins to pass through the receiver. In the event failure occurs, the cross member will contact the storage collars of the elevated leg member as an added safety feature to minimize the chance for significant injury during use.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A multiple configuration bed frame system for allowing a single or multiple bed frames to be configured in many different ways to accommodate available space and the creativity of the user includes at least one main frame member, an optional rail member, raised bed leg members, and short leg members that also serve as frame connectors for joining two or more main frame members. A plurality of receivers are coupled to the main frame member and positioned to permit joining of the components of the invention to form the various configurations. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/977,960 entitled “Reconfigurable CMOS Image Sensor,” filed Apr. 10, 2014, the contents of which are hereby incorporated by reference.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0002] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND AND SUMMARY OF THE INVENTION
[0004] Stacked CMOS image sensor chips are known in the art. In a common configuration, a chip optimized for image sensing functions is stacked on top of another chip optimized for processing functions. Light capture, charge integration, pixel readout, and conversion to digital signal are typically performed on the top chip. The bottom processing chip typically performs downstream processing of the digital signals received from the image sensor chip. Among the various processing functions that may be performed are, for example, color derivation, data compression, and conversion of data to standard graphics file formats for export to the device memory or other destinations external to the image sensor chip.
[0005] While some aspects of the circuitry on the processing chip may be standardized, these chips are generally customized and specifically designed for each particular image sensor. The chip layout design and the development of fabrication schemes required for the manufacture of prior art chips are significant undertakings and are generally very expensive. This high non-recurring engineering cost presents a significant barrier to the development of chips performing new processing schemes, for example specialty image sensors for small markets. Accordingly, there is a need in the art for simplified means of producing customized image sensors.
[0006] The present invention fulfills the unmet need in the art for affordable and facile image sensor customization. The image sensors of the invention comprise reconfigurable components that can be programmed and customized to perform a very broad set of operations. These novel image sensors and associated methods provide the art with a means of obtaining a customizable image sensor without the substantial non-recurring engineering costs encountered using current technologies. In the semiconductor business model, the production cost per part is highly dependent on the total manufacturing volume of the part and tends to go down with higher manufacturing volumes. The methods of the invention allow a single image sensor to be utilized in a variety of applications, significantly reducing the cost per part.
BRIEF DESCRIPTION OF THE DRAWING
[0007] FIG. 1 is an exploded view of the two wafers of a stacked image sensor chip of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The invention is directed to image sensors comprising at least two layers, the two layers being stacked and bonded to create a functional image sensor. The top layer will be referred to herein as the top chip or imaging chip. This top chip is stacked atop one or more lower layers comprising processing chips. For convenience, the description herein will be directed to a two-layer image sensor, wherein a single processing chip, referred to as the bottom chip is stacked below the imaging chip. However, it will be understood that the various components and functions of the bottom chip can be implemented on multiple stacked processing chips, for example, two, three, or four processing chips.
[0009] The description of the invention provided herein will make reference to various components, such as “memory components” or “ADC components.” It will be understood that each such component may be comprised of multiple elements which enable its function. For example, the ADC component of a processor chip may comprise multiple elements such as comparators, amplifiers, and capacitors.
[0010] A major aspect of the invention is the use of one or more configurable components in the processor chip. “Configurable,” as used herein, refers to the ability of a component to be programmed or otherwise set up or commanded to function in two or more alternate operational modes. Configuration may be performed via the I/O interfaces residing on the processing chip, or by other external data transmission components. Configurable components may comprise one-time programmable processor technologies. Alternatively, the configurable component may comprise as a fully programmable processor technology. Fully programmable processors are generally preferred in most implementations, as these allow for updates and upgrades to the components or system to be implemented. The programmable components allow a single chip design to serve multiple input, processing, and output operations, allowing novel chip designs to be tested and applied without the usual prohibitory up-front costs of developing a custom chip.
[0011] The Imaging Chip. The top layer of the stacked image sensors of the invention is the imaging chip. This chip comprises an array of pixels. The pixels comprise the standard components of a CMOS image sensor including a photodiode, transistors and other components for integrating charge, charge readout, and reset. Components for correlated double sampling can also be included. The top chip will also comprise control signal lines and buses for directing operation of the imaging chip and readout of signals from each pixel.
[0012] The photodiode of the imaging chip pixels may be of any type known in the art. The selection of photodiode type will depend on the specific applications for which the sensor is designed. The optimal substrate materials and processing methods will depend on the type of photodiode selected, as known in the art. Any photodiode type known in the art may be employed in the practice of the invention. For example, a P-well/n-substrate may be utilized. The photodiodes of the invention may also comprise N-well/p-substrate designs, as known in the art. P-N, P-I-N, avalanche photodiodes, reverse avalanche photodiodes may also be used. The use of pinned photodiodes is preferred. Non-silicon photodiode materials, for example gallium arsenide (GaAs), Indium gallium arsenide, or germanium may also be used to the extent that they are compatible with wafer level processing or integration with silicon wafers and to the extent that they may be efficiently bonded with silicon wafers.
[0013] The pixel designs may be of any type known in the art. For example, 3T designs, 4T designs, global shutter designs, and pixels having hybrid global shutter/rolling shutter functions, as known in the art, may be used.
[0014] It will be understood that the pixel array of the top imaging chip may be overlaid by any number of various filters (e.g. Bayer arrays) or microlens assemblies, as known in the art.
[0015] In one implementation, the control lines that direct operation of the imaging chip are connected to components of the bottom processing chip, such that the bottom processing chip can operate the pixels of the top imaging chip. In an alternative embodiment, the control lines are operated independently of the bottom processing chip, however this implementation does not allow customized operation of the top chip by the configurable components of the processing chip.
[0016] In one implementation, the imaging chip comprises analog-to-digital conversion (ADC) components, such that signals from the individual pixels can be converted to digital signals on the top imaging chip. These digital signals can be routed by vias or other stacked wafer interconnects to the processing components of the bottom processing wafer for storage and further operations. In an alternative embodiment, the analog outputs from the pixel array are stored in an array of sample-and-hold circuits residing on the top chip, the outputs of which can be routed, by vias or other stacked wafer interconnects, to the bottom processing wafer for conversion to digital signals by ADC components present on the bottom processing wafer.
[0017] The Processing Chip. The bottom processing chip comprises any number of components, as described next.
[0018] Configurable Signal Receiving and Initial Processing Components. Components on the bottom chip receive and perform initial processing of analog or digital pixel readout signals from the top chip. The signal receiving and initial processing components may be programmable, configurable circuitry that is used to receive and format pixel readout data from the top image sensor chip for subsequent processing. Advantageously, a customizable signal receiving and initial processing means can be used to accept a range of readout speeds and a to accommodate a wide range of signal output formats.
[0019] In one embodiment, the top imaging wafer comprises a series of sample-and-hold circuits, these being in connection series of ADC components on the bottom processing wafer and which convert the analog signals from the top wafer pixels to digital signals. Generally, in this configuration, to avoid noise, parasitic capacitance, and other data quality issues, it will be optimal that the ADC components of the bottom chip be stacked directly below the sample-and-hold components of the top wafer, such that the length of the signal path between them is minimized.
[0020] Memory Components. The processing chip also comprises one or more memory components, wherein signal data can be stored prior to, during, or after signal processing. Any suitable memory module known in the art may be used. SRAM, RAM, DRAM, mixtures thereof, and other memory types known in the art can be used. The one or more memory elements serve the other components of the processor chip by providing transient data storage, buffering, and other functions where memory means are required. The memory means are optionally configurable for efficient interfacing with other components.
[0021] Configurable Image Sensor Control Components. Some implementations of the invention comprise image sensor control components residing on the bottom processing chip. This configurable element or group of elements can be programmed to drive the operation of the image sensor in any desired mode, frame rate, readout scheme, etc., limited only by the innate abilities of the pixel design in the overlaying image sensor chip. The image sensor control means can drive clocks, control signals (e.g. opening and closing of gates), and readout bus selection, among other functions normally encompassed in the operation of image sensing chips. Image sensor control components are connected to the upper imaging sensor chip by control lines which deliver signals to the upper chip.
[0022] The image sensor control functions can be implemented by one or more configurable microcontrollers. The microcontrollers may be of any type known in the art.
[0023] Configurable Signal Processing Components. The bottom processing chip comprises one or more configurable processors that can be programed to perform any number of logic or computational operations. These components allow customizable signal processing. General purpose processor modules may be used, preferably of sufficient size, speed, and power to effectively perform a wide range of complex operations. These custom processor components may be used for any number of standard and non-standard data processing steps, as described below. The custom processor means may optionally employ field-programmable gate array technologies known in the art, or similar technologies which enable broad customization of processor function. The signal processing components may also comprise one or more embedded systems for the efficient performance of common image data processing functions.
[0024] Configurable I/O. The bottom processor chip comprises one or more configurable I/O components. The configurable I/O components enable efficient communication and interfacing with the device in which the imaging module resides.
[0025] The configurable I/O components allow for inputs to the processor chip. Exemplary inputs include programming instructions for configuring the components of the image sensor. Configuration of image sensor operations can be input, and updates to previously installed programming can be readily delivered. Commands to switch image sensor operational modes can also be input via the I/O interface.
[0026] The configurable I/O components also enable efficient output of processed image data to the external memory or device in which the image sensor resides, enabling utilization of a wide range of signal outputs from the image sensing chip.
[0027] The I/O may perform “handshake” operations, perform data format conversion operations, perform channel selection, and other standard I/O functions. The configurable I/O preferably encompasses sufficient hardware elements and processing power and versatility to perform operations across a wide range of output data formats and interfaces. For example, the configurable I/O means may be compatible with various system interfaces, including: network connections (e.g. Ethernet, Wi-Fi, Bluetooth, etc.); memory standards (e.g. DDR3, DDR4); external processors (e.g. MIPI, XAUI); and output formats (e.g. PCIe, USB, CameraLink, etc).
[0028] Wafer Materials and Processing. The distribution of imaging and signal processing components on different chips provides advantages in manufacturing and performance. This allows for optimized substrate material selection and processing techniques for the components of each wafer, avoiding compromises in sensor performance and alleviating the need for complicated fabrication schemes that result when all components of a pixel and associated signal processing components are required to use a single fabrication process regime. For example, pixels can be made using substrates, tools, processing methods, and rules which are optimal for the creation of high-quality photodiodes. For example, the top wafer may be fabricated using elemental silicon and may be made using 180 nm processing. The bottom processing wafer may be fabricated using materials, rules, and processes optimized for high-performance devices, for example being fabricated using 65 nm processing.
[0029] Arrangements of the Components. The invention is not limited to any specific combination or arrangement of the various components. Within the processor chip, the size, distribution, and design of each component may be selected to effect any desired range of capabilities. It will be understood that each component may be present as a singular component or as multiple or distributed components.
[0030] The alignment, bonding, and interconnection of the top image sensor chip and underlying processor chip may be accomplished by any means known in the art for stacking multiple wafers, for example by bump bonding, direct wafer bonding, thermocompressive bonding, adhesive bonding, etc. Through-silicon vias, and other interconnects known in the art may be employed to connect top wafer and bottom wafer components.
[0031] An exemplary embodiment of the invention is depicted in FIG. 1 , which is an exploded view of a stacked image sensor assembly. In this implementation, the stacked image sensor comprises a top imaging chip ( 101 ) and a single bottom processing chip ( 102 ). The imaging chip comprises an array of pixels ( 103 ) and a series of sample-and-hold circuits ( 104 ) which receive and store pixel signal outputs. Configurable signal receiving and initial processing components (e.g. ADC components) ( 105 ) reside on the bottom processing wafer directly below the sample-and-hold circuits of the top wafer. The bottom signal processing wafer also comprises a configurable memory component ( 107 ), a configurable signal processing component ( 106 ), a configurable microcontroller ( 108 ) and a configurable I/O series of components ( 109 ).
Operation of the Configurable Processor Chip
[0032] Advantageously, the use of a multiple configurable components enables fully customized operation of the image sensor chip, allowing the user to implement operations that optimize noise reduction, control power consumption, or adapt the image sensor for specific conditions. For example, in high speed photography or for extending dynamic range, operation of the image sensor chip at high frame rates is desirable. Conversely, if low power consumption is a desired feature, the image sensor chip may be configured to run at lower frame rates or with readout schemes that reduce power consumption. These competing performance objectives can be balanced as desired with the programmable image sensors of the invention.
[0033] The programmable processor is versatile and able to perform any number of data processing functions. Exemplary processing capabilities include color derivation, noise cancellation, tone mapping, image artifact rectification, data compression, etc. Advantageously, these operations can be customized as desired, allowing users to implement specific needs, or enabling providers with unique capabilities to make their technology available without manufacturing a custom chip. Exemplary specialized functions include WRGB or other irregular color processing, gesture recognition, facial recognition or other biometric functions, event detection, high dynamic range implementation, rolling shutter artifact correction, data reduction or compression schemes, and any number of other image data processing steps known in the art.
[0034] The image sensor chips can be programmed to operate in a single mode, or may be programmed to dynamically switch between two or more operational modes. For example, different modes may be enabled by manual selections made by users. Alternatively, automated switching between modes may be performed based on external conditions or stimuli (e.g. low light, camera movement, etc.), for example as detected by the signal processing functions of the processing chip or in response to inputs from components external to the stacked image sensor (e.g. light meters, gyroscopes, etc).
[0035] The scope of the invention further encompasses methods of using the stacked image sensors disclosed herein. In one embodiment, the methods of the invention comprise the initial programming of the configurable components of the stacked image sensor. In another embodiment, the methods of the invention comprise reprogramming, updating, or upgrading of a previously configured stacked image sensor of the invention.
[0036] Image sensor ADC elements currently in use may be configured in numerous ways. For example single slope, successive approximation, pipeline, flash, and folding ADC's all use comparators, amplifiers, and capacitors in various proportions and numbers. Each such fixed configuration will have unique properties, and performance characteristics will represent trade-offs in conversion rate, noise, and power consumption.
[0037] The reconfigurable image sensors of the invention may encompass general purpose ADC's having sufficient numbers of comparators, amplifiers, and capactiors as well as configurability of these elements such that they may be configured in various ways, for example in two or more ADC modes known in the art, including for example, two or more modes selected from the group consisting of the following: single slope, successive approximation, pipeline, flash, and folding ADC's. It is understood that image sensor control elements, memory elements, and processor elements are also configurable as necessary to enact and support the various ADC modes.
[0038] Configurability of ADC elements in the reconfigurable image sensors of the invention allows a single image sensor type to operate in a variety of modes. For example, using column parallel ADC's for image sensors is advantageous for high resolution arrays, because the data from an entire row of pixels is converted simultaneously. In contrast, higher frame rates can be achieved by reducing the number of rows (vertical resolution), but it's not possible to increase frame rate by reducing the number of columns (horizontal resolution). Utilizing the methods of the invention, a column parallel ADC can be reconfigured to utilize a smaller number of higher speed, serial ADC's for lower resolution, obtaining significantly higher frame rate when both vertical and horizontal resolutions are reduced.
[0039] Flexibility in the configuration of ADC's and supporting components allows for operation of a single image sensor in multiple modes. For example, the sensor can be configured for regular picture or video capture (in high resolution configuration), but can then be reconfigured to a low-resolution, high-speed sensr, for example, for iris recognition (for biometric applications) in the same camera.
[0040] In one embodiment, the column parallel ADC's can be slower single slope or dual slope ADC's, as known in the art. Each such ADC configuration would utilize one comparator. These comparators could alternatively be reconfigured to make a “flash” ADC that uses many comparators (8-bit flash ADC uses 256 comparators—generally N-bit flash uses 2̂N comparators) that is much faster than a single slope and can accept data from fewer columns as well as rows.
[0041] Conversely, if lower noise or bit-resolution is required, the single slope ADC's can be reconfigured to an over-sampling (or sigma-delta) ADC that uses one comparator per ADC. However, the over-sampling ADC uses a significant amount of digital processing (decimation) during the conversion. If the digital circuits are made from configurable digital processing blocks, they can be reconfigured to change the ADC type.
[0042] In general, digital processing is an important part of modern ADC's and reconfigurable processing allows enhancement and modification of the ADC's for each configuration.
[0043] The disclosed embodiments are presented for purposes of illustration and not limitation. While the invention has been described with reference to the described embodiments thereof, it will be appreciated by those of skill in the art that modifications can be made to the structure and elements of the invention without departing from the spirit and scope of the invention as a whole. | CMOS image sensors are generally customized and designed for specific functions and capabilities. Chip layout design and the development of fabrication schemes are very expensive. This high non-recurring engineering cost presents a significant barrier to the development of chips performing new processing schemes, for example specialty chips for small markets. Accordingly, there is a need in the art for simplified means of providing customized image sensors. Disclosed herein are novel stacked image sensors comprising an image sensor wafer stacked on one or more customizable processing wafers. The processing wafer comprises one or more reconfigurable components that can be programmed and customized to perform a very broad set of operations, providing the art with a means of obtaining a customizable image sensor without the substantial non-recurring engineering costs encountered using current technologies. Reconfigurable components include ADC components, memory components, chip control components, data processing components, and I/O interface components. | 7 |
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a Continuation-In-Part application of International Application No. PCT/US2011/063429, filed Dec. 6, 2011, designating the United States which claims the benefit of U.S. Provisional Application No. 61/420,268, filed Dec. 6, 2010; this application is also a Continuation-in-Part of U.S. application Ser. No. 13/312,156, filed Dec. 6, 2011, which claims the benefit of U.S. Provisional Application No. 61/420,268, all of which are hereby incorporated herein by reference in their entireties.
TECHNICAL FIELD
[0002] This invention relates generally to fluid couplings and more particularly to fluid couplings having seal assemblies including flexible gaskets and flexible retainers for those gaskets.
BACKGROUND
[0003] Ring seals are typically annularly shaped, defining an axially aligned hole for gas or fluid passage, two axially opposed end surfaces, a radial inner surface and a radial outer surface. A simplistic ring seal has planar end surfaces and smooth circular radial inner and outer surfaces that define the inner diameter (ID) and outer diameter (OD) of the ring seal. However, it is common practice in the industry to utilize seals having different radial cross-sections to obtain varying sealing capabilities for different fluid flow environments.
[0004] A commonly used ring seal is circular and has a radial cross-section of a “C” shape. These “C seals” are constructed with the open side of the C construction facing the center of the ring such as is described in U.S. Pat. No. 5,354,072, (“the '072 patent”) or with the open side of the C facing away from the center of two mating surfaces are brought together with the C seal in the middle, where the C seal is compressed with the open side of the C cross-section closing during compression. The ductile properties of the seal permit plastic deformation to occur without damaging the mating surfaces.
[0005] Additional seals that have been available include “V” seals, which are also circular, but instead of having a “C” cross-section, have a “V” cross-section with the low point of the V constructed to point either inwardly or outwardly towards the center of the seal. Other seals known in the art include “Z” seals and simple O-rings. These other types of seals are discussed, for example, in U.S. Pat. No. 6,708,985 (“the '985 patent”). Both of the '072 and '985 patents are herein expressly incorporated by reference, in their entirety. Still another type of ring seal known in the industry is the “W” seal. Such a sealing system is disclosed, for example, in U.S. Pat. No. 7,140,647 (“the '647 patent”), also herein expressly incorporated by reference, in its entirety. The “W” seal in the '647 patent uses a snap ring situated on the inside of a retaining ring, identified in the patent as a guide, to retain the W-seal in the retainer and to keep the sealing surfaces on the W-seal or gasket protected from scratches. The '647 patent retainer or guide also has a snap ring situated on its outside diameter to keep the retainer engaged in the ‘counterbore.’
[0006] FIGS. 1-4 illustrate a typical prior art W-seal 2 , comprising a retainer sleeve 2 a, and a metal seal 2 b. As discussed above, the assembly 2 further comprises an interior snap ring 2 c and an exterior snap ring 2 d. To accommodate these snap rings, there is provided a first Outside Diameter (OD) groove 2 e on the outer surface of the retainer sleeve 2 a, and an Inside Diameter (ID) groove 2 f on the inner surface of the retainer sleeve 2 a. Additionally, a second OD groove 2 g is provided on the outer surface of the metal seal 2 b, which corresponds to the ID groove 2 f, wherein the second OD groove 2 g and the ID groove 2 f together accommodate the interior snap ring 2 c. It should be noted that the cut in the ring and seal shown in FIG. 2 is illustrative only, for the purpose of illustrating particular constructional features of the seal assembly. In actuality, both the seal and the retaining ring are circumferentially continuous and unbroken.
[0007] Thus, each prior art W-seal requires four separate parts, including two snap rings and three formed grooves for accommodating those snap rings, resulting in manufacturing complexity and relatively high cost. Additionally, these snap rings have been found to make it substantially more difficult to remove the seal from the counterbore when desired, causing productivity problems and sometimes damage to the seal assembly. For instance, when the seals are used to connect two channels designed to carry very high purity gases such as in a silicon deposition environment, impurities introduced into the system by the seal can impact the performance of an entire system. For example, out-gassing of impurities from the surfaces exposed to the interior of the vacuum environment in the system can unacceptably pollute the system. Because known W-seals are made to have a tight slip fit between the seal 2 b and the retainer sleeve 2 a and between the retainer sleeve 2 a and the counterbore, minor damage to the counterbore material and the retainer sleeve during installation and removal during maintenance can increase the amount of material exposed to the vacuum environment, thereby increasing the potential for introduction of excess impurities from out-gassing from that material.
[0008] In one operation environment, gas and vapor handling equipment deliver reactant and inert gasses and vapors to a tool such as an epitaxial reactor, a plasma etcher, and the like, which are used in the manufacture of semiconductors. Such equipment includes gas sticks, which employ a semi-modular design and may be rapidly constructed and easily and quickly maintained. Maintenance would include replacement of active gas delivery and metering components along a gas flow path. Such active components may include valves, pressure regulators, mass flow meters and mass flow controllers. The active components are secured in a gas flow path through a substrate or substrate blocks by the use of block or face type connectors.
[0009] The block connectors minimize contamination of the gas flow path by reducing the wetted surface. The wetted surface is the interior surface of a gas flow path that contacts the gas. The smaller the wetted surface that is presented the smaller the amount or likelihood that the surface will be contaminated with unwanted gas species during assembly during an initial build or during maintenance when the flow path is torn down.
[0010] Some prior seals and retainers for face block systems may introduce unwanted contaminants via abrasion and physisorption and chemisorption on the seal surfaces. The existing face seal systems use a small area, sealing zone to reduce contamination by reducing the wetted area at the connector joint. This is done by making sure the sealing zone is essentially flat with no portions of one connector extending into the other connector as is common in less stringent applications. The threaded members holding the connector halves are positioned a substantial distance away from the flow path to avoid contaminating it with particulates generated during tightening or loosening of the connector bolts Likewise there is no threading along the outside of the flow path at the connector break of the type found in a garden hose. Such a “threaded pipe” construction might generate particulates in the immediate vicinity of the flow path during tightening. Despite this some problems remain. The W-seal is an example.
[0011] The above described seal uses a retainer that cannot be characterized as “low force.” The snap ring on the outer surface or its retainer comes in sliding contact with the wall of the counterbore during assembly. Because a relatively large force is needed to set the seal and retainer, alignment problems can arise and the snap rings abrade the counterbore walls generating contaminating particulates.
[0012] What is needed, for certain sealing system applications, is a seal system that affords certain functional advantages without the necessity and expense involved in employing snap rings, and which is preferably constructed to permit easy removal from the counterbore.
SUMMARY
[0013] Pursuant to these various approaches, a ring sealing system suitable for applications such as a semiconductor manufacturing modular gas delivery system is described.
[0014] More specifically, an example sealing system includes a retainer for a seal (also called a gasket) used to connect modular piping in a modular gas delivery system to the gas flow controlling components. The retainer design protects the polished sealing surface of the seal from scratches before assembly by suspending the seal inside the retainer, with some clearance around the seal regardless of orientation. Additionally, a slit or gap in the circumference of the retainer allows the retainer to flex open for insertion of the seal gasket. A small chamfer on the ID of the retainer, in certain aspects, aids the easier insertion of the seal into the retainer. A similar chamfer on an edge of the seal further aids this insertion process.
[0015] The gap in the circumference of the retainer also allows the retainer to compress to a smaller circumference, for a tight fit inside the sealing counterbore. A groove in the ID of the retainer includes a protruding portion for the seal to engage. The depth of this groove is configured such that with a complete compression of the retainer where the circumferential gap is completely closed, the protruding edge of the seal still has some clearance inside the retainer. This clearance, which acts as a stop to prevent the retainer from being overly compressed, ensures that the seal and retainer assembly will not jam during insertion of the assembly into the counterbore.
[0016] The slit or gap in the circumference of the retainer allows for a larger tolerance in the machining on the OD of the retainer. With current designs, a slightly oversized OD will prevent insertion of the retainer and seal assembly into the counterbore because there is no room for compression. In one example of the retainer described herein, the retainer is free to close up to 0.010 inches. The gap in the circumference can be made larger and achieve the same results.
[0017] There is a slight chamfer around the OD of the retainer for easier location of the retainer on the counterbore. The top half of the retainer has a slightly smaller OD for easy alignment of surface mount components. For instance, an installer can grasp this smaller OD and use the larger OD to engage a particular sealing point of multiple sealing points on the same block.
[0018] In one example application, there is provided a ring seal assembly, which comprises an annular seal member having an inner diameter (ID) and an outer diameter (OD), and having an axial hole defined by the ID for fluid passage, wherein the OD of the seal member comprises a smaller OD portion and a larger OD portion. An annular retaining member is also provided, having an ID and an OD, wherein the ID of the retaining member is larger than the OD of the seal member. Advantageously, the ID of the retaining member comprises an axially cylindrical first portion and a second portion comprising a groove extending radially outwardly of the first portion for receiving and accommodating the larger OD portion of the seal, which extends radially outwardly into the groove.
[0019] An additional feature in certain examples is the employment of a chamfer on at least one outside corner of the annular retaining member for easing installation of the retaining member into a counterbore. A chamfer may also be disposed on at least one inside corner of the annular retaining member for easing insertion of the sealing member into the retaining member. Yet another feature in certain examples is the inclusion of a load adjustment groove disposed on the seal member for improving the elastic response of the seal.
[0020] In yet another aspect, there is provided a ring seal assembly, which comprises an annular seal member having an inner diameter (ID) and an outer diameter (OD), and having an axial hole defined by the ID for fluid passage. An annular retaining member has an ID and an OD, wherein the ID of the retaining member is larger than the OD of the seal member. A chamfer is disposed on at least one inside corner of the annular retaining member for easing insertion of the sealing member into the retaining member. Another chamfer is disposed on at least one outside corner of the annular retaining member for easing insertion of the retaining member into a counterbore.
[0021] In still another aspect, a method for assembling a ring seal assembly includes radially expanding a retainer during insertion of a seal into the retainer to be supported by a groove in an inside surface of the retainer. The retainer expands at a slot or slots in the retainer's circumference. The retainer in certain examples includes a chamfer on an inside corner of the retainer, and the seal may include a chamfer on a seal outer corner to facilitate seal insertion. There is space around the seal to allow the retainer to compress around the seal during insertion of the retainer into a counterbore. For instance, a chamfer on an outside corner of the retainer guides the insertion by engaging the counterbore surface, which engagement slightly compresses the retainer at the slots with the slots restricting the compression such that the compression does not result in mechanical compression of the seal. After insertion into the counterbore, the retainer expands into the counterbore while supporting the seal for compression between elements defining the flow path.
[0022] So configured, a retainer according to these teachings when used in a semiconductor manufacturing environment may act as shield to reduce abrasion and contamination of the seal during assembly with the retainer and while stored and being handled prior to and during assembly with a counterbore of a block, a handle to avoid contamination of the seal during assembly of the retainer and seal combination with a block, and a low force locator to avoid generating contaminants at the flow path adjacent the counterbore and spreading those contaminants throughout the downstream portion of the remainder of the flow, into a tool, and onto a semiconductor being processed. The low force retainer spreads the contact force at the counterbore wall along a larger surface reducing pressure and the likelihood of abrasion.
[0023] In certain aspects, the retainer provides an outer handling jacket to avoid contacting the seal with any solids that could cling to the surface or even abrade it. Even small scratches on a mating surface of a seal increase the wetted area and provide additional sites for sorption of contaminating gasses and water vapor prior to assembly in a gas stick.
[0024] The face type connectors when properly assembled should not have a seal touching anything other the mating beads of the flow path defining elements. This avoids contaminating the flow path by scraping a seal along a tight counterbore during assembly. The seal in this approach should be in registration with the beads during connector closure. In some aspects, an example retainer of these teachings solves these problems by allowing the seal to “float” slightly. The seal only has very low forces applied to it by the retainer. The low forces avoid abrasion of the seal by the interior of the retainer and abrasion of the retainer by the seal. This avoids introducing particulates into the flow path.
[0025] These and other benefits may become clearer upon making a thorough review and study of the drawings and the following detailed description. In these accompanying drawings, like reference numerals designate like parts throughout the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is an isometric view of a prior art W-seal;
[0027] FIG. 2 is an isometric view of the W-seal shown in FIG. 1 , wherein a circumferential portion has been removed to illustrate a cross-section of the seal;
[0028] FIG. 3 is a cross-sectional view of the prior art W-seal shown in FIGS. 1 and 2 ;
[0029] FIG. 4 is an exploded view of the prior art W-seal shown in FIGS. 1-3 ;
[0030] FIG. 5 is a top view of one example a retaining ring constructed in accordance with various principles of the invention;
[0031] FIG. 6 is a cross-sectional view of the retaining ring shown in FIG. 5 ;
[0032] FIG. 7 is a detailed cross-sectional view of the portion of FIG. 6 denoted by the letter A;
[0033] FIG. 8 is an isometric view of the retaining ring of FIGS. 5-7 ;
[0034] FIG. 9 is a top view of a modified example retaining ring constructed in accordance with various principles of the invention;
[0035] FIG. 10 is a cross-sectional view of the retaining ring shown in FIG. 9 ;
[0036] FIG. 11 is a detailed cross-sectional view of the portion of FIG. 10 denoted by the letter B;
[0037] FIG. 12 is an isometric view of the retaining ring of FIGS. 9-11 ;
[0038] FIG. 13 is a top view of an example seal gasket constructed in accordance with various principles of the invention;
[0039] FIG. 14 is an elevation of the gasket shown in FIG. 13 ;
[0040] FIG. 15 is a cross-sectional view of the gasket shown in FIGS. 13 and 14 ;
[0041] FIG. 16 is a detailed cross-sectional view of the portion of FIG. 15 denoted by the letter C;
[0042] FIG. 17 is an isometric view of the gasket shown in FIGS. 13-16 ;
[0043] FIG. 18 is a top view of a modified example seal gasket constructed in accordance with various principles of the invention;
[0044] FIG. 19 is an isometric view of the gasket shown in FIG. 18 ;
[0045] FIG. 20 is an elevation of the gasket shown in FIGS. 18 and 19 ;
[0046] FIG. 21 is a cross-sectional view of the gasket illustrated in FIGS. 18-20 ;
[0047] FIG. 22 is a cross-sectional view illustrating an example retaining ring and gasket in an assembled state constructed in accordance with various principles of the invention;
[0048] FIG. 23 is a cross-sectional view similar to FIG. 22 illustrating the assembled seal after it has been fully installed and compressed to its operational status;
[0049] FIG. 24 is an isometric view of another example seal constructed in accordance with various principles of the invention;
[0050] FIG. 25 is a side view of another example seal constructed in accordance with various principles of the invention;
[0051] FIG. 26 is a side view of another example seal constructed in accordance with various principles of the invention;
[0052] FIG. 27 is a perspective view of an example retainer constructed in accordance with various principles of the invention;
[0053] FIG. 28 is a top view of an example fluid flow system constructed in accordance with various principles of the invention;
[0054] FIG. 29 is a cross-sectional view taken through lines 29 - 29 of FIG. 28 ;
[0055] FIG. 30 is a cross-sectional view taken through lines 30 - 30 FIG. 29 ;
[0056] FIG. 31 is an exploded isometric view of the fluid sealing system shown in FIGS. 28-30 ;
[0057] FIG. 32 is an enlarged exploded isometric view of the portion of the system illustrated in FIG. 31 denoted by the letter E;
[0058] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
DETAILED DESCRIPTION
[0059] Referring now more particularly to FIGS. 5-30 , wherein the terms “lower” and “upper” are with respect to the figures only and not necessarily with the orientation of the sealing assembly in an actual installation, there is shown in FIGS. 22 and 23 an example ring seal assembly 10 including a retainer or retaining ring 12 surrounding, in circumferential fashion, an annular gasket or seal 14 . As illustrated in FIG. 22 , the seal 14 comprises a center hole 16 and an annular body element 18 . The retainer 12 is also annular in construction and comprises an annular body element 20 defining a center hole 22 into which the seal 14 is inserted. The retainer material should have sufficient elastic properties to allow expansion and compression as described herein and recover its original shape and be machined or otherwise formed into the described shapes; such materials may include metal, polymer, or any other suitable material. The seal material should have an elastic property to allow compression and spring back for good sealing along an axial flow path when compressed between elements that define the flow path. In a seal used in a wafer fabrication environment where high purity of the gases passing through the flow path is required, materials such as 316 double melt stainless steel, nickel, HASTELLOY (available from Central States Industrial Equipment & Service, Inc.), and AL-6XN (available from Central States Industrial Equipment & Service, Inc.) are exemplary suitable materials.
[0060] In the illustrated example of FIGS. 22 and 23 , the outer diameter (OD) of the retaining ring 12 is stepped, having a smaller OD portion 24 and a larger OD portion 26 . A retainer ID groove 28 is disposed on the ring 12 , within the larger OD portion 26 . An outer chamfer 30 is disposed on each corner on the OD of the retainer 12 . Inner chamfers 32 are disposed on the lower corners of the ID of the retainer 12 .
[0061] The seal 14 comprises a substantially cylindrical ID 34 surrounding and defining the center hole 16 . The OD of the seal 14 comprises a smaller OD portion 36 and a larger OD portion 38 . In certain approaches, between these two portions 36 , 38 is disposed a load adjustment groove 41 (see, for example, FIGS. 18-21 ), or, in another approach, bores 40 (see, for example, FIGS. 13-16 and 25 ). The load adjustment groove 41 or bores 40 provide a elasticity to the seal 14 that facilitates a sealing engagement with the fluid path defining elements. For example, the load adjustment groove 41 or bores 40 increase the elasticity of the seal 14 . This improved elasticity better distributes the forces applied by the beads of the flow path defining elements during the sealing process. The beads may not be axially aligned, and in such a situation, the seal having insufficient elasticity may deform in a manner applying excess transverse forces to the beads, which can result in a poor sealing effect and/or damage the beads such that they cannot from a new seal after being reset. The seal elasticity provided by the load adjustment groove 41 or bores 40 at least partially better manages these forces to alleviate these potential adverse results during the sealing process. The bores 40 may have a variety of depths or shapes other than those illustrated and can be tailored to a given application.
[0062] FIG. 23 illustrates the ring seal assembly 10 in an installed configuration. As illustrated, the seal assembly 10 is disposed within a gas or fluid flow path 42 , wherein the fluid flow moves in the direction of the arrow 44 . Defining the fluid flow path 42 are a component 46 and a base block 48 . A component counterbore 50 is machined into the component 46 , while a complementary base block counterbore 52 is machined into the base block 48 . It is noted that the outer chamfers 30 are advantageously designed to permit easy insertion of the retaining ring 12 into the counterbores 50 , 52 . The inner chamfers 32 facilitate ready insertion of the seal 14 into the center hole 22 of the retainer 12 .
[0063] Upon installation of the seal assembly 10 into the flow path 42 , the component 46 and base block 48 are compressed axially about the seal assembly 10 , causing a sealing bead 54 to engage the seal 14 , as illustrated in FIG. 23 . It is noted that, even when fully compressed, the retainer 12 remains spaced from the walls defining the counterbore 50 , 52 , as shown in FIG. 23 , allowing continued play between the retainer 12 and the counterbore 50 , 52 .
[0064] The retainer 12 extends axially substantially above and below the seal 14 . So configured, even when compressed, the upper and lower surfaces of the seal 14 , which are highly polished, are protected from damage such as scratching to preserve optimal seal integrity.
[0065] With reference now to FIGS. 5-21 and 25 , various embodiments of each of the retainer 12 and seal 14 are illustrated. It should be noted that any of the retainer examples and seal examples may be employed, as shown in FIGS. 22 and 23 , within the scope of these teachings, with a caveat that specific complementary features and dimensions of each element should be coordinated to fit together appropriately. The specific dimensions shown in the figures are exemplary only.
[0066] With respect to FIGS. 5-8 , one example retaining ring 12 is shown. As illustrated, a slot or gap 56 is configured to facilitate fixation of the retainer 12 and seal 14 within the counterbore. The radial slot 56 passes completely through the wall of the retainer 12 for its entire axial length, thereby making it feasible to temporarily spread the slot (gap) 56 elastically. This spreading of the gap 56 enlarges the effective diameter of the center hole 22 sufficiently to accept the larger outside diameter portion 38 of the seal 14 , and to easily position the retainer inside diameter groove 28 over the larger outside diameter portion 38 of the seal 14 . This arrangement thus allows the seal 14 to effectively float within the confines of the retainer 12 and reduces scraping of the seal 14 and the retainer 12 during positioning of the seal 14 in the retainer 12 . The angles of the various chamfers may be defined according to a given application with an example angle being about forty-five degrees.
[0067] FIGS. 9-12 illustrate a somewhat modified example retaining ring 12 . The primary difference between this example and that of FIGS. 5-8 is the utilization of a retaining ring having a stepped OD. The retainer 12 includes a retainer outer surface having a first outer diameter 24 and a second outer diameter 26 with the first outer diameter 24 being smaller than the second outer diameter 26 . The retainer 12 further includes a retainer inner diameter of the center hole 22 , the inner diameter being stepped to define a groove 28 in an inner surface of the retainer 12 inside and opposite of the retainer outer surface's second outer diameter 26 . The groove's diameter is larger than the retainer's center hole 22 ID and smaller than the second outer diameter 26 .
[0068] FIG. 22 illustrates another example retainer 12 , in this case having a hook-like edge feature to facilitate identification of the orientation of the retainer and removal of the retainer from a counterbore. In this example, the first outer diameter 24 of the retainer 12 defines a step 25 radially inward from the first outer diameter 24 to a third outer diameter 27 that is smaller than the first outer diameter 24 . The step 25 is configured to facilitate engagement with a member to extract the second outer diameter 26 from a counterbore.
[0069] FIG. 27 illustrates yet another example retainer 12 , in this case having three partial slots 57 defined in the second outer diameter 26 . These slots 57 operate like the slot 56 that fully splits the retainer 12 in that the slots 57 allow for elastic expansion of the retainer 12 during insertion of the seal and for elastic compression of the retainer 12 during insertion of the assembly into a counterbore. Although three slots 57 are illustrated, the number of slots 57 can be tailored to a given application.
[0070] FIGS. 13-17 illustrate an example seal having a smaller OD portion 36 and a larger OD portion 38 and having a plurality of bores 40 spaced and disposed in each of the smaller OD portion 36 and the larger OD portion 38 . The ring shaped seal 14 includes top 35 and bottom 37 surfaces configured to be compressed when in a sealing configuration. A stepped outer diameter is defined between the top 35 and bottom 37 surfaces with a first outer diameter 36 being smaller than the second diameter 38 . A plurality of bores 40 are defined in at least two rows in one or both of the first outer diameter 36 and the second outer diameter 38 . The plurality of bores 40 are sufficient to effect resiliency in the seal 14 in response to compression of the seal 14 on the top 35 and bottom 37 surfaces. The bores 40 in the example of FIGS. 12 and 13 circumferentially alternate so that only one is shown in FIG. 12 .
[0071] FIGS. 18-21 illustrate a somewhat modified example of the gasket or step seal 14 . The primary difference, other than with respect to certain dimensions, between the two examples is that in the FIG. 18 example a single circumferential load displacement groove 41 is employed, instead of the bores 40 of FIGS. 13-17 . The groove 41 is defined between the first outer diameter 36 and the second outer diameter 38 sufficient to effect resiliency in the seal 14 in response to compression of the seal 14 on the top 35 and bottom 37 surfaces.
[0072] FIG. 25 illustrates an example seal 14 having a step between a smaller OD portion 36 and a larger OD portion 38 , but having no groove or bores. FIG. 26 illustrates another example seal having a stepped OD, comprised of smaller OD portion 36 and larger OD portion 38 . In this example, a portion 43 of the smaller OD portion 36 adjacent the larger OD portion 38 includes bores 40 distributed around the perimeter of the portion 43 . Although the example of FIG. 26 shows the portion 43 as having a smaller OD than that of the smaller OD portion 36 , the portion 43 may have an OD co-extensive with that of the smaller OD portion 36 . The seal 14 of FIG. 26 further includes a chamfer 39 disposed on a edge of the outer diameter portion of the seal 14 . The chamfer 39 is configured to facilitate placement of the seal 14 in the retainer by reducing the load needed to slide the seal 14 into the retainer. The chamfer 39 may be place on any outside edge that may engage the retainer during insertion of the seal 14 into the retainer.
[0073] Referring once again to FIG. 23 , it is noted that there is play between the seal and the retainer, even when assembled. The reason for this is to ensure that when the retainer compresses, it does not hit the seal, because otherwise it would not be able to be compressed to a dimension smaller than the counterbore, which would affect seal integrity. The split or slot 56 facilitates this feature because it serves as the stop to control the amount of compression of the retaining ring 12 . Upon compression, the ring 12 compresses until the two surfaces defining the slot engage one another. Also illustrated in FIG. 23 , the larger OD portion 38 of the stepped seal is captured top and bottom by the retainer 14 in its relaxed or pre-compression position. There is no interference between the retainer and the elastic response modifying portions (perforations or load adjustment groove 40 ) of the seal.
[0074] In still another approach, FIG. 24 illustrates an annular seal 114 defining an aperture 116 with an inner diameter 134 . The seal 114 defines no perforations or groove and has a single OD 118 between a top surface 160 and a bottom surface. In one example, this seal 114 (or a similar seal with a single OD 118 that defines a groove or bores) can be inserted into a retainer 12 as described herein to provide a sealing assembly with benefits similar to those discussed above with respect to FIGS. 22 and 23 .
[0075] FIGS. 28-32 illustrate an example ring seal assembly 110 in a typical sealing environment, wherein a fluid flow path 142 to be sealed is defined by a component 146 and a base block 148 , which are attached by bolts 182 or other suitable means. The seal 110 is adapted to be fitted within the space formed by the component counterbore and corresponding base block counterbore and to form a leak-tight fluid connection therein, via sealing beads 154 .
[0076] FIGS. 31 and 32 illustrate the process of snapping the metal seal assembly into the seal port counterbore to install the seal. A method of assembling a ring-shaped retainer having at least one slot and a ring seal includes engaging the ring seal against a chamfer on an inside edge of the retainer to spread the retainer and sliding the seal into proximity with a retainer groove on an inside portion of the retainer. The retainer relaxes at least partially when the seal ring is in the groove such that the retainer in a relaxed state surrounds the right seal without clamping the ring seal. To position the seal assembly 110 in the counterbore, the retainer is squeezed with the seal retained in the groove, and the squeezed retainer is positioned relative to a counterbore. The retainer is released to effect placement of the retainer in the counterbore. The retainer inside diameter groove 28 supports the seal 14 and locates the seal at the center of the fluid path 142 .
[0077] While this invention has been described with respect to various specific examples, it is to be understood that various modifications may be made without departing from the scope thereof. Therefore, the above description should not be construed as limiting the invention, but merely as an exemplification of preferred embodiments thereof and that the invention can be variously practiced within the scope of the following claims. | An example sealing system includes a retainer for a gasket wherein the retainer protects the polished sealing surface of the seal gasket from scratches before assembly by suspending the gasket inside the retainer, regardless of orientation. A gap in the circumference of the retainer allows the retainer to flex open for insertion of the seal gasket. A small chamfer on the inner diameter of the retainer aids the insertion of the seal into the retainer. The gap in the circumference of the retainer also allows the retainer to compress to a smaller circumference for a tight fit inside the sealing counterbore. A groove in the inner diameter of the retainer includes a protruding portion for the seal to engage. The depth of this groove is configured to provide some clearance inside the retainer for the protruding edge of the seal during a complete compression of the retainer. | 8 |
FIELD OF THE INVENTION
The invention relates generally to vehicular safety systems, and more particularly to a mobile vehicular safety system for securely storing and placing markers onto a road surface.
BACKGROUND OF THE INVENTION
Our nation's roads and highways represent the life blood of our transportation system and impact on our daily lives in significant and myriad ways. Commercial enterprises such as commerce, industry, trucking and livery and public-funded entities such as police, firefighters, emergency response units, and countless other organizations and individuals in both the private and public sectors rely on local, state, and federal transportation departments to provide and maintain a sound infrastructure of roads and highways.
However, in order to support such an infrastructure, road construction and maintenance represents an ongoing and essential activity. While most travelers view road construction and road crews merely as an annoyance or impediment to timely arrival at their intended destination, clearly such a view is misplaced. Rather those who work to build and maintain the roadways facilitate, in the long run, quick easy and efficient access to location that would otherwise be difficult, if not impossible, to reach. In addition, road crew personnel assume a substantial risk of bodily injury from both unwary or inattentive drivers, as well as from other road construction equipment. For example, in the course of placing road markers such as cones, barriers, or signs, used to notify and alert drivers, road crew personnel have often been injured and even killed.
A number of solutions have been developed in the past to prevent such injuries to road crew personnel and to provide a safer and more secure work environment to those individuals in the act of placing or retrieving markers from the road surface. For example, an impact attenuation device placed on the back of a truck or other vehicle provides some measure of security to such road crew personnel. However, it is typical that in the course of placing or retrieving markers, such persons performing the task walk alongside the maintenance vehicle, and are thus left unprotected and susceptible to injuries from other drivers or by the vehicle itself. Accordingly, it is highly desirable to obtain a more secure apparatus and method for retrieving and placing markers onto a road surface.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a mobile unit operative for securely storing and placing markers onto a surface, comprising a front cab; a bed coupled to a rear of the front cab, the bed comprising a planar surface for storing the markers; a well area coupled to a rear portion of the bed and having an at least one well structure coupled to the first planar surface, the well structure having a bottom and side walls for housing a person for placing or retrieving the markers on the surface, wherein the at least one well structure and the first planar surface are positionally aligned to permit retrieval/storage of a marker from the first planar surface for placement/retrieval on the surface via the person located within the well.
It is a further object of the present invention to provide a method for securely storing and placing markers onto a road surface from a mobile vehicle comprising the steps of providing a first planar surface for storing the markers; coupling at least one well structure to an end of the first planar surface, the well structure having a first side wall integrally coupled to the end of the first planar surface, a second side wall opposite the first side wall, an interior side wall connected between said first and second opposite side walls, an exterior opening and a bottom floor; and placing a person within the well and operating in a first mode by removing the markers from the first planar surface and placing on the road surface by the person within the well, and in a second mode, removing from the surface the markers and storing onto the first planar surface by the person within the well structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the mobile vehicle apparatus having a well structure for retaining a crew member for storing or retrieving markers according to an embodiment of the present invention;
FIG. 2A is a perspective view of the mobile vehicle apparatus of FIG. 1 from the opposite side as that shown in FIG. 1;
FIG. 2B is a side view of the mobile vehicle apparatus according to the embodiment depicted in FIGS. 1 and 2A;
FIG. 2C is a top view of the embodiment of FIGS. 1 and 2A;
FIGS. 3A-B show perspective views of the mobile vehicle apparatus including a crash attenuation unit mounted thereon;
FIG. 4 is a perspective view of a well structure for containing a crew member according to an embodiment of the present invention; and
FIG. 5A is a perspective view of the mobile vehicle apparatus having a well structure for retaining a crew member for storing or retrieving markers according to an alternative embodiment of the present invention;
FIG. 5B is a side view of the mobile vehicle apparatus according to the alternative embodiment depicted in FIG. 5A;
FIG. 5C is a cross-sectional view along lines A—A of FIG. 5B;
FIG. 5D is a top view of the alternative embodiment of FIG. 5A;
FIG. 6A is a side view of the mobile vehicle apparatus having a well structure for retaining a crew member for storing or retrieving markers according to another embodiment of the present invention;
FIG. 6B is a cross-sectional view along lines A—A of FIG. 6A;
FIG. 6C is a top view of the alternative embodiment of FIG. 6 A.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown a perspective view of a preferred embodiment of the present invention. FIG. 1 illustrates a mobile vehicle apparatus 10 such as a truck comprising a cab portion 20 for housing a driver 22 . The truck is equipped with a bed 30 integrally coupled to a rear of the cab portion 20 by conventional means. The bed comprises a first substantially planar surface 40 having a width WI and a length Lt. The surface 40 is substantially flat for accommodating road markers such as road signs, cones, barrels, and so on. Retainer walls 50 extend vertically upward from the sides 32 and 34 of the planar surface to help retain and support markers 100 stored onto the planar surface bed area. A well area 90 comprising first and second well structures 60 , 62 each disposed opposite one another and positioned in an integral manner with the end portion 64 of planar surface 40 is connected to the bed 30 via conventional means. Each corresponding well structure 60 , 62 comprises each of the same elements as will be identified below. In referring to the drawings, like parts are indicated by like reference numerals.
Referring now to FIG. 1, well structure 60 includes three side walls 64 , 66 , 68 extending vertically from a bottom surface 70 at right angles to one another forming a box-like region for housing a road crew member 230 (FIG. 2) tasked to distribute markers onto a road the surface 200 . An opening 72 opposite wall 66 permits entry and exit of the well structure 60 to and from the road surface and is located on a lateral side 34 (i.e. 32 for well structure 62 ) of the truck. The bed 30 is mounted to and supported by a chassis or frame 84 using well known, conventional means. The well area including the well structures 60 , 62 is preferably made of a strong and durable material, such as steel, capable of withstanding various weather conditions (for example rain, snow, heat, cold etc.), as well as high impact collisions. Well area 90 comprising each of the well structures 60 and 62 is of a length d extending in a substantially vertical downward direction from a top portion 12 which is coplanar with surface 40 . The well area is disposed behind both sets of front and rear wheels 210 , 220 to provide an additional safety measure for preventing a worker from injury via the truck wheels. The structure 90 extends downward to a point such that bottom surface 70 of well structure 60 is a distance x from road surface 200 . Preferably the distance x is approximately 6 inches to facilitate a natural step-up/step-down from the road surface. Stiffeners 99 are welded to the underside of bottom surface 70 via conventional means to provide rigidity and stiffness to the standing surface 70 . The surface 70 is preferably coated with an anti-skid material to prevent slippage.
FIG. 2A shows a perspective view of the mobile unit 10 from side 32 showing identically oriented well structure 62 oppositely positioned with respect to well structure 60 , while FIG. 2B provides a more schematic side view of the moblie unit and well structure. FIG. 2C illustrates a top view of the bed and well area positioned behind the rear tandem wheels 220 according to the first embodiment. As shown in FIGS. 1 and 2, the well area 90 may further comprise a sign board area 83 interposed between the first and second well structures 60 , 62 which supports a notification area 34 such as an electronic arrow board or solar or battery-operated information board for alerting oncoming drivers of road construction. The sign board is typically connected to the well area structure by a series of steel beams 93 and may be either welded and/or bolted together to form a secure structure. The well area itself may also be formed by means of a series of welds and/or bolts bonding the first well structure, the board structure, and the second well structure together, or may be formed as a single monolithic molded steel or metal structure which is then connected to the end of planar surface 40 .
A retaining mechanism comprising a chain 94 is coupled to a hook 96 extending from a side of opening 70 and extends across the opening to detachably connect with a second hook 98 on the opposite side. The side walls within each well structure extend vertically approximately 4 feet while the dimensions of the well structure are approximately 4 ft.×3 ft. in order to securely retain the person within the well structure. Similarly, chain 94 extends across the opening at substantially the top of the side walls and at a point substantially near the mid-section of a normal sized male in order to permit one to reach or lean over the side of the truck to pick up or place a marker while preventing him from tipping over onto the road surface. The size and height of the well structures may be adjusted depending on safety requirements and regulations, or other safety related concerns. Note also that each well structure 60 , 62 may also be formed having different shapes and/or dimensions according to particular requirements.
The well structure 60 , 62 may further include a harness arrangement 75 shown in FIG. 4, comprising a belt 77 used for securing around the body of a crew member within the well and a chain 79 which has a first end coupled to the belt using conventional means such as a hoop 82 fastened to the belt, and a second end connected to a hook 81 extending from one of the sidewalls. In this manner the harness operates to securely retain the person within the well structure so as to prevent inadvertent exit therefrom. Such protection is twofold, preventing a member from either inadvertently exiting onto the road surface or entering onto the bed portion of the truck. The chain is of a length sufficient to permit movement within the well structure while limiting migration outside of the structure.
As best shown in FIG. 3B, a crash attenuation unit 20 may be adapted to be mounted to the back of the well area 90 of the truck in order to direct the motion of a vehicle colliding with the attenuator so as to dissipate its impact energy. Such an attenuator unit is disclosed in U.S. Pat. No. 5,697,657 entitled “VEHICLE MOUNTED CRASH ATTENUATION SYSTEM” by Albert W. Unrath, Sr., issued Dec. 16, 1997, and incorporated herein by reference. As shown in FIG. 3, the crash attenuator generally comprises a frame 22 adapted to be mounted on a vehicle, and a slider 24 mounted on the frame to telescope relative to the frame toward the vehicle in response to an impact where at least one collapsible energy-absorbing member is positioned between the slider 24 and the frame 22 to absorb energy as the slider telescopes relative to the frame. A crushable energy-absorbing crash cushion 28 is provided on the outboard side of the slider. The crushable energy-absorbing crash cushion is pivotally mounted to the slider about its horizontal axis to allow pivoting between a horizontally-deployed position in which the cushion extends generally outwardly from the vehicle, and the vertical position in which the crash cushion extends vertically upward. FIGS. 1, 2 and 3 A illustrate portions of a crash attenuation unit connected to the posterior well area 90 , including hinge 95 which allows vertical and horizontal deployment. Alternatively, a lift apparatus in combination with an attenuator cushion as disclosed in co-pending patent application Ser. No. 09/181,191 filed Oct. 28, 1998, entitled “LIFT APPARATUS FOR ATTENUATOR CUSHION” by Albert W. Unrath, Sr., the subject matter being incorporated herein by reference, may be utilized and mounted to the back of the well area 90 of the truck in order to direct the motion of the vehicle colliding with the attenuator in order to dissipate its impact energy. As previously mentioned, the crash attenuator is mounted to the well area such that the well area is interposed between the crash attenuator unit and the truck bed thereby providing additional security and safety measures to the road crew members. As shown in FIG. 3, each well structure 60 is disposed at a location distant to the rear truck wheels 220 so as to minimize the potential for a crew member operating within the well structure from falling under the wheels. Note that the bottom of the well structure is a short distance, preferably about six inches, from the road surface to allow easy step up/step down from/to the road.
In an alternative embodiment depicted in FIG. 5A-D, the well area 90 is disposed at a location between the front wheels 210 and the rear wheels 220 in order to provide a more structurally secure and safer area for housing road crew members displacing the markers. This embodiment provides better protection to the crew member from the motoring public because the rear tandem wheels act as an additional buffer to the well structure. FIG. 5A provides a perspective view of the mobile unit according to this second embodiment, while FIGS. 5B-D provide side, top, and cross sectional views (along AA of FIG. 5 B), respectively, of this well structure configuration. As shown in FIG. 5, the well area comprises oppositely disposed well structures 60 , 62 separated by a stepped portion 72 . Stepped area 72 comprises a planar surface 76 extending between opposite sidewalls and operable as either a seat for a road crew member or as a step to either of the other well structure or to bed portion 30 . A parallel bar 84 extends across each well structure to prevent inadvertent exit. The bar comprises a first section 55 and a second section 57 which is retractable from the first section by conventional means to enable entry and exit from the well structure. As one can ascertain, the well area according to this embodiment is interposed between a first planar surface 40 and a second planar surface 41 . A Sideboard area 83 and attenuation unit 20 (not shown) may be coupled to portions of the second planar surface 40 using conventional means and in a manner analogous to that described in the first embodiment, where such units attached to well area 90 . Accordingly, in this embodiment, road markers 100 are accessible to a crew member within the well structure from either the first planar surface 40 or the second planar surface 41 , thus allowing greater ease of handling and manipulation of road markers.
In a third embodiment illustrated in FIGS. 6A-C, the well area 90 comprising the two well structures 60 , 62 may be attached directly to the rear cab portion of the truck vehicle and secured at wall 103 via conventional means. In this embodiment, the bed portion 30 on which the markers are retrieved is positioned distal to the truck bed in view of the location of each well structure. While this embodiment also provides a well structure which is located between the front and rear wheels, such a position has the disadvantage that the driver of the truck vehicle can not always or easily see the crew member in the well, due to the proximity and peripheral location of the structure vis-a-vis the cab driver. This is in contrast to both the first and second embodiments, which provide sufficient distance between the driver and the well or pod position to permit visual perception of the crew member.
As one can ascertain from the preceding discussion, the present invention allows one to securely store and place markers onto a surface by providing a first planar surface for storing the markers, coupling the well area to the end of the first planar surface, and positioning a person within the well area so that he/she may remove markers from the planar surface and place them on the road without exiting the truck. Conversely, the crew member may also remove markers from the road surface and store them onto the truck bed while the vehicle is in motion without undue risk of injury from the vehicle itself or from oncoming traffic. Preferably, the vehicle is moving at a relatively slow and even speed to allow efficient and safe placement/pickup of markers. Alternatively, the vehicle may come to a complete stop so as to allow a person to more safely place/retrieve a marker.
While preferred embodiments of the present invention have been shown, it should be understood that a person skilled in the art may make many variations and modifications to these embodiments utilizing functionally equivalent elements to be described herein without departing from the present scope of the invention. Any and all such variations or modifications as well as others which may become apparent to those skilled in the art, are intended to be included within the scope of the invention as defined by the attended claims. | There is disclosed a mobile unit operative for securely storing and placing markers onto a surface, comprising a bed coupled to a portion of the mobile unit comprising a planar surface for storing the markers; a well area coupled to a rear portion of the bed and having an at least one well structure coupled to the first planar surface, the well structure having a bottom and side walls for housing a person for placing or retrieving said markers on the surface, wherein the at least one well structure and the first planar surface are positionally aligned to permit retrieval/storage of a marker from the first planar surface for placement/retrieval on the surface via said person located within the well. | 4 |
PRIORITY
This application is a continuation of and claims priority under 35 U.S.C. §120 to U.S. application Ser. No. 11/462,963 filed Aug. 7, 2006, which is a continuation of and claims priority under 35 U.S.C. §120 to U.S. application Ser. No. 09/727,593 filed Dec. 4, 2000 and now U.S. Pat. No. 7,174,306, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 60/168,394 filed Dec. 2, 1999, the disclosures of which are incorporated by reference herein in their entirety.
TECHNICAL FIELD
This invention relates to providing electronic access to consumer-customized nonverbal information regarding products and services, and may also relate to enabling collaborative shopping for products and services using a broadband medium such as the Internet.
BACKGROUND
Before purchasing merchandise, it is sometimes desirable and/or necessary for a consumer visiting a merchant to obtain feedback or approval from a third party remote to that merchant. Often, in seeking this feedback and/or approval, it is desirable to supplement a verbal description of the merchandise with non-verbal information that describes the product as it relates to the consumer. For instance, when shopping for clothing, a visual image significantly enhances a third party's understanding of the clothing and the appearance of the clothing when worn by the consumer (e.g., fit).
Conventionally, catalogs have been used to provide generic information for products and services offered by merchants. In a similar vein, merchant web sites recently have been used to store and reproduce online catalogs consisting of generic product descriptions for persons accessing the Internet. While helpful in gaining a general understanding of the products and services offered by a merchant, these catalogs do not relate products and services to any particular consumer, verbally or visually. Rather, they relate the products and services of a merchant to models and staged sets that leave the consumer to wonder how well the product or service will satisfy their needs.
For a third party to obtain nonverbal information that relates the sought-after product or service to the consumer, the third party must resort to other means. For instance, in the clothing example provided above, for a third party to obtain non-verbal information that relates the clothing to a consumer seeking their feedback and/or approval, the third party has generally had to accompany the consumer to the merchant and observe the consumer being fit with the clothing.
SUMMARY
Rather than requiring third parties to personally visit the merchant, real time or stored nonverbal information that conforms to consumer specifications is collected by a merchant and made electronically available to third parties remote to the merchant. Wired or wireless networking systems enable electronic communications between merchant and third party systems.
In this manner, the generic information provided by printed and online catalogs may be supplemented or replaced by information that is customized for or related to the consumer, enabling a third party to more fully understand the purchase decision and thus offer more informed feedback.
These concepts find particularly utility for merchants offering goods and services whose sale is premised on visual appearances. They may be used to reduce cycle time, increase market reach, enhance product exposure, and elevate the consumer excitement level to increase the likelihood of ultimate purchase. They also are used to establish an enduring record of transactions to enable future comparisons.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will become apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a system capable of providing consumer-customized nonverbal information to a party accessing a merchant system;
FIG. 1A shows an example of components within the remote user and/or merchant computer systems of FIG. 1 ;
FIG. 1B shows an example of the merchant computer system of FIG. 1 ;
FIG. 2 shows an example overview of a process for providing consumer-customized nonverbal information to a party accessing a merchant system from the perspective of a consumer;
FIG. 3 shows an example overview of a process for providing consumer-customized nonverbal information to a party accessing a merchant system from the perspective of a merchant;
FIG. 3A shows a sample record relating consumer-customized nonverbal information to identifying information and/or notes;
FIG. 3B shows an example of a process for enabling access to consumer-customized nonverbal information; and
FIG. 3C shows an example of screen used to display consumer-customized nonverbal information.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Referring to FIG. 1 , a system 100 capable of providing consumer-customized nonverbal information generally includes input equipment 110 , merchant computer system 120 , remote user computer system 130 , and network 140 .
Input equipment 110 and merchant computer system 120 collectively gather merchandise information and make that information available to parties accessing the merchant computer system 120 . The merchandise information may include consumer customized nonverbal information, e.g., nonverbal information describing merchandise arranged or configured as specified by the consumer. In one particular example, the consumer-customized nonverbal information includes clothing being modeled by the consumer or by some other person of the consumer's choosing. In another particular example, the consumer-customized nonverbal information includes tools or equipment arranged as specified by the consumer to demonstrate their utility or adaptability.
Input equipment 110 and merchant computer system 120 may be operated independently in which case information collected by input equipment 110 is merely communicated to merchant computer system 120 . Alternatively, input equipment 110 may be operated in conjunction with merchant computer system 120 to collect and communicate input from the consumer in response to requests received from merchant computer system 120 .
More specifically, input equipment 110 generally includes equipment capable of collecting audio, video and other input from a consumer (hereinafter “primary consumer”). Input equipment 110 may include video or still camera equipment of digital type, but alternatively may include video or still camera equipment of the analog type accompanied with a digitizing device such as a digital scanner. In any case, the camera equipment is generally capable of collecting full or partial length images and of manipulating collected images. Input equipment 110 may also include other standard input/output devices, such as, e.g., a microphone, and interfacing equipment. Where a video camera or microphone is used, a continuous stream of data may be communicated by input equipment 110 to merchant computer system 120 .
Merchant computer system 120 generally includes devices capable of soliciting, collecting and providing access to nonverbal consumer-customized information, consumer identification information and other related information (hereinafter “notes”), from input equipment 110 or otherwise. Examples of identification information include consumer name, billing and shipping addresses, telephone numbers, electronic mail (e-mail) address and passwords of at least the primary consumer, and examples of notes include image or merchandise description, merchandise price, and consumer comments. Merchant computer system 120 generally includes a personal computer, but may include an intranet with several interconnected intelligent or dumb workstation terminals having simultaneous or shared access to a central or distributed repository of data. In any case, merchant computer system 120 includes a modem (e.g., standard, cable, digital subscriber line (DSL)) or other communication device to enable communications over network 140 .
Remote user computer system 130 generally includes interfacing equipment capable of enabling access to network 140 and thus merchant computer system 120 , one or more output devices capable of enabling an operator of remote user computer system 130 (hereinafter “secondary consumer”) to perceive information, and input devices capable of communicating feedback from the secondary consumer to the primary consumer or merchant computer systems. Remote user computer system 130 generally includes a personal computer, an example of which will be described with respect to FIG. IA. Remote user computer system 130 may also include a wired or wireless information device such as a personal digital assistant (PDA) or web-enabled telephone.
Network 140 enables electronic communications between merchant computer system 120 and remote user computer systems 130 . Network 140 may be wired or wireless. It 120 generally includes a computer network, e.g., a wide area network (WAN) such as the Internet, or local area network (LAN). Network 140 may also or alternatively include other networks such as the plain old telephone system (POTS) network. Through network 140 , one or more remote user computer systems 130 may gain access to information within the merchant computer system 120 , and may communicate feedback to the consumer or merchant computer system 120 .
Although not shown, a second network and corresponding interfacing equipment may be used to enable the primary consumer or merchant to notify the secondary consumer of information to be accessed at the merchant computer system 120 . For instance, a plain old telephone system (POTS) may be used to enable the primary consumer and/or merchant to request feedback from a secondary consumer, or to notify the secondary consumer of consumer-customized nonverbal information that is available for downloading or streaming. In another example, merchant computer system 120 may include equipment or software (e.g., automated telephone equipment, instant messaging software, and/or email software) to enable automatic or manual notification. Correspondingly, remote user computer system 130 may include equipment or software to enable perception of the notification, delayed or immediate feedback to the notification, delayed or immediate access to the referenced information, and feedback regarding that referenced information.
Referring to FIG. 1A , a computer system 160 represents an example of a hardware setup for executing software that allows a user to perform tasks such as communicating with other computer users, accessing various computer resources, and viewing, creating, or otherwise manipulating electronic content—that is, any combination of text, images, movies, music or other sounds, animations, 3D virtual worlds, and links to other objects. The computer system 160 of FIG. 1A may also be programmed with computer-readable instructions to enable content to be perceived (e.g., viewed) without being captured (e.g., copied, saved, or printed).
The system 160 includes various input/output (I/O) devices 161 and a general purpose computer 162 . I/O devices 161 may include mouse 161 A, keyboard 161 B, and display 161 C, as shown and may also or alternatively include other devices such as touch screens, video cameras, microphones, scanners, printers, wired or wireless devices (e.g., cellular telephone, personal digital assistant (FDA) or appliance). General purpose computer 162 may include central processor unit (CPU) 162 A, I/O unit 162 B and memory 162 C that stores data and various programs such as operating system 162 C- 1 and one or more application programs 162 C- 2 . The computer system 160 preferably also includes some sort of communications card or device 163 (for example, a modem or network adapter) for exchanging data with network 1 64 via communications link 165 (e.g., a telephone line).
Referring to FIG. 1B , a combination of more than one computer system may be used to implement merchant computer system 120 . For instance, merchant computer system 120 may include computer 122 and computer 124 . Computers 122 and 124 may by physically independent, communicating by physical communications link 126 , and requiring implementation on independent devices. Conversely, computers 122 and 124 may share devices, such that their independence is virtual and the communications link 126 interconnecting those computers is implemented through software. Either or both of computers 122 and 124 may be implemented using devices such as those shown by FIG. 1A .
Computer 122 is generally a merchant host computer, providing an interface for remote users 130 to perceive when communications are enabled through network 140 . For instance, computer 122 may include software or links to software enabling web page access and/or search functionality. More specifically, computer 122 may store or access and display a screen that includes an embedded link to a search program capable of searching and retrieving information from within computer 124 . The screen may result from code written in any of various languages, such as hypertext markup language (HTML), standard generated markup language (SGML), extensible hypertext markup language (XHTML), extensible markup language (XML), or otherwise.
Computer 124 generally includes software for generating, storing and accessing records relating consumer-customized nonverbal information to consumer identifying information and notes. The software stored on computer 124 typically includes a relational database that stores records including related consumer-customized nonverbal information, identifying, information for the primary consumer, and notes. Software 128 also may be used to control input equipment 110 and/or to integrate identifying information and notes entered at computer 124 with input received from input equipment 110 . One example of the aforementioned software includes the Filemaker™ program equipped with a Troy™ plug-in module. Using this software, computer 124 can be used to control input equipment 110 , to collect information from the primary consumer regarding images and other information collected by input equipment 110 to create records combining the related information to be stored and/or streamed, and to collect feedback from the secondary consumer when received.
Additional integrating software may also be incorporated into computer 124 to automate the notification process based on information collected from the primary consumer regarding the secondary consumer. For instance, if instant messaging or electronic mail software is installed on or accessible to computer 124 , computer 124 may be configured to automatically send an instant message or email to the secondary consumer when an instant messaging or email address for the secondary consumer is entered by the primary consumer. As such, the identifying information collected from the primary consumer and related to the record or data stream may include identifying information for the secondary consumer, such as an instant messaging address, email address and/or telephone number. The instant message or email may be sent immediately upon entry of the address for the secondary consumer, or it may be sent at some later time as instructed by the primary consumer.
Similar software may also be stored on computer 124 to enable notification of feedback from secondary consumer to the primary consumer and/or merchant. In this manner, the primary consumer may make a prompt purchasing decision once feedback is received, or the merchant may expedite processing of an order once authorization is received from the secondary consumer. For instance, where the primary consumer provides standing instructions indicating that the purchase may be completed upon authorization or approval of the secondary consumer, processing of the purchase may be expedited through communication of that authorization or approval to the merchant. In this case, the request for feedback may include a request for payment information from the secondary consumer to enable a purchase.
Implementing merchant computer system 120 using more than one computer, whether physical or virtual, allows the merchant the flexibility to inhibit access to the consumer-customized nonverbal data without inhibiting access to the merchant web page, thus enhancing security and flexibility.
Referring to FIG. 2 , an exemplary process 200 perceived and performed by consumers includes several general steps. After the primary consumer selects merchandise of interest (step 210 ), the merchandise is arranged and/or configured according to primary consumer specification (step 230 ), and still or video images are obtained of the consumer-customized arrangement or configuration of merchandise (step 240 ). For instance, where a consumer is shopping for clothing, the clothing that is selected (step 210 ) may be modeled by the consumer or another consumer-selected individual (step 230 ), and an image of the clothing being modeled may be obtained by the merchant (step 240 ).
The primary consumer or merchant may attempt to contact the secondary consumer at various times throughout this process. For instance, as shown by step 220 , an attempt may be made before the merchandise is configured according to consumer specification (step 230 ) and before consumer-customized nonverbal information is collected (step 240 ), allowing the secondary consumer to receive streaming of information substantially in real-time. However, an attempt also may be made after either of steps 230 and 240 to enable viewing of stored images or data streams. In any case, to make such an attempt, a standard or cellular telephone, instant messaging, email or some other means may be used.
Once a digital image or stream of the consumer-customized arrangement or configuration of merchandise has been obtained, the secondary consumer may perceive the image or stream (step 250 ), and may provide feedback generally in the form of comments and/or authorization (step 260 ). Authorization may include payment information, particularly where the secondary consumer is relied upon for purchasing decisions.
Finally, the feedback is registered and/or communicated to the primary consumer and/or merchant. Thereafter, the purchase may be automatically enabled/refused, or the primary consumer may take additional steps to enable/refuse the purchase, e.g., with reference to registered feedback.
Referring to FIG. 3 , an exemplary process 300 perceived and performed by the merchant includes several general steps. Images and other information are received from input equipment 110 , and related identifying information and notes are received from the primary consumer (step 310 ). Where the images are obtained for future access, records that relate the received images to identifying information and/or notes may be created and stored (step 320 ). Similarly, where a stream of images is obtained for future access, one or more records that relate the images within the stream to identifying information and/or notes may be created and stored (step 330 ). FIG. 3A illustrates a sample record reflecting the relationship established between images and identifying information and notes.
However, where real-time access and viewing of the image, images or data stream is desired, it may be unnecessary to store the record and image(s) or data stream. In this instance, the identifying information may be stored merely to enable remotely-located secondary consumers to locate the image(s) or data stream for streaming, thus saving storage space.
Once records and/or data streams have been created based on the images and identifying information and/or notes, access is enabled for remote secondary consumers to the record or data stream, and thus the consumer-customized nonverbal information (step 340 ). For instance, referring to FIG. 3B , merchant computer system 120 enables secondary consumers access to stored records or data streams through an interface to, e.g., computer 322 of merchant computer system 120 (step 341 ). Identifying information or search criteria from the secondary consumer is then received, and a search is performed to identify a desired record or data stream using, e.g., an HTML page specified by searching software provided or accessed by computer 324 of merchant computer system 120 (step 342 ). Based on the search criteria, a search of available records and/or data streams is performed to return search results. When more than one record or data stream matches the received identifying information or search criteria (step 343 ), merchant computer system 120 prompts secondary consumer for additional information or selection among the identified records or data streams, and receives this selection information or further search criteria to repeat steps 342 and 343 (step 344 ). When a record or data stream is ultimately identified by the secondary consumer, an authentication process may be performed to ensure that the primary consumer desires to enable access to this particular secondary consumer. For instance, a password or other information may be collected from the secondary consumer and compared with information specified by the primary consumer. In this manner, different levels of security may be enabled to provide different secondary consumers with access to different images. Ultimately, for secondary consumers that are authenticated, records or data streams identified are displayed or streamed, e.g., in the format shown by FIG. 3C .
Based on the information accessed, feedback from the secondary consumer is received ( 350 ), communicated to the consumer, stored and/or used to authorize or disallow purchase of the merchandise (step 360 ).
The systems and processes described above have particular utility in retail applications where consumers sometimes prefer to compare the goods of one retail operation to the goods of another retail operation, and where enabling comparison of consumer-customized arrangements or configurations may be preferred. For instance, apparel, jewelry and other accessories are each items that consumers like to see customized to their choosing, e.g., by trying them on, before purchasing. The systems and processes may also find particular utility when used to display images or data streams to demonstrate services available to meet consumer specifications. Furthermore, these systems and processes are useful where primary consumers seek feedback or are required to obtain authorization or payment approval for purchases from secondary consumers, e.g., in a guardian-minor and employer-employee relationships.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed invention. For example, although the terms primary and secondary consumer are used in the above description, they may be the same entity and either may be a non-consumer. More specifically, the secondary consumer may not be a consumer at all; they may instead be a third party to the transaction, merely providing feedback to the first consumer. Similarly, the primary consumer may be a third party to a transaction between the secondary consumer and the merchant, the primary consumer merely choosing items for review by the secondary consumer. Furthermore, the primary and secondary consumer may be the same entity. Still further, although the consumer-customized nonverbal information is described as being viewed from locations remote to a merchant site, this information may also be available for viewing at the merchant site (e.g., useful in comparing outfits during a fitting process, or at a later date), or at or in conjunction with other merchant sites. For instance, where several related merchants (e.g., by affiliation, location, product type) provide electronic access as described herein, the customer-customized nonverbal information for two or more of those merchants may be jointly displayed or linked. Accordingly, other implementations are within the scope of the following claims. | Generic information provided by printed and online catalogs may be supplemented or replaced by information that is customized for and/or related to the consumer, enabling a third party to more fully understand the purchase decision and thus offer more informed feedback. A party accessing a merchant system may be provided electronic access to consumer customized nonverbal information by, e.g., collecting an electronic version of consumer-customized nonverbal information at a merchant site, and displaying the electronic version of the consumer-customized nonverbal information for a party accessing the merchant system. | 6 |
RELATED APPLICATIONS
This application claims priority to provisional application serial No. 60/402037 filed Aug. 9, 2003 (inventor: Linette Demers), which is hereby incorporated by reference in its entirety.
BACKGROUND
New forms of carbon including carbon nanotubes have commercially attractive properties. Better, more commercially attractive methods are needed to produce such materials for nanotechnological advancement. In addition, better methods are needed to provide purer materials and to locate materials in existing structures. Location is vital, for example, to building nanoelectronic and nanooptical devices. Also, better methods are needed to produce single wall carbon nanotubes. Nanolithography provides a commercially attractive route to improve carbon nanotube technology and provide high resolution and high alignment capabilities.
SUMMARY
One embodiment of the present invention is a method for producing carbon nanotubes, the method comprising:
a) providing a substrate with a top surface,
b) forming an island of catalyst material on the top surface using a tip having a patterning compound thereon,
c) heating the substrate and catalyst island, and
d) contacting the catalyst island with a carbon-containing gas for a period of time sufficient to form the nanotubes on the catalyst island. The tip can be a scanning probe microscopic tip including an atomic force microscopic tip. The island can have a length or width dimension other than height which is less than about one micron in size. The island can be a dot or line. The substrate top surface can be also passivated.
The invention also provides a method for producing carbon nanotubes comprising the steps of:
a) providing an ink-coated AFM tip, wherein the ink comprises a catalyst for carbon nanotube growth;
b) forming a pattern of catalyst on the top surface of a substrate with use of direct-write nanolithography using the ink-coated AFM tip, wherein the pattern is characterized by a size dimension other than height which is less than about one micron; and
c) contacting the catalyst with a carbon-containing gas under conditions sufficient to form the carbon nanotubes on the catalyst. The dimension can be less than about 100 nm. The catalyst can be a nanoparticle, including a metallic or metallic oxide nanoparticle. The pattern can comprise an array of dots or lines.
The invention also provides a method for producing carbon nanotubes comprising the steps of:
a) providing an ink-coated AFM tip, wherein the ink comprises a catalyst precursor for carbon nanotube growth;
b) forming a pattern of catalyst precursor on the top surface of a substrate with use of direct-write nanolithography using the ink-coated AFM tip, wherein the pattern is characterized by a size dimension other than height which is less than about one micron;
c) converting the catalyst precursor to catalyst;
d) contacting the catalyst with a carbon-containing gas under conditions sufficient to form the carbon nanotubes on the catalyst. The catalyst can be a metal or metal oxide. The dimension can be about 100 nm or less. The catalyst can be a metal or metal oxide and the dimension can be about 100 nm or less. The catalyst precursor can comprise a dendrimer or a protein.
The invention also provides a method for producing carbon nanotubes comprising the steps of:
a) providing an ink-coated AFM tip,
b) forming a template pattern on the top surface of a substrate with use of direct-write nanolithography using the ink-coated AFM tip, wherein the pattern is characterized by a size dimension other than height which is less than about one micron;
c) binding carbon nanotube catalyst to the pattern;
d) contacting the catalyst with a carbon-containing gas under conditions sufficient to form the carbon nanotubes on the catalyst.
The invention also provides a method for producing carbon nanotubes comprising the steps of:
a) providing an ink-coated AFM tip,
b) forming a template pattern on the top surface of a substrate with use of direct-write nanolithography using the ink-coated AFM tip, wherein the pattern is characterized by a size dimension other than height which is less than one micron;
c) binding carbon nanotube catalyst precursor to the pattern;
d) converting the catalyst precursor to a catalyst;
e) contacting the catalyst with a carbon-containing gas under conditions sufficient to form the carbon nanotubes on the catalyst.
The invention also provides a method for producing nanotubes or nanowires consisting essentially of the steps of:
a) forming a catalyst pattern on the top surface of a substrate with use of direct-write nanolithgraphic printing without use of a resist or a stamp and a scanning probe microscope tip having a patterning ink thereon, wherein the catalyst is bonded to the substrate, and
b) contacting the catalyst with a gas under conditions sufficient to form the nanotubes or nanowires on the catalyst, wherein the catalyst pattern is characterized by a size dimension other than height which is less than about 500 nm. The nanotubes or nanowires can consist essentially of carbon. The catalyst can be formed directly on the surface without use of a precursor. Or, the catalyst can be formed indirectly on the surface with use of a precursor ink which is converted to catalyst after patterning.
The invention also comprises articles and devices produced by the methods of the invention, and methods of using the articles and devices. Microelectronic and optical devices, including logic elements, transistors and other semiconductor devices, are particularly of importance. Devices comprising nanoscopic functional elements are also important.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates an ink-coated AFM tip used to pattern a substrate surface by nanolithography.
FIG. 2 illustrates an ink-coated AFM tip used to pattern a substrate surface by nanolithography including use of a template pattern.
FIG. 3 illustrates an ink-coated AFM tip used to pattern a substrate surface by nanolithography including use of catalyst particles.
FIG. 4 illustrates an ink-coated AFM tip used to pattern a substrate surface by nanolithography including use of catalyst particles.
FIG. 5 illustrates an ink-coated AFM tip used to pattern a substrate surface by nanolithography, wherein a negative mode is used so that the deposited pattern resists deposition of catalyst ink.
DETAILED DESCRIPTION
This application claims priority to provisional application serial No. 60/402037 filed Aug. 9, 2003 (“Apparatus, Materials, and Methods for Fabrication and Catalysis”; inventor: Linette Demers), which is hereby incorporated by reference in its entirety.
Direct-write technologies can be carried out by methods describe in, for example, Direct - Write Technologies for Rapid Prototyping Applications: Sensors, Electronics, and Integrated Power Sources , Ed. by A. Pique and D. B. Chrisey, Academic Press, 2002. Chapter 10 by Mirkin, Demers, and Hong, for example, describes nanolithographic printing at the sub-100 nanometer length scale, and is hereby incorporated by reference (pages 303–312). Pages 311–312 provide additional references on scanning probe lithography and direct-write methods using patterning compounds delivered to substrates from nanoscopic tips which can guide one skilled in the art in the practice of the present invention.
Direct-write nanolithography, in addition, has been described in the following documents which are each hereby incorporated by reference in their entirety and form part of the present disclosure.
(1) Piner et al. Science, 29 Jan. 1999, Vol. 283 pgs. 661–663. (2) U.S. Provisional application 60/115,133 filed Jan. 7, 1999. (3) U.S. Provisional application 60/207,713 filed Oct. 4, 1999. (4) U.S. Regular patent application Ser. No. 09/477,997 filed Jan. 5, 2000. (5) U.S. Provisional application 60/207,713 filed May 26, 2000. (6) U.S. Provisional application 60/207,711 filed May 26, 2000. (7) U.S. Regular application Ser. No. 09/866,533 filed May 24, 2001. (8) U.S. patent publication No. 2002/0063212 A1 published May 30, 2002. (9) U.S. Provisional application 60/341,614 filed Dec. 17, 2001. (10) U.S. Regular application Ser. No. 10/320,721 filed Dec. 17, 2002. (11) M. Su et al., J. Am. Chem. Soc. , vol. 124, No. 8, pages 1560–1561, 2002. (12) Demers et al. Angew Chem. Int. Ed. Engl. 2001, 40(16), 3069–3071. (13) Demers et al. Angew Chem. Int. Ed. Engl. 2001, 40(16), 3071–3073. (14) Liu et al. Adv. Mater. 2002, 14, No. 3, Feb. 5, 231–234. (15) B. W. Maynor et al., Langmuir, 2001, 17, 2575–2578. (16) Li, Y. et al., J. Am. Chem. Soc., 2001, Vol. 123, 2105–2106. (17) Maynor et al., J. Am. Chem. Soc. , Vol. 124, No. 4, 522–523, 2002. (18) L. A. Porter et al., NanoLetters, 2002, Vol. 2, No. 12, 1369–1372 (Au, Pd, and Pt nanoparticles from metal salt coated AFM tips) (19) M. Zhang et al., Nanotechnology, 13 (2002), 212–217 (parallel DPN printing with array of microfabricated probes). (20) A. Ivanisevic et al., J. Am. Chem. Soc., 2001, 123, 12424–12425 (particle assembly with opposite charged species). (21) U.S. Patent Publication 2003/0022470 published Jan. 30, 2003 to Liu et al. (“Parallel, individually addressable probes for nanolithography”) (22) U.S. Patent Publication No. 2003/00668446 (“Protein and peptide nanoarrays”) published Apr. 10, 2003 to Mirkin et al.
DPN™ and DIP PEN NANOLITHOGRAPHY™ are trademarks of Nanoink, Inc. and are used accordingly herein. In the DPN™ printing process, an ink is transferred to a substrate from a tip. The transferred ink, if desired, can be used as a template for further fabrication. The advantages and applications for DPN™ printing are numerous and described in these references. DPN™ printing is an enabling nanofabrication/nanolithographic technology which allows one to practice fabrication and lithography at the nanometer level with exceptional control and versatility. The present invention enables the preparation of surfaces patterned with discrete catalyst materials at nanometer scale and nanometer resolution with facile control. DPN™ printing provides for fine control of the patterning which is not provided by other methods. However, DPN™ printing can also be automated which provides rapid production. Moreover, the structures produced by DPN™ printing are generally stable, as DPN™ printing allows for the catalysts to be covalently bonded or chemically adsorbed to the substrate rather than merely physically adsorbed or mechanically locked in. DPN™ printing does not require that the substrate surface be made porous to accept the catalyst in a mechanical lock. Rather, the strategically patterned catalyst materials, chemically bound at predefined locations by DPN™ printing, are then used for growing desired materials such as, for example, carbon nanotubes at the predefined locations on the substrate.
U.S. Patent Publication 2002/0063212, published May 30, 2002 to Mirkin et al., discloses many useful embodiments which are hereby incorporated by reference including, for example, use of tips (paragraphs 0052–0054); substrates (0055); patterning compounds (0056–0078); tip coating methods (0079–82); patterning (0083–88); alignment (0089); nanoplotter format (0090–0092); multiple patterning compounds (0093); other methods (0094–0095); resolution parameters (0096–0100); uses including arrays and detection methods (0101–0106); software (0107–0128); kits (0129); instruments (0130); and imaging methods (0130–0136). Seven working examples are provided (0137–0211), which are incorporated by reference in their entirety. An appendix related to computer software is also provided and incorporated by reference (0212–0264).
In addition, the Demers articles noted above as references 10 and 11 describe use of nanolithographically generated templates to control building structures with nanoparticles. Particle organizational strategies are also disclosed, and are incorporated by references for specific teachings concerning these topics.
The Su article noted above also describes production of nanolithographic patterns using sol-gel chemistry to form, for example, metal oxide structures.
This type of nanofabrication and nanolithography in particular can be difficult to achieve with many technologies that are more suitable for micron scale work.
Carbon nanotubes are described in Marc J. Madou's Fundamentals of Microfabrication, The Science of Miniaturization, 2 nd Ed., pages 454–455, including carbon nanotube preparation by CVD from patterned catalysts. This Madou text also describes microlithography and nanolithography, and the use of carbon nanotubes at tips of AFM and STM probes. Carbon nanotubes are also described in the text, Carbon Nanotubes , by Dresselhaus et al., Springer-Verlag, 2000. See also, Special-Section, “Carbon Nanotubes” Physics World , vol. 13, pp. 29–53, 2000. Carbon nanotubes can be single-walled carbon nanotubes (SWNTs), multi-walled carbon nanotubes (MWNTs), nanohorns, nanofibers, or nanotubes. They can be conducting or semiconducting depending on the form of the nanotube. They can be open, closed, and have different kinds of spiral structure. Uses include storing fuels such as hydrogen or methanol for use in fuel cells and as supports for catalysts. They can be in zigzag and armchair form and have varying steepness which alters the chiral form.
Chemical vapor deposition (CVD) is one method for carbon nanotube production. In the CVD method, a catalyst for carbon nanotube growth is disposed on a surface and exposed to a carbon source and reaction conditions which promote carbon nanotube growth at the catalyst site. If the catalyst is patterned onto the surface, the carbon nanotube growth can result in a pattern of carbon nanotubes reflected the catalyst pattern. Although carbon nanotubes can be considered a part of nanotechnology, generally they have been prepared using micron level patterning. A number of references are noted herein which can be used by one skilled in the art to practice the present invention and, for example, grow carbon nanotubes from a catalyst site. For example, U.S. Pat. No. 6,346,189 to Dai et al., which is incorporated by reference, discloses micron technology, wherein nanotube structures are grown on catalyst islands. There is, however, no expressed or implicit suggestion that these islands can be at a nanometer scale, on the order of less than one micron. Hence, this technology is limited in its ability to connect nanotube technology with nanotechnology.
In another example, the publication by Kind et al. ( Adv. Mater. Sci. 1999, 11, 15, 1285–1289; incorporated herein by reference) also discloses nanotube production with use of microcontact printing at micron scale, not at nanometer scale. Again, these methods are not enabling for nanolithography or nanofabrication, particularly nanofabrication done at dimensions of 100 nm or less.
In addition, attempts to do nanofabrication and nanolithography can be cumbersome as reflected in the paper by Wang et al. ( Appl. Surf. Sci., 181 (2001), 248–254. Here, micropatterns, not nanopatterns, were formed by three methods including: (1) physical mask patterning using TEM grids, (2) electron beam lithography coupled with lift-off techniques, and (3) photolithography. Lines produced by electron beam lithography had a width of 10 microns, and at page 251, this paper states that the smallest width and space of self-oriented nanotube lines synthesized by our method are 2 microns. In sum, the goal of nanotechnology is miniaturization at the nanometer level, not the micron level, and DPN™ printing provides that miniaturization.
An important application of CVD preparation of nanotubes is the preparation of scanning probe microscopic tips, including AFM tips (see, for example, U.S. Pat. No. 6,346,189 to Dai et al.), and the present invention also enables the efficient fabrication of carbon nanotube scanning probe microscopic (SPM) tips including atomic force microscope (AFM) tips. It is very difficult and expensive presently to fabricate carbon nanotube SPM tips, including AFM tips, without a precise method of positioning catalysts or nanotubes.
Other advantages of the present invention are many and include, for example: (1) flexibility in terms of length scale of pattern and the substrate for catalyst immobilization, (2) multiple types of catalyst particles can be patterned on the same substrate in high registration, and (3) patterning can be done in serial or in parallel with patterning probe arrays. These features provide an improved method of fabricating, for instance multiple SPM nanotube tip probes at once, instead of one-at-a-time.
Computer simulation can be used to understand and control the fabrication process according to the present invention.
The present invention is illustrated by a series of embodiments illustrated in FIGS. 1–5 . In FIG. 1 , for example, an ink-coated AFM tip is used to pattern a substrate surface by dip pen nanolithographic printing. This patterned surface is then converted to a surface with a corresponding nanoscale catalyst pattern. The catalyst pattern is then exposed to conditions for growth of a solid material such as a nanotube or a nanowire.
In FIG. 2 , a more detailed illustration is provided. First, a template pattern is generated on a surface by DPN printing. In forming a template, any patterning compound can be used provided it is capable of modifying the substrate to form stable surface structures. The template pattern can be formed on the substrate by dip pen nanolithographic printing methods, as described in the documents above. For example, arrays and patterns can be generated including those in the form of dots and/or lines. The patterns produced have lateral dimensions as large as many microns and as small as 10 nm. In an optional step, after pattern formation, the unpatterned part of the surface is passivated with another material. In the next step, the patterned surface is exposed to catalyst particles which results in the binding of catalyst particles to the template pattern to form a catalyst pattern. Binding of the particle to the substrate can be covalent or electrostatic. From this catalyst pattern, additional structures can be formed, depending on the catalyst material composition and subsequent reaction conditions. For example, in one particular embodiment single-walled carbon nanotubes may be formed at the patterned regions, when the catalyst particles comprising the pattern are composed of a mixture of iron and molybdenum and the reaction conditions are CVD with a carbon-containing feedgas such as CO.
In FIG. 3 , a more general embodiment is illustrated wherein catalyst particles are applied to a patterned surface. A surface of nanoscale patterns is produced using a molecular glue. A catalyst material is applied. From the patterned catalyst, a three dimensional structure is formed such as, for example, a nanotube or nanowire. In another form of this invention, a catalyst precursor material may be applied to the template pattern. The precursor can be converted to an active catalyst in a separate step, for example by application of energy in the form of heat. In an alternative embodiment, preformed catalyst molecules or nanoscale catalyst particles are applied to a substrate directly via DPN printing or another such positive patterning technique. In this case, the catalyst material is in the form of an “ink” which is transferred to the substrate surface as part of the DPN printing process. This direct catalyst deposition is illustrated in FIG. 4 . Additionally, surfaces can be patterned in positive and negative modes. In a negative mode, for example, a surface can be patterned to resist deposition of the catalyst ink. In this mode, the catalyst would be preferentially bound to the remainder of the surface as illustrated in FIG. 5 .
In the present invention, a wide variety of substrates can be used. DPN printing substrates are disclosed in the above-cited DPN printing references. Substrates can be any material which can be modified by a patterning compound to form stable surface structures. In other words, the DPN printed substrate can be tailored to be chemically bound to the ink transferred to the substrate during DPN printing. The substrate can be, for example, relatively hard, inorganic materials including elemental materials, oxides of the elements, ceramics, metals semiconductors, magnetic materials, polymer or polymer-coated materials, and superconductor materials. These include, for example, silicon, silicon oxide, alumina, quartz, and silicon nitride. The substrate can be flat, non-flat, or curved, although in general a flat substrate is preferred. The substrate can be porous. The substrate can be, for example, a conductor, a semi-conductor, or an insulator. The substrate can be surface treated to improve performance by, for example, improving adhesion.
In addition, the substrate can be, for example, materials and shapes of interest for production of one or more scanning probe microscopic tips, including atomic force microscope tips and electrostatic force microscopy probe tips. The materials can be, for example, silicon and silicon nitride, microfabricated in the shapes of cantilevers with integrated pyramidal tips. Such tips are disclosed, for example, in the paper by Cheung et al. ( Proc. Nat'l Acad. Sci. , Apr. 11, 2000, vol. 97, no. 8, 3809–3813), which is incorporated by reference. Also, U.S. patent publication 20020046953 to Lee et al., published Apr. 25, 2002, discloses tips and related methods of fabricating tips, and is incorporated by reference. Another class of suitable substrates can be, for example, surfaces containing microfabricated structures of interest for production of sensors, field emission sources, or other optical or electronic devices.
Specific examples of preformed catalyst or catalyst precursor materials include nanoparticles having dimensions ranging from several microns to several nanometers. The particles can be polymeric, metals, semiconductors or insulators. The catalyst can be transition metal catalysts including, for example, Fe, Ni, Mo, and Co, or other metals such as, for example, titanium, platinum, and palladium. Catalysts can also be mixtures of metals, such as Fe/Mo. Composite nanostructures can be, for example, aluminum oxide, silicon oxide, tin oxide, and iron oxide. In preferred embodiments, the catalyst can be, for example, iron oxide (Fe 2 O 3 ), iron, molybdenum, cobalt, nickel, ruthenium, or zinc, and oxides thereof. The catalytic regions or islands can be also formed from thermal decomposition of metallic salts. For example, iron (III) nitrate can be oxidatively decomposed into iron (III) oxide. Catalysts with magnetic properties can be used including, for example, magnetic iron oxide. In addition, supported catalysts can also be used such as, for example, alumina-supported iron. Specific examples include inactive particles (such as polystyrene, titanium dioxide, alumina, silica) which act as supports for the catalytic particles. Catalysts are described in, for example, U.S. Pat. No. 6,346,189 including supported and unsupported catalyst particles.
An advantage of the DPN process is the ability to form closely spaced nanometer level structures. The distance between separated catalyst regions can be on the many micron scale or as small as 5 nm, or can be the minimum inter-feature distance achieved with DPN printing. Thus, multiple catalyst materials can be patterned using this method, including two or more catalyst components, with each component in discrete patterns. Thus, combinatorial arrays of catalyst materials can be produced.
The catalyst region can have a length or width dimension, other than height, which is less than about one micron in size, more particularly less than about 500 nm in size, more particularly less than about 250 nm in size, more particularly less than about 100 nm in size, more particularly less than about 50 nm in size, and more particularly less than about 25 nm in size. The catalyst region can have a length or width dimension, other than height, which is at least about 1 nm in size, more particularly, which is at least about 5 nm in size.
The DPN printing can be carried out with a reactive transfer of ink to the substrate, or with non-reactive transfer of ink to the substrate.
The catalyst pattern can be a series of patterned catalyst dots, or can be a series of patterned catalyst lines.
Once patterned, the catalyst regions or islands can be used to grow electrically conductive, semiconducting, or insulating structures from the catalyst. The resulting structures can be, for example, nanotubes, nanowires, or mixtures thereof, and may include carbon nanotubes, Si or Ge crystalline nanowires, cobalt nanowires, various sulfides, oxides, and nitrides, for example silicon nitride, copper sulfite, silicon oxide.
In one embodiment, carbon structures can be fabricated from the patterned catalysts including fullerenes, nanohorns, and carbon nanotubes. The carbon structures can be conductive or semi-conductive doped nanotubes, or mixtures thereof. The nanotubes can be single-walled, double walled, or multi-walled nanotubes. The nanotubes can be in the form of fibrils and ropes.
Carbon nanotubes can be generated by methods known in the art with use of carbon sources such as, for example, methane, carbon monoxide, acetylene, or ethylene.
Instrumentation is available from, for example, NanoDevices (Santa Barbara), for growing carbon nanotubes by catalyzed chemical vapor deposition (EASYTUBE™ NANOFURNACE).
Documents which are incorporated by reference, and which relate to nanotube technology, including CVD fabrication and catalysis, applications of carbon nanotubes in devices, purification of nanotubes once formed, and which can be used to in practicing the present invention include:
(1) Hannes Kind et al. Advanced Materials, 1999, 11, 1285. (2) Y. Y. Wei et al. J. Vac. Sci. Technol. B, 2000, 18(6), 3586 (3) H. Wang et al. Applied Surface Science, 2001, 181, 248–254. (4) Chin Li Cheung, PNAS, 2000, 97(8), 3809–3813. (5) J. H. Hafner, J. Am. Chem. Soc., 1999, 21, 9750–9751. (6) Cao et al. Applied Surface Science, 2001, 181, 234–238. (7) Dai et al., “Growth and Characterization of Carbon Nanotubes,” book chapter in “Topics in Applied Physics”, Vol. 80, Ed. M. Dresselhaus, Springer Verlag (2000). (8) Dai et al. Appl. Phys. Lett., 75, 3566–3568 (1999). (9) Dai et al. J. Am. Chem. Soc., 121 7975–7976 (1999). (10) Dai et al. Phys. Chem., 103, 6484–6492 (1999). (11) Dai et al. Appl. Phys. Lett., 627–629, 75 (1999). (12) Dai et al. Science, 283, 512 (1999). (13) Dai et al. Nature, 395, 878,(1998). (14) M. S. Dresselhaus et al., Science of Fullerenes and Carbon Nanotubes , Academic Press, San Diego, 1996. (15) Li et al, Chem. Mater., 13, 1008–1014,(2001). (16) U.S. Patent Publication, 2003/0148577 (“Controlled Alignment of Catalytically Grown Nanostructures in a Large Scale Synthesis Process”) by Merkulov et al., published Aug. 7, 2003. (17) U.S. Patent Publication 2002/0127336, published Aug. 1, 2002 to Richard Smalley et al. (18) U.S. Patent Publication 2002/0113714, published Aug. 1, 2002 to Richard Smalley et al. (19) U.S. Patent Publication 2002/0102203, published Aug. 1, 2002 to Richard Smalley et al. (20) U.S. Pat. No. 6,183,714 (“Method of Making Ropes of Single-Wall Carbon Nanotubes”) to Richard Smalley et al., issued Feb. 6, 2001. (21) U.S. Patent Publication 2002/0088938 to Colbert et al., published Jul. 11, 2002 (“Methods for forming an array of single-wall carbon nanotubes and compositions thereof”). (22) U.S. Patent Publication 2003/0143327, published Jul. 31, 2003 to Rudiger et al. (23) U.S. Pat. No. 6,146,227 to Mancevski issued Nov. 14, 2000 (Method for manufacturing carbon nanotubes as functional elements of MEMS devices”). (24) U.S. Pat. No. 6,277,318 to Bower et al., issued Aug. 21, 2001 (“Method for fabrication of patterned carbon nanotube films”). (25) U.S. Pat. No. 6,333,016 to Resasco et al. issued Dec. 25, 2001 (“Method of producing carbon nanotubes”). (26) U.S. Patent Publication 2002/0130353 to Lieber et al., published Sep. 19, 2002 (Nanoscopic wire-based devices, arrays, and methods of their manufacture”).
Nanotubes and nanowires, which are preferred embodiments of the present invention, are important materials because of their unique mechanical and electrical properties. In this invention, nanotubes and nanowires can be positioned on substrates with high resolution, on the order of many microns to several nanometers. Growth can extend in a direction perpendicular to the substrate, or can extend more laterally. In lateral growth, the possibility exists for connection between different catalyst regions, or between a catalyst and a non-catalytic region. In this embodiment, circuits can be formed. The circuits may act as components in sensors, biosensors, and other nanoelectronic devices. Other applications of such structures are in field emission sources and photonics, as well as others noted in the above-cited references.
The carbon nanotube length can vary greatly depending on how they are made, and can be nanoscopic or microscopic. The aspect ratio can be, for example, about 100 to about 100,000, more particularly, 100 to 10,000.
Preferred Embodiments
A. An Example of a Fabrication Method for Nanostructures Described Above.
Method used for generating gold surfaces with nanoscale carbon nanotube patterns via dip pen nanolithographic printing.
1. Monodispersed Fe/Mo particles (14 nm) are prepared by thermal decomposition of Fe(CO) 5 and Mo(CO) 6 by refluxing in octyl ether solvent in the presence of surfactants octanoic acid and/or bis-2-ethylhexylamine (as described by Li et al Chem. Mater., 2001, 13, 1008–1014.) 2. Patterns of 16-mercaptohexadecanoic acid are generated via Dip Pen Nanolithography on a polycrystalline gold substrate (60 nm of Au thermally evaporated onto a 5 nm thick Ti adhesion layer). Typically, patterns of dots and lines are generated with lateral feature dimensions on the order of microns down to 50 nm. After patterning the template molecule, the unpatterned gold surface is protected by exposure to a 1 mM solution of 1-octadecanethiol in ethanol for 10 min., then rinsed with ethanol. 3. After generation of the template pattern, the substrate is exposed to a solution of the Fe/Mo nanoparticles in n-heptane for 0.5 h. The substrate is then rinsed carefully with n-heptane to remove any particles that are not bound to the template pattern. 4. The catalyst patterned substrate is then heated to 700° C. in air to remove organic coatings on the particles. 5. Single-walled carbon nanotubes are grown from the catalyst regions via CVD using a high temperature furnace setup with H 2 /CO feedgas (described by Zheng et al, Nano Letters, 2002, Vol. 2, No. 8, 895–898.)
B. An Example of a Fabrication Method for Nanostructures Described Above.
Method used for generating insulator or semiconductor (silicon or silicon oxide) with nanoscale carbon nanotube patterns via dip pen nanolithography.
1. Monodispersed Fe/Mo particles (3 nm) are prepared by thermal decomposition of Fe(CO) 5 and Mo(CO) 6 by refluxing in octyl ether solvent in the presence of surfactants octanoic acid and/or bis-2-ethylhexylamine (as described by Li et al Chem. Mater., 2001, 13, 1008–1014.) 2. Patterns of 3-aminopropyltrimethoxysilane are generated via dip pen nanolithography on a silicon/silicon oxide substrate (500 nm of thermally grown oxide on silicon). Typically, patterns of dots and lines are generated with lateral feature dimensions on the order of microns down to 10 nm. 3. After generation of the template pattern, the substrate is exposed to a solution of the Fe/Mo nanoparticles in n-heptane for 0.5 h. The substrate is then rinsed carefully with n-heptane to remove any particles that are not bound to the template pattern. 4. Carbon nanotubes are grown from the catalyst regions as described above.
C. An Example of a Fabrication Method for Nanostructures Described Above.
Method used for generating insulator or semiconductor (silicon or silicon oxide) with nanoscale carbon nanotube patterns via dip pen nanolithography.
1. Monodispersed Fe/Mo particles (3 nm) are prepared by thermal decomposition of Fe(CO) 5 and Mo(CO) 6 by refluxing in octyl ether solvent in the presence of surfactants octanoic acid and/or bis-2-ethylhexylamine (as described by Li et al Chem. Mater., 2001, 13, 1008–1014.) 2. Patterns of catalyst particles are generated via dip pen nanolithography on a silicon/silicon oxide substrate (500 nm of thermally grown oxide on silicon). Typically, patterns of dots and lines are generated with lateral feature dimensions on the order of microns down to 10 nm. 3. Carbon nanotubes are grown from the catalyst regions as described above.
D. An Example of a Fabrication Method for Nanostructures Described Above.
Method used for generating gold surfaces with nanoscale carbon nanotube patterns via dip pen nanolithographic printing.
1. Monodispersed Fe/Mo particles (14 nm) are prepared by thermal decomposition of Fe(CO) 5 and Mo(CO) 6 by refluxing in octyl ether solvent in the presence of surfactants octanoic acid and/or bis-2-ethylhexylamine (as described by Li et al Chem. Mater., 2001, 13, 1008–1014.) 2. Patterns of 1-octadecanethiol are generated via Dip Pen Nanolithography on a polycrystalline gold substrate (60 nm of Au thermally evaporated onto a 5 nm thick Ti adhesion layer). Typically, patterns of dots and lines are generated with lateral feature dimensions on the order of microns down to 50 nm. After patterning the resist molecule, the unpatterned gold surface is modified with 16-mercaptohexadecanoic acid by exposure to a 1 mM solution in ethanol for 10 min., then rinsed with ethanol. 3. After generation of the negative pattern, the substrate is exposed to a solution of the Fe/Mo nanoparticles in n-heptane for 0.5 h. The particles bind selectively to the regions consisting of 16-mercaptohexadecanoic acid, and do not bind to the regions containing 1-octadecanethiol. The substrate is then rinsed carefully with n-heptane to remove any particles that are not bound to the 16-mercaptohexadecanoic acid regions. 4. The catalyst patterned substrate is then heated to 700° C. in air to remove organic coatings on the particles. 5. Single-walled carbon nanotubes are grown from the catalyst regions via CVD using a high temperature furnace setup with H 2 /CO feedgas (described by Zheng et al, Nano Letters, 2002, Vol. 2, No. 8, 895–898.)
E. Additional Preferred Embodiment
The useful properties of single-walled carbon nanotubes are generally understood to be a function of their diameter and chirality. It is generally understood, for example, that the diameter of SWNTs produced from metal oxide catalyst particles can be related to the diameter of the catalyst nanoparticle. Therefore, a need exists to control the size of the deposited catalyst particles. The following embodiments of DPN printing can be used to pattern discreet packages of catalyst material using a carrier. A carrier can be used to closely control the diameter of the resulting particle, and thus the diameter of the SWNT produced.
A carrier can be, for example, a synthetic or biological polymer including a dendrimer or a protein carrier such as, for example, ferritin. Dendrimer carriers are described in, for example, H. C. Choi et al., J. Phys. Chem. B. , Vol. 106, No. 48, Dec. 5, 2002, pages 12361–12365, which is hereby incorporated by reference in its entirety. DPN printing of dendrimers is described in, for example, R. McKendry et al., NanoLetters, 2002, Vol. 2, No. 7, pages 713–716, which is hereby incorporated by reference in its entirety. Proteins having cores and metal carrier ability can be used. For example, use of cores of the iron-storage protein ferritin is described in, for example, Y. Li et al., J. Phys. Chem. B., 2001, 105, 11424–11431. In this embodiment, small iron particles of about 1 nm to about 5 nm in diameter can be used to prepare single tubes.
E1. Artificial Protein Carriers for Iron Deposition Via the DPN Printing Process.
Method used for generating silicon oxide surfaces with SWNTs with well defined diameters via dip pen nanolithographic printing.
1. Apoferritin molecules (available from Sigma-Aldrich) are reconstituted with Fe(III) using standard procedures (see Li et al J. Phys. Chem. B 2001 reference, for example, cited above). 2. Different sizes of final catalyst particles can be made by controlling the amount of iron in the ferritin. The loading of ferritin with controllable amount of iron yields iron oxide particles with well defined diameters and narrow size distributions, for example, ˜200 iron atoms yield about 1.9 nm diameter particles, while 1100 iron atoms yield about 3.7 nm diameter particles. 3. The iron-loaded protein, dissolved in distilled water is used as ink for patterning nanoscale features on a substrate via the DPN printing process. Protein printing is described in, for example, U.S. patent application Ser. No. 10/442,189 filed May 21, 2003 to Mirkin et al. which is hereby incorporated by reference. 4. Following patterning, the substrate is heated to 800° C. in air to remove the organic layer and to obtain fully oxidized iron catalyst particles. 5. Single-walled carbon nanotubes are grown from the catalyst regions via CVD using a high temperature furnace setup with H 2 /CO feedgas (described by Zheng et al, Nano Letters, 2002, Vol. 2, No. 8, 895–898.)
E2. Dendrimer Carriers for Iron Deposition Via the DPN Printing Process.
Method used for generating silicon oxide surfaces with SWNTs with well defined diameters via dip pen nanolithographic printing.
1. Dendrimer molecules (hydroxyl terminated PAMAM G6 available from Dendritech) are loaded with Fe(III) using standard procedures (Li et al J. Phys. Chem. B 2001, cited above). 2. The iron-containing dendrimers dissolved in an aqueous solution are used as the ink to form nanoscale patterns on a substrate via the DPN printing process. 3. Following patterning, the substrate is heated to 800° C. in air to remove the organic dendrimer and yield fully oxidized iron catalyst particles. 4. Single-walled carbon nanotubes are grown from the catalyst regions via CVD using a high temperature furnace setup with H 2 /CO feedgas (described by Zheng et al, Nano Letters, 2002, Vol. 2, No. 8, 895–898.)
E3. Dendrimer Carriers for Iron Deposition Via the DPN Process.
Method used for generating silicon oxide surfaces with SWNTs with well defined diameters via dip pen nanolithographic printing.
1. Dendrimers (hydroxyl terminated PAMAM G6 available from Dendritech) dissolved in an aqueous solution are used as the ink to form nanoscale patterns on a substrate via the DPN printing process. 2. Following patterning, the substrate is exposed to an aqueous solution of FeCl 3 (6H 2 O) for several seconds to fully load the dendrimers with Fe(III). The substrate is briefly rinsed to remove uncomplexed iron. 3. Following patterning, the substrate is heated to 800° C. in air to remove the organic dendrimer and yield fully oxidized iron catalyst particles. 4. Single-walled carbon nanotubes are grown from the catalyst regions via CVD using a high temperature furnace setup with H 2 /CO feedgas (described by Zheng et al, Nano Letters, 2002, Vol. 2, No. 8, 895–898.)
While the invention has been described above with particularity, other embodiments will be known to those skilled in the art which are not expressly disclosed herein but nevertheless form part of the invention. In the present invention, what can be claimed is: | A method for producing carbon nanotubes, the method comprising: (a) providing a substrate with a top surface, (b) forming an island of catalyst material on the top surface using a tip having a patterning compound thereon, (c) heating the substrate and catalyst island, and (d) contacting the catalyst island with a carbon-containing gas for a period of time sufficient to form the nanotubes on the catalyst island. | 3 |
The present invention relates in general to vibratory feeders for disc-like objects and in particular to a vibratory feeder for coins to be fed to a coin sorter.
BACKGROUND OF THE INVENTION
In the sorting of large quantities of disc-like objects such as coins, consideration of labor costs dictates that as much work as possible should be accomplished by automatic means. There are many machines available for mechanically sorting and counting coins but, generally speaking, these machines are of a complex structure with electric motors and many mechanical parts; they are costly to produce and they are subject to breakdowns. Such devices often utilize vibratory means in a feeder portion to induce movement of the objects to a sorter or other equipment. Also while the present invention relates particularly to the feeding of coins it is understood that feeders for other disc-like objects such as washers, buttons and bottle-caps are afflicted with the same problems as are coin feeders and sorters. Representative devices are found in Canadian Pat. Nos. 946,008 (Gess) and 946,009 (Hodgins) both issued Apr. 23, 1974 and in U.S. Pat. No. 3,752,168 (Bayla) issued Aug. 14, 1973. The two Canadian Patents use spiral vibratory feeders to move articles (bottle caps and buttons respectively) in a single line to a chute device which feeds the articles, one at a time, to a subsequent work station. Such equipment would not be suited to feeding disc-like objects having different diameters and thicknesses as they would be prone to jamming and piling. The U.S. patent shows a vibratory feeder for feeding a random mix of coins to a coin sorter but the structure thereof is complex, expensive to produce and could be prone to jamming. Specific means must be provided to avoid piling up of coins and the feeding of unwanted coins.
There is also a need for a feeding device for manual coin sorters such as that defined in my Canadian Pat. No. 769,469 issued Oct. 17, 1967. That coin sorter is a small unitary device provided with chutes of different widths and depths for the sorting of coins into stacks convenient for wrapping. To operate this sorter the operator feeds coins by hand to a receiving area at the top thereof, allowing the coins to proceed, by gravity, along their respective chutes until he has coins sorted for a roll. He than proceeds to roll-wrap and he thus alternates between feeding and roll-wrapping. This sorter is ideal for small volume coin handling but does not have the capacity for large volume jobs. It is desirable, therefore, to combine this device with a mechanical coin feeder which could at least double the coin handling efficiency of the sorter. In order to make such a feeder attractive from an economic standpoint it must be less complex than previously available units, it must reduce as much as possible any jamming of the coins, it must be relatively inexpensive to produce and it must be readily mountable on the coin sorter.
SUMMARY OF THE INVENTION
To meet the above-identified requirements I have devised a mouldable vibratory feeder which can be inexpensively produced, avoids the possibility of serious jamming situations and which will accept coins in small groups, say 10 to 20 at a time, up to larger volumes of coins, say several hundred. It is readily adaptable to my previous coin sorter and it effectively reduces coins from a large volume to a uniform flow suitable for the capacity of the coin sorter or the capacity of the operator who wishes to complete subsequent coin handling operations such as counting and wrapping.
The present invention is not limited to the feeding of coins although that was the original purpose for which it was designed. It would be readily adaptable to the feeding of other disc-like objects such as washers, buttons or bottle caps whether such objects have uniform or different diameters and/or thicknesses.
The present invention provides a box-like structure having a particularly profiled bottom which results in the desired flow pattern for the objects. The bottom has a main trough establishing a first flow path, the trough extending the length of the structure and terminating in an opening for feeding the objects to a subsequent work station. An auxiliary flow path feeds objects to the main trough and includes a second trough parallel to but shorter than the main trough and at a higher elevation than the main trough. A plurality of longitudinally angled upwardly projecting guide fins extend between the two troughs and are separated by downwardly inclined guide troughs providing flow paths from the second trough to the first trough. A raised area between the first and second troughs at the end opposite the opening permits objects placed thereon to flow to each of those troughs. A vibratory motor is also provided to impart vibrations to the entire structure the vibrations produced thereby serving to induce movement of the objects along the flow paths and to vibrate loose any objects that might jam together. The fins tend to reduce the flow rate along the auxiliary flow path, thereby reducing the possibility of jamming and reducing the pressure of objects against the objects flowing from the auxiliary to the main flow path. All troughs are contoured so that even the smallest object to the fed will not lie flat in any of the troughs. When supported in this manner the objects will readily rock on the opposed points thereby aiding in separating the objects from groups to a single layer. They will flow more readily as there is less friction, due to minimum surface contact. Also the operation will be quieter as there will be less tendency for the objects to bounce than if they were flowing on a vibrating flat surface. Essentially each object is supported in each trough at diametrically opposed points on its outer circumferential edge. The contoured bottom may be moulded as a unitary component of the feeder and then the side and end walls attached or, in fact, the entire structure could be moulded as a sngle unit. Means may be provided for attaching the structure to a subsequent work station such as a coin sorter as defined in Canadian Pat. No. 769,969.
In its broadest form therefore the present invention may be defined as a feeder for disc-like objects comprising a generally box-like structure having opposed side and end walls and a bottom wall, said bottom wall defining a first flow path extending the length of said structure and terminating adjacent one end wall at an opening in said bottom wall, a second flow path having a first portion parallel to said first path and auxiliary portions linking said first portion to said first path, said first portion being raised relative to said first path and said auxiliary portions being angled forwardly relative to said first portion, each of said paths having an upper surface contoured so that the smallest object to be fed will not lie flat thereon, and a raised area adjacent the other end wall between said first path and first portion, said area defining flow routes towards each of said flow paths, and means for imparting vibrations to said structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the coin feeder of the present invention in position on a coin sorter (shown in dash-dot lines);
FIG. 2 shows a top view of the coin feeder of the present invention;
FIG. 3 shows a bottom view of the coin feeder;
FIGS. 4, 5 and 6 show sections of the coin feeder as taken along the lines 4--4, 5--5 and 6--6 respectively of FIG. 2;
FIG. 7, appearing on the same sheet as FIG. 1, shows a section of the coin feeder as taken along the line 7--7 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As is readily seen in FIGS. 1, 2 and 3 the coin feeder of the present invention comprises a generally box-like structure 10 having opposed end walls 12 and 14, opposed side walls 16 and 18 and a bottom wall 20. While the side and end walls may each be generally rectangular so as to retain coins within the structure, the bottom wall is profiled in a particular manner in order to provide an optimum flow pattern for coins to be fed.
Turning now to FIGS. 2, 4 and 7 it is seen that bottom wall 20 is provided with a trough portion 22 defining a first flow path and extending substantially from one end wall 12 to the other end wall 14, adjacent one side wall 16. The trough portion 22 has a cross-section which results in a concave upper surface, the radius of curvature being such that even the smallest coin to be fed will not lie flat on the surface but will be supported only at two diametrically opposed points. While the trough portion 22 may extend to a smooth straight line from end wall 12 to end wall 14 it is preferred that a section 24 of the trough portion 22 slope downwardly in the vicinity of end wall 14. This feature is shown in the longitudinal section of FIG. 4.
The bottom wall 20 is provided with a second trough portion 26 seen in FIGS. 2, 5 and 7. The second trough portion defines a first portion of a second flow path and starts adjacent end wall 12 extending adjacent the other side wall 18 to a zone 28 intermediate the end walls 12 and 14. As seen in FIG. 7 trough portion 26 is also provided with a generally concave upper surface, that surface being raised relative to the upper surface of trough portion 22. As with trough portion 22, the radius of curvature for trough 26 is such that even the smallest coin to be fed will not lie flat thereon.
FIG. 2 illustrates auxiliary portions of the second flow path linking the first portion (trough 26) with the first flow path (trough 22). A connecting trough 30 merges smoothly with trough portions 26 and 22 and inasmuch as trough portion 26 is raised relative to trough portion 22, the connecting trough will actually slope downwardly from trough portion 26 to trough portion 22. As shown in FIG. 2 the connecting trough 30 merges smoothly with the trough portion 26 at the zone 28 and, further, connecting trough 30 is angled with respect to the direction of flow defined by the trough portions 22 and 26 as being from the end wall 12 towards the end wall 14.
A suitable angle for the trough 30 is found between 40 and 60 degrees with respect to the flow direction with 50° being optimum.
Immediately adjacent the connecting trough 30 is a generally upright protruding guiding fin 32, the fin 32 extending no higher than the upper edge of the end and side walls. The fin 32 is parallel to the connecting trough 30 and it extends between the inside longitudinal edge of the trough portion 26 and the trough portion 22. Spaced apart from but parallel to the fin 32 are other guiding fins 34, being substantially identical to the fin 32. Between guiding fin 32 and the next adjacent fin 34 as well as between each pair of fins 34 is a guide trough 36, each trough 36 merging smoothly with the trough portions 26 and 22 in the same manner as the connecting trough 30. As with trough 30, the troughs 36 will slope downwardly from the trough portion 26 to the trough portion 22 and they are contoured in the same manner as trough portions 22 and 26.
FIGS. 2, 4 and 7 illustrate the fins 32, 34 and the troughs 30, 36 in greater detail. The upper peripheral edge 38 of the fins is smoothly curved and the side edges of each fin curve downwardly and outwardly to form the sides of the intervening trough 36.
As viewed in FIG. 2 the left hand side of the fin 34 adjacent end wall 12 merges smoothly into a raised contoured area 40 having a ridge portion 42 and sloping sides 44, 46. The ridge portion extends between end wall 12 and the adjacent fin 34 and is at substantially the same height as the fins 34. The ridge portion 42 is also positioned in the area 40 so as to be closer to the trough 22, resulting in side 44 having a steeper slope than the side 46. Each side 44, 46 is smoothly curved so as to have a slightly concave upper surface, which surface merges smoothly with the respective trough 22, 26.
Between the trough 30 and the end wall 14 the bottom 20 is provided with a two-level planar portion 48 having an edge wall 50 defining one edge of the trough 30 and a second edge wall 52 defining a portion of the edge of trough 22. Edge wall 52 terminates in a curved wall portion 54 which leads to an opening 56 in the bottom wall 20. Opening 56 is sized to permit several of the largest coins to be fed to pass therethrough. In order to facilitate coin flow to opening 56 a curved wall 58 is provided in the corner defined by walls 14 and 16.
As indicated above, planar portion 48 has two levels, level 60 being raised relative to level 62, although level 60 is no higher than the top of the side or end walls. Level 62 is at a height sufficient to define the edge of the troughs 30 and 22 passing thereby.
Turning now to the bottom view of FIG. 3 it is seen that level 60 forms a cavity defined by a wall 64 to which is attached a vibratory motor 66. This motor may be of any of the commercially available units and it has a cord 68 connectable to a standard AC outlet, the cord 68 passing through an opening 70 in level 62. The motor 66 is also connected by an electrical cord, (not shown) to an on-off switch 72 and a rheostat 74 mounted in the end wall 12 of the device. These control the operation of the feeder and, being commercially available, need not be described. As shown in FIGS. 3 and 5 these controls may be sealed in a cavity 76 formed adjacent end wall 12, the cavity being accessible via a removable closure plate 78.
As indicated previously, the feeder of the present invention may be advantageously used with a coin sorter as defined in Canadian Pat. No. 769,469 and such a sorter is shown in phantom outline in FIG. 1 by reference number 80. To enable assembly to such a coin sorter a pair of downwardly depending lugs 82 may be provided as extensions of the side walls 16, 18 adjacent end walls 14. On the inside wall of each lug may be held a captive nut 84 which may receive a threaded screw portion 86 and a wing nut 88. Each screw 86 is receivable in a slot (not shown) provided in the upper side walls of the sorter, thereby providing a pivot axis for the feeder relative to the sorter. The feeder may be clamped to the sorter by the wing nuts 88 which clamp the adjacent side wall of the sorter against the respective lug 82.
In order to support the other end of the feeder above the sorter the bottom wall is provided with a pair of parallel rack members 90 having a plurality of spaced indentations 92. A U-shaped wire member 94 may be pivotally attached to the sorter as at 26 so that the bottom of the U is engageable with the indentations 92. The slope of the feeder relative to the sorter can be adjusted by placing the member 94 in different sets of indentations 92.
It is expected that the entire unit can be injection moulded of ABS or styrene in a single operation with the mould dies producing the sides and imparting the specific contour to the bottom. The sides 12, 14, 16, 18 may be formed from sheet material to which the bottom is attached in a conventional manner. It is suggested that the entire unit may be formed from a plastics material such as polystyrene or polyvinylchloride.
The operation of the coin feeder according to the present invention will now be described, assuming that the feeder 10 is assembled to a sorter 80 as illustrated in FIG. 1, utilizing the assembly components described hereinabove. It is noted that end wall 14 is adjacent the upper end of the inclined sorter so that opening 56 is positioned just above the normal inlet area 98 of the sorter 80. It is also suggested that the feeder 10 be positioned so that it has a slight downwards slope relative to the horizontal from end 12 towards end 14. This slope is not essential especially if trough 22 is sloped as at 24 as suggested above, but such a slope will aid in the feeding of coins.
A random quantity of coins is then placed in the feeder, primarily in the vicinity of the contoured area 40 although if a substantial quantity of coins is to be fed and sorted the coins may initially fill the troughs 22, 26, 30, 36 and in fact may be piled thereon to at least the height of the walls 12, 14, 16, 18. The walls are of a suitable height to provide ample volume and to eliminate overloading by allowing excess coins to spill thereover. With control 74 set for minimum vibratory output from motor 66, switch 72 is turned on. Control 74 may then be operated to increase the output of motor 66 so that the vibratory output thereof is transmitted to the feeder. The vibrations are transmitted to the coins piled in the feeder thereby greatly reducing the effects of friction or jamming and, aided slightly by gravity if the feeder is sloped and also aided by the inclinations designed into the troughs 22, 30, 36 and the sloping sides 44, 46 the coins will begin to follow the troughs 22, 26, 30, 36 in a general direction towards the opening 56. As the coins encounter the opening 56 they will pass therethrough one at a time or in small groups into the receiving area 98 of the sorter 80 from whence they will flow downwardly in the sorter to their appropriate sorted locations.
The particular configuration of troughs, fins and contoured areas in the present invention aids greatly in avoiding or rectifying any jamming of coins. A uniform flow rate can be established along trough 22 leading to opening 56. Coins piled in the remainder of the feeder will flow along troughs 26, 30, 36, around fins 32, 34 and area 40 towards the trough 22 but their flow rate is retarded relative to that of the coins in trough 22, primarily by the fins 32, 34. Also should coins jam at an exit from a trough 30, 36 coins will continue to flow to another trough and thence to the trough 22. Any jammed coins, caused by a smaller coin occupying open space between larger coins, and bridging an exit, will be shaken loose by the vibrations imparted by the motor 66. This is aided by the flow pattern of the coins which effectively reduces any pressures formed by a build-up of coins behind a jam of coins.
To summarize the operation and advantages of the present coin feeder, it is seen that the construction is such as to enable coins to follow a main flow path, trough 22, with a plurality of auxiliary flow paths defined by trough 30, 36 providing a supply of coins for the main flow path. Coins which may be prevented, due to a temporary jam, from flowing along a trough 36 have a second exit in the form of trough 26 which carries coins generally towards the opening 56. Fins 32, 34 retard the flow of coins so that the flow rate is more easily controlled and the raised area 40 ensures that there will be no area in the feeder where coins will not flow as the sloping sides thereof provide for gravity flow at the very least. Tests have shown that vibrations tend to be cancelled in the vicinity of area 40 and hence it is advisable to counter-act such a dead area vibration-wise with the raised area 40 for coin flow.
The rate of coin flow can be controlled by altering the slope of the feeder relative to the sorter and/or by altering the amplitude of the vibrations via control 74. In any event the operator can adjust the flow rate so that as coins are sorted in the sorter 80 he can comfortably wrap the coins as the required quantity of each denomination is reached. He can, at any time as is convenient, place more coins in the feeder and he can accordingly obtain a higher rate of wrapping as it is no longer necessary for him to manually place a handful of coins in the loading zone of the sorter, wait for those coins to be sorted, reload the sorter, wrap, and repeat these various operations as required.
It should be pointed out that the use of the present feeder device does not prevent the use of the sorter in a fully manual mode. Furthermore, the present feeder should not be restricted to use with a coin sorter such as that defined in Canadian Pat. No. 769,469. It is conceivable that the present feeder could be utilized to feed, at a desired flow rate, other disc-like objects such as washers or buttons and that it could be used with other coin handling devices as well. It is also expected that skilled practitioners in the art could effect changes in the design of the present invention without affecting the basic concept. Accordingly, the protection to be afforded the present invention should be determined from the appended claims. | A vibrating feeder for feeding disc-like objects such as coins to a subsequent work station such as a coin sorter has a unitary box-like structure provided with a particularly contoured bottom. The bottom defines a main flow path and an auxiliary flow path leading to the main flow path which in turn terminates in an exit for the coins. The auxiliary flow path has longitudinally inclined fins for guiding coins to the main flow path while somewhat retarding the flow rate to avoid jamming of coins and to avoid an excessive flow rate. Each flow path also includes one or more troughs contoured so that a coin will not lie flat thereon. The feeder is inexpensive to produce, is simple in execution and operation and provides a controlled flow rate for coins or other objects to the subsequent work station. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to foreign European Patent Application EP 13002377.3, filed on May 3, 2013, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to an anti-backbend chain, in particular for door and window drives, comprising a plurality of alternate chain links joined by respective chain hinges, and a stiffening means, which stiffens the anti-backbend chain in a first pivot direction, wherein a spring element comprising at least a first spring arm is provided, the spring element rests on a chain hinge, the first spring arm extends to a neighboring chain hinge and is movably in contact therewith under the biasing force of the spring element, so as to obstruct bending of the anti-backbend chain in a first pivot direction, the chain links are provided with chain link plates, and the chain link plates of neighboring chain links are joined via the chain hinge. The invention additionally relates to a corresponding chain drive with such an anti-backbend chain.
BACKGROUND
A chain with anti-backbend properties on the first and second sides is known from DE 10 2005 099 154 A1. In the case of this anti-backbend push chain for power transmission in a chain drive, the chain elements are pivoted radially inwards on a chain drive wheel. The hinge openings of the chain link plates are implemented as elongate holes and have a certain amount of play relative to the hinge pins, so that the effective chain pitch in the push strand is reduced. In addition, the ends of the hinge pins have rollers provided thereon, which guide the anti-backbend chain in a separate roller rail guide in the push strand. The hinge openings configured as elongate holes additionally allow a reliable contact of the stiffening contours formed on the end faces of the chain link plates in the push strand.
DE 1 450 699 C1 discloses a further anti-backbend chain. The outer link plates of the outer chain links and the inner link plates of the inner chain links have provided between them stiffening link plates, which are each arranged on a hinge pin and provided with a projection protruding in a direction of chain travel, the end faces of said projection being configured as support surfaces. One end face is configured as a protrusion and the other end face as a recess. The protruding and recessed end faces of the stiffening link plates stiffen the chain in a first pivot direction, whereas the chain remains flexible in the other, second pivot direction. Therefore, this chain runs in a push strand in a guide means so as to prevent, for power transmission through this anti-backbend chain, bending of the chain in the second pivot direction.
The prior art comprises a plurality of additional, very different structural designs of anti-backbend chains. Reference DE 1 180 318 B, for example, shows an anti-backbend chain drive with alternate inner and outer chain links, the contour of the chain link plates being provided with an end face-side stiffening means and the chain being guided between the chain link plates in a guide channel in a push strand. DE 2001 002 310 U1 discloses an anti-backbend chain with identical fork-shaped chain links provided with interengaging stiffening contours on their rear sides. In addition, EP 1 744 079 A1 discloses a chain with anti-backbend properties on the first and second sides, in the case of which the end faces of the chain link plates have complementary stiffening contours, at least one hinge opening being configured as an elongate hole so as to allow in the push strand a reliable interengagement of the end face-side stiffening contours by means of a reduced chain pitch.
Reference DE 1 046 422 B1 discloses a further anti-backbend plate link chain comprising a locking mechanism, which prevents the chain links from being pivoted relative to one another and which is disengaged by means of a lateral guide during deflection. A further locking mechanism of an anti-backbend chain is shown in DE 20 2007 002 767 U1, where an arresting element, which is pivotable transversely to the direction of chain travel, is disengaged by means of a guide rail.
The anti-backbend chains and chain drives known in the prior art make use of very different concepts and constructions so as to guarantee stiffening of the chain in the push strand and allow simultaneously deflection of the chain around a chain drive wheel. Many of the known anti-backbend chains are joined by additional measures after stiffening behind the chain drive wheel in the push strand or the chains are locked by means of arresting mechanisms in the second or in both pivot directions. Although many of the anti-backbend chains which have hitherto been used in the prior art proved to be very useful, the mechanisms used are partly complex stiffening and/or locking mechanisms as well as intricate constructions that often require additional space.
JP H07 172786 A deals with a lift chain for a forklift truck whose chain links can be biased relative to one another by means of a leg spring. Every second hinge pin has attached thereto such a leg spring, the two legs of said spring resting on the respective neighboring pin. The chain is therefore always forced back from a stretched position to the folded position.
US 2009/124445 A1 discloses a toothed chain comprising wire spring elements between the chain links. These wire spring elements are intended to make the chain resistant to bending.
GB 12985 A discloses a roller chain. Some of the chain links have upwardly protruding projections having a leaf spring element arranged thereon, which imparts to the chain a certain degree of spring elasticity.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide an anti-backbend chain as well as a chain drive, which allow reliable stiffening of the chain in the push strand on the basis of the simplest possible structural design of the chain and of the stiffening mechanism.
According to the present invention, this object is achieved by an anti-backbend chain according to claim 1 . The spring element used here in the anti-backbend chain only obstructs bending of the chain in the first pivot direction, so that the chain, when operated in a pushing mode, can transmit sufficient power. The tendency of the anti-backbend chain according to the present invention to yield, when subjected to bending forces that act transversely to the pushing direction of the chain, is reduced in accordance with the spring force, so that, when deflected around a chain wheel, the chain will yield and can be passed around the chain wheel without releasing a locking mechanism or elongating the chain pitch. The anti-backbend chain is deflected around the chain wheel against the spring force of the spring element. Due to the elastic biasing force between neighboring chain hinges, the spring element additionally reduces the influence of vibrations and the polygon effect in the push strand of the anti-backbend chain, so that also comparatively small chain drive wheels can be used and operation in a vibration-prone region is possible.
The anti-backbend chain according to the present invention comprises a stiffening means, which stiffens the anti-backbend chain in the second pivot direction. When the anti-backbend chain is deflected only in the first pivot direction, such stiffening means allow reliable stiffening in the second pivot direction and, consequently, also a reliable power transmission in the push strand. Slight overstretching in the second pivot direction can here reliably prevent unintentional bending of the chain during power transmission in the push strand. For preventing unintentional bending of the chain in the second pivot direction, also a second spring element with one or two spring arms may, alternatively, be provided instead of a stiffening means, said second spring element obstructing a bending of the anti-backbend chain also in the second pivot direction.
According to a first solution, the chain link plates of neighboring chain links have end face-side support portions for stiffening the anti-backbend chain in the second pivot direction. The provision of end face-side support portions allows the chain to be stiffened in the second pivot direction without making use of additional function link plates. The chain link plates are here provided with support portions on the rear side facing the second pivot direction, said support portions overlapping such that bending of the chain in the second pivot direction is prevented. Such chain link plates with support portions for stiffening an anti-backbend chain in the second pivot direction are described e.g. in DE 10 2011 107 047 A1.
According to a second solution, stiffening link plates are provided, the respective stiffening link plates being arranged on at least one chain hinge and comprising end face-side support contours so as to stiffen the anti-backbend chain in the second pivot direction. Due to the formation of complementary support contours on both end faces of the stiffening link plates, the stiffening function will always take place in the plane of the stiffening link plates, so that the stiffening of the chain will not cause any lateral forces. In addition, conventional link plates can be used for all the other chain link plates of the chain links.
According to a preferred embodiment, the spring element may comprise a second spring arm, which extends to a second neighboring chain hinge and is movably in contact therewith under the biasing force of the spring element, so as to obstruct bending of the anti-backbend chain in the first pivot direction. A second spring arm extending from the spring element, which rests on a chain hinge, to a second neighboring chain hinge, which is positioned in opposed relationship with the first neighboring chain hinge, allows inherent securing of the chain hinge in the first pivot direction through the two spring arms, so that they can rest on the first or on the second neighboring chain hinge in a freely movable manner without being guided on the neighboring spring element.
According to an advantageous embodiment, the chain hinge comprises a hinge pin, the hinge pin extending through the spring element so as to join the spring element to the chain hinge. The spring element can thus be supported reliably, independently of a fixing of the spring element on the chain hinge. Especially when two spring arms are provided, the arrangement of the spring element around the hinge pin allows a flexible inherent bend protection.
The spring element may be configured as a torsion spring in a simple way. A torsion spring formed from a spring wire by means of bending allows, without any additional manufacturing steps being necessary, the formation of one or two spring arms as well as of a central opening for receiving therein the hinge pin of the chain hinge. Therefore, a torsion spring represents a particularly costs-efficient embodiment of a suitable spring element.
According to an expedient embodiment, the first spring arm and the second spring arm of the spring element abut freely on the two neighboring chain hinges and are arranged such that they are displaceable relative to the two neighboring chain hinges. The two spring arms can thus be slidingly arranged on the neighboring chain hinges of the supported chain hinge in an unfixed manner, so that they will be displaced on the neighboring chain hinge, when the anti-backbend chain bends while it is being deflected around an associated chain wheel. An unfixed positioning of the spring arms on the neighboring chain hinges or on the respective spring elements arranged on these chain hinges allows easy mounting without positioning the spring arms precisely in a suitable guide means.
According to a special embodiment, the chain links are alternately provided with stiffening link plates and the respective stiffening link plates are arranged on two neighboring chain hinges. The stiffening link plates can thus replace the conventional chain link plates of the respective chain links, so that the amount of material used as well as the width of the anti-backbend chain can be reduced.
According to a further embodiment, the stiffening link plates are configured as intermediate link plates, the intermediate link plates are arranged on a respective chain hinge, are positioned between the chain link plates of adjoining chain links and have complementary end face-side support contours. Stiffening link plates configured as intermediate link plates can be produced with a comparatively small wall thickness. The intermediate link plates can thus stiffen the anti-backbend chain in its second pivot direction reliably and in an essentially torsion-free manner.
The present invention additionally relates to a chain drive comprising one of the above-described embodiments of the anti-backbend chain according to the present invention and a chain wheel for deflecting the anti-backbend chain. In cooperation with the chain wheel, the anti-backbend chain is deflected in the first pivot direction against the biasing force of the spring element, without any lock being released. In the case of a linear drive of the anti-backbend chain, the chain wheel may only deflect the chain, optionally without engaging between the elements of the chain in a form-fit manner, or it may also serve to drive the chain in the case of a radial drive. When the chain runs off the chain wheel, it stretches automatically from the bent condition into the first pivot direction due to the biasing force of the spring element and allows thus power to be transmitted in the pushing direction of the chain.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, embodiments of the present invention will be explained in more detail making reference to drawings, in which:
FIG. 1 shows a perspective view of an anti-backbend chain according to the present invention,
FIG. 2 shows a top view of the anti-backbend chain according to the present invention shown in FIG. 1 ,
FIG. 3 shows a side view of the anti-backbend chain according to FIG. 1 in an exploded view,
FIG. 4 shows an enlarged view of a detail of the anti-backbend chain according to FIG. 2 ,
FIG. 5 shows a top view of a further anti-backbend chain according to the present invention,
FIG. 6 shows a side view of the anti-backbend chain according to FIG. 5 in an exploded view, and
FIG. 7 shows a perspective top view of a chain drive with the anti-backbend chain according to FIG. 5 .
DETAILED DESCRIPTION
The chain 1 with anti-backbend properties on the first and second sides, which is shown in FIG. 1 , comprises alternate inner chain links 2 and outer chain links 3 , which are joined via respective chain hinges 4 . The outer chain links 3 comprise two outer link plates 5 , which are spaced apart in parallel, as well as a central link plate 7 which is arranged substantially centrally between the outer link plates 5 . The outer link plates 5 and the central link plate 7 are joined via a hinge pin 6 arranged perpendicularly thereto. The hinge pins 6 also extend at right angles to the longitudinal axis of the chain through the inner link plates 8 of the inner chain links 2 . Each inner link plate 8 has two hinge openings 9 through which the hinge pin 6 extends and in which it is fittingly accommodated so as to allow pivoting of the inner chain links 2 relative to the outer chain links 3 . The hinge pin 6 is press fitted into respective hinge openings (not shown) of the outer link plate 5 . The anti-backbend chain 1 according to the present invention, which is shown in FIG. 1 as well as in the associated detailed representations in FIG. 2 to FIG. 4 , is configured as a leaf chain structure without any bushes or rollers between the inner link plates 8 .
Between the inner link plates 8 of the inner chain links 2 and the central link plates 7 of the outer chain links 3 , intermediate link plates 10 are arranged. In the embodiment used here, the intermediate link plates 10 comprise a hinge opening 11 through which the hinge pin 6 extends, and, in addition, on the upper side 14 of the anti-backbend chain 1 shown in the top view according to FIG. 2 , a protruding support contour 12 on a first end face of the intermediate link plates 10 as well as a recessed step 13 on the second end face of the intermediate link plate 10 . The protruding support contour 12 on the first end face of the inner link plate 8 fits into the recessed step 13 on the second end face of the following inner link plate 8 . As can clearly be seen in the partly exposed side view of the anti-backbend chain 1 in FIG. 3 , the engagement of the above-mentioned support contour 12 of an intermediate link plate 10 with the recessed step 13 of the next intermediate link plate 10 on the upper side 14 allows the anti-backbend chain 1 to be stiffened in the second pivot direction, which is opposed to the direction of deflection around an associated chain wheel (not shown). The intermediate link plates 10 extend from the hinge opening 11 towards the support contour 12 , so that the step 13 is formed substantially above the hinge opening 11 on the upper side 14 . On the lower side 15 of the anti-backbend chain 1 , which is in engagement with a chain wheel or a pulley in a chain drive, the intermediate link plate 10 ends in spaced relationship with the lower side 15 so as to save material in the production of the intermediate link plates 10 and avoid an inadvertent locking effect in the direction of the first pivot direction during deflection of the chain around the chain wheel or the pulley.
On the side of the central link plates 7 facing away from the intermediate link plates 10 , a respective spring element 16 is provided between the central link plates 7 and the second inner link plate 8 of the inner chain link 2 . Each of the spring elements 16 has a first spring arm 17 and a second spring arm 18 . The spring element 16 is provided with a central opening 19 through which the hinge pin 6 of the respective chain hinge 4 extends. The first spring arm 17 and the second spring arm 18 extend from this chain hinge 4 to different sides (in the longitudinal direction of the chain) to the respective next chain hinge 4 and abut from the lower side 15 on the chain hinges 4 or on the respective spring elements 16 of these chain hinges 4 under the biasing force of the spring element 16 . As can clearly be seen in FIG. 4 , the first spring arm 17 of a spring element 16 and the second spring arm 18 of the following spring element 16 are arranged such that they are displaced relative to one another transversely to the direction of travel of the chain 1 , so that they do not overlap and obstruct one another as regards their spring action. The first spring arm 17 of the spring element 16 is positioned on the spring element side facing the central link plates 7 and the second spring arm 18 of the spring elements 16 is positioned on the spring element side facing the inner link plates 8 . In addition to the annular spring elements 16 , which are clearly visible in FIG. 4 , the spring elements 16 may also be configured as torsion springs that can be produced from a spring wire in one piece by means of bending. In the case of such a torsion spring the ends of the spring wire simultaneously define the two spring arms 17 , 18 and the winding of the spring wire for establishing the biasing force acting on the two spring arms 17 , 18 simultaneously defines the opening 19 used for receiving therein the hinge pin 6 .
In the following, the mode of operation of the anti-backbend chain 1 will be explained in more detail, in particular on the basis of FIG. 3 . The anti-backbend chain 1 shown in FIGS. 1 to 3 exhibits on the first and second sides the chain stiffening, which is necessary for power transmission in the push strand. The chain 1 is here stiffened on the upper side 14 by means of the intermediate link plates 10 so as to block the chain 1 in the second pivot direction. To this end, the support contour 12 protruding on the first end face of the intermediate link plates 10 engages the step 13 of the next intermediate link plate 10 , said step 13 being formed above the hinge opening 11 of the intermediate link plates 10 , so that further bending of the anti-backbend chain 1 in this second pivot direction is prevented.
In the direction of deflection around a chain wheel (not shown) of an associated chain drive, which is the first pivot direction, bending of the chain 1 with anti-backbend properties on the first and second sides is merely obstructed by the spring elements 16 . The first spring arm 17 and the second spring arm 18 of the spring element 16 abut, under the biasing force of the spring element 16 , from the lower side 15 of the chain 1 on the spring elements 16 arranged on the hinge pins 6 of the neighboring chain hinges 4 . Although each of the two spring arms 17 , 18 is in contact with the respective neighbouring chain hinge 4 , they are neither fixed nor guided thereon. The two spring arms 17 , 18 of the spring element 16 force the chain 1 in a direction opposite to the first pivot direction by means of the biasing force of the spring element 16 until the blocking caused by the intermediate link plates 10 prevents further movement in the direction of the second pivot direction. This has the effect that the anti-backbend chain 1 stretches in the longitudinal direction of the chain 1 thus allowing power transmission in the pushing direction. In addition, the biasing force of the spring elements 16 also prevents unintentional bending of the chain 1 with anti-backbend properties on the first and second sides.
If the chain is driven by means of a linear drive or by means of a radial drive with a driving chain wheel, the spring elements 16 allow, when the chain 1 with anti-backbend properties on the first and second sides is deflected around a chain wheel, a pulley or a guide means, free deflection against the force of the spring elements 16 , i.e. deflection without releasing a lock on the anti-backbend chain 1 or without guidance in the push strand, which would otherwise be necessary. The resistance to bending of the anti-backbend chain 1 during deflection around a chain wheel, a pulley or a guide means can be adjusted by the biasing force imparted by the spring element 16 to the two spring arms 17 , 18 . The force required for deflecting the chain 1 in the first pivot direction around the chain wheel is applied by the driven chain wheel itself or by some other drive of the chain, so that the biasing force of the spring elements 16 stiffens the anti-backbend chain 1 automatically in the first pivot direction when the chain runs off the chain wheel.
A further embodiment of an anti-backbend chain 1 according to the present invention is shown in FIG. 5 , where this anti-backbend chain 1 is configured as a classical bush chain or roller chain. Also this classical structural design comprises alternate inner chain links 2 and outer chain links 3 , which are joined by respective chain hinges 4 . Each of the inner chain links 2 comprises inner link plates 8 which are spaced apart in parallel, the two inner link plates 8 being joined by means of bushes 20 . The hinge pin 6 of the chain hinge 4 extends through the bushes 20 of the inner link plates 8 so as to join the inner chain links 2 and the outer chain links 3 . The hinge bush 20 of the inner chain link 2 is surrounded by a hinge roller 21 between the inner link plates 8 so as to reduce the wear of the chain hinge 4 when the chain engages a chain wheel associated therewith. The outer link plates 5 of the outer chain links 3 and the inner link plates 8 of the inner chain links 2 have provided between them a respective intermediate link plate 22 and a spring element 16 on both sides of the chain 1 , the intermediate link plate 22 adjoining the outer link plate 5 and the spring element 16 adjoining the inner link plate 8 .
The alternatively configured intermediate link plates 22 of this embodiment of an anti-backbend chain 1 according to the present invention are positioned between two respective hinge pins 6 and comprise two segment-shaped contours 23 for fixing the intermediate link plates 22 between the hinge pins 6 , said segment-shaped contours 23 abutting on the hinge pins 6 . A support contour 24 , which adjoins the segment-shaped contours 23 , is formed above the hinge pins 6 . As can be seen in the partially exposed side view of the anti-backbend chain 1 in FIG. 6 , the fact that the support contour 24 of an intermediate link plate 22 abuts on a complementary support contour 24 of an adjoining intermediate link plate 22 allows the anti-backbend chain 1 to be stiffened in a second pivot direction, which is opposed to a direction of deflection around an associated chain wheel (not shown). The support contours 24 of the intermediate link plates 22 extend here from the hinge pin 6 up to the upper side 14 of the anti-backbend chain 1 . On the lower side 15 of the anti-backbend chain 1 , which is in engagement with a chain wheel in a chain drive, the intermediate link plate 22 ends in spaced relationship with the lower side 15 and, starting from the hinge pin 6 , it is additionally provided with beveled edges so as to avoid an inadvertent blocking effect in the direction of the first pivot direction.
Between the intermediate link plates 22 and the inner link plates 8 of the inner chain link 2 a respective spring element 16 is provided. Also in this embodiment, the spring elements 16 comprise a first spring arm 17 and a second spring arm 18 , which extend from the receiving chain hinge 4 to different sides to the respective next chain hinge 4 and which abut, in a biased condition, from the lower side 15 on this chain hinge 4 or on the respective spring elements 16 provided thereon. As can clearly be seen in FIG. 5 , the spring element 16 is configured as a torsion spring, so that the first spring arm 17 and the second spring arm 18 are displaced relative to one another in the direction of travel of the chain 1 and the spring arms 17 , 18 of neighboring spring elements 16 do not overlap each other.
FIG. 7 shows a perspective view of a chain drive 25 with a chain 1 with anti-backbend properties on the first and second sides, corresponding to the embodiment of a classical bush chain or roller chain shown in FIGS. 5 and 6 , which is moved via a linear drive on one end thereof. In this chain drive 25 , the chain 1 is bent by means of a deflection guide 26 in the first pivot direction and deflected in the direction of the desired pushing direction. When the chain runs off the deflection guide 26 , the spring elements 16 cause the chain 1 to stretch and stiffen in the first pivot direction. | An anti-backbend chain comprises a plurality of alternate chain links joined by respective chain hinges, a spring element comprising at least a first spring arm being provided. The spring element rests on a chain hinge and the first spring arm extends to a neighbouring chain hinge and is movably in contact therewith under the biasing force of the spring element, so as to obstruct bending of the anti-backbend chain in a first pivot direction. In addition, an anti-backbend chain drive is provided, in particular a chain drive for driving automated door or gate systems. | 5 |
REFERENCE TO A RELATED APPLICATION
[0001] This is a non-provisional application relating to the content of, and claiming priority to, Mexican Patent Application No. NL/a/2005/000053, filed Jun. 22, 2005, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention.
[0003] The present invention relates to the field of crude oil production and, more specifically, to a system and method for optimizing transferred fluid volume by a traveling valve during a pumping cycle.
[0004] 2. Background of the Invention.
[0005] In its broadest definition, an oil well is a perforation into the earth aimed to producing hydrocarbon liquids and gases. The life of a well typically has four stages: drilling, completion, production, and abandonment. The well is created by using a rig that turns a drill bit to drill into the earth. A casing pipe slightly smaller than the drilled hole is then run into the hole and cemented thereto. This casing provides structural support for the hole, which is subjected to a number of violent compressive forces and caustic chemicals during the drilling process. The casing also serves to isolate potentially dangerous high pressure zones from each other and from the surface. Wells frequently have multiple sets of progressively smaller hole sizes nested inside one another, each cemented with casing.
[0006] After drilling, the well is “completed,” which means that well is made capable of producing hydrocarbon products. In cased well bores, a section of the casing in the hydrocarbon producing zone is often perforated to allow the oil and gas to flow into the well bore from the surrounding formation. When a hole is not cased, which is called an open hole completion, a filter material such as sand or gravel may be used with the hole to facilitate the flow of oil and gas into the hole.
[0007] After completion, the drilling and completion tools are removed from the drill site, and the production tubing is connected to a collection of valves for regulating pressure and flow. This network of valves, sometimes called a “Christmas tree,” allows the hydrocarbons to be routed in a plethora of directions that may lead to different pipelines for moving the product off site.
[0008] Ideally, the well will produce hydrocarbons for a very long time, but inevitably, during the abandonment phase of the well's life, it becomes uneconomical to produce from the well. In most wells, the natural pressure of the subsurface reservoir is high enough to push the oil or gas to the surface, but this is not always the case. In depleted fields, such as fields with a high density of wells that causes the overall pressure to be widely disbursed, decreasing the production tubing diameter may be enough to help the production, but other types of artificial lift might also be used, such as downhole pumps or surface pumpjacks.
[0009] Real time monitoring of the upstroke and downstroke of an oil well is not new, but the primary focus of such applications have been directed toward minimizing or eliminating conditions known as “pump off” and “fluid pound.” See, e.g., U.S. Pat. No. 4,594,665; U.S. Pat. No. 4,666,375. Pump off occurs in depleted wells when fluid is withdrawn from the well at a rate greater than the rate at which fluid enters the well from the formation. In other words, the upstroke of the pump is removing the oil faster than the oil is produced by the formation. When pump off occurs, the subsequent down strokes begin to pound the fluid in the well, which causes severe jarring of the entire pumping unit potentially resulting in damage to the well equipment.
[0010] Other methods are directed primarily toward increasing the efficiency of the well. For example, U.S. Pat. No. 6,854,518 discloses a method for enhancing production of oil that reduces the pressure at the top of the well. The resulting increased difference between the well pressure at the surface and the well pressure at the formation results in a higher production flow.
[0011] U.S. Pat. No. 5,064,349 addresses both the pump-off and optimization problems by providing a method that includes measuring the displacement and the load on a rod string, determining when the well is pumped off due to stoppage of fluid flow, and subsequently adjusting the delay between each pumping cycle, meaning one upstroke and one downstroke. The delay time between cycles is determined from measuring the rod load during the downstroke until the rod load reaches a point of substantial stabilization.
[0012] Similarly, U.S. Pat. No. 6,497,281 also addresses both the pump-off and optimization problems by providing a “smart pump” that adjusts the rate of the well's pumping cycle to coincide with the well's production history. The invention uses stored production data to time the cycle appropriately for the rate of fluid produced from the formation.
[0013] In contrast to the prior art, the present invention optimizes the volume of hydrocarbons transferred during the upstroke of the pumping cycle. This allows a well operator to recover hydrocarbons from wells from which production would otherwise not be economically viable.
SUMMARY OF THE INVENTION
[0014] The present invention provides a method and system for optimizing the amount of fluid transferred during the upstroke of a pumping cycle. The system comprises a casing pipe. disposed in the ground and extending from the surface of the well to beneath a hydrocarbon production zone. The casing pipe has a perforated section for permitting petroleum to flow into the casing pipe from the surrounding hydrocarbon production zone. According to the preferred embodiment of the invention, a filtering material surrounds the casing pipe from the bottom of the well to a level above the production zone, thus requires any hydrocarbons flowing into the casing pipe to move through this filtering material. Concrete encircles the remainder of the casing pipe from the level of the filtering material to the surface.
[0015] A production pipe is nested within the casing pipe, and the production pipe further contains a system of valves for moving accumulated petroleum from the bottom to the top of the production pipe. As hydrocarbon fluid flows into the casing pipe through the perforated section thereof, the fluid accumulates at the bottom of the casing and production pipes. The valve assemblies, which are similar to ball-and-seat valves commonly used in the industry, operate to lift the hydrocarbon fluid from the bottom to the top of the production pipe, where it is forced though a first pipe and into a collection reservoir for later retrieval.
[0016] According to the preferred embodiment of the invention, the valve assemblies are functionally connected to a lift assembly located at the surface over the well. The lift assembly comprises a hydraulic lift moveable along a vertical axis that is parallel to the longitudinal axis of a pumping rod attached to a traveling, or moving, valve and a lift anchor affixed to the hydraulic lift. This assembly also includes a lift tower for providing the hydraulic lift with structural support and guidance for the movement of the hydraulic lift and a lift controller functionally connected to the hydraulic lift for controlling the valves according to a predefined program. A lift sensor measures the speed of the hydraulic lift and returns this speed measurement to the lift controller.
[0017] According to the method of the invention, the speed of the traveling valve is monitored to determine at what point during its downstroke the traveling valve contacts the hydrocarbon fluid that has accumulated in the bottom of the petroleum pipe. The system then analyzes speed data returned by the lift sensor and adjusts the speed of the traveling valve either upward or downward during the upstroke to optimize the amount of hydrocarbon fluid transferred. The system can be configured to handle different ascent speeds, and chooses the most suitable speed depending on the petroleum level detected within the production pipe during the route of the traveling valve downwards.
[0018] In the preferred embodiment, the operation of the fixed, traveling, and main valves generally apply typical ball-and-seat valve principles. A ball-and-seat valve is a device used to restrict fluid flow to one direction. It consists of a polished sphere, or ball, usually of metal, and an annular piece—the seat—that is ground and polished to form a seal with the surface of the ball. Gravitational force or the force of a spring holds the ball against the seat. Flow in the direction of the force is prevented, while flow in the opposite direction overcomes the force and unseats the ball. A more detailed description of this ball-and-seat operation as it pertains to the present invention is included herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention, as well as further objects and features thereof, is more clearly and fully set forth in the following description of the preferred embodiment, which should be read with reference to the accompanying drawings, wherein:
[0020] FIG. 1 describes operation of the system of the present invention; and
[0021] FIG. 2 describes the pump assembly positioned within a production pipe of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] As shown in FIG. 1 , the system of the present invention may be installed in a hydrocarbon producing zone 3 by drilling a vertical borehole 2 through the earth's surface 1 to determine the depth of the producing zone 3 . Thereafter, the borehole 2 is further extended under the producing zone 3 and a casing pipe 4 disposed therein. Filtering material 5 is interposed between the casing pipe 4 and the wall and floor of the borehole 2 . The filtering material 5 fills the space between the casing pipe 4 and borehole until a depth at least sufficient to span the producing zone 3 . Concrete 6 fills the remaining space between the casing pipe 4 and borehole 2 wall above the filtering material 5 .
[0023] The casing pipe 4 comprises a perforated section (not shown) positioned at the depth of the producing zone 3 for providing an ingress path for petroleum 50 that migrates through the filtering material 5 . Petroleum 50 may be forced to the top of the casing pipe 4 by natural well pressure, where the petroleum 50 can flow through a casing unloading pipe 7 to a collection reservoir 8 for storage and later retrieval.
[0024] A production pipe 52 positioned within the casing pipe 4 extends from the bottom 10 of the casing pipe 4 to above the surface 1 . By operating the system, petroleum 50 lifted to a production unloading pipe 11 , which is interposed between the production pipe 52 and the collection reservoir 8 , flows into the collection reservoir 8 for storage and later retrieval. Petroleum 50 is moved to a position where it may flow through the production unloading pipe 11 by a pump assembly 9 substantially contained within the production pipe 52 and operably attached to a lift assembly 54 , the operation of which is described hereinafter.
[0025] A structure 12 affixed to the surface 1 over the casing pipe 4 provides support for the lift system 54 , which drives the pump assembly 9 . The pump assembly 9 is operably connected to a lift anchor 14 through the pumping rod 16 . The lift anchor 14 , in turn, is affixed to a hydraulic lift 13 partially housed within a lift tower 15 , which provides guidance and support for the hydraulic lift 13 during operation. The hydraulic lift 13 vertically moves the lift anchor 14 along the lift tower 15 to cause the attached pumping rod 16 to drive a traveling valve 17 of the pump assembly 9 , the operation of which is more thoroughly shown in FIG. 2 . Centering bushings 18 are fixed within the production pipe 52 to guide movement of the pumping rod 16 and maintain a centered position thereof within the production pipe 52 .
[0026] A lift sensor 20 returns the speed and position of the lift anchor 14 to a lift controller 19 . Using the received speed and position information of the lift anchor 14 , the lift controller 19 determines the position of the lift anchor 14 during a downstroke thereof when the traveling valve 17 encounters petroleum 50 within the production pipe 52 . When the downward movement of the traveling valve 17 is impeded by petroleum 50 , this resistance is detected by the lift sensor 20 from the speed reduction of the lift anchor 14 , and the level of petroleum can be calculated. Based on the petroleum level within the production pipe 52 , the lift controller 19 adjusts the speed (if needed) of the anchor 14 during the subsequent upstroke to ensure that the greatest possible volume of petroleum 50 is transferred. The greater the amount of petroleum to be transferred, the faster the anchor 14 must move the pumping rod 16 and traveling valve 17 . The lift controller 19 is configurable to handle different upstroke speeds, from which the controller 19 will choose the most suitable speed depending on the level of petroleum 50 detected within the production pipe 52 .
[0027] The pump assembly 9 comprises a main valve 21 fixed to the production pipe 52 near or at the bottom thereof. As more thoroughly shown by FIG. 2 , the main valve 21 comprises a metallic main sphere 22 and a metallic main cone 23 having an opened base attached to the production pipe 52 at the circumference thereof and an opened apex of smaller diameter than the main sphere 22 . The apex of the main cone 21 is oriented toward the bottom 10 of the production pipe to allow the main sphere 22 to rest therein. The opened base of a grid code 24 is affixed to the base of the main cone 21 with the apex of the grid cone 24 oriented toward the surface 1 to contain the main sphere 22 therebetween and facilitate the operation of the main valve 21 . To optimize sealability of the main valve 21 and prevent the flow of petroleum 50 from above the main sphere 22 down through the main cone 23 , the main sphere 22 and the main cone 23 are coated with a sealing liquid sprayed on the valve through a washing hose 25 . As petroleum 50 moves from the producing zone 3 through the filtering material 5 and into the casing pipe 4 , the accumulation of petroleum 50 causes the level of petroleum to raise and unseat the main sphere 22 from the apex of the metallic first cone 23 so the petroleum may move therethough.
[0028] The traveling valve 17 , which is attached to the pumping rod 16 and moved by the upstroke and downstroke thereof, collects the petroleum 50 that has moved through the main valve 21 and raises the petroleum 50 to and through a fixed valve 26 . Disposed in the traveling valve 17 are a four traveling cones 28 and traveling spheres 32 that function similarly to the main cone 23 and main sphere 22 described hereinabove, although alternative embodiments of the invention may have more or fewer of these traveling cones 28 and traveling spheres 32 . The traveling cones 28 each have an opened base and an opened apex to allow petroleum communication therethrough. In addition, because the traveling valve 17 moves vertically within the production pipe 52 , the side of the traveling valve is coating with a friction reducing material 27 (shown in FIG. 1 ).
[0029] As the traveling valve 17 encounters petroleum 50 in the production pipe 52 that has already moved through the main valve 21 , the petroleum 50 is channeled through the opened bases of the traveling cones 28 to contact the traveling spheres 32 seated on the open apexes. This causes the traveling spheres 32 to lift, thereby allowing the petroleum to flow through the apexes to a position above the traveling valve 17 . The transfer process is further facilitated by injecting a liquid flow enhancer (not shown) from the surface through a flow enhancer hose 29 . As the traveling valve 17 initiates an upstroke, the traveling spheres 32 descend by the weight of the petroleum 50 to seal and seat against the apexes of the traveling cones 28 , thereby impeding the exit of transferred petroleum 50 back through the traveling valve 17 . As the traveling valve 17 moves to complete the upstroke, it pushes the collected petroleum 50 through a fixed valve 26 , which also has a plurality of fixed spheres 33 seated on apexes of fixed cones 30 to prevent the petroleum 50 from flowing back through the fixed valve 26 in a downward direction. The fixed spheres 33 are unseated from the apexes of the fixed cones 30 when the petroleum is forced though the bases thereof, then are reseated when the traveling valve 17 initiates its next downstroke.
[0030] The petroleum 50 moved through the fixed valve 26 is pushed upwards by each upstroke of the traveling valve 17 until the level of accumulated petroleum reaches the production unloading pipe 11 , by which the accumulated petroleum will flow through the production unloading pipe 11 to the collection reservoir 8 for storage and later collection.
[0031] The present invention is described in terms of a preferred illustrative embodiment in which a specifically described system is described. Those skilled in the art will recognize that alternative embodiments can be used when carrying out the present invention. Other aspects and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims. | A system and method for optimizing transferred fluid volume during an oil well pumping cycle. The speed of a traveling valve, which lifts the petroleum from the well, is monitored to determine at what point during its downstroke the traveling valve contacts the hydrocarbon fluid that has accumulated in the bottom of a petroleum pipe. The system then analyzes speed data returned by a lift sensor and adjusts the speed of the traveling valve either upward or downward during the next upstroke to optimize the amount of hydrocarbon fluid transferred. The system can be configured to handle different ascent speeds, and chooses the most suitable speed depending on the petroleum level detected within the production pipe during the route of the traveling valve downwards. | 4 |
BACKGROUND OF THE INVENTION
The present invention pertains generally to the art of endless chain conveyors and, more specifically, to conveyors of the type utilizing two parallel strands of chain with conveyor flights attached therebetween and supported for movement by a series of rollers mounted on each strand of chain. The invention herein relates particularly to roller assemblies for use in such conveyors.
A wide variety of chains and conveyor flights are known in the art because of the extremely wide range of materials which may be conveniently conveyed in this manner. One type of conveyor widely used to convey bulk materials is commonly known in the art as an apron conveyor or a pan conveyor. This type of conveyor utilizes a series of open-ended overlapping pans mounted between two parallel strands of chain to provide a continuous substantially flat conveying surface. The conveyor chains are supported by rollers which operate over a pair of rails along the conveyor path. The supporting rollers may be of the "inboard" type wherein they are mounted on the conveyor chain bushings between the chain sidebars, as shown for example in U.S. Pat. No. 3,331,490; or they may be of the "outboard" type wherein the rollers are mounted on the outside of the conveyor chain sidebars, most commonly in pairs on a shaft extending through the sidebars thereof, as shown for example in U.S. Pat. No. 2,517,208.
In apron conveyors using an outboard roller construction, the rollers are commonly made of cast iron and are provided with cylindrical through bores which are mounted for rotation on plain cylindrical iron or steel bushings. Pairs of bushings and rollers are mounted on ends of the shaft and outwardly of the respective chain sidebars, as is shown in the above mentioned U.S. Pat. No. 2,517,208. Preferably, some means of securing the bushings against rotation on the common shaft is used and thus the roller rotates on the bushing in the manner of a plain journal bearing. Square shaft ends and corresponding square bores in the bushings are an example of one means of preventing bushing rotation, such as shown in U.S. Pat. No. 3,214,008.
Such cast iron rollers have been widely accepted as inexpensive, strong and durable components in apron conveyors used to convey a wide variety of bulk materials, such as castings, sugar cane, solid waste, limestone, coal and other minerals and ores. Most of these materials are, however, dusty, dirty, or highly abrasive and these contaminants inevitably work their way during operation of the conveyor into the bearing areas between the rollers and bushings, resulting in wear and eventual failure of the roller assembly. The rollers may be provided with internal grease cavities or reservoirs which are periodically regreased via an external grease fitting and some of the foreign material will be purged in the regreasing process. However, not only is such purging less than completely effective, but the basic problem of immediate re-entry of contaminants remains.
An effective means of sealing the bearing area against contaminant entry has therefore been long sought in the art. Labyrinth seals of many types are well known in the bearing art, however, the complex constructions and high cost of these seals make them generally unsuitable for use in roller assemblies of the type disclosed herein. U.S. Pat. No. 3,490,773 discloses a labyrinth seal for use in a cast iron roller of the type used in an outboard roller assembly of an apron conveyor. The labyrinth is comprised of two spaced rings, one fitted to the outside diameter of the bushing and the other to the inside diameter of a counterbore in the roller member. The two rings form a two-chamber labyrinth which, when filled with grease in the lubrication process, is intended to prevent the entry of contaminants from outside the assembly. However, since neither sealing ring is fitted tightly to the bushing or the roller, respectively, the resultant clearances in seal constructions of this type can allow "short circuiting" of the labyrinth and direct entry of contaminants along the bushing surface into the bearing area.
Seals of the general type heretofore described also exhibit two other deficiencies. First, loose fitting sealing rings must be retained in place by additional retaining means, such as a snap ring, thus adding to the complexity and cost of the assembly. Second, the lateral thrust loads often imposed on rollers in operation require a substantial thrust bearing surface which has been deficient or totally lacking in prior art constructions.
SUMMARY OF THE INVENTION
In the present invention, an effective labyrinth seal and thrust bearing surface are provided in a simple two piece assembly comprising, in the preferred embodiment, a pair of rings of L-shaped cross section mounted with a press fit on the bushing and the roller member, respectively. The tight press fits of the rings prevent short circuiting of the labyrinth passages by contaminants and also eliminate the need for separate seal retainers. The inner ring of each pair provides a large thrust bearing surface to absorb axial thrust loads. The seal is also adaptable for use in roller assemblies of plastic construction and with rollers incorporating antifriction bearings between the bushing and roller member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apron conveyor on which roller assemblies of the present invention may be used.
FIG. 2 is an enlarged perspective view of a single pan and conveyor chain link of FIG. 1 showing generally the mounting arrangement of a roller assembly thereon.
FIG. 3 is a cross sectional view through the center of a roller assembly of the preferred embodiment.
FIG. 4 is an end elevation of the roller assembly of FIG. 3.
FIG. 5 is a partial cross sectional view of an alternate embodiment of the roller assembly of the present invention.
FIG. 6 is a partial cross sectional view of a second alternate embodiment of the roller assembly of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the general arrangement of an apron conveyor 10 wherein a series of open-ended, overlapping pans 12 is mounted on a pair of spaced, parallel conveyor chains 14 (only the chain on the near side bearing shown in FIG. 1). The chains 14 are supported for travel over rails 16 by a series of roller assemblies 18 of the present invention. Referring also to FIG. 2, roller assemblies 18 are conveniently mounted in pairs on the ends of a stub shaft 20 which extends through holes in the sidebars 22 thereof. The roller assemblies 18 may be held on the shafts 20 in any suitable manner, such as with cotter pins 24.
In the preferred embodiment shown in FIGS. 3 and 4, the roller assembly 18 includes a roller member 26 having a cylindrical outer surface 28 between generally flat parallel end faces 30, and a cylindrical bore 32 extending therethrough. The roller member 26 also preferably includes a flange 34 extending radially outward from the outer surface 28 adjacent one of the end faces 30 to keep the apron conveyor 10 on the rails 16 over which it travels.
A bushing 36 having an outer cylindrical surface 38 is journaled in the bore 32 of the roller member for relative rotation therein. In practice, of course, the roller member 26 is adapted to roll over the supporting rail 16 and the bushing 36 is preferably held from rotating by use, for example, of a square shaft 20 and a corresponding square through bore 40 in the bushing. The roller member 26 and the bushing 36 are both commonly made of cast iron and the mating bearing surfaces on the bore 32 and the outer surface 38, respectively, are hardened to enhance the wear life.
Each end face 30 of the roller member is provided with a counterbore 42 having a cylindrical surface concentric with the bore 32 and an end wall 44 lying parallel to the end face 30. An inner sealing ring 46 of L-shaped cross section having an axially extending leg 48 and a radially extending leg 50 is pressed onto the outer surface 38 of each end of the bushing 36 and into the counterbores 42 in each end face 30. The inner sealing rings 46, which are preferably made of formed metal stampings, are pressed onto the bushing with a tight interference fit in the range of approximately 0.003 to 0.012 inch. This tight interference fit secures the roller member on the bushing against axial displacement and a slight clearance is provided between the radially extending leg 50 of each inner sealing ring and the corresponding end wall 44 of the counterbore. The clearance forms the inner passage of the labyrinth seal, as will be described in greater detail below, and defines the limits of axial movement of the roller member in either direction. The axial inner face of the radially extending leg 50 also provides a substantial thrust bearing surface against which the end wall 44 of the counterbore may bear when the roller member is displaced by an axial thrust load.
An outer sealing ring 52, also of L-shaped cross section, includes an axially extending leg 54 and a radially extending leg 56. In a manner similar to the inner sealing rings, each outer sealing ring 52 is preferably a formed metal stamping and is sized to be pressed with a tight interference fit into the counterbore 42 in each end face of the roller member. The axially extending leg 54 is preferably of a length equal to the depth of the counterbore 42, such that its inner edge abuts the end wall 44 of the counterbore and the radially extending leg 56 lies flush with the end face 30 of the roller member.
The respective radially extending legs 50 and 56 of the inner and outer sealing rings 46 and 52 are axially spaced and the clearance therebetween forms the outer passage of the labyrinth seal. These radially extending legs 50 and 56 are each respectively radially spaced from the axially extending legs 54 and 48 of the corresponding outer and inner sealing rings. Thus, proceeding outwardly from the bearing surface between the roller member and the bushing, a labyrinth seal of a generally U-shaped configuration is formed by the clearance between the counterbore end wall 44 and the radially extending leg 50 of the inner sealing ring 46, the space between the outer edge of said leg 50 and the axially extending leg 54 of the outer sealing ring 52, the clearance between the radially extending legs 50 and 56 of the inner and outer sealing rings, and the space between the edge of said leg 56 and the axially extending leg 48 of the inner sealing ring. In addition, the clearance between the radially extending legs 50 and 56 of the inner and outer sealing rings 46 and 52, respectively, is greater than the clearance between the radially extending leg 50 of the inner sealing ring and the counterbore end wall 44. In this manner, axial thrust loads are always taken by the inner sealing ring and never transmitted to the outer sealing ring. As a result, the press fit by which the outer sealing ring is held in the counterbore 42 need not be as tight as the press fit of the inner sealing ring on the bushing 36.
To provide an effective seal, a labyrinth must be kept filled with an appropriate lubricant, such as grease, and means for periodically purging contaminated lubricant from the labyrinth should also be provided. Thus, referring to FIG. 3, the roller member 26 is provided with and internal annular grease reservoir 58 having open communication with the bearing surfaces 32 and 38 of the roller member and bushing, respectively. Grease is supplied to the reservoir via an external grease fitting 60, an axial passage 62 in the bushing 36, and cross hole 64 in alignment with the reservoir opening. As grease is injected into the assembly, the reservoir 58 is filled and the excess grease is forced between the bearing surfaces 32 and 38, and into and through the labyrinth passages in both roller end faces. The labyrinths are thus kept filled with grease, which tends to work out in operation, and any contaminated grease is simultaneously purged from the passages. Alternately, grease may be supplied to the reservoir 58 from a grease fitting and supply passage in the roller member itself (not shown).
The bushing 36 has an axial length greater than the roller member 26 and extends axially beyond both end faces 30 thereof. On the end face 30 including the flange 34, the axially outer face 65 of the extended portion of the bushing 36 is adapted to abut the outer sidebar 22 of the conveyor chain 14 to space the roller member 26 therefrom and enable it to rotate without rubbing against the chain. The extended portion of the bushing on the roller end face 30 opposite the flange 34 may optionally be provided with an annular groove 66 into which an ordinary snap ring 68 is inserted as a safety measure to retain the inner sealing ring 46 should it be forced to loosen under an axial thrust overload or similar failure.
The outer ends of the axially extending legs 48 of inner sealing rings 46 are adapted to lie flush with the outer face 65 of the bushing and the inner face 70 of the annular groove 66, respectively. The faces 65 and 70 can thus be used as locators to establish the precise positioning of the inner sealing rings 46 on the bushing 36 to provide the exact clearances desired between the radially extending legs 50 and the ends walls 44 of the counterbores 42.
An alternate embodiment of the invention is shown in FIG. 5 where the roller member 72 is constructed of a non-metallic material, such as urethane. In addition, a plain cylindrical sleeve bearing 74 is mounted within the bore 76 in the roller member. The bearing may be of any of the many self-lubricating types known in the art and relubrication capability is therefore unnecessary. The roller member and integrally mounted bearing are adapted to rotate on the bushing 78 in a manner similar to the assembly of the preferred embodiment of FIGS. 3 and 4. The roller assembly of FIG. 5 also includes a pair of inner sealing rings 80 pressed onto the bushing and into a counterbore 82 in each end face 84 of the roller member 72. However, the bushing 78 is provided with stop means in the form of an annular shoulder 86 positioned slightly axially outward of the end walls 88 of each counterbore 82. The shoulders 86 define bushing end portions 90 of reduced diameters, but slightly larger than the inside diameters of the axially extending legs of the inner sealing rings 80 within the limits of the desired interference fit, so that the inner sealing rings will engage the shoulders when pressed onto the bushing and accurately establish the desired spacing between the radially extending legs of said rings 80 and the respectively adjacent end walls 88 of the counterbore.
The outer sealing ring 92 may be of rectangular cross section and include only a radially extending leg which, due to much greater elasticity of the urethane roller member, can be conveniently snapped into an annular groove 94 in the counterbore 82. The same relative clearances are maintained between the inner and outer sealing rings and between the inner rings and the end wall of the counterbore as in the preferred embodiment, so that no thrust loads are transmitted to the outer sealing ring.
In the second alternate embodiment shown in FIG. 6, several of the elements are the same as in the FIG. 5 embodiment and are, therefore, identically numbered. In this embodiment, however, an antifriction needle bearing 96 is secured within the bore of the roller member 72 for rotation therewith about the bushing 98. Bushing 98 is metal and preferably has a hardened outer surface 100 to provide a durable, long-wearing inner race for the needle bearing 96. In addition, lubrication must be provided for the bearing in the same manner as for the FIG. 3 preferred embodiment, to wit, via grease fitting 60, axial passage 62 and cross hole 64 in the bushing 98.
Interposed in the space between the radially extending leg of the inner sealing ring 80 and the end wall of the counterbore 82 is a supplemental sealing means in the form of an annular flexible wiping seal 102. Seal 102 is held in position by a backing ring 104 which is pressed into the counterbore 82. The free radially inner edge of the seal 102 provides full wiping contact with the surface 100 of the bushing 98 and serves to supplement the labyrinth seal both in the retention of lubricant within the bearing cavity and the exclusion of contaminants therefrom. | A roller assembly for use on a conveyor chain to provide rolling support for the working run thereof includes a roller journaled on a mounting bushing and held thereon from axial displacement by a double sealing ring arrangement at each roller end face. The double sealing rings are arranged to provide a labyrinth seal to aid in the retention of lubricant within and the exclusion of contaminants from the assembly, and the inner ring of each pair also provides an axial thrust bearing surface for the roller. The sealing rings are preferably of L-shaped cross section and are adaptable for use with rollers of either metal or platic construction. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices for the transmission of light through the adjoining ends of two fiberoptic cables, and more particularly to connectors adapted to connect an end of a fiberoptic cable to another fiberoptic cable or to a LED or to a laser.
2. Description of the Prior Art
Fiberoptic connectors utilized to join the ends of the fibers to two fiberoptic cables are well known. A complete connector consists of two conical plugs and an alignment sleeve. The sleeve allows the two optical fibers within the two plugs to be aligned with a tolerance of a few microns, such that correct fiberoptic transmission can occur.
The prior art connector plugs are typically molded utilizing a glass-epoxy resin into the desired conical shape. For added strength, some prior art plugs include a metal sleeve that is centrally disposed within the plug along a portion of its length; however, the conical tip of the plug is completely composed of the glass-epoxy resin.
Other prior art connector plugs have been formed entirely out of metal. Such metal connector plugs are susceptible to scratching and deformation if mishandled or dropped, thus leading to misalignment. Additionally, metal plugs cannot be effectively utilized as electrical connectors due to the lack of insulation.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a fiberoptic connector plug having a metal core and a glass-epoxy resin body formed thereabout.
It is another object of the present invention to provide a metal core fiberoptic connector plug having a metal tip for improved heat dissipation.
It is a further object of the present invention to provide a metal core fiberoptic connector plug having a plastic body for ease of handling and reliability.
It is yet another object of the present invention to provide a metal core fiberoptic connector plug having a metal tip that may be crimped to provide a mechanical holding of the optical fiber within the tip.
It is yet a further object of the present invention to provide a fiberoptic connector having an electrically conductive metal core which facilitates electrical connection as well as optical connection through the connector plateau.
It is still another object of the present invention to provide a metal core fiberoptic connector for high-power applications having an air gap between the optical fiber and the metal tip to facilitate heat dissipation.
The metal core fiberoptic connector of the present invention includes a connector plug having a cone shaped connection interface, such that it is compatible with existing connection plugs and alignment sleeves. The present invention includes a metal core that extends throughout the length of the connector. The metal core terminates in the connection tip of the plug in an exposed plateau, and a bore is formed in the plateau through which the optical fiber passes. A glass-epoxy resin body surrounds the metal core. In the preferred embodiment, the metal core includes radially projecting portions which facilitate a firm engagement with the outer body which surrounds the metal core.
In an alternative embodiment of the present invention for high-power applications, a relatively large bore is formed in the metal tip. The optical fiber is held within a glass sleeve that is centrally disposed in the bore, and an air gap surrounds the glass sleeve within the bore. This embodiment provides enhanced heat dissipation and thereby facilitates the connection of high-power optical fibers.
It is an advantage of the present invention that it provides a fiberoptic connector plug having a metal core and a glass-epoxy resin body formed thereabout.
It is another advantage of the present invention that it provides a metal core fiberoptic connector plug having a metal tip for improved heat dissipation.
It is a further advantage of the present invention that it provides a metal core fiberoptic connector plug having a plastic body for ease of handling and reliability.
It is yet another advantage of the present invention that it provides a metal core fiberoptic connector plug having a metal tip that may be crimped to provide a mechanical holding of the optical fiber within the tip.
It is yet a further advantage of the present invention that it provides a fiberoptic connector having an electrically conductive metal core which facilitates electrical connection as well as optical connection through the connector plateau.
It is still another advantage of the present invention that it provides a metal core fiberoptic connector for high-power applications having an air gap between the optical fiber and the metal tip to facilitate heat dissipation.
The foregoing and other objects, features and advantages of the present invention will be apparent from the following description of the preferred embodiments which make reference to the several figures of the drawings.
IN THE DRAWINGS
FIG. 1 is a perspective view of the metal core fiberoptic connector plug of the present invention;
FIG. 2 is a cross-sectional view of the present invention taken along lines 2--2 of FIG. 1;
FIG. 3 is an enlarged view of the connector tip of the device depicted in FIG. 2, showing a fiberoptic cable disposed therewithin;
FIG. 4 is a perspective view of an alternative embodiment of the metal core fiberoptic connector plug of the present invention;
FIG. 5 is a cross-sectional view of the present invention taken along lines 5--5 of FIG. 4;
FIG. 6 is an enlarged view of the connection tip of the device depicted in FIG. 5, showing a fiberoptic cable disposed therewithin; and
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A perspective view of the metal core fiberoptic connector plug 10 of the present invention is depicted in FIG. 1. The connector plug 10 is outwardly shaped to be compatible with standard fiberoptic connection devices which include two connector plugs (that are outwardly shaped substantially identical to the connector plug 10) and an alignment sleeve which is utilized to align the two connector plugs.
The connector plug 10 is formed with a frontal cone portion 12 and a rearward cable insertion portion 14. The connector 10 has a body portion 16 into which annular grooves 18 are formed to facilitate the handling of the connector 10. Three such grooves 18 are provided in the preferred embodiment. The cone portion 12 is truncated to form a frustrum shaped nose 20 which is designed to properly fit into preexisting, conventional fiberoptic alignment sleeves which serve to join two fiberoptic connector plugs in a nose to nose configuration. The nose 20 includes a flat connection face 22 having a slightly raised plateau 24 centrally disposed therein, and an optical fiber bore 26 is centrally formed through the plateau 24. As will appear from the following description, the plateau 24 is formed from a thermally and electrically conductive material such as a metal, whereas the body 16, including the nose 20, is formed from a non-conducting material such as a glass-epoxy resin.
FIG. 2 depicts a cross-sectional view of the fiberoptic connector 10 shown in FIG. 1. As depicted therein, the plateau 24 is the frontal tip of a generally cylindrical core 30 which traverses the length of the connector plug 10. The core 30 has a smooth, cylindrical inner bore 32 formed therein for holding a fiberoptic cable as is discussed hereinbelow. The inner bore 32 terminates at its forward end in a cone shaped cavity portion 34 having an apex 36 which peaks at the inner terminus of the optical fiber bore 26 through the plateau 24. The . .inner bore.!. .Iadd.core 30 .Iaddend.is substantially surrounded by the generally cylindrical body 16 that is composed of a thermally and electrically non-conductive substance such as a glass-epoxy resin.
In the preferred embodiment, the outer surface of the core 30 is formed with a plurality of radially extending annular ridges 40 which project into and are generally surrounded by the body 16 of the connector 10. The ridges 40 serve to hold the core 30 and the body 16 fixedly together.
As an alternative feature, as depicted in FIG. 2, an annular groove 42, which is one of the three annular grooves 18 described hereinabove, may penetrate through the body 16 to expose the core 30 at one of the ridges 40. The exposure of the electrically conductive core material through groove 42 provides an access point for an outside connector, not shown, to make an electrical contact with the core 30.
FIG. 3 depicts an enlarged view of the connection tip of the device depicted in FIG. 2, having a fiberoptic cable disposed therein. For ease of comprehension, the elements of the invention depicted in FIG. 3 are numbered identically to those elements as previously discussed. A fiberoptic cable 50 is disposed within the inner bore 32 of the core 30. The fiberoptic cable 50 includes an optical fiber 52 that is centrally disposed within the cable 50. The cable 50 is shown fully inserted within the inner bore 32, such that the outer portions 54 of the end 56 of the cable 50 make contact with the inner surface 60 of the cone-shaped portion 34 of the inner bore 32. The optical fiber 52 extends beyond the end 56 of the fiberoptic cable 50 and penetrates through the apex 36 of the cone-shaped cavity 34, into and through the optical fiber bore 26. The optical fiber 52 terminates at the face of the plateau 24.
The protrusion of the metal plateau 24 beyond the face 22 of the plug permits the mechanical crimping of the metal plateau about its edges to collapse the optical fiber bore 26 about the optical fiber 52 disposed therein. Such crimping achieves a mechanical holding of the optical fiber within the plug, thus eliminating the use of an epoxy or other typical adhesive. Such a mechanical holding permits the plug 10 to be utilized for higher power applications where the use of an epoxy adhesive is not effective.
While the embodiment depicted in FIGS. 1, 2 and 3 is shown for a single fiber cable it is equally suitable for multiple fiber cables. In such an installation, the multiple fibers all protrude through the bore 26, which must be enlarged in its diameter, and the metal tip may be crimped to achieve a mechanical holding of the optical fibers within the tip. Of course, for lower power applications, an epoxy sealant may be utilized to hold the multiple fibers within the tip.
It is therefore to be understood that when the connector 10 is joined with a similar connector or with a properly configured LED or laser, that an optical connection will be achieved through the alignment of the optical fibers of the devices, and also that an electrical connection can be achieved through the surface of the electrically conductive plateau 24 with an electrically similarly configured electrically conductive member formed in the device to which the present invention is connected. The metal tip provides enhanced heat dissipation over that of conventional glass-epoxy resin plugs. In high-power applications, the thermal buildup can melt the tips and thereby destroy conventional glass-epoxy resin plugs. Thus, the present invention permits the connection of higher power fiberoptic cables. The glass-epoxy resin body of the present invention is an improvement over pre-existing metallic plugs. Such metallic plugs are susceptible to deformation upon dropping and mishandling, whereas the glass-epoxy resin body of the present invention acts as a shock-absorbing protectant from mishandling and from scratching as well.
To manufacture the present invention, a metal core 30 is placed in a mold of an injection molding machine. The core does not have an optical fiber bore formed therein. The connector body 16 is then molded around the core 30 within the injection molding machine. The use of an injection molding machine increases the accuracy of the manufacturing process, such that the angle and the roughness of the cone portion 12 of the connector are accurately formed. Thereafter, the connector is placed in a high precision drill which accurately drills the optical fiber bore 26 through the plateau 24, in such a manner that the bore 26 is centrally disposed relative to the cone surfaces 12.
FIGS. 4, 5, 6 and 7 depict an alternative embodiment 100 of the present invention. This embodiment 100 is suitable for high-power multiple fiber connection. The plug 100 includes a metal core 102 which extends throughout the length of the plug 100. The metal core 102 is surrounded by a connector body 104 which is preferably formed from a glass-epoxy resin. As is best depicted in FIGS. 5, 6 and 7, the metal core 102 extends throughout the length of the connector 100. The metal core 102 is substantially formed as a hollow cylinder having a cable bore 110 formed axially therethrough for holding a fiberoptic cable bundle 112 therein. A bore of larger diameter than the optical cable bundle 112 is axially disposed in the metal core from the connection end 114. The connection bore 120 is of sufficient diameter that a relatively substantial air gap 122 will exist between the outer surface of the optical fibers of the bundle 112 disposed therein and the inner surface of the bore 120.
To facilitate the alignment and holding of the optical fibers within the bore 120, the optical fibers 112 are held within a thin-walled high temperature glass tube 130. The length of tube 130 corresponds to the depth of the bore 120. A metal sleeve 140 is disposed around the glass tube 130 proximate the inner end of the glass tube. The metal sleeve acts as a frictional engagement to hold the glass tube and optical fibers 112 disposed therewithin a fixed, centrally disposed location in the tip of the connector plug 100. After the optical fibers 112 with glass tube and metal sleeve is installed within the tip of the connector 100, the tip is polished, such that the optical fibers 112, glass tube 130 and the metal core 102 all terminate in a flush manner. It is therefore to be realized that an air gap 122 will exist between the outer surface of the glass tube 130 and the inner surface of the bore 120 within the metal core 102. In high-power optical cable connections it is known that even the metal tips of the connector plugs can be melted by the optical beam power. The present invention utilizes a high temperature glass tube 130 to surround the optical fibers 112 at the connection point, whereby higher power can be transmitted because the high temperature glass can withstand higher temperatures than the metal sleeve. The air gap serves to dissipate the thermal energy absorbed by the glass tube and the heat that is then absorbed by the metal core 102 is thermally conducted away from the tip. The connector plug 100 thus serves to provide a means of connecting high power optical fibers.
In the preferred embodiment of the connector plug 100, the bore 120 is formed with a depth of approximately 0.3 inches and a diameter of approximately 0.1 inches. The glass tube 130 is formed with a diameter of approximately 0.07 inches such that the air gap 122 which surrounds the glass tube 130 is approximately 0.015 inches. The metal sleeve 140 has a length of approximately 0.15 inches to aid in holding and centering the fiber bundle 112 and glass tube 130 within the bore 120.
While the invention has been particularly shown and described with reference to certain preferred embodiments, it will be understood by those skilled in the art that various alterations and modifications in form and detail may be made therein. Accordingly, it is intended that the following claims cover all such alterations and modifications as may fall within the true spirit and scope of the invention. | The present invention relates to devices for the transmission of light through the adjoining ends of two fiberoptic cables, and more particularly to connectors adapted to connect an end of a fiberoptic cable to another fiberoptic cable or to a LED or to a laser. | 6 |
This application is a division of application Ser. No. 320,604 filed Nov. 12, 1981 now U.S. Pat. No. 4,408,568.
Field of Invention
The present invention relates to pulverized coal fired boilers and steam generators used in power production.
BACKGROUND OF THE INVENTION
In the operation of a pulverized coal-fired boiler a significant fraction of the ash contained in the coal is deposited on the water walls of the combustion chamber and on the tubes of the convection section of the boiler. The ash deposits have a low thermal conductivity, modify the radiative properties of the surfaces and insulate the tubes from the flame. Both of these effects interfere with the efficient flame and gas-to-tube heat flux transfer.
Uncontrolled accumulation of ash often assumes catastrophic proportions necessitating boiler shutdowns. Often physical damage results to tubes in the furnace hopper when large masses of ash detach and fall there.
As a result of the generally decreased heat fluxes, a larger heat transfer surface is required than otherwise would be the case. The increased use of fouling-type coals has led to a substantial increase in furnace size for a particular load, leading to an increased initial capital cost.
Boiler operation is controlled by maintaining superheat steam temperature and flow rate by use of the available operating variables, such as, gas recirculation, burner tilt, gas tempering and steam atemperation. A need for frequent use of these adjustments is indicative of uneconomic operation.
The build up of ash on the furnace walls is controlled by the intermittent operation of soot blowers, which remove the built-up ash from the walls. At the present time the boiler operator is not provided with any direct measurement of the degree of fouling of the combustion chamber and convection section.
The degree of fouling, in general, however, is random and unpredictable with respect to its distribution on the various parts of the furnace walls, and also as to its severity at any one point. In the mode of operation, as practised according to the presently available state of the art, soot blower actuation is based on operator judgment of the indirect evidence from superheated steam and economizer temperature, burner position, and/or amount of gas recirculation and steam atemperation.
Because the boiler response time (i.e., the time where changes in degree of fouling are reflected in these variables) is long, control is erratic. Moreover, in order to avoid catastrophic loss of control, boilers are designed with larger furnaces than they otherwise might need to be. If methods and instrumentation were provided to directly monitor the degree and distribution of fouling, both the boiler control would be improved, and smaller and therefore less costly furnaces would prove adequate. As far as the applicants are aware, there has been no development to date of ash deposit-measuring instrumentation to provide such means.
SUMMARY OF INVENTION
In accordance with the present invention of the parent application, there is provided a furnace wall ash monitoring system which utilizes flux meters, or similar flux detectors. One flux meter, which is of unique construction and directly views the furnace flame, is always maintained free of any deposits, and hence receives the full heat flux from the flame. Such flux meter forms the subject of this invention. The full heat flux is also equivalent to the flux to be received by a perfectly clean water wall. Another flux meter is permitted to become fouled by ash deposits in identical manner to the water walls themselves, so that heat flux which is received by the fouled flux meter is equivalent to that received by the fouled wall.
The fluxes, detected simultaneously by each of the two meters, are converted to electrical signals indicating the detected flux values. The electrical signals are either continuously displayed by separate traces on a chart plotted by an electronic recorder, or combined electrically by special electronic circuitry and displayed by a recorder as a signal proportional to the degree of fouling of the furnace wall. Either or both of these signals can be used by the operator in boiler control. In practice, several fouled meters may be combined with a single clean meter to indicate the degree of fouling of a larger furnace wall area. Still further, several sets of clean-and-fouled-meter combinations may be judiciously distributed over all the furnace walls at various levels so as to obtain separate but continuous indications of the degree of fouling in these areas.
These signals, which indicate the degree of furnace fouling, may then be used by the operator as a basis of soot blower actuation. More importantly, he may more judiciously actuate other suitable boiler controls. Furthermore, the totality, or groups, of these signals may be recorded and manipulated by on-line use of digital computers (both macro and micro) in order to assist the automatic control of the whole boiler.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic representation of one typical embodiment of a pulverized coal-fired furnace to which the present invention is applied;
FIG. 2 is a sectional view of a flux meter which is permitted to become fouled by ash deposits in this invention;
FIG. 3 is a perspective view of a flux meter which is intended to be maintained free of ash deposits in this invention;
FIG. 4 is a schematic view of a typical electrical circuit used in this invention; and
FIG. 5 is a graphical representation of typical experimental results obtained using the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, a schematic representation of one particular example of a pulverized coal-fired furnace 10 is shown in FIG. 1. Pulverized coal and air are fed through burners 12 into the interior 13 of the furnace 10. As is well known, the furnace walls 14 are comprised of a plurality of parallel tubes wherein steam is generated for feed to a steam collection system (not shown).
Combustion gases pass up into a chamber 16, known as the boiler convection section, wherein may be located superheating surfaces for the generated steam, etc. The combustion gases then may pass over an economizer and air heater before exhausting to atmosphere through a stack.
During operation of the furnace 10, ash and slag form on the furnace walls 14 sticking to the tubes, decreasing heat absorption in the furnace and otherwise causing operating difficulties. Furnace wall soot blowers (not shown) are located throughout the furnace walls and each soot blower is operative to clean a section of the furnace wall.
In accordance with the present invention, a plurality of flux meters are located in the walls 14 of the furnace 10 directly facing the flame. In the illustrated embodiment, a single flux meter 20 is maintained clean at all times while three flux meters 22 are permitted to become fouled by ash and slag during furnace operation. As stated above, any desired number of flux meters 20 and 22, or other flux detectors, may be used to achieve the desired monitoring.
The heat flux meters 22 are illustrated in FIG. 2 and include a meter disc sensor 44 and a meter sensor body 46 constructed of dissimilar metals and to which wire leads 48 and 50 are respectively connected. Heat flowing to the surface of the disc 44 is conducted radially to the meter body 46 and thence through an attachment mold 52 to the boiler tubes. The thermal resistance of the disc 44 causes a temperature difference between the centre of the disc and its periphery. The dissimilar metal e.m.f. generated by the flux meter is proportional to the magnitude of the disc radial temperature difference and hence to the heat flux to the meter.
The specific construction of the flux meter 20 is shown in the perspective view of FIG. 3. The flux meter 20 includes a housing 24 which has a smaller diameter portion 26 extending through the furnace wall 14 and terminating at the internal surface 28 of the wall 14 and an integral larger diameter portion 30 located outside the furnace wall 14.
The housing 24 has an opening 32 in the end plate 33 of the larger diameter portions 30 for feeding air into the housing 24 and openings 34 in the end of the smaller diameter portion 26 to permit air to pass therethrough into the furnace interior 13.
Located in the interior of the housing 24 is an evacuated elongate tube 36 filled to about 5% of its volume with a fluid, such as water. At one end of the tube 36, remote from the end plate 33, an external copper sleeve 38 is provided, acting as a heat sink. A flux meter 40, of any convenient type, such as, that described above with respect to FIG. 2, is mounted on the forward end of the copper sleeve 38. The lead wires to the flux meter 40 have been omitted for convenience of illustration.
The opposite end of the elongate tube 36 is provided with a plurality of heat dissipating fins 42 located in the larger diameter housing portion 30. The illustrated structure of the probe 20 enables the flux meter 40 to be maintained at a relatively constant temperature near the temperature of the wall tubes while the air envelope emerging from the opening 34 prevents build up of ash fouling on the flux meter 40.
The copper sleeve 38 acts as a heat sink which removes heat from the flux meter 40. This heat causes water present in the evacuated tube 36 to evaporate thereby cooling the copper sleeve 38. The heat exchange fins 42, which are cooled by flowing air over them through the opening 32, cause the fluid steam to recondense, thereby removing heat from the system. Meanwhile, the air flowing through the housing, from the inlet 32 to the output 34, passes over the surface of the flux meter 40 and prevents the build up of ash on that surface.
When both the flux meter 20 and the flux meter 22 are clean, on start up or after a soot removal operation, the net voltage generated by the suitably attenuated combination is zero. As the flux meter 22 becomes fouled while the flux meter 20 remains clean, the difference in voltage is a measure of the extent of the fouling of the flux meter 22. The electrical signals produced by the flux meters 20 and 22 may be recorded and continuously displayed as by separate traces on a chart plotted by an electronic recorder. Alternatively, the signals may be combined and displayed as a signal proportional to the degree of fouling of the furnace wall.
An electrical circuit suitable for monitoring the voltage difference is illustrated in FIG. 4. Input amplifiers 54 and 56 respectively receive the voltages produced by the flux meters 20 and 22 as a result of the detected heat fluxes. The positive and negative terminals of the flux meter 20 are connected to the positive and negative inputs respectively of the amplifier 54 to generate a positive output signal in wire 58 while the positive and negative terminals of the flux meter 22 are connected to the negative and positive inputs of the amplifier 56 to generate a negative output signal in wire 60. The wires 58 and 60 join to form an input to the positive terminal of an output gain amplifier 64, thereby generating an output signal in wire 66. The output may be recorded and displayed on a suitable recorder (not shown).
When the flux meters 20 and 22 are both clean, the amplifiers 54 and 56 are adjusted to provide a zero voltage output in wire 66, the positive potential in wire 58 balancing the negative potential in wire 60. As fouling of flux meter 22 occurs, the negative potential in wire 60 decreases and the potential in wire 62 becomes more positive, thereby producing a positive potential in wire 66 which is proportional to the decrease in heat flux through the furnace water walls due to fouling of the flux meter 22.
In the above description, the flux meter which is maintained clean at all times is essentially of the same design as the one allowed to be fouled, except that flux meter 40 is mounted in a special manner, as seen in FIG. 3. In another embodiment of this invention, in place of heat flux meter 40, mounted as shown in FIG. 3, a recording radiation pyrometer, sensitive in the infra-red region of the electromagnetic spectrum, and/or a total radiation pyrometer, can be used. Both the latter instruments are commercially available and are known to those familiar with temperature measurement. They have not yet been put to use in such an application as the present.
In this invention, therefore, heat flux sensors or detectors, preferably in the form of flux meters, but also including pyrometers and/or thermocouples, are directly exposed to the heat flux within the furnace. Two different types of detectors are used, one of which is maintained free from contamination at all times and the other of which is allowed to become contaminated in the furnace. The voltages generated by the detectors are simultaneously measured and compared to provide an instantaneous indication of the heat flux loss due to fouling of the probe 22 and hence fouling of the furnace walls in the location of the probe 22.
The signal indicative of the degree of furnace fouling may be used by a furnace operator as a determination for initiation of soot blower operation and/or other furnace control action known in the art. Alternatively, the signal may be utilized for automatic initiation of soot blower operation or automatic control of the whole boiler.
EXAMPLE
A coal fired boiler of the type shown in FIG. 1 was operated for a two month period with probes 20 and 22 located therein. The boiler was a 150 MW Combustion Engineering Superheater corner-fired pulverized coal boiler, operated at 1800 psi and a superheat steam temperature of 1000° F. (585° C.).
The value of the combined signal in wire 66 was monitored as heat flux loss and the actual heat flux values detected by the probes 20 and 22 were also monitored separately. The results were recorded graphically and the results for a typical six hour run are shown in FIG. 5.
As may be seen from FIG. 5, the combined output signal (curve III) expressed as heat flux loss, was near zero immediately after a soot blow (shown at the right of FIG. 5). The heat flux loss slowly increased as the ash deposit built up. The heat flux measured by the clean probe (curve II) increased slowly as the fouling of the furnace walls decreased the total rate of heat transfer from the flame to the water walls, causing the temperature of the latter to increase. The flux measured by the fouled probe (curve I) fall rapidly initially, went through a vacillation phase due to ash deposit consolidation, and then fell less rapidly.
SUMMARY OF DISCLOSURE
In summary of this disclosure, the present invention provides a novel and accurate pulverized coal-fired boiler furnace monitoring system which utilizes the simultaneous measurement of heat flux within the furnace by two probes. Modifications are possible within the scope of this invention. | The build up of ash in a pulverized coal-fired boiler is achieved by comparing the heat flux simultaneously detected by a first flux detector which is maintained free of deposits and a second flux detector on which deposits are permitted to form. The net values from the heat flux comparison is proportional to the heat flux which is not reaching the boiler walls as a result of the ash deposits. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to a coding apparatus and a coding method.
BACKGROUND ART
[0002] The methods disclosed in NPL 1 and NPL 2, which have been standardized by ITU-T, are known as coding schemes enabling efficient coding of sound-related data such as speech data in the Super-Wide-Band (SWB, usually a band of 0.05-14 kHz). In these methods, sounds in a band of 7 kHz or lower (hereinafter referred to as a “low band”) are encoded by a core coding section and sounds in a band of 7 kHz or higher (hereinafter referred to as an “extension band”) are encoded by an extension coding section.
[0003] CELP (Code Excited Linear Prediction) is used in coding processing by the core coding section. The extension coding section decodes a low-band signal encoded by the core coding section, transforms it into the frequency domain by using MDCT (Modified Discrete Cosine Transform), and makes use of the obtained spectra (or transform coefficients; hereinafter referred to as “transform coefficients”) in encoding in the extension band.
[0004] The extension coding section uses the “envelope” of spectral power to normalize the core encoded low-band transform coefficients generated by the core coding section. In particular, the extension coding section calculates energy in each subband, smoothens out the subband energy to make a variation of the energy smooth in the direction of the frequency domain, and normalizes the transform coefficients in each subband with the smoothened energy. The normalized transform coefficients obtained in this manner are hereinafter referred to as “normalized low-band transform coefficients.”
[0005] The extension coding section searches for a subband having a large value of correlation between the normalized low-band transform coefficients and transform coefficients from an input signal in the extension band (hereinafter referred to as “extension-band transform coefficients”) and encodes information indicating the subband as lag information. The extension coding section copies the normalized low-band transform coefficients in the subband having a large value of correlation to the extension band and utilizes the copied normalized low-band transform coefficients as a spectral fine structure of the extension band. Thereafter, the extension coding section calculates a gain to adjust energy of the extension-band transform coefficients and encodes the gain. The coding apparatuses according to the related art perform the above-described processing to generate transform coefficients in the extension band using transform coefficients in the low band.
[0006] The value of correlation between the normalized low-band transform coefficients and the extension-band transform coefficients is calculated in the following manner in NPL 1 and NPL 2.
[0007] First, extension band is divided into a plurality of subbands (hereinafter referred to as “extension-band subbands”). Next, for each extension-band subband, a value of correlation between the normalized low-band transform coefficients and the transform coefficients in the extension-band subband is calculated. Then, a position of the normalized low-band transform coefficients where the value of correlation with the extension-band subband becomes largest is searched. However, calculating the value of correlation in this manner has a problem in that the method involves a large amount of calculation because the normalized low-band transform coefficients and all the transform coefficients in the extension-band subband are used for the calculation.
[0008] As a solution to this problem, PTL 1 discloses a technique in which the value of correlation is calculated by using only large transform coefficients in terms of amplitude among the extension-band transform coefficients. Accordingly, the amount of calculation for calculating the value of correlation can be reduced by limiting the number of transform coefficients used in the calculation of the value of correlation.
CITATION LIST
Patent Literature
PTL 1
[0000]
International Publication No. WO 2011/000408
Non-Patent Literature
NPL 1
[0000]
ITU-T Standard G.718 AnnexB, 2008
NPL 2
[0000]
ITU-T Standard G.729.1 AnnexE, 2008
SUMMARY OF INVENTION
Technical Problem
[0012] The technique disclosed in PTL 1, however, requires a large amount of calculation for extracting transform coefficients, which diminishes the effect of reduction in the amount of calculation by limiting the number of transform coefficients. For example, if an extension-band subband includes M transform coefficients, and largest N transform coefficients in terms of amplitude are to be extracted from among the M transform coefficients, branching processing has to be performed at least M×N times, leading to a large amount of calculation.
[0013] As another way of extracting transform coefficients having a large amplitude, PTL 1 illustrates a technique in which the mean value and the standard deviation of extension-band transform coefficients are calculated, a threshold is set based on these parameters, and then transform coefficients that exceed the threshold are extracted.
[0014] However, since speech and music have complex characteristics in a high band, a narrow subband width has to be set to generate high quality sound. Accordingly, the number of transform coefficients included in an extension-band subband becomes inevitably small, which makes it difficult to set a statistically reliable threshold. For this reason, it is difficult to obtain a threshold that enables extraction of a desired number of transform coefficients. For example, if the threshold is too high, the number of extracted transform coefficients becomes small, so that accuracy of the calculated value of correlation decreases, which makes it no longer possible to determine an appropriate position. On the contrary, if the threshold is too low, the number of extracted transform coefficients becomes large, so that the amount of calculation for calculating a value of correlation cannot be reduced drastically. Moreover, the number of extracted transform coefficients reaches the predetermined number N in the middle of the extraction loop, so that transform coefficients having a large amplitude in the rest of the loop may not be extracted.
[0015] An object of the present invention is to provide a coding apparatus and a coding method for extracting an appropriate number of transform coefficients that can reduce the amount of calculation for extracting the transform coefficients, drastically.
Solution to Problem
[0016] A coding apparatus according to an aspect of the present invention includes: a core coding section that encodes transform coefficients in a band lower than a reference frequency among input signal transform coefficients obtained by transforming an input signal from a time domain to a frequency domain; and an extension-band coding section that encodes transform coefficients in an extension band by using core encoded low-band transform coefficients obtained by decoding data encoded by the core coding section, the extension band being a band higher than the reference frequency, in which the extension-band coding section includes: a threshold calculation section that calculates, for each of extension-band subbands obtained by splitting the extension band, a threshold based on statistics on transform coefficients included in the subband; a representative transform coefficient extraction section that compares, for each of the extension-band subbands, an amplitude of the transform coefficients with the threshold to extract a transform coefficient having an amplitude larger than the threshold, as a representative transform coefficient; and a matching section that calculates, for each of the extension-band subbands, a value of correlation between the representative transform coefficient and a normalized core encoded low-band transform coefficient and selects a subband having a largest value of correlation, in which: when a number of the representative transform coefficients extracted by the representative transform coefficient extraction section is less than a predetermined number, the threshold calculation section updates the threshold in accordance with a shortage number of the representative transform coefficients with reference to the predetermined number; and the representative transform coefficient extraction section performs processing to extract a transform coefficient again by using the updated threshold.
[0017] A coding method according to an aspect of the present invention includes: a core coding step of encoding transform coefficients in a band lower than a reference frequency among input signal transform coefficients obtained by transforming an input signal from a time domain to a frequency domain; and an extension-band coding step of encoding transform coefficients in an extension band by using core encoded low-band transform coefficients obtained by decoding data encoded in the core coding step, the extension band being a band higher than the reference frequency, in which the extension-band coding step includes: calculating, for each of extension-band subbands obtained by splitting the extension band, a threshold based on statistics on transform coefficients included in the subband; comparing, for each of the extension-band subbands, an amplitude of the transform coefficients with the threshold to extract a transform coefficient having an amplitude larger than the threshold as a representative transform coefficient; when a number of the extracted representative transform coefficients is less than a predetermined number, updating the threshold in accordance with a shortage number of the representative transform coefficients with reference to the predetermined number; performing processing to extract a transform coefficient again by using the updated threshold; and calculating, for each of the extension-band subbands, a value of correlation between the representative transform coefficient and a normalized core encoded low-band transform coefficient, and selecting a subband having a largest value of correlation when the number of the extracted representative transform coefficients reaches the predetermined number.
Advantageous Effects of Invention
[0018] According to the present invention, the number of loops required to extract a predetermined number N of transform coefficients can be reduced and therefore the amount of calculation for extracting the transform coefficients can also be reduced, drastically.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a block diagram illustrating a configuration of a coding apparatus according to an embodiment of the present invention;
[0020] FIG. 2 is a block diagram illustrating a configuration of an extension-band coding section according to the embodiment of the present invention;
[0021] FIG. 3 illustrates the operation of extraction processing of transform coefficients according to the technique according to the related art;
[0022] FIG. 4 illustrates the operation of extraction processing of transform coefficients according to the embodiment of the present invention;
[0023] FIG. 5 is a block diagram illustrating a configuration of a decoding apparatus according to the embodiment of the present invention; and
[0024] FIG. 6 is a block diagram illustrating a configuration of an extension-band decoding section according to the embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0025] Embodiments of the present invention will be described in detail below in reference to the accompanying drawings.
[0026] When N transform coefficients having a large amplitude are extracted from among the transform coefficients in the extension band, a coding apparatus according to the present embodiment statistically calculates such a high threshold that the number of extracted transform coefficients does not reach N transform coefficients at first, and then uses the calculated threshold to extract transform coefficients having a large amplitude. Next, the coding apparatus lowers the threshold in accordance with how many more transform coefficients have to be extracted to obtain N transform coefficients, and then uses the newly calculated threshold to extract transform coefficients having a large amplitude. The coding apparatus repeats the threshold calculation and the extraction of transform coefficients until N transform coefficients are extracted. This can reduce the number of loops required to extract N transform coefficients, resulting in a significant reduction in the amount of calculation for extracting transform coefficients. In addition, determining how much the threshold is lowered in accordance with how many more transform coefficients have to be extracted to obtain N transform coefficients makes it possible to reduce variation in the number of extracted transform coefficients, which may be very wide in the case where transform coefficients are extracted based on statistical processing alone, and therefore to perform encoding without loss of coding quality.
[0027] A description will be given of components of the coding apparatus according to the present embodiment below. FIG. 1 is a block diagram that illustrates a configuration of the coding apparatus according to the present embodiment.
[0028] As shown in FIG. 1 , coding apparatus 10 mainly includes time-frequency transform section 1 , core coding section 2 , extension-band coding section 3 , and multiplexing section 4 .
[0029] Time-frequency transform section 1 transforms an input signal from the time domain to the frequency domain and outputs the obtained input signal transform coefficients to core coding section 2 and extension-band coding section 3 . It should be noted that although the present embodiment is described for the case where the MDCT transformation is used, the present invention is not limited to the MDCT transformation and an orthogonal transform such as FFT (Fast Fourier Transform) and DCT (Discrete Cosine Transform) that perform transform from the time domain to the frequency domain may be used.
[0030] Core coding section 2 encodes, among the input signal transform coefficients, transform coefficients in a low band (a band lower than a reference frequency (for example, 7 kHz)) by transform coding and outputs the encoded data to multiplexing section 4 as core encoded data. Core coding section 2 also outputs core encoded low-band transform coefficients obtained by decoding the core encoded data to extension-band coding section 3 .
[0031] Extension-band coding section 3 uses the core encoded low-band transform coefficients to perform coding processing on transform coefficients in an extension band (a band higher than the reference frequency) (hereinafter referred to as “extension-band transform coefficients”) among the input signal transform coefficients and outputs the obtained extension-band encoded data to multiplexing section 4 . The internal configuration of extension-band coding section 3 will be described in detail later.
[0032] Multiplexing section 4 outputs encoded data obtained by multiplexing the core encoded data and the extension-band encoded data.
[0033] With the configuration described above, the coding apparatus 10 encodes an input signal and outputs encoded data.
[0034] The internal configuration of extension-band coding section 3 will be described next. As shown in FIG. 2 , extension-band coding section 3 mainly includes normalization section 30 , extension-band analyzing section 31 , threshold calculation section 32 , representative transform coefficient extraction section 33 , matching section 34 , and extension-band generation/coding section 35 .
[0035] Normalization section 30 normalizes the core encoded low-band transform coefficients and outputs the obtained normalized low-band transform coefficients to matching section 34 and extension-band generation/coding section 35 . In general, normalization section 30 calculates the envelope of the core encoded low-band transform coefficients and obtains the normalized low-band transform coefficients by dividing the core encoded low-band transform coefficients by the envelope. It should be noted that the normalized low-band transform coefficients can also be obtained, for example, by dividing the core encoded low-band transform coefficients into subbands, calculating subband energy, and dividing each of the transform coefficients in each subband by the subband energy.
[0036] In general, the distribution of energy is very uneven in the low-band portion of the transform coefficients while the distribution of energy is relatively uniform in the high-band portion of the transform coefficients. Thus, encoding can be performed more efficiently by calculating values of correlation with the extension-band transform coefficients after the normalization processing for smoothening out the unevenness in the distribution of energy of the core encoded low-band transform coefficients.
[0037] Extension-band analyzing section 31 analyzes the extension-band transform coefficients and outputs the resulting statistics to threshold calculation section 32 as extension-band statistical parameters. Assuming that the extension-band transform coefficients follow the normal distribution, extension-band analyzing section 31 calculates the mean value (hereinafter referred to as an “absolute-value mean”) and the standard deviation value of absolute-value amplitudes, which are absolute values of the amplitudes, as the statistical parameters. The operation of extension-band analyzing section 31 will be described in detail later.
[0038] Threshold calculation section 32 calculates a transform coefficient extraction threshold based on the extension-band statistical parameters and outputs the calculated transform coefficient extraction threshold to representative transform coefficient extraction section 33 . In addition, threshold calculation section 32 updates the transform coefficient extraction threshold in accordance with the shortage number of transform coefficients, and outputs the updated transform coefficient extraction threshold to representative transform coefficient extraction section 33 . The operation of threshold calculation section 32 will be described in detail later.
[0039] For each extension-band subband, representative transform coefficient extraction section 33 extracts extension-band transform coefficients having an amplitude larger than the transform coefficient extraction threshold and outputs the extracted extension-band transform coefficients to matching section 34 as representative transform coefficients. Representative transform coefficient extraction section 33 also outputs the shortage number of transform coefficients to threshold calculation section 32 when the number of representative transform coefficients is less than the predetermined number N. The operation of representative transform coefficient extraction section 33 will be described in detail later.
[0040] Matching section 34 calculates a value of correlation between the representative transform coefficients and the normalized low-band transform coefficients for each extension-band subband, selects a subband having the largest value of correlation, and outputs information indicating the selected subband to extension-band generation/coding section 35 as lag information.
[0041] Extension-band generation/coding section 35 uses the extension-band transform coefficients, the lag information, and the normalized low-band transform coefficients to generate extension-band encoded data and outputs the generated extension-band encoded data. In particular, extension-band generation/coding section 35 copies the normalized low-band transform coefficients in the subband indicated by the lag information to the extension band and utilizes the copied normalized low-band transform coefficients as a frequency fine structure of the extension band. Extension-band generation/coding section 35 encodes the lag information used for this copying operation and includes the encoded lag information in the extension-band encoded data. Furthermore, extension-band generation/coding section 35 calculates a gain, which is an amplitude ratio (the square root of an energy ratio) between the extension-band transform coefficients obtained by copying the normalized low-band transform coefficients and the extension-band transform coefficients that are transform coefficients in the extension band among the input signal transform coefficients, encodes the gain, and includes the encoded gain in the extension-band encoded data. Extension-band generation/coding section 35 multiplies the extension-band transform coefficients obtained by copying the normalized low-band transform coefficients by the calculated gain to obtain the extension-band transform coefficients.
[0042] The operation of extension-band analyzing section 31 , threshold calculation section 32 , and representative transform coefficient extraction section 33 will be described in detail next. Assuming that the extension-band transform coefficients follow the normal distribution in the present embodiment, how to set the transform coefficient extraction threshold (hereinafter simply referred to as the “threshold”) in a stepwise manner will be described.
[0043] When the extension-band transform coefficients are assumed to follow the normal distribution, extension-band analyzing section 31 outputs the absolute-value mean and the standard deviation of amplitudes of the transform coefficients for each extension-band subband as the extension-band statistical parameters.
[0044] Extension-band analyzing section 31 calculates the absolute-value mean by equation 1 below. In equation 1, j is the index of a subband, the total number of transform coefficients included in each extension-band subband is M, and i (i=1 to M) is the index of a transform coefficient included in each subband. Fhavg(j) represents the absolute-value mean of transform coefficients included in a subband j and Fh represents the amplitude of an extension-band transform coefficient. That is, Fh(j, i) represents the amplitude of the i-th extension-band transform coefficient included in the j-th subband. For ease of explanation, it is assumed that the number of transform coefficients included in every subband of the extension-band transform coefficients is M.
[0000]
(
Equation
1
)
Fhavg
(
j
)
=
∑
i
=
1
M
Fh
(
j
,
i
)
/
M
[
1
]
[0045] Next, extension-band analyzing section 31 calculates the standard deviation for each subband. The standard deviation is calculated by equation 2 below. In equation 2, σ(i) represents the standard deviation of a subband j.
[0000]
(
Equation
2
)
σ
(
j
)
=
(
∑
i
=
1
M
Fh
(
j
,
i
)
2
/
M
)
-
Fhavg
(
j
)
2
[
2
]
[0046] Extension-band analyzing section 31 outputs the calculated absolute-value mean and the standard deviation to threshold calculation section 32 as the extension-band statistical parameters.
[0047] Threshold calculation section 32 performs different calculations in accordance with whether the initial threshold is calculated or the existing threshold is lowered. The calculation of the initial threshold will now be described.
[0048] Threshold calculation section 32 determines the initial threshold based on the extension-band statistical parameters. When the extension-band transform coefficients are assumed to follow the normal distribution, threshold calculation section 32 calculates the threshold by equation 3 below. In equation 3, Fhthr(j) is the threshold for a subband j and β is a constant for controlling the threshold. For example, β is set to about 1.6 to extract the largest 10% of the extension-band transform coefficients or about 2.0 to extract the largest 5% of the extension-band transform coefficients. The set value of β can be calculated according to the normal distribution table. In this calculation, threshold calculation section 32 extracts a relatively large value of β such that the initial threshold is relatively high to prevent the threshold from being too low, with the result that the number of extracted extension-band transform coefficients becomes equal to or exceeds the predetermined number. For example, in order to extract N extension-band transform coefficients from among M extension-band transform coefficients, β is set to a value with which N or less extension-band transform coefficients are expected to be extracted when the extraction processing is actually performed, i.e., β is set to a value with which P extension-band transform coefficients are to be extracted, where P is less than N.
[0000] [3]
[0000] Fhthr( j )=Fhavg( j )+σ( j )*β (Equation 3)
[0049] The operation of threshold calculation section 32 for lowering the threshold will be described later.
[0050] For each extension-band subband, representative transform coefficient extraction section 33 compares the amplitude of the extension-band transform coefficients with the threshold set by threshold calculation section 32 to extract the extension-band transform coefficients having an amplitude larger than the threshold. Representative transform coefficient extraction section 33 stores the extracted extension-band transform coefficients as the representative transform coefficients and outputs how many more representative transform coefficients have to be extracted to obtain a predetermined number of transform coefficients to threshold calculation section 32 as the shortage number of transform coefficients.
[0051] If the number of extracted representative transform coefficients reaches the predetermined number, then representative transform coefficient extraction section 33 stops the extraction processing and outputs the extracted representative transform coefficients to matching section 34 . Otherwise if the number of extracted representative transform coefficients does not reach the predetermined number, representative transform coefficient extraction section 33 stores the extracted extension-band transform coefficients as the representative transform coefficients. At this point, representative transform coefficient extraction section 33 stores all the extension-band transform coefficients in the subband with the amplitude of the already-extracted representative transform coefficients set to zero as an extraction candidate transform coefficient group. This can prevent the already-extracted extension-band transform coefficients to be extracted again in the next extraction processing.
[0052] If the number of extracted representative transform coefficients does not reach the predetermined number, representative transform coefficient extraction section 33 performs additional extraction of transform coefficients. In this case, representative transform coefficient extraction section 33 performs the extraction processing not on all the extension-band transform coefficients included in the subband but on the extraction candidate transform coefficient group. The newly-extracted extension-band transform coefficients are added to the stored representative transform coefficients and the shortage number of transform coefficients decreases by the number of the added representative transform coefficients.
[0053] In the additional extraction of representative transform coefficients by this stepwise processing, when the number of extracted representative transform coefficients reaches the predetermined number and the extraction processing stops, there may be an extension-band transform coefficient having an amplitude larger than the newly-extracted extension-band transform coefficients in a band that has not been searched yet in the additional extraction processing. However, since in the initial step (i.e., the extraction processing initially performed before the additional extraction of transform coefficients), extension-band transform coefficients having an amplitude larger than the extension-band transform coefficients in the unsearched band are extracted, even if extension-band transform coefficients in the unsearched band cannot be extracted, it has little impact on the whole extraction processing.
[0054] The predetermined number is not limited to one fixed number and may be set in a range of numbers. For example, the predetermined number is set to N as a reference, and when the number of extracted extension-band transform coefficients reaches a range between N-δ and N+δ as a result of the extraction processing by using a calculated threshold, the calculation of a new threshold may stop and the extraction processing of transform coefficients may end.
[0055] The operation performed when the number of extension-band transform coefficients extracted by representative transform coefficient extraction section 33 is less than the predetermined number will be described in detail next.
[0056] Threshold calculation section 32 controls the threshold adaptively based on the shortage number of transform coefficients outputted from representative transform coefficient extraction section 33 , so as to extract more extension-band transform coefficients. In particular, threshold calculation section 32 lowers the threshold greatly when the shortage number of transform coefficients is large and lowers the threshold slightly when the shortage number of transform coefficients is small.
[0057] Updating the threshold by means of multiplication by a suppression coefficient that is calculated in accordance with the shortage number of transform coefficients will be described herein as an example of techniques for adapting the shortage number of transform coefficients. In equation 4 below, Sc(j) represents a suppression coefficient in a subband j, Nlp(j) represents the shortage number of transform coefficients in the subband j, a represents a minimum amount of suppression, and b represents a maximum amount of suppression. 1.0≧a>b>0.0 for a and b.
[0000]
(
Equation
4
)
Sc
(
j
)
=
-
a
-
b
N
*
Nlp
(
j
)
+
a
[
4
]
(
Equation
5
)
Fhthr
(
j
)
=
Fhthr
(
j
)
*
Sc
(
j
)
[
5
]
[0058] In this manner, the threshold is adaptively lowered in accordance with the shortage number of transform coefficients. For example, if a=0.9 and b=0.5, Fhthr(j) in equation 5 is suppressed to a range between 0.9 times and 0.5 times the current value of Fhthr(j).
[0059] The threshold calculated as described above is outputted to representative transform coefficient extraction section 33 . The above-described operation of threshold calculation section 32 is repeated until the number of representative transform coefficients extracted by representative transform coefficient extraction section 33 reaches the predetermined number.
[0060] For example, if the threshold is updated two times (if three thresholds, including the initial threshold, are used for the extraction processing) to extract N, which is the predetermined number, representative transform coefficients, when the number of transform coefficients in the subband is M, the extraction processing according to the above-described approach requires only the amount of calculation for performing branching processing M×3 times.
[0061] The operation of updating the transform coefficient extraction threshold as described above and the associated extraction processing will be described next in reference to FIG. 3 and FIG. 4 . FIG. 3 illustrates extraction processing according to a conventional technique and FIG. 4 illustrates the extraction processing according to the present embodiment.
[0062] The horizontal axis of FIG. 3 and FIG. 4 represents the frequency and the horizontal axis of FIG. 3 and FIG. 4 represents the absolute-value amplitude which indicates extension-band transform coefficients in a subband j. As an example for illustration, the number of transform coefficients included in the subband M=25 and the predetermined number N=10. Extension-band transform coefficients are denoted by f1, f2, f3 from a low band to a high band and an extension-band transform coefficient corresponding to the highest frequency is denoted by f25.
[0063] An example of the operation of extraction processing in the technique according to the related art will be described in reference to FIG. 3 . In this technique, since extension-band transform coefficients are extracted in descending order of the absolute-value amplitude, ten extension-band transform coefficients f15, 122, f9, f3, f17, f21, f6, f14, f12, and f7 are extracted in this order. This extraction processing has to perform branching processing M×10 times.
[0064] The operation of the extraction processing according to the present embodiment will be described next in reference to FIG. 4 . The absolute-value mean and the standard deviation of f1 to f25 are calculated by extension-band analyzing section 31 and a transform coefficient extraction threshold is calculated by threshold calculation section 32 . This transform coefficient extraction threshold is denoted by threshold) in FIG. 4 .
[0065] At this point, three extension-band transform coefficients f15, f22, and f9 are extracted and the shortage number of transform coefficients is 10−3=7. If a=0.9 and b=0.5, a suppression coefficient Sc(j)=0.62 according to equation 4 above. As a result, the transform coefficient extraction threshold is updated with 0.62×threshold1. This new transform coefficient extraction threshold is denoted by threshold2.
[0066] The extraction with the use of threshold2 provides three additionally extracted extension-band transform coefficients f3, f17, f21 and the shortage number of transform coefficients is 7−3=4. As a result, the suppression coefficient Sc(j) becomes 0.78 and the transform coefficient extraction threshold is updated with 0.78×threshold2. This new transform coefficient extraction threshold is denoted by threshold3.
[0067] The extraction with the use of threshold3 provides three additionally extracted extension-band transform coefficients f6, f14, f12 and the shortage number of transform coefficients is 4−3=1. The number of extracted extension-band transform coefficients is nine, which is less than ten, but assumed to be in an allowable range to stop the extraction processing.
[0068] In the above example, the transform coefficients can be extracted by performing the extraction processing three times (branching processing M×3 times) with the transform coefficient extraction threshold initially set once and updated twice. In this illustrative example, f7, which is extracted by the method according to the related art, cannot be extracted, according to the present embodiment. However, since f7 has an absolute-value amplitude smaller than that of the extracted nine transform coefficients, even if f7 cannot be extracted, it has little impact on the accuracy of calculation of a value of correlation.
[0069] The configuration and operation described above allow extension-band coding section 3 to extract an appropriate number of representative transform coefficients from among extension-band transform coefficients with a small amount of calculation when a value of correlation between the extension-band transform coefficients and the normalized low-band transform coefficients is calculated. This enables a coding apparatus that has reduced the amount of calculation without degradation of performance.
[0070] As described above, the coding apparatus according to the present embodiment calculates a threshold based on statistics on extension-band transform coefficients first and then extracts extension-band transform coefficients having a large amplitude by using the threshold. If the number of extracted extension-band transform coefficients is less than a predetermined number, the coding apparatus determines how much the threshold is lowered in accordance with the shortage number of transform coefficients and updates the threshold. The coding apparatus repeats the update of the threshold and the extraction of extension-band transform coefficients until the number of extracted extension-band transform coefficients reaches the predetermined number. Thus, the coding apparatus can extract a required number of transform coefficients representative of the features of au extension band with a smaller amount of calculation. In other words, the amount of calculation for extracting transform coefficients can be reduced significantly by reducing the number of loops required to extract a predetermined number N of extension-band transform coefficients.
[0071] The coding apparatus according to the present embodiment sets the threshold such that the number of the first extracted extension-band transform coefficients is less than the predetermined number. The coding apparatus updates the threshold in accordance with how many more extension-band transform coefficients have to be extracted to obtain a predetermined number of extension-band transform coefficients, and adds extension-band transform coefficients extracted by using the updated threshold to a group of extension-band transform coefficients extracted by using the threshold before the update. The coding apparatus stops the extraction processing once the number of extension-band transform coefficients extracted during the extraction processing reaches the predetermined number. This extraction processing of extension-band transform coefficients can reliably extract extension-band transform coefficients having a large amplitude.
[0072] The coding apparatus according to the present embodiment may limit the number of times the threshold is updated to a fixed number and stop the extraction processing if the number of times the threshold is updated reaches the limit (fixed number). This can further reduce the amount of calculation in the worst case.
[0073] A decoding apparatus according to the present embodiment will be described next. FIG. 5 is a block diagram that illustrates a configuration of the decoding apparatus according to the present embodiment.
[0074] Decoding apparatus 20 mainly includes demultiplexing section 5 , core decoding section 6 , extension-band decoding section 7 , and frequency-time transform section 8 .
[0075] Demultiplexing section 5 receives encoded data outputted by coding apparatus 10 , splits the encoded data into core encoded data and extension-band encoded data, outputs the core encoded data to core decoding section 6 , and outputs the extension-band encoded data to extension-band decoding section 7 .
[0076] Core decoding section 6 decodes the core encoded data and outputs the resulting core encoded low-band transform coefficients to extension-band decoding section 7 and frequency-time transform section 8 .
[0077] Extension-band decoding section 7 decodes the extension-band encoded data, uses the resulting encoded data and the core encoded low-band transform coefficients to calculate extension-band transform coefficients, and outputs the calculated extension-band transform coefficients to frequency-time transform section 8 . The internal configuration of extension-band decoding section 7 will be described in detail later.
[0078] Frequency-time transform section 8 combines the core encoded low-band transform coefficients and the extension-band transform coefficients to generate decoded transform coefficients, transforms the decoded transform coefficients into the time domain, for example, by an orthogonal transform to generate an output signal, and outputs the output signal.
[0079] The internal configuration of extension-band decoding section 7 will be described in detail next. As illustrated in FIG. 6 , extension-band decoding section 7 mainly includes normalization section 70 and extension-band decoding/generation section 71 .
[0080] Normalization section 70 normalizes the core encoded low-band transform coefficients and outputs the normalized low-band transform coefficients. Normalization section 70 performs the same processing as normalization section 30 illustrated in FIG. 2 and thus is not described in detail.
[0081] Extension-band decoding/generation section 71 generates the extension-band transform coefficients using the normalized low-band transform coefficients and the extension-band encoded data. In particular, extension-band decoding/generation section 71 decodes lag information and a gain from the extension-band encoded data, first. Next, extension-band decoding/generation section 71 copies the normalized low-band transform coefficients to the extension band as a frequency fine structure according to the lag information. Then, extension-band decoding/generation section 71 multiplies the extension-band transform coefficients copied from the normalized low-band transform coefficients by the decoded gain to generate the extension-band transform coefficients.
[0082] The configuration and operation described above allows decoding apparatus 20 according to the present embodiment to decode encoded data generated by coding apparatus 10 .
[0083] The coding apparatus and decoding apparatus according to the present embodiment have been described above. It should be noted that the above description of the present embodiment is an example of implementing the present invention and the present invention is not limited to this example.
[0084] For example, although the present embodiment is described above using an example in which threshold calculation section 32 and representative transform coefficient extraction section 33 operate repeatedly until the number of extracted transform coefficients reaches a required number, the present invention is not limited to this example. Representative transform coefficient extraction section 33 , for example, may determine that the extraction of more transform coefficients is not needed when the extraction is repeated a fixed number of times, and end the extraction processing after outputting the already-extracted representative transform coefficients.
[0085] In the present embodiment above, the calculation of extension-band transform coefficients is described using an example in which the transform coefficient extraction threshold is updated in the same manner in all subbands, but in the present invention, the transform coefficient extraction threshold may be updated to a degree that varies for each subband. For example, the probability of extracting transform coefficients may be reduced in a higher band by setting at least one of a and b in the above equation 4 larger in a higher band. This approach enables further reduction in the amount of calculation by taking advantage of a fact that the fine structure of transform coefficients has smaller impact in a higher band.
[0086] In the present invention, as the number of loops for updating the threshold as described above increases, the threshold may be set in different manners. For example, as the number of loops increases, at least one of a and b in the above equation 4 is decreased to lower the threshold, which allows more transform coefficients to be extracted to reach the predetermined number and solve the shortage of transform coefficients.
[0087] The present embodiment is described above for the case where extension-band transform coefficients are assumed to follow the normal distribution and threshold calculation section 32 illustrated in FIG. 2 calculates the threshold from an absolute-value mean and a standard deviation. In the present invention, however, extension-band transform coefficients may be assumed to follow a distribution other than the normal distribution and the threshold may be set in accordance with the distribution. Moreover, in the present invention, the absolute value of the largest amplitude of transform coefficients included in a subband that is multiplied by a fixed rate less than 1.0 may be used as the threshold.
[0088] Although in the present embodiment, a technique for updating the threshold by threshold calculation section 32 illustrated in FIG. 2 is described, in which the threshold is updated by multiplying the threshold by a suppression coefficient calculated in accordance with the shortage number of transform coefficients, in the present invention, another technique may be used for updating the threshold. For example, the threshold can be updated by subtracting 0.2 from the threshold when the shortage number of transform coefficients is large and subtracting 0.1 from the threshold when the shortage number of transform coefficients is small, or by subtracting 0.5 from β when the shortage number of transform coefficients is large and subtracting 0.1 from β when the shortage number of transform coefficients is small.
[0089] If the number of extracted transform coefficients is more than the predetermined number when representative transform coefficient extraction section 33 illustrated in FIG. 2 performs extraction processing by using the threshold calculated based on extension-band statistical parameters from extension-band analyzing section 31 , representative transform coefficient extraction section 33 may cancel the transform coefficient extraction and issue an instruction back to threshold calculation section 32 to increase the threshold. In this case, threshold calculation section 32 updates the threshold to increase and representative transform coefficient extraction section 33 can perform the extraction processing again by using the updated threshold to extract a predetermined number of or less transform coefficients.
[0090] Although the present embodiment is described above using an example in which threshold calculation section 32 illustrated in FIG. 2 sets a relatively large threshold such that the number of the first extracted transform coefficients is equal to or less than the predetermined number, in the present invention, threshold calculation section 32 may set a threshold such that the number of the first extracted transform coefficients is equal to the predetermined number. In this case, the number of the first extracted transform coefficients may often exceed the predetermined number. In such cases, where the number of extracted transform coefficients exceeds the predetermined number, representative transform coefficient extraction section 33 instructs threshold calculation section 32 to increase the threshold and performs extraction processing again by using the updated threshold. This process is repeated until the number of extracted transform coefficients becomes equal to or less than the predetermined number.
[0091] Although the present embodiment is described above using an example in which a value of correlation between representative transform coefficients among extension-band transform coefficients and normalized low-band transform coefficients is calculated, in the present invention, modified extension-band transform coefficients may be used. For example, extension-band transform coefficients filtered in consideration of influences of auditory masking and the like may be used.
[0092] The present invention is also applicable to cases where a signal processing program is recorded and written to a machine-readable recording medium such as memory, disk, tape, CD, and DVD, and is operated, and operations and effects similar to those in each of the above-mentioned embodiments can be obtained in this case.
[0093] Also, although cases have been described with the above embodiment as examples where the present invention is configured by hardware, the present invention can also be implemented by software.
[0094] Each function block employed in the description of the aforementioned embodiment may typically be implemented as an LSI constituted by an integrated circuit. These functional blocks may be individual chips or partially or totally contained on a single chip. “LSI” is adopted here but this may also be referred to as “IC,” “system LSI,” “super LSI,” or “ultra LSI” depending on differing extents of integration.
[0095] Further, the method of circuit integration is not limited to LSI, and implementation using dedicated circuitry or general purpose processors is also possible. After LSI manufacture, utilization of a programmable FPGA (Field Programmable Gate Array) or a reconfigurable processor where connections and settings of circuit cells within an LSI can be reconfigured is also possible.
[0096] Further, if integrated circuit technology comes out to replace LSI as a result of the advancement of semiconductor technology or a technology derivative of semiconductor technology, it is naturally also possible to carry out function block integration using this technology. Application of biotechnology is also possible.
[0097] The disclosure of Japanese Patent Application No. 2011-237818, filed on Oct. 28, 2011, including the specification, drawings, and abstract, is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
[0098] The coding apparatus according to the present invention is suitable for encoding sound-related data such as speech data, music data, and audio data.
REFERENCE SIGNS LIST
[0000]
1 Time-frequency transform section
2 Core coding section
3 Extension-band coding section
4 Multiplexing section
5 Demultiplexing section
6 Core decoding section
7 Extension-band decoding section
8 Frequency-time transform section
10 Coding apparatus
20 Decoding apparatus
30 Normalization section
31 Extension-band analyzing section
32 Threshold calculation section
33 Representative transform coefficient extraction section
34 Matching section
35 Extension-band generation/coding section
70 Normalization section
71 Extension-band decoding/generation section | Provided is an encoding apparatus. A threshold value calculating unit ( 32 ) calculates a threshold value from a statistical amount of conversion factors of an extended band. A representative conversion factor extracting unit ( 33 ) uses the calculated threshold value to extract conversion factors having large amplitudes. If the number of extracted conversion factors does not reach a specified number, the threshold value calculating unit ( 32 ) determines, in accordance with a lacking number of conversion factors, an amount by which the threshold value should be lowered, and modifies the threshold value accordingly. The representative conversion factor extracting unit ( 33 ) uses the threshold value, which has been modified, to extract conversion factors. Such threshold value modification by the threshold value difference calculating unit ( 32 ) and such conversion factor extraction by the representative conversion factor extracting unit ( 33 ) are repeated until the number of extracted conversion factors reaches the specified number. | 6 |
BACKROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a reversible combination cutting and ironing board, and more particularly, pertains to a turntable structure incorporating a disk-shaped plate having a cutting surface on one side thereof, and a second disk-shaped plate forming an ironing board on the opposite side, which are rotatable about a transverse center axis relative to each other.
[0003] In the field of quilting wherein numerous and the most diverse types of designs and patterns are employed for the purpose of forming quilts of the most decorative natures, pieces of fabric are cut into appropriate sections or squares by employing templates which are maintained in position on the fabric, the latter of which is positioned on a mat or planar cutting surface. Heretofore, in order to provide the appropriate sections of fabric being cut with a high degree of accuracy, through the intermediary of templates and the application of cutting tools while positioned on a mat, it has been the norm to turn the template and the material on the supporting mat or surface which is not only inconvenient fort he cutting person, but frequently causes some slippage of the templates and fabric relative to each other so as to render the entire procedure rather inaccurate and difficult to implement.
[0004] In order to improve upon the foregoing fabric cutting procedure, in recent years the present inventor devised a unique structure which combines the accuracy of using templates in the cutting of fabric pieces for quilting with the convenience of rotary cutting on a rotatable turntable possessing a planar self-healing cutting surface, thereby enhancing accuracy in cutting an comfort to user in being able to avoid the repositioning of the fabric and template during cutting. In particular, the rotating turntable was supported on a rotatable ball-bearing structure which, in turn, was adapted to be positioned on a suitable support surface, and thereby facilitating turning of the cutting surface of the rotating turntable through any angle of rotation about a central axis to render easier the cutting of the fabric without any slippage or misdirected cuts inasmuch as the necessity of having to shift or move the fabric and template relative to its supporting mat or cutting surface was essentially eliminated. This particular rotating turntable having the plate possessing the cutting surface mounted on a rotational ball-bearing base have been copyrighted by the present inventor under the name “Brooklyn Revolver” by Come Quilt With Me Inc., and is an extremely useful tool in enabling an easy and accurate cutting all sides of fabric below the template, while being of a light weight and portable construction.
[0005] Although the foregoing revolving turntable having the planar cutting surface clearly and dramatically improved upon the usually rectangular and non-rotatable cutting boards or mats employed for quilting or similar trimming and fabric cutting operations, subsequent to cutting the individual pieces of fabric, these generally required ironing on a separate ironing surface prior to further processing into quilts or other kinds of fabric arrangements.
[0006] In order to solve the problem of having separate fabric cutting surfaces and ironing or pressing stations utilized in forming the fabric material pieces, there have been developed portable cutting and ironing or pressing units which combine both units into a single interconnected or integrated physical structure.
[0007] 2. Discussion of the Prior Art
[0008] In particular, reference is made to Ziegler, U.S. Design Pat. No. 333,540, which discloses a combination cutting and ironing board consisting of a rectangular, laminated plate structure of which one external side is a rigid cutting surface adapted for cutting fabrics through the intermediary of a template and a rotary or linear cutter, and wherein the other opposite external side of the laminated structure has a surface which includes an ironing board-type cover of material and whereby, upon reversing the position of the board subsequent to cutting the fabric material, the material may then be ironed on the opposite surface. The entire structure is portable and may be carried by means of a handle which is attached to one edge of the board.
[0009] Pursuant to another structure, there is described a foldable device called “The FoldAway”, produced by the Omnigrid Company of Spartanburg, S.C., in which a rectangular board has a grided mat adapted for cutting fabrics, such as by means of a rotary cutter and a template, and wherein etched along a fold line is a second surface which can be employed as an ironing board or pressing surface. The entire structure can be folded together and includes a handle carrying the arrangement in a compact manner. Also known are so-called “Rotary Cutting Mats” which are laminated plates manufactured by June Tailor of Richfield, Wis. wherein a first rectangular plate having a carrying handle at one end thereof has a cutting surface on one side, and is laminated to a plate with an ironing or pressing surface on the opposite side thereof. This structure is designated as a so-called rotary cutting mat due to its being reversible between one side and the other for selectively either cutting or pressing utilizations implemented on fabric pieces.
[0010] Although the foregoing structures each incorporate surfaces for cutting and further surfaces for pressing or ironing, these structures are essentially rectangular boards which are not adapted to provide for the advantages of the rotating turntable as designed by the present inventor.
SUMMARY OF THE INVENTION
[0011] Accordingly, in order to further improve upon the technology in a novel and unique manner, pursuant to the present invention there is provided a reversible combined cutting and ironing board in the nature of a turntable, in which a disk-shaped plate having a cutting surface is supported for relative rotation on a ball-bearing arrangement, and wherein the opposite or distal side of the ball bearing arrangement provides for a spacer mounting a second disk-shaped plate of essentially the same size as the cutting plate is fastened to the ball bearing arrangement and is rotatable relative to the cutting plate about a central transverse axis. An ironing board cover may be mounted on the exterior surface of the second plate so as to provide for an ironing surface on the inverted side of the rotatable turntable structure opposite to the orientation of the cutting surface, but extending in parallel therewith.
[0012] In particular, the ironing board surface or cover on the second plate may be located on a horizontal support surface while the upwardly facing surface of the cutting plate is employed in a rotatable manner for cutting fabric sections by means of a template and a suitable cutting tool, such as a rotary cutter as is well known in the art, and as is disclosed in the structure of the present inventor's “Brooklyn Revolver” turntable as discussed hereinbefore.
[0013] Thereafter, it is a relatively simple matter for a user to invert the entire assembly so that the cutting plate now forms the bottom surface which rests on a support surface, and the ironing board surface is oriented upwardly so as to enable the previously cut fabric sections or pieces to be ironed, while the ironing board is rotatable relative to the cutting plate which is supported therebeneath.
[0014] In order to implement the foregoing, the entire structure is constituted of relatively inexpensive and dependable components imbued with lengthy service lives, most of which are essentially of plastic material construction, and wherein the disk-shaped elements which are rotatable relative to each other are of essentially light weight and sturdy construction so as to afford all of the advantages of the above described “Brooklyn Revolver” structure as designed and commercialized by the present inventor, while incorporating the advantage pursuant to the present invention of providing a further plate structure which is rotatable with regard to the cutting plate and is adapted to mount an ironing board cover to thereby enable the ironing of cut fabric pieces without difficulty upon the entire structure simply being inverted. To that effect, the entire structure is provided primarily by components consisting of a first plate arrangement having a planar cutting surface and which is essentially a turntable or disk-shape, and including a parallel spaced disk-shaped second plate which is connected to the first plate by means of a ball-bearing assembly to enable relative rotation between the two plate structures, and wherein the second plate is adapted to mount an ironing board cover so as to form an ironing surface on the opposite side of structure from that of the cutting plate surface.
OBJECTS OF THE INVENTION
[0015] Accordingly, it is a primary object of the present invention to provide a novel reversible combined cutting and ironing board.
[0016] Another more specific object of the present invention is to provide for a novel independently rotatable cutting board and ironing board structure, wherein a pair of parallel spaced rotatable disk-shaped plate members has one of the pate members equipped with a cutting surface, and the other plate member equipped with an ironing surface, and which are adapted to be inverted relative to each other so as to be utilized selectively as a cutting board and in the inverted position as an ironing board for fabric pieces which have previously been cut on the cutting surface.
[0017] Yet another object of the present invention is to provide a rotatable turntable structure comprising a combined cutting plate and an ironing board which are rotatable relative to each other so as to enable the cutting of fabric without having to move the template on the cutting surface and thereafter to be able, upon inverting the structure, iron the cut fabric pieces on the ironing board in a readily and easily accessible manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Reference may now be made to the following detailed description of a preferred embodiment of the invention, taken in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 illustrates a side view of the reversible turntable comprising the combined rotatable cutting and ironing board pursuant to the invention;
[0020] FIG. 2 illustrates an exploded side view thereof, taken along line 2 - 2 of FIG. 1 , generally diagrammatically representing details of the internal structure of the turntable structure;
[0021] FIG. 3 illustrates a plan view showing the cutting mat or surface;
[0022] FIG. 4 illustrates a sectional view taken along FIG. 4-4 in FIG. 2 ; and
[0023] FIG. 5 illustrates a plan view of the ironing board surface.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring in detail to the drawings, particularly FIG. 1 , there is illustrated a turntable assembly 10 constituted of a circular disk member 12 having a cutting surface 14 as also shown in FIG. 3 of the drawings, and which is constituted of a die cut and hot stamp decorated top cutting board of a rigid plastic material. The cutting surface 14 may be of a so-called “self-healing nature” when subjected to cutting action.
[0025] Laminated thereto is a stock race assembly 16 comprising a disk-shaped plate member 17 of rigid plastic, which is attached to the opposite surface 14 a of member 12 by gluing as is well known in the art, and which on the opposite side thereof has a grommet and sleeve member 19 rotatably connected to a stock race unit 18 constituted of plastic material. As shown in FIG. 2 , in the exploded transverse sectional view thereof, taken along line 2 - 2 in FIG. 2 , the stock race includes a first member 20 of a molded plastic ring-shaped configuration, having an annular raised portion 22 adapted to receive a series of annularly spaced ball bearings 24 housed in a plastic cage structure 26 which is fully rotatable about a central axis 27 .
[0026] This arrangement, in effect, causes the top member 12 having the cutting surface 14 to be equipped with a rotatable stock race configuration, essentially analogous with that provided for in the “Brooklyn Revolver” rotating turntable structure, as set forth hereinabove.
[0027] Pursuant to the present invention, there is provided a vacuum formed spacer 34 which is essentially a ring shaped disk member having a circular central opening 34 a outwardly about the stock race structure 20 and including an annular raised flange 36 , the bottom surface thereof facing towards plate 17 being glued thereto. This particular spacer ring 34 is a vacuum-formed plastic member, and an annular raised surface 38 is adapted to have a further annular disk or plate member 40 loosely supported thereon. The plate member 40 is an essentially acrylic material disk of a diameter analogous to that of plate structure 12 and has the inner radial portion glued to the stock race raised surface 22 so as to be rotatable therewith. The outer surface of plate member 40 is adapted to be covered by an ironing board cover 42 having an annular elastic band 44 extending thereabout so as to be able to be snapped over the plate 40 , and thereby provide an ironing surface 46 , as is shown in FIG. 5 of the drawings.
[0028] Basically, the connection of the plate 40 to the stock race assembly or ring member 20 enables them to be rotatable in conjunction with each other, and also rotatable relative to the ball bearing race which is fastened to the lower surface of plate 17 . Consequently, both the plate structure 12 and the plate 40 mounting the ironing board cover 42 are rotatable relative to each other about their common central axis.
[0029] In essence, during use as a cutting board for the segmenting or cutting of fabric pieces, the ironing board cover as is positioned in stationary relationship facing downwardly on a support surface (not shown) so as to enable the upper cutting surface 14 to rotate during use. The ironing board cover provides adequate friction to prevent the entire arrangement 10 from sliding about the support surface.
[0030] When it is desired to employ the arrangement 10 as an ironing board, it is merely necessary to invert the entire structure so as to have the surface 14 facing downwardly so as to be supported on the previously mentioned support surface and the ironing board 42 now faces upwardly to enable the fabric to be ironed. The pressure of the iron is adequate to prevent slipping between the support surface and the smooth surface of the plate 12 , while permitting rotation of the upper ironing board structure 40 , 42 relative to the cutting member during ironing, as may be desired by a user.
[0031] From the foregoing it thus clearly appears that the entire arrangement is of an essentially simple inexpensive and portable nature constituted primarily of readily molded or stamped plastic components, which are attached to each other. Furthermore, although described as being a circular turntable, the cutting and ironing plate members thereof may be of polygonally-sided configurations, such as squares, hexagons, or the like. | A reversible combination cutting and ironing board, and more particularly, pertains to a turntable structure incorporating a disk-shaped plate having a cutting surface on one side thereof, and a second disk-shaped plate forming an ironing board on the opposite side, which are rotatable about a transverse center axis relative to each other. | 3 |
TECHNICAL FIELD
The present application is a continuation-in-part of patent application Ser. No. 164,281, filed June 30, 1980, now abandoned.
This invention relates to a safety circuit for an extensible crane boom of the type which may be rotated between a horizontal and a vertical position and used as a personal lifting device. The safety circuit provides cutout functions which inhibit boom extension or rotation which would cause the boom moment about a pivot point to exceed precalculated safe load levels. The circuit includes solid state logic adapted to process electrical step functions related to boom length and boom angle.
BACKGROUND OF PRIOR ART
The use of safety circuits to prevent overloading an extensible boom crane and thus damaging the boom or causing the device to topple are well known in the art, but of the multitude of devices, all incorporate compromises which result in significant shortcomings in the applied systems.
The prior art safety devices may be grouped in two broad categories, one category which comprises those systems which prevent an operator from extending or lowering a boom into a region of unsafe operation and a second type which provides an alarm to warn an operator of an impending disaster such as crushing the boom or tipping the crane.
R. Sterner, U.S. Pat. No. 3,641,551 on "Safe Load Control System For Telescopic Crane Booms" issued Feb. 8, 1972 is typical of the first type of safety systems which include both an overload prevention and an indicator system. These devices typically include an electrical circuit responsive to a first electrical network which changes as a function of boom length and a second electrical circuit which changes as a function of boom angle for providing a warning indication and inhibiting the operation of a hydraulic boom drive means.
The safety control systems such as found in Sterner include series circuits comprised of a large number of electrical contacts that are subject to contamination and failure. A malfunction of the system can lead to an inoperative boom in one failure mode or a short circuited, bypassed safety system in a second failure mode which would allow an operator unknowingly to exceed safe limits of his device.
C. Kezer et al, in U.S. Pat. No. 3,740,534 on "Warning System For Load Handling Equipment" issued June 19, 1973 is exemplary of systems adapted primarily to provide an operator with a warning that continued operation will be hazardous and may result in a catastrophic failure. Systems such as this do not provide a system inhibit function such as provided by the Sterner type systems discussed above and thus do not provide the safety feature of a system capable of overriding the actions of an imprudent operator. Kezer et al illustrates the current trend of replacing electro-mechanical control systems with electronic logic systems. However, the advances in this phase of the art have been relatively complex and incorporate extensive electronic systems which are costly to manufacture and subject to a high failure rate due to the large number of interdependent circuits.
OBJECTIVES OF THE INVENTION
Therefore, it is a primary objective of the present invention to provide a safety control circuit for a boom actuation system which is comprised of a mixture of electromechanical and solid state logic devices interacting to provide a safer system having a minimum number of electro-mechanical and solid state elements.
A further objective of the present invention is to provide a solid state logic control means responsive to electrical functions representing boom angle and boom length for inhibiting boom extension or boom lowering which would cause the boom to exceed a safe operational envelope.
A still further objective of the present invention is to provide a relatively simple solid state logic system responsive to incremental voltage levels provided by a pendulum potentiometer, and boom length control functions provided by a group of electrical switches which function in a mutually exclusive manner.
Another objective of the present invention is to provide a boom warning system and a safer operator override means which is inexpensive to produce, easy to maintain and relatively safer with respect to the prior art.
A still further objective of the present invention is to monitor the plurality of electromechanical devices for malfunction, and if malfunctioning, to inhibit boom extension and boom lowering.
BRIEF SUMMARY OF THE INVENTION
The boom safety control system disclosed herein includes integrated NAND logic circuits which provide a warning indication and inhibit the boom extension function or boom lowering function when the boom has reached a predetermined position within a prescribed safe operational envelope.
Boom angle data is provided to the logic circuit via a stepping comparator which provides a boom angle pulse coded word. The stepping comparator compares adjustable limit values with stepped voltages provided by a pendulum potentiometer driven by the boom. Boom length or extension data is provided to the logic circuitry in the form of a code word generated by a plurality of switches responsive to boom position and adapted to close in a mutually exclusive fashion.
The boom length coded word or expression is combined with the coded word or expression generated by the boom angle stepped comparator in two separate logic systems which inhibit boom lowering or boom extension if safe limits will be exceeded.
A monitoring circuit examines the coded word indicative of boom length to determine whether any of the plurality of switches is malfunctioning and, if so, for inhibiting boom extension and lowering. An override switch is operator actuable to permit boom lowering even if one or more of the plurality of switches is malfunctioning.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the principle components of the described safety system.
FIG. 2 is a schematic diagram of the boom angle stepped comparator and boom angle word generating circuit.
FIG. 3 is a schematic diagram of the boom length sensing means and boom length word generating circuit.
FIG. 4 is a schematic diagram of the boom extension inhibit logic circuit.
FIG. 5 is a schematic diagram of the boom down inhibit logic circuit.
FIG. 6 is a graphic illustration of the boom safe operational envelope.
FIG. 7 is a schematic diagram of the boom length word generator monitoring circuit.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram depicting the basic functional elements of the present invention.
The boom angle word generator, 20, produces a coded word or expression comprised of high and low voltage levels across a plurality of parallel conductors 11 which are branched and applied to both the boom angle logic circuit 40 and boom length logic circuit 50.
The boom length word generator 30 produces a coded word or expression comprised of high and low voltage levels across a plurality of conductors 12 which are branched and applied to both the boom angle logic circuit 40 and boom length logic circuit 50.
Further, the output of the boom length word generator 30 is applied to a monitoring circuit 60, as will be explained in detail with respect to FIG. 7. The monitoring circuit 60 determines whether the generator 30 and in particular a series of switches, as will be explained with respect to FIG. 3, are operative or malfunctioning; if malfunctioning, the monitoring circuit 60 generates and applies a pair of inhibit signals NTELEINH and NLIFDNINH to amplifiers 13 and 16 to respectively inhibit the extension and lowerin of the boom. The boom angle logic circuit 40 and the boom length logic circuit 50 are each coupled to the monitoring circuit 60 and normally actuate the monitoring circuit 60 to render each of the signals NTELEINH and NLIFDNINH signals high whereby the amplifiers 13 and 16 are enabled to permit, respectively, the extension and lowering of the boom. However, when the boom angle logic circuit 40 determines from its inputs that it is unsafe to lower the boom due to its length, the circuit 40 actuates the monitoring circuit 60 to dispose the NLIFDNINH signal low or to a zero level to inhibit the operation of the amplifier 16. In a similar matter, if the boom angle logic circuit 40 determines that it is unsafe to extend the length of the boom, the monitoring circuit 60 is actuated to dispose the NTELEINH signal low thus defeating the operation of the amplifier 13. Further, the monitoring circuit 60 includes an override switch 744, as will be explained with respect to FIG. 7, that may be closed to override the inhibit signal NLIFDNINH forcing it to its high state to permit energization of the amplifier 16 and the lowering of the boom.
In particular, the amplifier 13 functions as a solenoid driver which energizes the hydraulic control valve 14 for the boom extension hydraulic circuit in response to a high voltage level applied to the input to amplifier 13 via the boom extension switch 15. However, if the boom angle logic circuit 40 determines that it is unsafe to extend the boom, the output of the logic circuit drops to 0 and amplifier 13 is inhibited. Thus depression of the boom extension switch 15 will not cause solenoid coil 14 to open the hydraulic valve permitting boom extension. Thus the control circuit includes a safer feature wherein failure of the logic circuit will inhibit operation of the boom extension mechanism.
The boom down circuit comprised of amplifier 16, solenoid 17 and boom down switch 18 functions in a manner similar to the boom extension circuit discussed above. A high signal NLIFDNINH biases the amplifier 16 so that it will conduct if a positive potential is applied to the input. The boom down switch 18 provides the required positive input when the operator selects boom down functions. The solenoid coil 17 is energized and the boom down hydraulic valve of the system is activated. On the other hand, if the NLIFDNINH signal is low, the depression of the down switch 18 will not energize solenoid coil 17 and the boom cannot be lowered until such time that the boom length is reduced to a safe value.
It should be understood that the above discussion is directed to a preferred embodiment utilizing hydraulic actuators for boom extension and boom lift/down functions. However, it is within the scope of this invention to use pneumatic, electrical, or other means controlled by amplifiers 13 and 16 to drive the boom.
FIG. 2 discloses in detail a schematic of the boom angle stepped comparator and boom angle word generating circuit identified in the block diagram of FIG. 1 as the boom angle word generator 20.
The circuit of FIG. 2 includes a type LM340-8 voltage regulator 201 which receives an input of 14 volts DC and provides a regulated 8 volts DC output. The 8 volt output is applied to pendulum potentiometer 202 which has 6 contact pads that are sequentially swepted by a contact arm mechanically coupled to the boom. The pendulum potentiometer functions as a voltage divider network with the 6 contact pads and contact arm dimensioned such that the voltage level delivered to the sweeping contact arm is a function of a specific boom angle range as indicated in the table below.
______________________________________BOOM ANGLE VOLTAGE CONTACT PAD______________________________________ 0° 0.5 volts a16° 1.77 volts b32° 3.04 volts c39° 3.60 volts d50° 4.47 volts e59° 5.19 volts f______________________________________
The output of voltage regulator 201 is also applied to the parallel voltage divider ladder comprised of potentiometers 203 through 208. Potentiometer 203 is adjusted to provide a voltage level equal to 0.5 volts or the output of contact pad a of pendulum potentiometer 202. In a similar fashion, potentiometers 204 through 208 are adjusted to provide voltage levels corresponding, respectively, to the voltages provided by contact pads b through f of pendulum ppotentiometer 202.
The outputs of potentiometers 203 through 208 are applied via a 47 kilohm resistance to the negative input of operational amplifiers 213 through 218 respectively. A 10 megohm feedback path to the negative input is provided for each of the operational amplifiers and they are adapted to function as comparators. Thus when contact pad a of the pendulum potentiometer 202 is connected via the sweeping contact arm to the positive input bus 219 of comparators 213 through 218, the output of comparator 213 will be a 1 or a high logic level and the outputs of the remaining comparators will be a 0 or a low logic level. As the boom is raised, the sweeping arm of pendulum potentiometer 202 contacts pad b and 1.30 volts is applied to bus 219. This causes the outputs of comparators 213 and 214 to become high and the remaining comparators to remain at 0. Thus as the boom is raised, the outputs of the parallel comparators 213 through 218 sequentially step to provide a digital word across the parallel outputs which begins as 100000 when the sweeping arm of pendulum potentiometer 202 reaches contact pad a and progresses to 111111 as the arm reaches pad f.
Inverters 223 through 228 are inverting amplifiers of the type CD4049C in a preferred embodiment. These amplifiers are associated with comparators 213 through 218 respectively and in response to a comparator providing a hight voltage level output, cause light emitting diodes 233 to 238 to sequentially become illuminated as a function of the sequential activation or conduction of the comparators. The light emitting diodes may be a type MV5153 which when connected to the unregulated system power source through 1 kilohm resistors will create a light indication of boom angle.
The boom length word generator 30 of FIG. 1 is illustrated in detail in FIG. 3 of the boom length sensing means and boom length word generator circuit. The boom length sensing means is comprised of 7 microswitches 301 through 307 which are single-pole double-throw microswitches adapted to provide either a positive voltage level output or a ground which logically provide either a 1 or 0 output on 7 parallel lines which comprises the boom length word.
Microswitches 301 through 307 are activated by a cam means mounted on the base of the boom and dimensioned to activate the switches sequentially in a mutually exclusive fashion so that only one switch at any given time will be connected to the positive voltage source.
The 7 parallel lines forming the boom length word are connected to light emitting diodes 321 through 327 respectively via inverters 311 through 317 respectively to switches 301 through 307 respectively. Thus only one inverter will provide a negative potential at the cathode of one of the light emitting diodes at any given boom length and the light emitting diode serves as an indication of boom extension. In a preferred embodiment, the inverting amplifiers may be CD4049C amplifiers and the light emitting diodes may be type MV5353.
The parallel output word of the boom length generator is applied to both the boom angle logic circuit 40 and boom length logic circuit 50 of FIG. 1 as is the parallel word output of the boom angle word generator.
The boom extension inhibit logic circuit of FIG. 4 includes the detailed logic schematic of the boom angle logic circuit 40 of FIG. 1. This logic circuit is based upon an 8 input NAND gate 401 which, in a preferred embodiment is a type NM74C30. The 8 input NAND gate is driven by a decoder circuit comprised of six 3 input NAND gates 413 through 428 responsive to the boom angle word, an inverse function of the boom angle word, and the boom length word. The six, 3 input NAND gates are type NM74C10's in a preferred embodiment and NAND gates 413 through 417 respectively receive inverse functions of the boom angle word via inverter amplifier 424 through 428, which in a preferred embodiment may be type NM74C04's. The NAND gates also receive combination functions of the boom length word via OR gates 441 through 445.
NAND gates 401 and 413 through 418 provide a high or 1 output if one or more of the inputs are low or 0. If all inputs are high, the output of the NAND gate will be low. Thus if all inputs to NAND gate 401 are high or 1, the output of the NAND gate will be low or 0.
A 0 output of NAND gate 401 provides a 0 output to inverters 431, 438, and 432 which are type CD4049C inverting amplifiers. When a zero potential is applied to inverter 431, light emitting diode 433 is energized via a 1 kilohm resistor and provides an okay telescope out indication. The light emitting diode 433 may be a type MV5253.
The 0 output of NAND gate 401 is applied to the boom length word generator monitoring circuit 60, which applies a positive, high bias enabling signal to amplifier 13, thus permitting the energization of the boom extension solenoid coil 14 as shown in FIG. 1. The output of NAND gate 401 is also applied to the monitoring circuit 60 as shown in FIG. 7 and in particular via OR gates 770 and 766 to an inverter 768, whose output is the NTELEINH signal applied to the amplifier 13. The output is also applied via an amplification and isolation network to a donot telescope outlight located in a remote control location such as a basket in the end of the boom. The remote isolation network is comprised in a preferred embodiment of a 2N6010 transistor 434 resistively coupled to a 1N914 diode 435 which is coupled via a D41D transistor 436 to the remote location via a fuse 437.
Logically the circuit functions as follows: assume the boom is in its fully retracted position. In this case switch 301 of FIG. 3 is closed and a logic 1 is applied to its output and a logic 0 applied to the outputs of microswitches 302 through 307. Thus the 6 bit word from the boom length word generator to the boom extension logic circuit is comprised of 6 zeros and NAND gates 413 through 418 uniformly provide a 1 output. The 6 high level outputs cause NAND gate 401 to produce a 0 or low level output and the boom extension amplifier is enabled. If the boom is now extended so that microswitch 302 closes, microswitch 301 will open and logic zeros will be applied from the boom length word generator to NAND gates 414 through 418 but a logic 1 will be applied to NAND gate 413.
In the above situation, if the boom is at a 0 angle the boom word will be 100000 with the output of comparator 213 providing the 1 or high level output which is coupled to one input of NAND gate 413. The remaining input to NAND gate 413 is provided by comparator 214. This comparator is producing a 0 logic level but inverter 424 causes the output to assume a high level and thus the three inputs of NAND gate 413 are high. This causes the output of the NAND gate 413 to be low which causes the output of NAND gate 401 to go high and inhibit amplifier 13 of FIG. 1 so that the boom cannot be extended.
However, if the boom is raised so that the sweeping arm of pendulum potentiometer 202 is on the c pad, comparators 213, 214 and 215 will provide a high level output to NAND gates 413, 414 and 415 respectively. NAND gate 413 will be inhibited however by the inverted output of comparator 214 via inverter 424 and NAND gate 414 will be inhibited by the inverted output of comparator 215 via inverter 425. However, the low level output of comparator 216 will be inverted via inverter 426 to provide a second high level input to NAND gate 415. This causes NAND gates 413 through 418 to produce high level outputs so long as the boom limit switch 301 or 302 remain closed. Thus the boom extension solenoid may be activated and the boom lengthened.
When the boom is extended to a point where microswitch 304 closes, the input word from the boom length word generator changes to 0001000 and in combination with the existing angle word causes NAND gate 416 to produce a low level output. This causes NAND gate 401 to produce a high level output and the boom extension system is inhibited as previously explained.
The boom down inhibit logic circuit of FIG. 5 includes the boom length logic 50 of FIG. 1. It is comprised of an 8 input NAND gate 501 which performs a function similar to NAND gate 401 of the boom angle logic circuit.
NAND gate 501 is a type MM74C30 and is controlled by inputs from six 2 input NAND gates 511 through 516 of the type MM74C00. This circuit utilizes a 3 NAND gate tree as opposed to the 2 NAND gate 3 of the boom angle logic circuitry 40 and thus a 1 output of NAND gate 501 provides a logic function which permits boom down activation. For instance, when a 1 or high logic level is available at the output of NAND gate 501, this high is applied through an inverter 532 to one input of a NOR gate 772 as shown in FIG. 7; in turn, the output of the NOR gate 772 is inverted by an inverter 773 and applied to a NOR gate 774 whose output comprises the boom down inhibit signal NLIFDNINH as applied to the amplifier 16 of FIG. 1. If the inhibit signal NLIFDNINH is a high or one, the amplifier 16 is enabled so that the actuation of the down switch 18 energizes the solenoid coil 17 to effect a lowering of the boom as described above.
A high or 1 level at the output of NAND gate 501 is applied through inverters and they provide functions similar to like components in the boom angle logic circuit. For instance, the high level applied to inverter 531 creates a low level at the cathode of light emitting diode 533. This light emitting diode is an MV5253 and the low level signal at its cathode causes it to illuminate and provide an okay lift down indication. The output of inverter 532 is applied to a coupling circuit comprised of transistor 535, isolation diode 536 and transistor 537 which, via a fuse 538 provides an energizing potential to a remote okay lift down indicator. The remote donot lift down indicator may be in a remote facility such as a personal basket at the end of the boom.
As previously stated, NAND gate 501 is controlled by the inputs from six NAND gates, 511 through 516 respectively. These are 2 input NAND gates and NAND gates 511 through 516 receive inputs from signal position functions of the boom angle word directly.
The six input NAND gates 511 through 516 also receive inputs from five additional NAND gates comprised of three 4 input NAND gates 541, 543 and 544 and two 8 input NAND gates 545 and 546.
The 8 input NAND gate 546 is jumpered to function as a 6 input NAND gate similar to NAND gates 401 and 501, and may illustratively take the form of a type MM74C30. NAND gate 545 is a type MM74C30 but is is jumpered to function as a 5 input NAND gate. NAND gates 541, 543 and 544 are 4 input NAND gates of the type MM74C20. NAND gate 541 is jumpered to function as a 2 input NAND gate, NAND gate 543 is jumpered to function as a 3 input NAND gate, and NAND gate 544 functions as a straight 4 input NAND gate. The inputs to NAND gates 541, 543, 544, 545 and 546 are provided by combinations of six of the seven bit positions of the boom length word as generated by microswitches 301 through 306. Thus if switches 301 through 306 are open, and switch 307 is closed, the bit positions of the boom length word applied to the boom length logic circuit are all 0 and inverters 551 through 556 provide high inputs to all inputs to NAND gates 541, 543, 544, 545 and 546.
In the above circumstance, the primary down logic NAND gates comprised of 541, 543, 544, 545 and 546 all provide low level or 0 outputs causing the six intermediate NAND gates 511 through 516 to produce high level outputs which causes NAND gate 501 to produce a low level output and inhibit the boom down amplifier 16. In this situation, the boom is fully extended and elevated to an angle of at least 59°.
With the boom fully extended and in the vertical position, the boom down circuit is thus inhibited. However, the logic 1 from the boom length word and the logic 1 from the boom angle word applied to NAND gate 418 of FIG. 4 cause the output of that NAND gate to be a logic 0 and thus the output of NAND gate 401 is a logic 1 which inhibits the boom extension circuit but it does not inhibit the boom retraction circuit. Therefore, the boom may be retracted and if retracted to a point where switch 306 closes, the resultant logic 1 at the 306 bit position of the boom length word causes the output of inverter 552 to go to 0 or a logic low. This causes NAND gate 546 to produce a 1 output which is applied to NAND gate 516. With the system in the condition as described above, a 1 is also provided to NAND gate 516. This results in a 0 output for NAND gate 516 and it causes the output of NAND gate 501 to go high. This enables boom down amplifier 16 so that the boom down switch 18 can activate solenoid coil 17 to lower the boom until the output of comparator 218 switches from 1 to 0, caused by the wiper arm of the pendulum potentiometer moving from pads e and f to pad d.
The boom cannot be lowered further under these circumstances until the boom length is shortened so that the boom will remain within the boom safe operational envelope of FIG. 6. For instance, if the boom is now shortened so that microswitch 305 is closed and 306 is open, a 0 will be applied to inverter 553 causing NAND gates 546 and 545 to produce high level outputs. Under these conditions, NAND gate 516 will maintain its low level output because the output of comparator 218 is low but the output of comparator 216 is high and thus NAND gate 501 is caused to produce a high level output which again activates the boom down amplifier 16.
The boom safe operational envelope of FIG. 6 includes a plurality of rays from the pivot point which are associated with microswitches 301 through 307 of FIG. 3. The upper ray of the diagram is annotated L1 through L7 to indicate the switch over points from microswitches 301 through 307 as the boom is extended or retracted. For instance, microswitch 301 of FIG. 3 will be closed as long as the boom is shorter than the length indicated between pivot point and L1. When the boom is extended between L1 and L2, microswitch 302 will be closed and all other microswitches will be open. When the boom moves to the segment between L2 and L3, microswitch 303 will close and all other microswitches will be open. In this fashion, microswitches 301 through 307 are sequentially and mutually exclusively turned on as the boom extends so that when the boom reaches the L7 arc of FIG. 6, microswitch 307 is closed.
The rays emanating from the pivot point of FIG. 6 describe arc segments associated with contact pads a through f of the pendulum boom potentiometer 202 of FIG. 2. For instance, when the boom is positioned between the 16° and 32° ray, the contact arm of the potentiometer maintains engagement with the b pad and 1.77 volts are applied to bus 219 of FIG. 2.
The monitoriong circuit 60 for detecting a malfunction within the boom length word generator 30 and in particular for detecting the malfunctioning of any one of the microswitches 301 through 307, as generally shown in FIG. 1, is described in more detail with respect to FIG. 7. More specifically, the monitoring circuit 60 detects whether any two of the microswitches 301 through 307 are closed at the same time or whether none of the microswitches 301 to 307 are activated and, if so malfunctioning provides inhibit signals that permit movement of the boom only in a mode that will serve to increase its stability, i.e., the boom may be only shortened or raised and may not be lowered or extended. However, while the boom is so inhibited from being lowered or extended, it is contemplated that if personnel were disposed within the basket of the boom, there would be no means of permitting the personnel to be brought to the ground. Therefore, the monitoring circuit 60 is provided with an override switch 774 to permit the inhibit signals to be overriden. Thus, it is further necessary to provide circuitry to detect the malfunction of the override switch 774.
As shown in FIG. 7, the monitoring circuit 60 is coupled to receive the outputs g, h, i, j, k, and l as derived from the microswitches 301 through 306, as shown in FIG. 3. If one of the microswitches 301 through 306 is activated or closed, its output signal will be at 12 volts DC and when not activated, its output will be at 0 volts. The output signals are variously connected to a plurality of OR gates 702, 704, 706, 708, 710, 712, 714, and 716, whereby it may be determined whether two of such output signals are present at the same instant. For example, each of the output signals i, j, k, and l are connected to the OR gate 706 which provides an output in response to the detection of any one of the aforementioned output signals to be applied to an input of the OR gate 716, whose other input is in turn connected to receive the output signal h. In turn, the output hl of the OR gate 716 indicating the presence of any one of the output signals h through l is applied to one input of a NAND gate 726, while the other input is derived from the output signal g. NAND gate 726 operates to provide a high output when one or more of its inputs are low or zero volts. Thus, if a one signal is applied to each of the NAND gates 726, as would happen when switch 301 and any of the switches 302 through 306 are closed or activated, a low or zero output is derived from the NAND gate 726, and is in turn applied to an input of a NAND gate 736. As also shown in FIG. 7, a NAND gate 724 is coupled to directly receive the output signal h and the output of OR gate 714 to indicate by its low output, the simultaneous activation of switch 302 and any of the remaining switches. In addition, NAND gates 722,720, and 718 are similarly connected to selected of the OR gates 712, 704, 710, 708, and 702 and indicate, respectively, by each of their low signals of the simultaneous activation of microswitches 303, 304, and 305, and any of the remaining switches. The outputs of each of the NAND gates 724, 722, 720, and 718, along with the output of NAND gate 726, are applied to the inputs of NAND gate 736. Thus, when the output signal TWOSW of NAND gate 736 is zero, the malfunction of two of the microswitches 301 through 306 does not exist; however, when the output signal TWOSW goes high, e.g., is disposed at 12 volts, there is an indication of a malfunction, i.e., simultaneous activation of two of the microswitches 301 through 306. The Boolean expression for the output signal TWOSW of NAND gate 736 is as follows:
L0(L1+L2+L3+L4+L5)+L1(L0+L2+L3+L4+L5)+L2(L0+L1+L3+L4+L5)+L3(L0+L1+L2+L4+L5)+(L4(L0+L1+L2=+L3+L5)=TWOSW
The monitoring circuit 60 of FIG. 7 also detects a malfunction in which none of the microswitches 301 through 306 is activated or closed. To this end, the output signal hl of the OR gate 716 is applied to a first input of an OR gate 728, while the other input receives the output g of the microswitch 301. Thus, if none of the output signals g through l are present, the output of the OR gate 728 will be low. As shown in FIG. 7, the output signal of the OR gate 728 is applied to an inverter 734 whose output is termed NOSW indicating when it is high the absence of any of the output signals g through 1; by contrast, when the output NOSW is low, there is an indication that the malfunction wherein no microswitches 301 through 307 are closed, does not exist. The Boolean expression for the signal NOSW is as follows:
L0·L1·L2·L3·L4·L5=NOSW
The output of the OR gate 738 termed LSFAIL goes high upon the occurrence of either of the TWOSW or NOSW signals and is applied to an inverter 740 to energize a light emitting diode LED 742 indicating the malfunction of the microswitches 301 through 306, i.e., the simultaneous activation or lack of activation of any of these switches.
Thus, if signals NOSW or TWOSW are high, inhibit signals NTELEINH and NLIFDNINH are applied, as shown in FIG. 1 generally, to the amplifiers 13 and 16, respectively, to inhibit the energization of the solenoid coils 14 and 17 thus preventing the activation of the hydraulic valves controlling boom extension and boom lowering. As shown in FIG. 7, a high signal NOSW is applied via OR gates 770 and 766 to inverter 768 which provides a low signal NTELEINH to inhibit boom extension. A high signal TWOSW is applied via OR gates 738 and 772, inverter 773 and OR gate 774 to provide a low signal NLIFDNINH to inhibit boom lowering. Even when a switch malfunction is detected, it is still desired to have the capability of lowering the boom and permitting the personnel carried by the boom's basket to be lowered to the ground. To this end, the override switch 744 is provided as shown in FIG. 7. The override switch 744 provides a first output signal termed ORS. When the switch 744 is closed, the ORS signal is high, e.g., 12 volts, and when the switch 744 is open, the ORS signal is low, e.g. zero volts DC. The second override switch output signal is termed NORS and is disposed high when the switch 744 is not activated and low when the switch 744 is activated. The ORS and NORS signals are monitored by the circuit 60 to determine both the simultaneous presence or absence of these signals. In particular, the NORS signal is applied via a NAND gate 746 acting as inverter to a first input of NAND gate 750, whereas the ORS signal is applied via a NAND gate 748 acting as inverter to the second input of the NAND gate 750. Thus, if each of the ORS and NORS signals is low, i.e., absent, the output of AND gate 750 will be high and is applied to an OR gate 754 which provides a high output signal ORFAIL. Similarly, when the high NORS and ORS signals are applied to the inputs of AND gate 752, it provides a high going signal to the other input of OR gate 754. Thus, if a high signal is applied to either of the inputs of the OR gate 750 indicating the absence or presence of both the ORS and NORS signals, an ORFAIL signal is generated and applied via an inverter 756 to energize a light emitting diode (LED) 758 to indicate the malfunction of the override switch 744. The Boolean expression for the operation of the aforedescribed circuit is as follows:
(ORS·NORS)+(ORS·NORS)=ORFAIL
The operation of the override switch 744 is designed to override the boom down inhibit signal NLIFDNINH only when the boom is fully retracted, i.e., telescoped in, and only the switch 301 is closed. Thus, the closure of the switch 744 will be defeated from overriding the inhibit signal NLIFDNINH if any of the switches 302 through 306 is closed and if any of their output signals h through l is present. To this end, the output hl of the OR gate 71 indicative of the presence of any one of the output signals h through l of the microswitches 302 through 306, is applied to a first input of a NAND gate 730. The ORS signal indicative of the closure of the override switch 744 is applied to the second input of the NAND gate 730. Thus, if both the ORS and hl signals are high, the NAND gate 730 provides a low output to be inverted by an inverter 732 to provide a high OLFAIL signal. The Boolean expression for the aforementioned circuit is as follows:
ORS(L1+L2+L3+L4+L5)=OLFAIL
The monitoring circuit 60 of FIG. 7 generates a low or zero signal NTELEINH to be applied to the amplifier 13 of FIG. 1 to inhibit the telescoping out of the boom as will now be described in more detail. In the presence of any of the high signals, NOSW, OLFAIL, or ORFAIL, a low signal NTELEINH will be generated. As shown in FIG. 7, a high ORFAIL signal is applied via the OR gates 764 and 766 to an inverter 768 which provides the low signal NTELEINH. The high OLFAIL signal is similarly applied via OR gates 764 and 766 to the inverter 768. The high NOSW signal is applied via OR gates 770 and 766 to the inverter 768. Thus, when the NTELEINH signal is low or at zero volts, the extending of or telescoping out of the boom is inhibited whereas when the NTELEINH signal is high, i.e., 12 volts, the boom extension switch 15 may be closed to extend the boom. The Boolean expression for the operation of this circuit is as follows:
NOSW+OLFAIL+ORFAIL=NTELEINH
The monitoring circuit 60, as shown in FIG. 7, senses the presence of a switch malfunction as indicated by high signals NOSW or TWOSW to generate a low or zero signal NLIFDNINH that is applied to the amplifier 16 to inhibit the boom down operation. In particular, the OR gate 738 responds to either of high signals NOSW or TWOSW as applied to its inputs to apply a high LSFAIL signal via OR gate 772 to an inverter 773 whose resultant low signal is applied to the OR gate 774, which provides the low signal NLIFDNINH to inhibit boom down operation.
The inhibit signal NLIFDNINH may be overriden and forced from a low to high state, e.g., to 12 volts, upon the closing of the override switch 744. In particular, the monitoring circuit 60 responds to a malfunction of the microswitches 301 through 306 as indicated by the presence of a high LSFAIL signal and to the successful operation of the override switch 744 as indicated by a low ORFAIL signal, to generate at the output of an AND gate 762 a high ORSG signal. In particular, the LSFAIL signal is applied to one input of the AND gate 762. Further, the low ORFAIL signal from the OR gate 752 is applied via an inverter 759 to a first input of an AND gate 760, while the high ORS signal is applied to the second input of the AND gate 760. Thus, if a high ORS signal is generated by the closure of the override switch 744 and the override 744 is operative as indicated by a low ORFAIL signal, the AND gate 760 applies a high output to the second input of the AND gate 762 which generates and applies a high ORSG signal to an input of the OR gate 774, thus driving the NLIFDNINH signal high and overriding the inhibit signal. The Boolean expression for NLIFDNINH is set out as follows:
LSFAIL+ORSG=NLIFDNINH
Thus, the monitoring circuit 60 operates to sense the malfunction of the limit microswitches 301 to 306, i.e., to detect the absence of actuation of any of or the actuation two or more of these switches. In the presence of such switch malfunctioning, the monitoring circuit 60 applies inhibit signals to each of the amplifier 13 and 16 to respectively inhibit the extension or lowering of the boom. An override switch 744 is provided to permit the lowering of the boom if the boom is fully retracted, thus permitting an operator as carried by the boom's basket to be lowered safely to the ground. Illustratively, the override switch 744 is disposed remotely at the boom's basket.
While preferred embodiments of this invention have been illustrated and described, variations and modifications may be apparent to those skilled in the art. Therefore, I do not wish to be limited thereto and ask that the scope and breadth of this invention be determined from the claims which follow rather than the above description. | A safety circuit for a lifting device extensible boom is presented wherein the boom angle of elevation and boom length are each converted into a parallel coded word. The two coded words, one representing boom angle and the other boom length, are processed in a digital logic network which provides inhibit functions that prevent boom extension or boom lowering when either of the two boom actions will place the boom in a position which will damage the boom or topple the machine. A plurality of switches are associated with the boom to generate and apply the boom length code word to a monitoring circuit, which responds thereto to provide a switch malfunction signal when one of the switches is defective, whereby boom extension or lowering are inhibited. | 1 |
BACKGROUND OF THE INVENTION
The invention described herein relates to a normally-closed two-port directional needle-valve, controlled by solenoid either directly, or indirectly, in which fluid under pressure is able to enter radially and exit axially or, alternatively, enter axially and exit radially.
The singular feature of this valve is embodied in the fact that the needle-obturator draws away from its relative seating to a generous distance--even using a quite low-power magnet and pressurizing fluid to some 400-bar--with the result that flow ports in the valve may range from a diameter of 1 mm for the direct-acting type up to 20 mm and more for piloted versions.
Valves of the type aforesaid in current use make provision, in basic terms, for a movable core able to travel axially and be attracted thus by a fixed core, the assembly formed by the two being ensheathed by a winding through which electric current may pass; the movable core incorporating a needle-type obturator serving to close off a fluid flow-port, and a spring compressed so as to maintain a given distance between the movable core and the fixed core.
In the case of normally-closed valves, this spring will be noticably weak, in that it serves merely to ensure engagement of the needle-obturator in its respective seating. On the other hand, once the same obturator is duly seated it falls under the thrust of fluid pressure, in consequence of which the effort produced by the solenoid must be sufficient to overcome both the strength of the spring and that of the value equivalent to: seating-section area multiplied by fluid pressure. What in fact happens is that the force with which the movable core is attracted by the fixed core becomes inversely proportionate to the distance existing therebetween--hence the maximum force of attraction between the two cores comes about once the movable core lies close as can be to the fixed core, wherefrom it will be clear that if one is seeking libera1 distances on separation, the need automatically arises for solenoids of some considerable power. The drawback thus outlined imposes serious limitations on the use of this type of solenoid valve for flow rate in excess of 15 liters per minute and with fluid pressure higher than 250-bar, in that the use of overlarge solenoid units would create enormous problems with regard to high input current and subsequent overheating of their coils, not to mention greater overall dimensions and the unacceptable cost increase. Another way of tackling the problem is to provide for the needle-obturator's open-stroke being limited to a few tenths of a millimeter (in such a way that the attractive force between fixed core and movable core remains markedly strong, given the closeness of the two)--although here one has other significant disadvantages--viz, considerable loss of fluid energy through choking-up of the outlet port and, worse still, problems in construction arising from extremely tight machining tolerances, perhaps leading to piece-by-piece adjustment of the valve's single components. At all events, one is left with the snag of unobtainable high flow-rates.
The overriding object of the invention described herein is that of allowing for the use of ultra-low power solenoids in conjunction with release-strokes of length such as to put as such as 3 or 3.5 mm between needle and seating upon opening of the obturator, even where fluid being checked might be pressurized to as much as 400-bar. Numerous advantages derive from this combination, amongst which the facility of holding the solenoid on-current for unlimited periods of time by virtue of its low power-consumption; reduced dimensions and significantly lower production costs; more generous machining tolerances, with no need for fine adjustments from valve to valve; handling of much higher flow-rates without significant loss of fluid power.
SUMMARY OF THE INVENTION
The above and other advantages besides are arrived at by the valve to which the invention relates, which is characterized by its comprising:
a needle-obturator capable of axial movement, with respect both to the movable core and valve proper;
reciprocating check-elements located on the needle-obturator and movable core respectively, and designed to effect a reciprocal interception whereby said movable core may carry along said needle-obturator, the reciprocal disposition of said elements being such that the movable core may intercept the obturator on arrival at a given point a short distance from the limit of its electromagnetically-induced travel toward the fixed valve core. The valve further provides for spring means such as will urge said needle-obturator towards its relative seating at the discharge orifice, and further spring means designed to urge the same said needle-obturator causing it to be raised with respect to said movable core--effort produced by the second said spring means being greater than that produced by the first said spring means--unimpeded movement of said needle-obturator being such as will permit a generous further movement upward following arrival of said movable core at the limit of its travel, brought about by electromagnet attraction as aforesaid.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention described herein will emerge more clearly from the detailed description of certain embodiments which follows, these illustrated as strictly unlimitative examples with the aid of the accompanying drawings, in which:
FIG. 1 shows an axial section through the vertical elevation of a first, direct-acting embodiment of the valve described herein;
FIG. 2 and FIG. 3 both show like axial sections of the valve in vertical elevation, in two differing pilot-operated embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment illustrated in FIG. 1 is especially intended for very small flow-rates of around 2 liters per minute, whilst those illustrated in FIGS. 2 and 3 utilizing a pilot--still adopting the same basic valve body as in FIG. 1--are able to offer considerably higher flow capacity (circa 40 lt/min) at fluid pressure in the region of 400-bar. The safe basic group of components seen in FIG. 1 can in fact be used in a whole range of normally-closed pilot-operated solenoid valves increasing in size up to a flow-rate handling capacity of some 300 lt/min. In the case of the embodiment in FIGS. 2 and 3, provision is made for a one-way valve capable of checking flow from the axial duct.
For the sake of convenience, throughout the description and claims which follow, the valves will be referred to as they appear in the drawings, i.e. as having a "top" and "bottom" part in terms of distance and orientation--although it should be made clear at the outset that the valve may well assume a different working position once carried into effect--viz, inclined, horizontal, or even up-turned through 180°.
With reference to FIG. 1: 1 denotes a valve body in which an inlet port 2 for fluid under pressure is located, likewise an outlet port 3 for outflow of the same fluid.
Outlet port 3 gives out from the bottom of a cavity 4 threaded at point 5 and engaging thus with a further body 6, this in its turn exhibiting a cavity 7 narrowing down into the hole denoted by 8 and then widening out into another cavity 9 which duly gives out into cavity 4.
Cavity 7 widens out at 10 and is threaded at 11, engaging thus with a tube 12 in stainless steel or other such non-magnetic material which exhibits a further threaded portion 13. A stem 14, fixed immovably into and forming a tight seal with hole 8, is possessed of an axial duct 15 terminating uppermost in an orifice 16 which offers the seating in which the needle-obturator point 17 is engaged. Stem 14 in fact closes off cavity 7 at the level of hole 8, thus obliging fluid entering through inlet port 2 to travel along cavity 7 itself and flow into section 10, whence it passes through orifice 16 aforesaid and down through duct 15 into cavity 9 before exiting finally by way of outlet port 3.
21 denotes a fixed core made from ferromagnetic material and lodged in the upper region of the cavity afforded by tube 12, where it is made fast to an electromagnetic coil 24 ensheathing said tube 12. 28 denotes a movable core located within tube 12 and occupying the space existing between the upper surface of stem 14 and the lower surface of said fixed core 21, said space affording freedom of axial movement to the movable core 28, which is possessed of a cavity 29 located along its internal axial length so as to accommodate a needle-type obturator 17, the latter having the ability to move with respect to said movable core 28. The lower part of cavity 29 narrows down relatively in section, producing a shoulder 51 in consequence, a matching shoulder 18 being presented thereto by the upper part of said obturator 17. The shoulder denoted 51 is designed to engage shoulder 18 when the movable valve core rises upward in response to the attraction brought about by the fixed core, and these shoulders 51 and 18 constitute first reciprocal check means.
To the top side of shoulder 18 one has a weak coil spring 19 housed in a recess 20 offered by fixed core 21, the latter being threaded at 13 and fitted with a seal 22, a locking ring 23 with outer thread serving to lock the fixed valve core tight once set at the desired adjustment. The solenoid coil itself 24 rests upon body 6 aforementioned and is bolted fast thereto by means of a machine screw 25 tightened into fixed core 21 and at the same time pressing down on a washer 26 holding fast the upper part of said coil 24.
To the lower side of shoulder 18 on obturator 17, one has a compressed coil spring 27 seated in movable core 28, whose natural tendency is to urge obturator 17 upwards. The movable core further comprises a longitudinal hole 30 positioned parallel with cavity 29, which places section 10 in direct communication with section 50 lying between the lower face of fixed core 21 and the upper face of movable core 28. Communication between hole 30 and cavity 29 is brought about by way of a radially-disposed hole 31 located therebetween at a given point below shoulder 51.
Two seals 32 and 33 ensure a fluid-tight fit between valve-body 6 and the outside, and between cavity 4 and the fluid inlet port 2, respectively.
Referring now to FIG. 2: amongst other slight variations here, stem 14 is replaced by a piloted piston-type obturator 34 which slides within cavity 7 whilst creating a tight seal therewith. When obturator 34 is in its lowered position the way is cut off between inlet port 2 and cavity 9, whilst raising of the obturator causes the two to communicate, with fluid passing straight from port 2 into cavity 9 and out through port 3. Obturator 34 has an axial duct 35 terminating uppermost in orifice 36 which duly offers the seat wherein obturator 17 engages by its pin-point. A second duct 38 located in obturator 34 and disposed parallel with hole 35 causes inlet port 2 to communicate direct with section 10, said duct 38 exhibiting a bottleneck portion 37 of diameter marginally less than that presented by orifice 36.
A ball 39 of suitable diameter is lodged in cavity 9 and held thus by means of a holed plate 40, this arrangement allowing the passage of fluid from inlet port 2 to outlet port 3, but not the other way about.
Referring now to FIG. 3, it will be seen that there are two basic differences between this embodiment and that illustrated in FIG. 2.
The first such difference is that provision is made for a pin 44 located within movable core 28 in such a way that, by its making contact with the uppermost surface of shoulder 18, the upward stroke of obturator 17 becomes limited with respect to said movable core 28. The distance between pin 44 and shoulder 51 is greater than the depth of shoulder 18 to an extent that obturator 17 is permitted a marked freedom of axial movement with respect to the movable core 28--in other words, the obturator 17 is able to move on upward to a generous degree once movable core 28 itself has been fully attracted by fixed core 21 theretoward by means of electromagnetic excitation (as will be made plain shortly). Spring 19 in FIGS. 1 and 2 is replaced by a spring 42 compressed between the lower face of fixed core 21 and pin 44 and set so as to exert a weak effort designed to urge movable core 28 downward. In place of spring 27 in FIGS. 1 and 2 one has a further spring 43 seated within movable core 28 in such a way as to exert a weak effort serving to raise obturator 17, bringing the latter to bear against pin 44 aforesaid. Shoulder 18 and pin 44 constitute the second reciprocal check means as aforementioned. This variant could equally well be applied to the embodiment illustrated in FIG. 1.
The second difference seen in FIG. 3 is in fact only relevant to the type of valve as shown in FIG. 2. In this case, ball 39 disappears and a smaller ball 45 is inserted into duct 35, the result being that when fluid shapes to pass from duct 35 to orifice 36, the ball comes to rest in a seating located at the point where orifice 36 gives out into duct 35, thus impeding the flow of hydraulic fluid therethrough. In this way, ball 45 performs the function of a small one-way valve serving to check the flow of fluid upward through 35 and 36. Provision is made for a stop-element 46, located in duct 35, by means of which to keep the ball 45 from dropping when fluid either flows downward or is at standstill--at any rate, stop-element 46 does nothing whatsoever to restrict the flow of hydraulic fluid one way or the other.
The application of this second variation in embodiment is quite independent of that of the first variation described.
The valve thus described to which the invention refers functions in the following manner:
Referring to the first embodiment illustrated in FIG. 1, as long as the coil 24 remains disexcited, needle-obturator 17 is maintained in position closing off orifice 16--thanks to the agency of spring 19 which urges down on the top face of shoulder 18 and, more significant yet, by the downward thrust of pressurized fluid which, entering the valve by way of inlet port 2, fills cavity 10 and all parts of the valve-interior communicating therewith by circulating through holes 30 and 31. The distance between the upper face of movable core 28 and the lower face of fixed core 21 (about 3 mm) is at this point a few tenths of a millimeter more than that existing between shoulders 18 and 51. When the coil 24 is excited, movable core 28 is drawn towards fixed core 21, at the outset overcoming the somewhat weak resistance offered by spring 27--remembering that obturator 17 will in practice be subject to a downward thrust being equal to orifice section-area multiplied by fluid-pressure. Thus, in this first instant, only the movable core itself is raised, compressing spring 27 in the event--seeing that the obturator is still urged downward; then, as movable core 28 all but makes contact with fixed core 21, shoulder 51 bears upon obturator-shoulder 18 and draws needle-obturator 17 upwards thus, freeing the passage through orifice 16. Orifice 16 is freed by the obturator, therefore, only when the movable core draws as close as can be to the fixed core--i.e. when attractive force between cores 21 and 28 is notably strong--assisted further by the fact that shoulder 51 comes up against shoulder 18 with a certain amount of kinetic force; hence one is provided with a set of conditions in which it becomes possible to raise the valve-obturator 17, even though subject to a considerable amount of fluid pressure holding it fast in closed position, by means of a relatively low-power coil. Once obturator 17 is in fact clear of the seating in orifice 16, inlet port 2 is placed in communication with outlet port 3 and the obturator surface itself pinned down by the force of fluid under pressure--held in perfect hydrostatic balance, in fact--the result being that lower spring 27, now able to exert a force greater than top spring 19, prevails over the latter and causes the obturator 17 to remain thus raised and clear of its seating for as long as the spring itself 27 remains distended to the full. These being the prevailing conditions in the valve, the flow port created at orifice 16 allows maximum passage-through of fluid, and the latter may pass on from inlet port 2 down to outlet port 3 without any hindrance whatsoever to flow being presented by the point of obturator 17.
Referring now to FIG. 2, the only difference one has is that the obturator, or piloted piston 34 is held fast by fluid pressure from inlet port 2 as long as the solenoid remains disexcited--fluid in this case passing through duct 38 and bottleneck 37, the result being that it is pressed down onto its seating at hole 8--remembering at the same time that needle-obturator 17 inserts to a tight fit within orifice 36 by virtue of the agency of spring 19 whose effect is to bear down simultaneously on both obturator 17 and movable core 28. In this state, fluid entering the valve by way of inlet port 2 is completely checked.
By exciting coil 24, the same chain of events is produced as described formerly for the embodiment in FIG. 1, with obturator 17 disengaging altogether from orifice 36 and section 10 and the rest of the valve-interior becoming de-pressurized by dint of the fact that fluid-power-loss through bottleneck 37 --whose diameter is less than that of orifice 36--creates a marked difference in pressure between inlet port 2 and valve-interior 10. As a result of the difference in section between seating 8 and cavity 7 wherein obturator 34 slides and fits exactly, the latter becomes subject to fluid pressure such as lifts it clear from seating 8 aforesaid. This done, the flow-port created between inlet and outlet ports 2 and 3 is considerable in size, and any loss in fluid power or other passive resistance will be entirely dependent upon the proportions of inlet port 2, seating 8 and the rest of the fluid-line downflow of cavity 9.
The ball 39 rests nicely on its plate 40 and offers no resistance to the fluid's passage--indeed it serves to check the flow of fluid in the reverse direction, should this be a requirement.
Looking now at the first variation as described for the embodiment in FIG. 3, the valve's function differs as a result only inasmuch as, when the solenoid is disexcited, obturator 17 is kept tight in orifice 36 by the agency of spring 42 which urges movable core 28 downwardly, this in turn urging down the obturator-shoulder 18 by way of pin 44 and causing the obturator-point to protrude beyond the lower face of said movable core 28. Thus, with coil 24 and fixed core 21 excited, a first stage sees only the movable core move upward whilst obturator 17 remains thrust against orifice 36 by fluid power, thereby compressing both spring 43 and spring 42 --which in any case offer only limited resistance. Once obturator 17 is in fact separated from its seat in orifice 36 by dint of shoulder 51 coming up against shoulder 18, spring 43 aforesaid proceeds to raise said obturator 17 still further with respect to the movable core--there being no resistance offered by a spring 19 as in FIGS. 1 ahd 2--up to the point where it makes contact with pin 44, thus affording maximum flow-passage possible through orifice 36.
The variation in embodiment described thus renders the obturator's final position opportunely dictated by pin 44 and, moreover, there exists no need for setting up the amount of reciprocal thrust generated by springs 42 and 43 since these operate independently of one another. In effect, one has greater degrees of precision and reliability in operation than with the embodiments illustrated in FIGS. 1 and 2.
It will be clear that this first variant might equally well be applied to the embodiment in FIG. 1.
As far as the second variant in FIG. 3 is concerned, it will be observed that the purpose behind this is one of widening the scope of usefulness with respect to the valve in FIG. 2.
Given the absence of ball 39 from the valve, and fluid directed from port 3 toward port 2, the following occurs: coil 24 being disexcited, obturator 34 is duly raised by fluid pressure alone as a result of the latter being pumped into the valve through cavity 9, and the passage of fluid from port 3 to port 2 is ensured, whilst with coil 24 excited this passage is by no means ensured and the valve's performance is rendered somewhat uncertain in view of the fact that its moving parts become subject to gravitational force (especially obturator 34)--hence its disposition on installation becomes a decisive factor.
On the other hand, the valve as embodied in FIG. 3 not only maintains its normally-closed directional pilot-operated function intact with fluid-flow from port 2 to port 3, it also allows for passage of fluid from port 3 to port 2 when installed any-way-about, and with solenoid excited or otherwise, with no problems whatever of the type aforementioned. If, in fact, fluid is pumped from port 3 toward port 2 then cavity 9 becomes pressurized and, since ball 45 will allow no passage through orifice 36 of fluid, valve-interior 10 is reduced to almost nil-pressure by dint of its communicating with port 2 via duct 38, --thus: the greater degree of pressure at work on the underside of obturator 34 brings about raising thereof and frees the flow-port from 3 to 2 for the hydraulic fluid. When fluid is directed from port 2 to port 3, the valve reverts to its designated normally-closed directional function, and obturator 34 duly checks the flow of fluid as described at the outset.
Attention should be drawn to the unified nature of components described in the specification, and to their extreme simplicity and interchangeability from from one to another of the three embodiments shown. The only change between these three is in fact body portion 6, --in which obturator 34 is interchangeable. Furthermore, differing forms of embodiment can be put together for pilot operation in which hydraulic and electrical parts 25, 26, 23, 21, 22, 19, 24, 17, 27, 42, 43 and 47 in the upper section of the valve may remain unchanged, whilst lower valve-parts may be varied in accordance with the flow-rate required.
Moreover, the valve as described furnishes the singular possibility of putting a generous distance between obturator 17 and its relative seating--even utilizing a lower-power solenoid--notwithstanding the hydraulic circuit being driven at high pressure and producing a markedly fast flow-rate. | The valve described herein comprises a movable core (28) which is drawn toward a fixed core (21) once the valve is opened by excitation of its coil, or solenoid (24). The valve's needle-obturator (17) is capable of moving axially with respect to the movable core (28) but, upon the coil's being excited, remains thrust into the orifice (16) during a first opening stage while the movable core only (28) is caused to rise. Subsequently--once the movable core (28) arrives within a few millimeters of the fixed core--a shoulder (51) offered by the movable core to a shoulder (18) incorporated in the obturator (17) duly makes contact and draws the latter upward, whereupon the action of a spring (27) overcomes such resistance as is offered by a further spring (19) and the obturator itself (17) is raised to a generous distance from its seat in orifice (16) aforesaid. | 5 |
[0001] This invention pertains to the process of taking a variety of organic and non-organic fruits, vegetables and cooked meats, pureed and then frozen in convenient packaging to make a wholesome and convenient food for babies and babies parents.
[0002] Preferably, foods will be purchased from organic certified growers, (but not restricted to) Foods will be prepared within 24 hours of being picked from the farms.
[0003] The process of preparing baby food to be as follows: Wash and rinse food. Some foods will be cooked, by method of boil, bake, steam or any suitable method.
[0004] Foods will then be pureed or softened by hand or machine to obtain the necessary consistancy for appropriate ages of child development. Foods may be strained and water or natural juices may be added.
[0005] Baby food can be packaged individually into single servings for convenient travel use and then frozen directly in its packaging or food items can be frozen into ice-cube like trays where they will be covered and protected from freezer contamination.
[0006] After freezing in trays, food cubes will be removed from trays, then placed in approximately 2 lb. resealable freezer bags. These approximate 2 lb. single or combination flavor bags will be combined with several other single or combination flavor bags to equal an approximate 4-10 lb. bag with a mixed variety of food items.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0007] N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0008] In the 1990's FDA deems frozen fruit and vegetable products to have equivalent or superior nutrient profiles as their fresh counterparts.
[0009] Organic is a labeling term that denotes products produced under the Organic Foods Protection Act. The principal guidelines for organic production are to use materials and practices that enhance ecological balance of natural systems and that integrate the parts of the farming system into an ecological whole.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0010] N/A
BACKGROUND OF THE INVENTION
[0011] This invention pertains to food subject matter. It references pureed organic and non-organic baby foods and frozen foods. The process of individually freezing servings has proven to allow for easy seperation of servings and offer less waste of product. One will be able to take out only what they will expect to consume. For example: a child of 6 months may have a healthier appetite at lunch times and therefore, a parent may wish to thaw 3 cubes for a child's lunch time meal oppose to breakfast time where the child may have a much smaller appetite and only consume two food cubes.
[0012] The process of freezing fresh fruits, vegetables, and meats has been around since the early 1900's. However, pureeing and then freezing is unique to the baby food industry. For many decades baby food has been canned, jarred, bagged and boxed. This process will be highly desirable to parents who may wish to feed their babies whole, pure, nutrient rich baby foods and may not have the time or resources to do so.
[0013] Frozen foods are the height of convenience. By using basic frozen ingredients such as vegetables, fruits and meats, we can help the consumer get a fresh, tasty and nutritious meal to babies and toddlers. Frozen fruits and vegetables are often more nutritious than their counterparts because freezing preserves the majority of nutrients in foods even when frozen for an extended period of time. Freezing prevents food spoilage by inhibiting microorganic and enzyme action and generally involves less loss of taste, flavor, and appearance than do other methods. In the 1990's FDA deems frozen fruit and vegetable products to have equivalent or superior nutrient profiles as their fresh counterparts. According the NPD Group, Inc. the frozen meal category has continued it's steady growth over the past 10 years. Statistics prove the desire, relevance, and need for this product.
[0014] Organic is a labeling term that denotes products produced under the Organic Foods Production Act. The principal guidelines for organic production are to
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] N/A
DETAILED DESCRIPTION OF THE INVENTION
[0016] This invention pertains to frozen human baby food consisting of a variety of organic and non organic fruits, vegetables and cooked meats in their most natural and purest form suitable for human consumption and then freezing to preserve the level of nutrients of raw fruits and vegetable.
[0017] The process of preparing baby food to be as follows: Wash and rinse food. Some foods will be cooked, by method of boil, bake, steam or any suitable method.
[0018] Foods will then be pureed or softened by hand or machine to obtain the necessary consistancy for appropriate ages of child development. Foods may be strained and water or natural juices may be added.
[0019] Baby food can be packaged individually into single serve for convenient travel use and then frozen directly in its packaging or food items can be frozen into ice-cube like trays where they will be covered and protected from freezer contamination.
[0020] After freezing in trays, food cubes will be removed from trays, and then placed in approximately 2 lb. resealable freezer bags or other convenient re-entry packaging. These approximate 2 lb. single flavor bags will be combined with several other single flavor bags to equal an approximate 8-10 lb. bag with a mixed variety of food items. use materials and practices that enhance ecological balance of natural systems and that integrate the parts of the farming system into an ecological whole. Farmers must grow produce for 3 years without the application of synthetic pesticides or chemical. The farm, it's equipment and any processing facilities are all inspected by an independent agent unaffiliated with the grower, the processor and the vender and are then issued certificates from that agency certifying the farms produce as “organic”. Certified Organic produce is not essentially healthier than produce that has been grown under non-organic conditions. The nutritional content of a particular vegetable dose not change but the lack of synthetic pesticidal residues on organically grown produce definitely makes for a safer product.
BRIEF SUMMARY OF THE INVENTION
[0021] This invention pertains to natural organic and non-organic frozen baby food consisting of a variety of organic fruits, vegetables and cooked meats in their most natural and purest form suitable for human consumption. Foods will be pureed (but not limited to) and then frozen to different consistencies, according to the different stages of child development. Portions may be frozen into small portions, individually packaged servings, or ice-cube like form without adding preservatives, additives, or artificial sweeteners. Portions may be stored in large quantity packaging or individually packaged for convenient travel use. | What we claim as our invention is the process of taking organic and non-organic fruits, vegetables, and meats and creating a frozen baby food product with no artificial additives or artificial sweetners. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/367,764, filed Jul. 26, 2010.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to survival and protective gear, and more particularly to a survival gear backpack incorporating ballistic-protective inserts.
[0004] 2. Description of the Related Art
[0005] Recent disasters perpetuated by man (terrorism, nuclear accidents, oil spills, etc.) along with natural disasters (floods, earthquakes, forest fires, etc.) have demonstrated the need for emergency preparedness. Government agencies have been established in many countries to address the need for emergency preparations in the event of one or more of the above-mentioned disasters. One of the many suggested ideas for preparations includes the acquisition of means to personally transport emergency and protective items. During a crisis such needed items as small tools, small firearms, food packets, medical supplies and other emergency, survival equipment must often be carried on ones person. In certain situations it may also be necessary to utilize some form of personal ballistic protection. Thus, a survival gear backpack solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0006] The survival gear backpack is a structure that includes a plurality of storage sections adapted to contain items that would be needed in crisis and non-crisis situations. Varying arrays of fixed and/or removable pockets are disposed in one or more of the storage sections. The backpack also includes pockets that are specifically designed to house ballistic protection inserts. The ballistic-protective inserts are positioned to protect the front, rear and sides of the upper torso. A strap/harness arrangement built within the backpack structure has structural load strengths equal to or exceeding that of rappel harnesses.
[0007] Accordingly, the invention presents a backpack designed to efficiently contain food, water, emergency medical supplies, defensive weapons, tools, etc. that might be needed in survival-type situations. The backpack also provides adequate personal storage volume for use during non-emergency situations. The backpack is designed to provide removable inserts that afford ballistic protection for the full upper torso. The invention provides for improved elements thereof in an arrangement for the purposes described that are inexpensive, dependable and fully effective in accomplishing their intended purposes.
[0008] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an environmental, perspective view of a survival gear backpack according to the present invention.
[0010] FIG. 2 is a front view of a survival gear backpack according to the present invention.
[0011] FIG. 3 is a front view of a survival gear backpack according to the present invention, shown with the front panels unfastened.
[0012] FIG. 4 is a perspective view of a survival gear backpack according to the present invention, showing a removable, side pocket affording ballistic protection.
[0013] FIG. 5 is a perspective view of a survival gear backpack according to the present invention, shown with the internal compartment in an open position.
[0014] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Attention is first directed to FIGS. 1 and 2 of the drawings, wherein the survival gear backpack is generally indicated at 10 . Backpack 10 can be fabricated from any suitable, substantially rugged material (canvas, nylon, etc.) and may be made water-resistant, if desired. The backpack 10 comprises vest-like front panels 12 adapted for positioning at the front torso area of the wearer. A pair of padded, oversized shoulder straps 16 is integral with and extend from front panels 12 . Front securing straps 18 , 19 having respective quick release fasteners 18 a , 19 a are provided to secure panels 18 in a closed position covering the stomach and chest areas of the torso. Securing straps 18 , 19 and shoulder straps 16 are provided with adjustment buckles or the like 20 ( FIG. 2 ) to permit adjustment of the panels 12 on the torso of the wearer or to secure excess webbing. Securing strap 19 is also provided with an adjustment buckle or the like 20 at each side thereof to further secure excess webbing.
[0016] One or more pockets 22 are provided on the front panels to house small emergency items and may include a universal plug-in port therein. As illustrated, each pocket 22 is provided with a slanted entrance to enhance access thereto. It should be recognized, however, that the entrance could assume vertical or horizontal orientation, if desired. The pockets may be provided with a conventional closure (zipper, button, hook-and-loop, etc.), if desired.
[0017] Identical respective harness straps 24 are secured to the outer surface of each front panel 12 . Each strap 24 is provided with a low profile handle portion 24 a to provide means for grasping the backpack. A main storage compartment 30 is securely attached to the front panel, shoulder straps, and harness strap assembly. As more clearly explained below, main compartment 30 includes therein at least one internal secondary compartment and may include a variety of auxiliary pocket arrangements. A conventional zipper 30 a or the like provides access to main compartment 30 . Ancillary compartments 32 are attached to the outer surface of compartment 30 . Compartments 32 can be removably attached to the outer surface in any convenient manner, e.g., hook and loop fasteners. Compartments 32 may house emergency items, including a small firearm.
[0018] As best seen in FIG. 3 , harness-strap webbing structure 24 is built within the backpack and allows the backpack to have the load strengths of rappel harnesses, as mentioned above. An array of attached hardware 26 (D-rings, ladder locks, buckles, etc.) is attached to the harness-strap webbing structure and other parts of the backpack. The hardware 26 is positioned in configurations as desired, and may be employed to attach other emergency items to the backpack. Respective pockets 28 having entrances at 28 a are formed on the inner surface of each panel 12 . Each pocket is adapted to house an insert P (shown in phantom lines) therein. The insert P is constructed from a material, such as Kevlar® (Kevlar is the brand name for a para-aramid synthetic fiber developed at DuPont and utilized as body armor) that offers a degree of ballistic protection for the stomach and chest areas of the torso. The inserts P may be removable from the pockets 28 or permanently secured therein. FIG. 4 discloses the backpack wherein identically configured removable side protective pockets 29 (only one is shown, the other being symmetrical) are utilized to protect the side areas of the torso. Each side pocket 29 is provided with an opening 29 a for receiving and retaining a protective ballistic insert P therein. Each pocket 29 is attached to the backpack via D-rings or by hook-and-loop fasteners or the like.
[0019] As best seen in FIG. 5 , an internal secondary compartment 34 is disposed adjacent main compartment 30 and is isolated therefrom. The secondary compartment 34 is provided with an opening adapted for closure by a conventional closure fastener, such as a zipper or the like. Whereas the main compartment 30 is adapted to house items of ordinary nature, the secondary compartment 34 is adapted to house items 36 that may be specific to emergency/medical/survival scenarios (bandages, water, medicine, etc.). Compartment 34 is configured with an array of fixed and removable pockets and includes hook-and-loop fasteners 38 for securing the items therein, including affixable modular containers or any form of structured storage dedicated for, but not limited to, emergency equipment storage. A ballistic insert is disposed in the secondary compartment behind the hook-and-loop fasteners for protecting the back area of the torso. Alternatively, the ballistic insert may be disposed in the main compartment, if desired.
[0020] It is to be understood that the present invention is not limited to the embodiment described above, but encompasses any and all embodiments within the scope of the following claims. | The survival gear backpack is a backpack having a plurality of internal pockets adapted to contain items that would be needed in crisis situations while maintaining its function as a viable storage vessel for personal items usable in non-crisis situations. The backpack also includes pockets that house ballistic-protective inserts. The pockets and inserts are positioned to protect the front, rear and sides of the upper torso. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This Application is a Continuation-In-Part of U.S. patent application Ser. No. 08/962,099 filed Oct. 31, 1997 now U.S. Pat. No. 6,017,516.
FIELD OF THE INVENTION
The present invention relates to preparation of pharmaceutical dental gel formulation for topical application of metronidazole benzoate and chlorhexidine gluconate and local anesthetic for the treatment of gingivitis and periodontitis.
DESCRIPTION OF THE PRIOR ART
The organism most often encountered in oral infections is viridans streptococci, a verity of anaerobes, and facultative streptococci. Anaerobes isolated from dentoalveolar abscesses were generally susceptible to benzylpenicillin, amoxycillin, erythromycin, clindamycin and metronidazole. Dental caries is caused by the erosion of tooth enamel due to acid produced by bacteria (especially streptococcus mutans) in plaque. Fluoride in various forms is used in dental caries prophylaxis, where it may promote remineralisation or reduce acid production by plaque bacteria. Periodontal diseases encompasses specific conditions affecting the gingiva and the supporting connective tissue and alveolar bone. Gingivitis is thought to be caused by a non-specific bacterial plaque flora that gradually changes from predominantly Gram-positive to more Gram-negative. Gingivitis may or may not develop into periodontitis, but periodontitis is always preceded by gingivitis. Priodontitis is associated with Gram-negative microflora.
Most gingivitis and periodontitis can be prevented and treated by adequate oral hygiene and plaque removal using mechanical means such as toothbrushes. Mechanical removal of calculus is necessary where the build up is significant. Disinfectants and other agents such as cetylpyridinium chloride or chlorhexidine also help to reduce plaque accumulation.
Metronidazole is a 5-nitroimidazole derivative with activity against anaerobic bacteria and protozoa. Its mechanism of action is thought to involve interference with DNA by a metabolite in which the nitro group of metronidazole has been reduced by bacterial nitroreductases to an unstable intermediate, which interacts with DNA, effectively preventing further replication.
Metronidazole is bactericidal. Minimum inhibitory concentration (MIC) for susceptible anaerobic bacteria generally ranges from 0.1 to 8 ugm/ml. It also has activity against the facultative anaerobes Gardnerella vaginalis and Helicobacter pylori and against some spirochetes. Moreover it is active against several protozoa and anaerobic bacteria, including Bacteroides and Clostridium sp. is sensitive in vitro to metronidazole. Metronidazole is also used in the treatment and prophylaxis of anaerobic bacterial infections. Activity of metonidazole against obligate anaerobic bacteria in vitro including the Gram-negative organisms Bacteroides fragilis and other Bacteroides sp., Fusobacterium sp., and Villanelle sp. and the Gram-positive organisms Clostridium difficile, Cl. pergringens.
Metronidazole is administered by mouth in tablets or as metronidazole benzoate, in oral suspension. The tablets are taken with or after food and the suspension is taken at least 1 hr before food. Metronidazole is also given rectally in suppositories, applied topically as a gel, or administered by intravenous infusion of metronidazole or metronidazole hydrochloride.
This gel when applied on the affected part, flows and fills out the gingival pocket after application, thereby comes in contact with the aqueous part of either gingival cravicular fluid or saliva containing esterases which hydrolyse metronidazole benzoate to free active metronidazole which exerts it activity on anaerobic bacteria present it periodontal region.
The long term use of oral metronidazole in chronic condition like periodontal diseases may be associated with certain side effects such as gastro-intestinal disturbances, nausea, an unpleasant metallic taste, anorexia, vomiting, diarrhea, dry mouth, a furried tounge and glossitis. However, to avoid the drawbacks of systemic administration, a dental gel for topical application of metronidazole is desirable in periodontitis.
A dental gel comprising of metronidazole benzoate 25% used for gingivitis and periodontitis, and its topical use seems to be as effective as conventional therapy in the treatment of adult periodontitis. (J. Clin. Periodontal 1992, :19, 715-729). The use of metronidazole benzoate 25% dental gel is associated with a limitation viz. when applied subgingivally, the active drug reaches sulcus for which special injector is required and the procedure is cumbersome and is done by dental surgeon only.
A dental gel comprising of chlorhexidine is also used for gingivitis and prevention of plaque. Chlorhexidine is a bisbiguanide antiseptic and disinfectant effective against a wide range of bacteria, some fungi, and some viruses. It is used in various preparations as the acetate or gluconate commonly with cetrimide, for disinfection of skin, wounds, burns. The dental gel or mouthwash comprising of chlorhexidine may discolour the tounge or teeth. Chlorhexidine is bactericidal or bacteriostatic against a wide range of Gram-positive and Gram-negative bacteria. It is more effective against Gram-positive than Gram-negative bacteria. Chlorhexidine is most active at a neutral or slightly acid pH.
Similarly a dental composition consisting of chlorhexidine gluconate in various strengths of 0.1 to 1% in the form of topical application also used for periodontal diseases (Br. Dental J. 1977, 142, 366-369). Chlorhexidine gluconate is also used in a 1% dental gel and 0.2% mouthwash for the prevention of plaque and the prevention and treatment of gingivitis and in the treatment of oral candidiasis.
Lidocaine is a local anaesthetic of the amide type and is widely used in injection and for local application to mucous membranes. It has rapid onset of action and anesthesia is obtained within a few minutes depending on the site of administration. It has an intermediate duration of action.
Benzocaine is ethyl ester of p-Aminobenzoic acid. It is usually used to relieve pain associated with ulcers, wounds and mucous membrane. Normally it acts only as long as it is in contact with skin or mucosal surface. Peak effect occurs within 1 min after the application and lasts for 36 to 60 min.
Thus taking into consideration the limitation and disadvantages associated with the conventional dental gels, the inventor has come out with a unique dental gel composition comprising of metronidazole benzoate and chlorhexidine gluconate & local anaesthetic in the form of aqueous gel having the effect on aerobic and anaerobic bacteria in periodontal diseases and this combination has been found to be therapeutically better over either metronidazole benzoate or chlorhexidine gluconate individually.
This application is continuation-in-part of the U.S. patent application Ser. No. 08/962,099 filed dated Oct. 31, 1997 claming dental gel comprising of metronidazole benzoate, chlorhexidine gluconate used for gingivitis and periodontitis.
The present application relates to the preparation of dental gel having the same composition as in U.S. patent application Ser. No. 08/962,099 with additional ingredient viz. local anaesthetic. The advantage of local anesthetics is, it reversibly blocks impulse conduction in any part of the nervous system and in all nerves, including sensory, motor and autonomic types, producing a transient loss of sensation in a circumscribed area of the body without causing a general loss of consciousness. This action is used to block the pain sensation to the areas where it is applied, hence it is useful to prevent pain in dental manipulations, injury and diseases.
Accordingly, it is among the objects of the present invention to provide dental gel formulations containing metronidazole benzoate, chlorhexidine gluconate and local anesthetic, which are stable, which may be readily employed without pain and other side effects or other undesirable characteristics.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the pharmaceutical dental gel formulation for topical application in the form of aqueous gel suitable for the treatment of periodontal diseases. The present formulation comprises of Metronidazole benzoate, chlorhexidine gluconate (20% solution), the active ingredient is incorporated in the dental gel formulations of the present invention in an amount of about 0.5 to 3.0% and 0.2 to 2 percent by the weight respectively, preferably from about 1% of active metronidazole and 0.25% active chlorhexidine by weight respectively.
The concentration of local anesthetic, especially lidocaine may fluctuate between 0.5 to 2 weight % in terms of lidocaine hydrochloride. The addition of a local anesthetic is not undesired also for medical reasons, for the prevention of dental pain. Preferred concentration is 0.5%.
Just like the lidocaine most of the local anesthetics are slightly basic substances forming salts with acids such as hydrochloride. The local anesthetics are expediently used in the form of their hydrochloride salt. Local anesthetics of the kind of lidocaine are, in particular, etidocaine, benzocaine. The concentration of benzocaine as a local anesthetic may fluctuate in the range of 1 to 20%, however preferred concentration is 7.5%.
As indicated hereinabove, the medium for the active ingredient comprises a mixture of water and propylene glycol. Propylene glycol concentration fluctuates between 5 to 80%. Preferred concentration is 5% by weight based on the total weight of the said composition. Other medium can be used in this specification refers to Glycerin, Polyethylene glycols, but preferred is propylene glycol.
The carboxyvinyl polymer used, as the gelling agent in the present invention is a hydrophilic polymer obtained by the polymerization of acrylic acid as the principal component. Preferred molecular weight of the polymer is in the range of 4×10 6 . Polymer present in the composition is in the range of 0.2 to 7% by weight based on the total weight of the said composition. Preferred polymer is carbomer 940 in concentration of which better results were obtained is 1.5%. Other polymer used for said gelling agent in the present invention is selected from carbomer 940, carbomer 934, Hydroxypropylmentylcellulose, sodium carboxymethylcellulose.
If the pH of the gel formulation of the present invention is in considerably acidic or basic side then it is desirable to add the pH modifier to the preparation of the present invention to adjust its pH in the range of 4.5-7, preferably 5 to 6. There are no specific limitations as to the kind of the pH modifiers are inorganic pH modifier, e.g. sodium hydroxide or potassium hydroxide. Preferred pH modifier in the present invention is sodium hydroxide solution.
An auxilliary agents used in the present invention is comprised of disodium EDTA, menthol, and sodium saccharine, were added to the gel preparation of this invention. Menthol imparts the cooling effect, EDTA acts as chelating agent and antioxidant, and sodium saccharine gives the sweetness to the dental gel. It is suitably incorporated in an amount of from about 0.025 to 0.5 percent by weight of the preparations.
Chelating agent used in this specification refers to disodium EDTA, Edetic acid, citric acid, Disodium calcium EDTA. Flavouring agent which imparts soothing action refers to menthol, peppermint oil, spearmint oil, Anis oil, clove oil. Sweetening agent here refers to Saccharine sodium, Aspartarnt Dihydrochalcones, D-tryptophan etc.
The present invention will now be further illustrated by, but is by no means limited to, the following examples wherein preferred embodiments of the metronidazole benzoate and chlorhexidine gluconate and local anesthetic containing dental gel preparations are expressed on the weight basis. Those who are skilled at the art can decide the percentage of other/auxilliary agents used to formulate the different example described below.
EXAMPLE 1
Active ingredient
Metronidazole
1.0%
(as Metronidazole benzoate)
Chlorhexidine gluconate
0.25%
(20% solution)
Lidocaine hydrochloride
0.5%
Other agents
Propylene glycol
5.0%
Carbomer 940
1.5%
Disodium EDTA
0.025%
Sodium saccharine
0.1%
Menthol
0.5%
Purified water
q.s.
Sodium hydroxide
pH modifier
Preparation Method:
The gel preparations of the invention can be prepared for example, by initially dissolving menthol in propylene glycol to this solution active metronidazole is added in portion with continuous stirring. Add carboxyvinyl polymer (carbomer 940) in portion with continuous stirring with homoginizer to form gel at 30 to 35° C. To the gel thus obtained is added a separately prepared aqueous solution of disodium EDTA, sodium saccharin, lidocaine hydrochloride and chlorhexidine gluconate with stirring till it dissolve. Further, sodium hydroxide, pH modifier is added to the resulting gel preparation, with stirring, in an amount sufficient to adjust the pH of the resulting gel preparation to about 5 to 6 which will form uniform viscous gel.
EXAMPLE 2
Metronidazole
0.5%
(as Metronidazole benzoate)
Chlorhexidine gluconate
0.2%
(20% solution)
Benzocaine
10%
The same procedure used in Example 1 was repeated, only change is benzocaine was dissolved in glycol medium.
EXAMPLE 3
Metronidazole
1.0%
(as Metronidazole benzoate)
Chlorhexidine gluconate
0.25%
(20% solution)
Benzocaine
7.5%
The same procedure used in Example I were repeated, only change is benzocaine was dissolved in glycol medium.
EXAMPLE 4
Metronidazole
0.5%
(as Metronidazole benzoate)
Chlorhexidine gluconate
2.0%
(20% solution)
Lidocaine hydrochloride
1.0%
The same procedure used in Example 1 was repeated.
EXAMPLE 5
Metronidazole
3.0%
(as Metronidazole benzoate)
Chlorhexidine gluconate
2.0%
(20% solution)
Benzocaine
10.0%
The same procedure used in Example 1 was repeated, only change is benzocaine was dissolved in glycol medium.
EXAMPLE 6
Metronidazole benzoate
2.0%
(as Metronidazole benzoate)
Chlorhexidine gluconate
2.0%
(20% solution)
Lidocaine hydrochloride
1.0%
The same procedure used in Example 1 was repeated.
All the gel preparations hereof has good stability. They do not show any substantial changes in viscosity at little higher temperature or other physical changes.
It is to be understood that the example and embodiments described hereinabove are for the purpose of providing a description of present invention by way of example and are not to be viewed as limiting the present invention in any way. Those who are skilled in the art can make various modifications or changes that may be made to the described invention and are also contemplated by it which can be included within the spirit and purview of this application.
Clinical Trials
To investigate the effectiveness of the present invention in periodontitis and other related diseases like dry sockets and apthous ulcer stomatitis, multicentric controlled clinical trials were carried out at five different centers all over India. Number of patients of different age groups were included in the trial.
These study is not disclosed to the public and the trials were done in confidence. The results of clinical study in India is given below:
1. In this study 50 patients having chronic gingivitis were considered and divided into 2 groups of 25 each. One group receives scaling as a treatment and other group received scaling plus formulation of present invention, twice a day for 2 weeks. On follow-up it was found that patients maintained on scaling plus the formulation of present invention were recovered faster in respect to bleeding on probing and probing pocket depth. The size of the pocket reduced faster with the present formulation as compared to group subjected to scaling. However, there is no feeling of dental pain. This indicates that application of present formulation was found to be superior to scaling alone in chronic gingivitis.
2. 40 patients suffering from acute ulcer gingivitis were included in the trial and they were divided into 2 groups. Group one received chlorhexidine 0.25% gel twice daily and other group received the gel of the present invention twice daily. In both the group through debridment was carried out. The group of the present formulation showed improvement much faster as compared to the group of 0.25% chlorhexidine gel alone. However in both the group gingivectomy was not required, and no complaint of pain was observed. This clearly indicates that present formulation is better choice than chlorhexidine alone.
3. 30 patients suffering from chronic periodontitis were included in the trial and divided into 2 groups of 15 each. One group received scaling and chlorhexidine gel 0.25% as a treatment whereas other group receiving scaling plus the present formulation. The group received gel of the present formulation showed faster improvement in probing pocket depth and bleeding on probing compared to scaling and chlorhexidine and no evidences of the dental pain.
4. Study was carried out on 30 patients undergoing extractions of tooth. They divided into 2 groups of 15 each. One group received the present formulation of dental gel twice daily whereas other group received only analgesic. The group receiving the present composition did not develop any dry socket whereas the group treated with only with analgesic shows dry socket in 4 patients. This clearly indicates the usefulness of the present dental gel formulation and is better than analgesic alone.
5. In this study 20 patients were included suffering from recurrent apthous stomatitis (Ulcer) and divided into 2 groups of 10 each. Group 1 was treated with dental gel formulation of present invention twice daily and other group was treated with analgesic and 0.25% chlorhexidine gluconate gel. The group treated with present formulation showed faster healing of ulcer and relief from pain compared to patients with analgesic and 0.25% chlorhexidine gluconate gel.
6. In this study 30 patients were included suffering from periodontitis were included in the trial and divided into 2 groups of 15 each. One group received scaling and formulation of Lidocaine hydrochloride (2%) and Chlorhexidine gluconate (0.25%) whereas other group receiving scaling plus the present formulation. The group receiving the gel of present invention twice daily showed faster improvement in probing pocket depth and in both the cases there is no evidence of dental pain.
7. Study carried out on 20 patients undergoing extractions of tooth. They divided into 2 groups of 10 each. One group received the formulation of local anesthetic whereas other group received the formulation of the present invention. The group receiving the present formulation did not develop any dry socket as against other group which shows dry socket in 6 patients. This indicates the advantage of the present dental gel.
Above clinical trials confirms the efficacy of the present dental gel formulation of this invention in following conditions like.
a. Chronic gingivitis (Edematous, Hyperplastic and Atrophic)
b. Acute ulcerative gingivitis
c. Chronic periodontitis
d. To prevent post extraction infections (dry socket)
e. In recurrent apthous stomatitis (Ulcer)
f. Dental pain due to infections. | Pharmaceutical dental gel preparation comprising of metronidazole benzoate, chlorhexidine gluconate, and local anesthetic as the active ingredient; glycol as the solvent medium; a carboxyvinyl polymer, cross-linked polymer of acrylic acid copolymerized with polyalkylsucrose as a gelling agent. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a radio frequency signal biasing circuit, particularly but not exclusively to a pull-up circuit for a differential optical device driver.
BACKGROUND OF THE INVENTION
[0002] Optical devices used in optical communications systems are generally driven with electrical signals in order to generate the optical signals. Driver circuits are available that can provide the required electrical signals to drive an optical device such as a laser diode or an external modulator. These optical device driver circuits are often available as integrated circuit (IC) packages, and can be easily incorporated into a driver system design.
[0003] An optical device driver circuit typically provides a modulation current to the optical device that switches the optical device between two or more states in order to convey communication information. The modulation current is typically a radio frequency (RF) signal.
[0004] An optical device driver system can typically provide the modulation current to an optical device either with a “single-ended” drive or a “differential” drive. With a single-ended drive, the modulation current is driven through the optical device in a single direction at different levels. With a differential driver, the modulation current is driven through the optical device in forward and reverse directions, or one output drives the optical device and the other output drives a dummy load. A general advantage of using differential drive is that the optical device can switch between states faster than with a single-ended driver. Differential drive also has the advantage of generating less electromagnetic emission, which means that there is less cross-talk from the transmitter to the receiver, and reduced atmospheric emission (to comply with FCC regulations and industry standards).
[0005] A typical optical device driver circuit for differential drive typically comprises two complementary outputs (often denoted + and −) for driving the modulation current in forward and reverse directions, or for driving an optical device and a dummy load at the same time. The output stage of a typical optical device driver circuit for differential drive usually comprises a pair of transistors, one for each of the complementary outputs. These transistors are often connected in an open-collector configuration or may have a back terminating resistor between the collector and the power supply. In such a configuration, the collector of the output transistor is connected directly to the respective output of the optical device driver. In order for the transistor to operate, the collector connected to the output is biased using a dc voltage. This is achieved using a “pull-up” circuit.
[0006] An optical device driver system 100 with a known pull-up circuit is shown in FIG. 1 . A differential driver circuit 102 (such as a differential driver IC) has complementary inputs 104 , 106 connected via AC-coupling capacitors 108 , 110 . The output stage of the differential driver 102 also receives a DC supply voltage VCC at 112 . The differential driver has two complementary open-collector outputs 114 , 116 . As stated above, these outputs need to be “pulled-up” by the supply voltage VCC, in order to bias the transistors in the output stage of the differential driver 102 . This has been achieved through the use of inductors 118 , 120 , whereby one inductor is connected between one output of the differential driver and VCC, and the other inductor is connected between the other output of the differential driver and VCC.
[0007] The inductors 118 , 120 provide a low impedance path to the DC supply voltage VCC, thereby ensuring that the open-collector outputs of the differential driver are at a voltage close to the DC supply voltage, thereby biasing the output transistors. The inductors 118 , 120 also provide a high impedance to the RF modulation signals from the outputs of the differential driver 102 , and this reduces the amount of RF modulation signal that is undesirably diverted away from the optical device 130 connected to outputs 126 , 128 .
[0008] The outputs 114 , 116 of the differential driver 102 are also connected to AC-coupling capacitors 122 , 124 , which provide a low impedance to the RF modulation signals, allowing the RF modulation signal to pass to the outputs 126 , 128 , for further connection to said optical device, such as a laser diode or an external modulator. The capacitors 122 , 124 also provide a high impedance to DC, thereby preventing the DC voltage provided to the outputs of the differential driver 114 , 116 from the inductors 118 , 120 from entering the outputs 126 , 128 and affecting the rest of the system.
SUMMARY OF THE INVENTION
[0009] It has been observed that there is a problem with this conventional approach to providing a pull-up for an optical device driver. If the modulation signal is a wideband RF signal, then it may comprise a range of frequencies from a relatively low RF component up to a relatively high RF component. In order to provide sufficient impedance to the low frequency RF component, a large value inductor was thought to be required, and large value inductors tend to be of a large physical size. Therefore, whilst using large value inductors can improve the impedance over a relatively wide RF frequency range, to do so is not conducive to reducing the size of the circuit and in particular is not conducive to fitting the circuit on a small printed circuit board (PCB) for, for example, a pluggable optical module.
[0010] It is an aim of the present invention to provide a new type of radio frequency signal device biasing circuit, and in particular it is an aim of the present invention to provide a new type of radio frequency signal device biasing circuit that can provide a good level of performance over a wide frequency range whilst at the same time being suitable for use in small devices.
[0011] It is another aim of the present invention to provide a biasing circuit that is particularly suitable for differential radio frequency signal devices, such as differential optical device drivers.
[0012] According to one aspect of the present invention, there is provided a circuit including a pair of radio frequency signal devices to each of which are connected in parallel a respective input or output and a respective dc bias input device for biasing the respective radio frequency signal device; each dc bias input device including a radio frequency transistor and at least two different types of inductors.
[0013] In one embodiment, the pair of radio frequency signal devices together constitute part of a differential driver.
[0014] In one embodiment, each dc bias input device includes a radio frequency transistor having a F T value greater than or equal to 25 MHz.
[0015] In one embodiment, the at least two types of inductors have different Q factors.
[0016] In one embodiment, said two types of inductors include a coil inductor and a ferrite bead inductor.
[0017] In one embodiment, the two dc bias input devices share a common power supply.
[0018] According to another aspect of the present invention, there is provided a system for producing an optical signal, including a pair of radio frequency signal input devices to each of which are connected in parallel a respective output and a respective dc bias input device for biasing the respective radio frequency signal input device; each dc bias input device including a radio frequency transistor and at least two different types of inductors; and further including an optic device connected to at least one of said outputs.
[0019] In one embodiment, said optic device is connected to both of said outputs.
[0020] In one embodiment, said optic device is connected to only one of said outputs, and a dummy load is connected to another of said outputs.
[0021] In one embodiment, the two radio frequency signal input devices constitute part of a differential driver. Providing two different types of inductors in combination with the radio frequency transistor facilitates the use of a radio frequency transistor having a lower transition frequency, and thereby facilitates the provision of a pull-up circuit displaying substantially identical performance for both differential outputs of the differential driver.
[0022] In one embodiment, the optical device is a laser diode or an external modulator.
[0023] In one embodiment, the two dc bias input devices share a common power supply.
[0024] According to another aspect of the present invention, there is provided a circuit including a radio frequency signal device to which are connected in parallel an input or output and a dc bias input device for biasing the radio frequency signal device:
the dc bias input device including a radio frequency transistor and at least two different types of inductors.
[0026] In one embodiment, the at least two types of inductors include a coil inductor and a ferrite bead inductor.
[0027] In one embodiment, the at least two types of inductors have different Q factors.
[0028] In one embodiment, the circuit further includes a capacitive element connected to said input or output in parallel with the dc bias input device and the radio frequency signal device.
[0029] According to another aspect of the present invention, there is provided a system for producing an optical signal including: a radio frequency signal input device to which are connected in parallel an optical device for producing an optical signal and a dc bias input device for biasing the radio frequency signal input device, the dc bias input device including a radio frequency transistor and at least two different types of inductors.
[0030] In one embodiment, the optical device is a laser diode or an external modulator.
[0031] The radio frequency signal device may, for example, be a device for outputting a radio-frequency signal for driving an optical device, or an optical device for receiving a radio-frequency signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] For a better understanding of the present invention and to show how the same may be put into effect, reference will now be made, by way of example, to the following drawings in which:
[0033] FIG. 1 shows an optical device driver system including a known pull-up circuit;
[0034] FIG. 2 shows a differential optical device driver system including a hybrid pull-up circuit according to an embodiment of the present invention;
[0035] FIG. 3 shows a single-ended optical device driver system including a hybrid pull-up circuit according to another embodiment of the present invention; and
[0036] FIG. 4 shows a differential optical device driver system including a hybrid pull-up circuit according to another embodiment of the present invention, but with the optical device connected to only one of the driver outputs and the other driver output being connected to a dummy load.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] Reference is first made to FIG. 2 , in which is shown an optical device driver system 200 including a hybrid pull-up circuit according to an embodiment of the present invention. The system 200 comprises complementary inputs 104 , 106 connected to a differential driver 102 (which may be a differential driver IC) via AC-coupling capacitors 108 , 110 . The differential driver 102 is connected to a DC voltage supply VCC at 112 . The output stage of the differential driver 102 has two complementary outputs 114 , 116 via which are output the RF modulation signals. The RF modulation signals pass through AC-coupling capacitors 122 , 124 (which have low impedance at RF) to outputs 126 , 128 , from which the RF modulation signals can be passed to an optical device 130 , such as a laser diode or an external modulator.
[0038] The outputs 114 , 116 are open-collector outputs, as described previously, and as discussed below are pulled-up by the supply voltage in order to bias the transistors in the output stage of the differential driver 102 .
[0039] Identical pull-up circuitry is included for each of the two complementary outputs 114 , 116 . The pull-up circuitry for the two complementary outputs comprises a high Q inductor, such as a coil inductor ( 202 for the “+” output 114 , 204 for the “−” output 116 ), a low Q inductor, such as a ferrite bead inductor ( 206 , 208 for the “+” and “−” outputs 114 , 116 , respectively) and a transistor ( 210 A, 210 B for the “+” and “−” outputs 114 , 116 , respectively). The transistors 210 A, 210 B are a matched pair of PNP bipolar transistors.
[0040] The ferrite bead inductors 206 , 208 are connected to the outputs 114 , 116 of the differential driver. Ferrite beads have a relatively small physical size and are able to provide high impedance to relatively high frequency RF signals. The ferrite beads are connected to the coil inductors 202 , 204 , which provide high impedance to mid-low RF frequencies. The combination of the passive ferrite bead inductors in series with the coil inductors provides the desired level of impedance over some of the required RF frequency range. The two different types of inductors give a combination of high Q and low Q inductors. Q is the quality factor for an inductor. Q is given by Q=X/R, where X is the inductive reactance and R is the equivalent series resistance.
[0041] The transistors 210 A, 210 B provide a large impedance at the low frequency part of the wideband RF signal. The frequency range over which the transistor provides a high impedance is related to the transition frequency, f T , of the transistor, wherein the f T value is the theoretical frequency at which the current gain (h fe ) of the transistor is unity (i.e. 0 dB).
[0042] The collector of transistor 210 A is connected to coil inductor 202 and the collector of transistor 210 B is connected to coil inductor 204 . The emitter of transistors 210 A and 210 B are connected to the supply voltage VCC. A resistor 212 is connected between the base and the collector of transistor 210 A, and a resistor 214 is connected between the base and the collector of transistor 210 B. The resistors 212 and 214 bias the transistors 210 A, 210 B together with the differential driver back termination (which may typically be 75Ω). The values of resistors 212 and 214 are chosen to give the appropriate voltage in the bias circuit, and their values depend upon the back terminating resistor values in the driver 102 and the desired bias voltage. The base terminals of the transistors 210 A and 210 B are connected together.
[0043] A capacitor 216 is connected between the supply voltage VCC and the base terminals of 210 A and 210 B. The capacitor creates a “virtual battery” which keeps the base emitter bias voltage constant for transistors 210 A and 210 B. Thus the current is constant in 210 A and 210 B. Capacitors 218 , 220 bleed off any stray AC signals from the supply voltage line.
[0044] The type of transistor used for 210 A and 210 B is deliberately chosen with a view to having two transistors of substantially identical characteristics, even if this means selecting a type of RF transistor that has a transition frequency lower than the highest that is available. In this embodiment, this is made possible by the co-use of the passive inductors 202 , 204 , 206 , 208 , which together provide the desired level of impedance over the entire frequency range. A typical value for the transition frequency for the transistors shown in FIG. 2 is ≧250 MHz. Typical values for the inductors are L 3 , L 4 =1 K@100 MHz (ferrite beads) and L 1 , L 2 =47 μH.
[0045] Using the hybrid technique of combining active components (an RF transistor) and passive components (ferrite beads and coil inductors), a high level of impedance is achieved for wideband RF signals, thereby ensuring that the RF signal is not significantly diverted from the optical device, but without the components being too large in entirety to be used in a small module.
[0046] FIG. 3 shows another embodiment of the present invention. In this embodiment, the driver for driving the optical device 304 is a single-ended ended optical device driver 302 . As a single-ended driver 302 only has a single output, only one transistor 210 A and two inductors 202 , 206 are required. Otherwise, the operation of the circuit is identical to that described with reference to FIG. 2 .
[0047] FIG. 4 shows another embodiment of the present invention. It is identical to that shown in FIG. 3 , except that the optical device 402 is connected to only one of the outputs, and the other output is connected to ground via a dummy load 404 .
[0048] In each embodiment, the supply Vcc is for the driver's output stage and also the pull-up. The driver may get a second power supply for its preceding stages or other parts of the circuitry.
[0049] The applicant draws attention to the fact that the present invention may include any feature or combination of features disclosed herein either implicitly or explicitly or any generalisation thereof, without limitation to the scope of any definitions set out above. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. | A circuit including a pair of radio frequency signal devices to each of which are connected in parallel a respective input or output and a respective dc bias input device for biasing the respective radio frequency signal device; each dc bias input device including a radio frequency transistor and at least two different types of inductors. | 7 |
SUMMARY OF THE INVENTION
The present invention accomplishes its desired objects by providing a router bracket having a pair of cylindrical ring means. Each ring means terminates into a pair of flanges spaced with respect to each other. A bridge member means is connected to each of the two cylindrical ring means. A lug means is bound to one of the cylindrical ring means for engaging a depth gauge means thereto. The lug means has a structure defining a lug aperture for receiving therethrough a depth gauge means. Each of the flanges has an aperture for receiving therethrough a nut-bolt assembly in order to tighten the rings and decrease the diameter of the same. The lug means and the bridge member means both have a structure that tapers. Both of the cylindrical ring means have an upper flanged perimeter and a lower flanged perimeter. A standard router is slidably disposed in one of the cylindrical ring means and a drill press is slidably disposed in the other cylindrical ring means.
The depth gauge of this invention comprises a standard secured to the drill press. The standard has a depth indicia. A platform is secured to the standard, and the platform has a slot wherethrough a gauge spacedly passes. The gauge has distance indicia and is removably disposed within the lug aperture of the lug means. At least one nut means threadably engages the top of the gauge above the slot.
Therefore, it is an object of the present invention to provide a router bracket for positioning and attaching a standard router to a drill press.
This object, together with the various ancillary objects and features which will become apparent to those skilled in the art as the following description proceeds, are attained by this novel router bracket, a preferred embodiment being shown with reference to the accompanying drawings, by way of example only, wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the router bracket of this invention positioned around a standard router and a drill press;
FIG. 2 is a top plan view of the router bracket;
FIG. 3 is a vertical sectional view taken in direction of the arrows and along the plane of line 3--3 in FIG. 2;
FIG. 4 is a vertical sectional view taken in direction of the arrows and along the plane of line 4--4 in FIG. 2;
FIG. 5 is a side elevational view of the router bracket with the standard router and the drill press being illustrated as dotted lines;
FIG. 6 is an enlarged partial vertical sectional view of the lug means with its lug aperture having a pair of opposed recesses for countersinking therein a pair of nuts in an opposed relationship such that the depth gauge can be stationarily affixed within the lug aperture;
FIG. 7 is a vertical sectional view taken in direction of the arrows and along the plane of line 7--7 in FIG. 2;
FIG. 8 is an end elevational view of the router bracket; and
FIG. 9 is an end elevational view of another end of the router bracket.
DETAILED DESCRIPTION OF THE INVENTION
Referring in detail now to the drawings for a detailed description of the invention wherein similar parts of the invention are identified by like reference numerals, there is seen a router bracket, generally illustrated as 10, comprising a first cylindrical ring, generally illustrated as 12, a second cylindrical ring, generally illustrated as 14, and a bridge member, generally illustrated as 16, for interconnecting or bridging together the two rings 12 and 14. A lug means 18 is connected to the ring 14. The router bracket 10 of this invention provides for positioning and attaching a standard router, generally illustrated as 20, to a drill press means, generally illustrated as 22.
The standard router 20 may be any of the various tools or machines for routing, hollowing out, or furrowing, or tools or machines for routing out parts of an etched plate or die; all well known in the art. The drill press 22 is also well known in art having a drill press shank 24 terminating in a drill press chuck 26. The drill press chuck 26 is shown for reference only, and is to be removed when using the router 20. To convert the assembly back to solely a drill press 22, the standard router 20 is removed and the drill press chuck 26 is reinstalled. The router bracket 10 is left in place. Secured to a side 28 of the drill press 22 is a depth gauge means, generally illustrated as 30, which may be expediently adjusted to set precisely the depth of a router cut.
The depth gauge means 30 of this invention comprises an upright standard 32 attached to the side 28 of the drill press 22 and has depth indicia 34 marked thereon equidistantly. Attached to standard 32 is a gauge platform 36 having a structure defining a slot 38. Spacedly passing through slot 38 is gauge 40 having distance indicia 41 which can be aligned with indicia 34. The lower end of gauge 40 passes through a lug aperture (to be identified below) and is sandwiched stationarily therein by nuts 44-44 as shown in FIG. 1. The top portion of gauge 40 above the slot 38 contains threadably engaged therewith a plurality of nuts 42 which are used to align the router 20 at a more accurate depth with distance indicia 41 while simultaneously preventing the router 20 from operating at too great a depth due to abutment of the underside of the lower nut 42 with the top surface of the platform 36 since typically nuts 42 would have a greater width than the width of slot 38. It should be understood that one of the manners of setting the depth of the router 20 would be to set the lower nut 42 at the desired distance indicia 41, lock the lower nut 42 in place with the upper nuts 42, and subsequently lower the router bracket 20 (including the attached gauge 40) until the underside of the lower nut 42 would indeed by flushed with and about the top surface of the platform 36.
The first cylindrical ring 12 comprises a cylindrical structure 50 which terminates in or defines a slot 52 having side boundaries partly formed by cylindrical wall ends 53-53 and a pair of flanges 54-54 which extend outwardly from the cylindrical structure 50. Each of the flanges 54 is formed with a flange aperture (not shown) wherethrough a bolt-nut assembly 56 passes. The cylindrical structure 50 has a diameter which is suitable to surround the router 20. The flanges 54 are spaced apart and may be brought together by tightening the nut of the bolt-nut assembly 56 such as to decrease the diameter of the cylindrical structure 50 to rigidly secure the router 20 within the cylindrical structure 50.
The second cylindrical ring 14 comprises a structure similar to ring 12. More specifically, ring 14 comprises cylindrical structure 58 which terminates in or defines a slot 60 having side boundaries partly formed by cylindrical wall ends 61--61 by a pair of flanges 62--62 which extend outwardly from the cylindrical structure 58. Each of the flanges 62 is formed with a flange aperture (not shown) wherethrough a bolt-nut assembly 64 passes. The cylindrical structure 58 has a diameter which is suitable to surround the drill shank 24. The flanges 62 are spaced apart and may be brought together by tightening the nut of the bolt-nut assembly 64 such as to decrease the diameter of the cylindrical structure 58 to rigidly secure the drill shank 24 within the cylindrical structure 58. As is obvious from the drawings, the diameter of the cylindrical structure 5 is smaller, or less than the diameter of the cylindrical structure 50. Furthermore, the length or height of the cylindrical structure 50 is longer or greater than the length or height of the cylindrical structure 58.
Both of the cylindrical structures 50 and 58 are hollow. The top and bottom of the cylindrical structure 50 respectively have upper circular flanged perimeter 66 and lower circular flanged perimeter 68. Similarly, the top and bottom of the cylindrical structure 58 respectively has upper circular flanged perimeter 70 and lower circular flanged perimeter 72. All of the flanged perimeters 66, 68 and 70, 72 respectively extend away from the cylindrical structures 50 and 58.
Interconnecting or bridging together the rings 12 and 14 is bridge member 16 which connects to the cylindrical structure 50 between upper and lower flanged perimeters 66 and 68 and connects to the cylindrical structure 58 between upper and lower flanged perimeters 70 and 72 as best illustrated in FIGS. 5 and 7. As further best illustrated in FIGS. 5 and 7, the bridge member 16 tapers from the cylindrical structure 50 towards the cylindrical structure 58 such that the bridge member 16 has a thickness greater at point 74, at the point where the structure 50 bonds to bridge member 16, than at point 76 where bridge member 16 is bound to structure 58. As best shown in FIG. 2, flanges 54--54 and flanges 62--62 are diametrically opposed to the bridge member 16.
The lug means 18 has an aperture 78 (see FIG. 2) for receiving therein the gauge 40, as was previously indicated. Aperture 78 is in close proximity to an extreme end 80 of the lug means 18 which may be defined as the extreme or farthest point from cylindrical structure 58. As illustrated in FIGS. 4 and 9, lug means 18 tapers outwardly towards end 80 and away from the cylindrical structure 58. The lug means 18 is connected to the cylindrical structure 58 between the upper and lower flanged perimeters 70 and 72.
While the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth. | A router bracket having a pair of cylindrical rings. A bridge member interconnects one cylindrical ring with another cylindrical ring. One of the cylindrical rings has a lug member bound thereto for engaging a depth gauge. | 5 |
TECHNICAL FIELD
[0001] This patent document pertains generally to data communications and more specifically to systems and methods for providing a user interface with a grid view.
BACKGROUND
[0002] Conventionally, when a user desires to access the content of a webpage of an enterprise or other organization, the user typically utilizes a web browser of a computer terminal, mobile device or similar apparatus to connect to a network (e.g., the Internet) and access the relevant webpage.
[0003] Often, the user may have questions regarding the features available on the webpage, and/or how to navigate the content of the webpage. For example, the user may have a specific question regarding whether a particular feature is available on the webpage and, if so, where that feature can be found on the webpage. In such a situation, the user typically contacts a customer service representative of the organization (typically via telephone) and speaks to the customer service representative, who can attempt to answer the user's questions and direct them to the appropriate features that are available on the webpage. Since the discussion between the user and the customer service representative typically takes place over the phone, the customer service representative must usually describe orally to the user where on the webpage the appropriate features may be found.
BRIEF DESCRIPTION OF DRAWINGS
[0004] Some embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings in which:
[0005] FIG. 1 is a block diagram illustrating an environment for navigating content, such as the content of a webpage which may be accessed over a network such as the Internet, according to example embodiment.
[0006] FIG. 2 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, according to an example embodiment.
[0007] FIG. 3 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0008] FIG. 4 illustrates a flowchart of a method performed by a client terminal, according to an example embodiment.
[0009] FIG. 5 is a block diagram illustrating an environment for navigating content, such as the content of a webpage which may be accessed over a network such as the Internet, according to another example embodiment.
[0010] FIG. 6 illustrates a flowchart of a method performed by a server, according to an example embodiment.
[0011] FIG. 7 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0012] FIG. 8 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0013] FIGS. 9 a - 9 d illustrate example portions of various user interface screens displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0014] FIG. 10 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0015] FIG. 11 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is overlaid over the content of a webpage, according to an example embodiment.
[0016] FIG. 12 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a user selects a line distance factor and/or toggles a drill-down mode, according to an example embodiment.
[0017] FIGS. 13 a - 13 c illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein lines of a grid are adjusted based on line distance factors, according to an example embodiment.
[0018] FIG. 14 illustrates a flowchart of a method performed by a client terminal or server, according to an example embodiment.
[0019] FIG. 15 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid includes a smaller-sized grid in a drill-down mode, according to an example embodiment.
[0020] FIG. 16 illustrates a flowchart of a method performed by a client terminal or server, according to an example embodiment.
[0021] FIG. 17 illustrates an example portion of a user interface screen of a browser, displayed on a display of a client terminal via a browser application, wherein a grid is adjusted based on a display resolution of a display screen, according to an example embodiment.
[0022] FIG. 18 illustrates a flowchart of a method performed by a client terminal or server, according to an example embodiment.
[0023] FIG. 19 is a block diagram of machine in the example form of a computer system within which a set instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed.
DETAILED DESCRIPTION
[0024] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of some example embodiments. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
[0025] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, there is described tools (systems, apparatuses, methodologies, computer program products, etc.) for improved system for navigating content, such as the content of a webpage which may be accessed over a network such as the Internet.
[0026] For example, FIG. 1 illustrates an environment 100 (e.g., a system) for navigating content, such as the content of a webpage which may be accessed over a network such as the Internet. As illustrated in FIG. 1 , the environment 100 includes a client terminal 102 connected to a network 111 (such as the Internet) to communicate with server 103 . The server may be associated with a webpage, and or may host a webpage accessible by a browser application operating on the client terminal 102 . That is, a user may utilize a web browser application (e.g. browser module 102 a ) of the client terminal 102 to connect to the network 111 and access the webpage hosted by the server 103 .
[0027] The client terminal 102 includes a browser module 102 a and grid control module 102 b . The browser module 102 a may correspond to a conventional browser application operating on the client terminal, and the browser module 102 a of the client terminal 102 is operable to access a webpage including content that is hosted on the server 103 , via the network 111 , and display the webpage (or cause the webpage to be displayed) on a display of the client terminal 102 .
[0028] FIG. 2 illustrates an example portion of a webpage 200 that is displayed on a display of the client terminal 102 , via the browser module 102 a . The webpage may be hosted by the server 103 , for example. The webpage 200 may include a grid selection button 202 (also referred to herein as a grid view button or grid view option button), which may be positioned in the button left hand corner of the display, for example, as illustrated in FIG. 2 . The grid selection button 202 may be generated and/or rendered by the browser module 102 a and/or grid control module 102 b based on instructions stored locally on the client terminal, or based on instructions received from the server 103 , or based on instructions/code (e.g. HTML5 or JavaScript) associated with the webpage hosted on the server 103 .
[0029] When the user of the client terminal 102 selects the grid selection button 202 displayed on the display of the client terminal, the grid control module 102 b detects the user selection of the grid selection button 202 , and the grid control module 102 b causes the browser module 102 a to display a grid on the display of the client terminal. The grid may be superimposed over the content of the webpage 200 , as illustrated in FIG. 3 . The grid may be generated by the grid control module 102 b at the client terminal 102 side, or by a similar grid control module at the server 103 side.
[0030] As illustrated in FIG. 3 , the grid, as initially generated, includes plural parallel horizontal lines that are evenly spaced, as well as plural parallel vertical lines that are evenly spaced. The plural horizontal lines are generated according to a vertical axis 304 , and the plural vertical lines are generated according to a horizontal axis 302 . The horizontal 302 axis includes plural alphanumeric indicia (e.g. numbers 1-11) that each identify a column of the grid bounded by at least two of the vertical lines. Similarly, the vertical 304 axis includes plural alphanumeric indicia (e.g. characters A through G) that each identify a row of the grid bounded by at least two of the horizontal lines. Each cell of the grid may be subsequently identified using the alphanumeric indicia of the corresponding column and row.
[0031] The grid selection button 202 may operate based on a toggle approach, according to an exemplary embodiment. That is, the grid first appears when the user clicks the grid selection button 202 . Thereafter, the grid will persist in place, even if the user clicks on a link or moves to a different webpage, until the user clicks the grid button 202 again, at which point the grid will be removed.
[0032] Thus, according to the exemplary embodiments of this disclosure, when a user accesses a webpage (e.g., via a network such as the Internet) and views the webpage on a display of the user's terminal, the user may click on a grid view button, and a grid is displayed on the display of the user terminal. The grid may include horizontal and vertical grid lines and corresponding grid indicia that are superimposed over the content of the webpage. Therefore, the user can easily navigate the content of the webpage, by referring to the grid lines and corresponding grid indicia to identify different parts of the webpage.
[0033] The exemplary embodiments of this disclosure are applicable in a wide variety of situations in various fields. For example, a customer browsing a webpage may have a specific question regarding whether a particular feature is available on the webpage and, if so, where that feature can be found on the webpage. Conventionally, the customer contacts a customer service representative of the webpage organization (typically via telephone), but the customer service representative can only describe orally to the user where on the webpage the appropriate features may be found.
[0034] In contrast, in accordance with the exemplary embodiments of this disclosure, both the customer service representative and the user may view the same webpage via their respective terminals, and select the grid view option when viewing the webpage. Thus, both the customer service representative and the user will be able to communicate meaningful information about the webpage by quoting the appropriate indicia of the grid. For example, with reference to example webpage of FIG. 3 , if the user wants to know where the “Policies” section of the webpage is, a customer service representative can identify that section as being within cell “G-8”.
[0035] Meanwhile, in an educational environment, such as class being conducted by an instructor (or likewise in a training environment, such as a seminar being presented by a speaker), the instructor may be presenting information to a group of students that each has their own computer workstations. Conventionally, the instructor may have to describe orally to the students how to perform certain operations on their computer terminals, such as navigating a webpage displayed on the displays of the terminals.
[0036] In contrast, in accordance with the exemplary embodiments of this disclosure, both the instructor and the students may view the same webpage via their respective terminals, and select the grid view option when viewing the webpage. Thus, both the instructor and students will be able to communicate meaningful information about the webpage by quoting the appropriate indicia of the grid. For example, with reference to example webpage of FIG. 3 , the instructor may say to the class: “Please see the ‘Policies’ section of the webpage within cell ‘G-8’. Thus, the present invention allows an instructor to keep a class of students on the same page, and greatly facilitates the instructor's ability to guide the navigation of a webpage of other content by large groups of people (especially when the people are viewing the content for the first time, or where complex steps are involved).
[0037] While the exemplary embodiments of this disclosure refer to a grid view being applied to a webpage viewed on a display of a terminal, the grid view may in fact be applied to any information being displayed on the display of the terminal. For example, the grid view may be superimposed over the displayed content of a browser application, word processing application, spreadsheet application, presentation application, video game application, or any other application that displays content on a display of a terminal.
[0038] The client terminal 102 and/or server 103 may be any network-connected device including but not limited to a personal, notebook or workstation computer, a terminal, a kiosk, a PDA (personal digital assistant), a tablet computing device, a smartphone, a scanner, a printer, a plotter, a facsimile machine, a multi-function device (MFD), a server, a mobile phone or handset, another information terminal, etc. Each device may be configured with software allowing the device to communicate through networks with other devices.
[0039] FIG. 4 is a flow chart illustrating a method performed by a client terminal, such as client terminal 102 illustrated in FIG. 1 , in accordance with an example embodiment. The method of FIG. 4 may be performed by any of the modules, logic, or components described herein in connection with the client terminal 102 .
[0040] In step 401 , the client terminal accesses a webpage including content, and displays the webpage at the client terminal 102 . An example of a webpage displayed on a display of a client terminal is illustrated in FIG. 2 . Then, in step 402 , the terminal receives a user specification of a grid view option. For example, the client terminal 102 may receive a user selection of the grid view button 202 illustrated in FIG. 2 , which is displayed by the browser application of the terminal on the display of the terminal. In step 403 , the client terminal 102 generates and displays the grid. The grid may be superimposed over the content of the webpage, as illustrated in FIG. 3 . In other instances, the grid may be otherwise incorporated into the display of the webpage using, for example, different colors, different textures, sounds played as the grid is traversed, different haptic (e.g. vibrations) as the grid is traversed, altering speed/resistance of mouse cursor movement as the grid is traversed.
[0041] As described above, various aspects of this exemplary embodiment may be performed at the client side, e.g. by executing instructions stored in a memory and executed by a processor of the client terminal 102 . However, it is appreciated by those of ordinary skill in the art that the aforementioned aspects may be performed remotely, or are performed at the server side.
[0042] For example, FIG. 5 illustrates an environment 500 (e.g., a system) similar to the environment 100 illustrated in FIG. 1 , wherein a more detailed illustration of the server 103 is provided, according to an exemplary embodiment. The client terminal 502 may be similar to client terminal 102 , and may include a browser application similar to the browser module 102 a of the client 102 illustrated in FIG. 1 .
[0043] The server 503 includes a webpage host module 503 a and a grid control module 503 b . The webpage host module 503 a is operable to host a webpage including content, the webpage being accessible by a browser application of a client terminal (e.g. 502 ). FIG. 2 illustrates an example of a webpage 200 that is accessed by a browser application and displayed on the display of the client terminal 502 , wherein the webpage is hosted by the webpage host module 503 a of the server 503 . The grid control module 503 b of the server 503 is operable to receive a user request to activate a grid view option from the client terminal 502 . For example, when the user selects the grid selection button 202 illustrated in FIG. 2 , the user's terminal 502 transmits data to the server 503 indicating that the user has selected the grid selection button 202 .
[0044] Once the grid control module 503 h receives the user specification of the grid view option, the grid control module 503 b generates a grid and causes the browser application of the client terminal (e.g. 502 ) to display the grid on the display of the client terminal, such that the grid is superimposed over the content of the webpage, as illustrated in FIG. 3 . For example, the grid control module 503 b may generate code (e.g. HTML5 or JavaScript) for the grid, and associate the code with the webpage hosted on the server 503 that is accessed by the browser application of the client terminal 502 . Alternatively, such code may be transmitted in the form of instructions to the browser application of the client terminal 502 . The grid may then be displayed on the display of the client terminal (e.g. 502 ), such that the grid is superimposed over the content of the webpage displayed on the display of the terminal, as illustrated in FIG. 3 .
[0045] FIG. 6 is a flow chart illustrating a method performed by a server, such as server 503 illustrated in FIG. 5 , in accordance with an example embodiment. The method of FIG. 6 may be performed by any of the modules, logic, or components described herein.
[0046] In step 601 , the server hosts a webpage including content, the webpage being accessible by a browser application of a client terminal and displayable on a display of a client terminal, such as client terminal 502 . An example of a webpage displayed on a display of a client terminal is illustrated in FIG. 2 . Then, in step 602 , the server receives a user specification of a grid view option. For example, the terminal may detect user selection of the grid view button 202 illustrated in FIG. 2 , and transmit a detection signal to the server. In step 603 , the server generates a grid and causes the grid to be displayed on the display of the client terminal, the grid being superimposed over the content of the webpage, as illustrated in FIG. 3 .
[0047] According to an aspect of an exemplary embodiment, after the grid control module 102 b of the client terminal 102 (see FIG. 1 ) receives a user selection of one or more of the indicia of the grid, the grid control module 102 b causes the browser module 102 a to display a visual marking proximate to a grid cell identified by the user selected indicia. Similarly, according to another aspect, after the grid control module 503 b of the server 503 (see FIG. 5 ) receives a user selection of one or more of the indicia of the grid, the grid control module 503 b of the server 503 causes the browser application of the terminal 502 to display a visual marking proximate to a grid cell identified by the user selected indicia.
[0048] More specifically, after the display of the terminal displays the grid (see FIG. 2 ), the user may select one or more of the indicia of the grid. For example, the user may utilize a mouse to click on one or more of the indicia. As another example, if the display of the client terminal displaying the webpage and grid is a touchscreen, the user may select one or more of the indicia on the touchscreen. After the user selects indicia, such as “F” and “4”, the cell grid of the grid corresponding to the selected indicia (i.e. the grid corresponding to F-4) may be marked visually, as seen in FIG. 7 . The visual marking may be highlighting the appropriate cell, changing the shading of the appropriate cell, changing a transparency factor of the appropriate cell, etc. The visual marking may be also include changing the color, line width, line weight or line style of the lines surrounding the appropriate grid cell.
[0049] Thus, simply by clicking on the desired indicia, the user is able to immediately see the appropriate grid cell corresponding to the indicia, to more easily navigate the content of the webpage.
[0050] Instead or in addition, after the user selects one or more of the indicia, the visual display of all the other non-identified cells may also be changed, in order to better highlight and enunciate the relevant cell to the user. For example, as seen in FIG. 8 , the lines corresponding to all the other cells (other than the user selected cell F-4) may be removed. As another example, a transparency factor of each grid cell of the grid—other than the grid cell of the grid identified by the user selected indicia—may be changed, such that only the webpage content of the grid cell identified by the user-selected indicia is fully transparent, whereas the webpage content under all the other grid cells appears obscured and/or opaque.
[0051] According to this aspect, after the grid control module 102 b of the client terminal 102 (see FIG. 1 ) receives a user selection of one or more of the indicia of the grid, the grid control module 102 b changes the visual display of all the other non-selected cells. Similarly, according to this aspect, after the grid control module 503 b of the server 503 (see FIG. 5 ) receives a user selection of one or more of the indicia, the grid control module 503 b of the server 503 causes the browser application of the terminal 502 to change the visual display of all the other non-relevant cells.
[0052] According to another exemplary embodiment, when the user selects the grid view option, the horizontal and vertical axes (including the indicia) appear, but the horizontal and vertical lines of the grid do not. Thereafter, when the user selects indicia, only the grid cell(s) corresponding to the user selected indicia appear, (see FIG. 9 a wherein the user selects indicia ‘8’, see FIG. 9 b wherein the user further selects indicia ‘9’, and FIG. 9 c wherein the user further selects indicia ‘F’). Thus, the user can more easily navigate the content of the webpage, by clearly seeing only the grid cells corresponding to the relevant indicia. This operation may be performed by, for example, the grid control module 102 b of the terminal 102 or the grid control module 503 b of the server 503 . The content of the webpage underneath the grid is not shown in FIG. 9 a through 9 d in the interests of clarity.
[0053] Moreover, according to this exemplary embodiment, once indicia with overlapping cells have been selected (i.e. at least one horizontal axis indicia and at least one vertical axis indicia have been selected), only the lines around the overlapping grid cell are displayed, and all other lines of the grid are removed. For example, as illustrated in FIG. 9 c , the user has already selected indicia ‘8’ and ‘9’, and the user further selects indicia ‘F’. Since the grid cells corresponding to all the selected indicia overlap, only the lines around the overlapping grid cell are displayed, and all other lines of the grid are removed, as seen in FIG. 9 d . The grid may be adjusted in this way by, for example, the grid control module 102 b of the terminal 102 or the grid control module 503 b of the server 503 . Thus, the user can more easily navigate the content of the webpage, by clearly seeing only the overlapping grid cells corresponding to the relevant indicia.
[0054] Various other techniques may be used in order to aid the user in navigating the grid and the content of the webpage, based on appropriate indicia. For example, the cells may adopt a shading pattern, where the cells corresponding to every second vertical indicia (B, D, F, . . . ) and the cells corresponding to every second horizontal indicia (1, 3, 5, . . . ) are shaded, as illustrated in FIG. 10 . Moreover, each of the cells may include a watermark or lightly shaded characters indicating the corresponding indicia, as illustrated in FIG. 11 . The content of the webpage underneath the grid is not shown in FIG. 10 and FIG. 11 in the interests of clarity.
[0055] Turning now to FIGS. 12 and 13 a - 13 c , according to another aspect of this disclosure, it is possible for the user to adjust the distance between each of the horizontal lines and vertical lines. When the user accesses the settings of the grid view option (e.g. by right-clicking the grid view button 202 ), the grid control module 102 b or 502 b may cause the browser application of the terminal to display the user interface 1201 of FIG. 12 , which allows the user to select the spacing between the horizontal lines and the vertical lines (also referred to herein as a line distance factor). For example, when the user selects ‘normal’ spacing for both the horizontal and vertical axes, as illustrated in FIG. 12 , the grid control module 102 b causes the grid lines to appear as they do in FIG. 3 . As another example, when the user selects ‘double’ spacing for both the horizontal and vertical axes, the grid control module 102 b causes the grid lines to appear as they do in FIG. 13 a . As yet another example, when the user selects ‘½’ spacing for the horizontal axis and ‘normal’ spacing for the vertical axis, the grid control module 102 b causes the grid lines to appear as they do in FIG. 13 b . As yet another example, when the user selects ‘half’ spacing for both the horizontal and vertical axes, the grid control module 102 b causes the grid lines to appear as they do in FIG. 13 c . The content of the webpage underneath the grid is not shown in FIGS. 13 a - 13 c in the interests of clarity. The aforementioned operations may be performed by, for example, the grid control module 102 b of the terminal 102 or the grid control module 503 b of the server 503 .
[0056] FIG. 14 is a flow chart illustrating a method performed by a terminal or a server, such as terminal 102 or server 503 , in accordance with an example embodiment. The method of FIG. 14 may occur after the steps in the method of FIG. 4 , or after the steps in the method of FIG. 6 . The method of FIG. 14 may be performed by any of the modules, logic, or components described herein.
[0057] The method begins at step 1400 , and in step 1401 the terminal or server detects user input. If the user input is a selection of one or more of the grid indicia (step 1402 , Yes), the terminal or server causes the browser application of the terminal to display a visual marking proximate to a first grid cell of the grid identified by the user selected grid indicia (step 1403 ; see FIG. 7 ). Otherwise (step 1402 , No), if the user input is a user selection of a line distance factor (step 1404 , Yes), the server or terminal adjusts a distance between each of the horizontal lines and a distance between each of the vertical lines, based on the user specified line distance factor (step 1405 ; see FIGS. 12 and 13 a - 13 c ). The method then ends in step 1406 .
[0058] According to an exemplary embodiment, the user is able to select a drill-down mode (see FIG. 12 ). If the user turns the drill-down mode on, then when the user selects particular indicia, such as ‘D’ and ‘6’, the grid control module 102 b causes the browser module of the terminal to display a reduced-size grid within the grid cell identified by the user selected indicia (e.g. the cell corresponding to D6), as illustrated in FIG. 15 . As seen in FIG. 15 , the reduced-size grid may itself include horizontal and vertical line(s) connected to a vertical and horizontal axis, wherein the axes include indicia, similar to the indicia described in accordance with the aspects of this disclosure. The content of the webpage underneath the grid is not shown in FIG. 15 in the interests of clarity. This operation may be performed by, for example, the grid control module 102 b of the terminal 102 or the grid control module 503 b of the server 503 .
[0059] FIG. 16 is a flow chart illustrating a method performed by a terminal or a server, such as terminal 102 or server 503 , in accordance with an example embodiment. The method of FIG. 16 may occur after the steps in the method of FIG. 4 , or after the steps in the method of FIG. 6 . The method of FIG. 16 may be performed by any of the modules, logic, or components described herein.
[0060] The method beings at step 1600 , and in step 1601 , the terminal or server detects user input. If the user input is a toggle selection of drill-down mode (step 1602 , Yes), the terminal or server can toggle the drill-down mode on or off as appropriate (step 1603 ), and the flow returns to step 1601 . If the user input is not a toggle selection of drill-down mode (step 1602 , No), but is instead a user selection of grid indicia (step 1604 , Yes), then the flow proceeds to step 1605 . If the drill-down mode is currently activated (step 1605 , Yes), then in step 1606 the terminal or server causes the terminal display to display a reduced-size grid within a first grid cell identified by the user selected grid indicia (step 1607 ; see FIG. 15 ), and the method ends (step 1608 ). If the drill-down mode is not currently activated (step 1605 , No), then in step 1607 the terminal or server displays a visual marking proximate to a first grid cell of the grid identified by the user selected grid indicia (step 1606 , e.g. see FIG. 7 ), and the method ends (step 1608 ).
[0061] According to another exemplary embodiment, the grid control module 102 b of the terminal 102 determines a display resolution and/or display size of the display of the client terminal 102 , and grid control module 102 b adjusts the lines of the grid, based on the display resolution and/or display size of the display of the terminal. Instead or in addition, at the server side, the grid control module 503 b of the server 503 determines a display resolution and/or display size of the display of the terminal 502 , and the grid control module 503 b adjusts the lines of the grid displayed by the display of the terminal, based on the display resolution and/or display size of the display of the terminal.
[0062] For example, it is common for the displays of different devices (workstations, terminals, mobile devices, etc.) to have different display resolutions and/or display sizes, in terms of the inherent configuration of the display, as well as the display resolution settings selected by the user of the device. As a result, the webpage displayed on the displays of each device may appear differently (e.g. larger, smaller, stretched, compressed, etc.). However, in order to assist users to navigate a webpage, the grid must be properly scaled on each device, such that a particular grid indicia (and corresponding cell) describes the same part of the webpage, regardless of the user's device, device display resolution or device display size. That is, the grid indicia E6 should refer to the same content of the webpage, regardless of the user's device, device display resolution or device display size.
[0063] Thus, according to this exemplary embodiment, the grid control module 102 b of the terminal 102 (or the grid control module 503 b of the server 503 ) determines a display resolution and/or display size of the display of the terminal. For example, the grid control module of the terminal or server may access configuration or capabilities information of the terminal, in order to determine the display resolution and/or display size of the terminal's display. In addition, the grid control module of the terminal or server may access user-selected settings for display resolution (since many users select a display resolution via their device's Operating System, for example), in order to determine a display resolution and/or display size of the display of the terminal. Thereafter, the grid control module 102 b of the terminal 102 (or the grid control module 503 b of the server 503 ) adjusts the size and scale of the grid, in order to compensate for the different resolutions and achieve a standard grid-to-pixel ratio.
[0064] As one example, the webpage of FIG. 3 may be displayed at a first resolution on a terminal display of a first size, and the grid is overlaid over the content of the webpage at a specific grid-to-pixel ratio. FIG. 17 illustrates the same webpage being displayed on a terminal display of a different display resolution and/or different display size. The grid control module of the corresponding terminal or server may determine that the display resolution or display size is different (e.g. the display in FIG. 17 has fewer pixels to display the same webpage). As a result, grid control module 102 b of the terminal 102 (or the grid control module 503 b of the server 503 ) adjusts the size of the grid, the distance between the lines of the grid, the size of the indicia, and so forth, to achieve the same grid-to-pixel ratio as seen in FIG. 3 . Thus, the grid cell corresponding to grid indicia E4 indicates the same content of the webpage, in both FIG. 3 and FIG. 17 .
[0065] According to another aspect, the HTML code of a webpage hosted by the server 503 may include a tag or data indicating a size of each grid column and grid row (e.g. the number of pixels corresponding to each grid column and row) of any grid to be superimposed over the webpage by the grid control module. The grid control module of the terminal or server may access this information, in order to generate the grid to be superimposed of the webpage displayed on the terminal display.
[0066] FIG. 18 is a flow chart illustrating a method performed by a client terminal or server, such as client terminal 102 (or server 503 ). The method of FIG. 18 may be performed by any of the modules, logic, or components described herein.
[0067] In step 1801 , the terminal accesses a webpage including content, and displays the webpage on a display module of the client terminal. An example of a webpage displayed on a display of a client terminal is illustrated in FIG. 2 . Then, in step 1802 , the terminal receives a user specification of a grid view option. For example, the terminal may detect user selection of the grid view button 202 illustrated in FIG. 2 , which is displayed by the browser application of the terminal on the display of the terminal. In step 1803 , the terminal determines a display resolution of the display of the terminal, and in step 1804 , the terminal generates a grid, and adjusts the lines of the grid based on the display resolution of the display of the terminal. In step 1805 , the terminal displays the grid on the display module, the grid being superimposed over the content of the webpage, as illustrated in FIG. 3 and FIG. 17 .
Modules, Components and Logic
[0068] Certain embodiments are described herein as including logic or a number of components, modules, or mechanisms. Modules may constitute either software modules (e.g., code embodied (1) on a non-transitory machine-readable medium or (2) in a transmission signal) or hardware-implemented modules. A hardware-implemented module is tangible unit capable of performing certain operations and may be configured or arranged in a certain manner. In example embodiments, one or more computer systems (e.g., a standalone, client or server computer system) or one or more processors may be configured by software (e.g., an application or application portion) as a hardware-implemented module that operates to perform certain operations as described herein.
[0069] In various embodiments, a hardware-implemented module may be implemented mechanically or electronically. For example, a hardware-implemented module may comprise dedicated circuitry or logic that is permanently configured (e.g., as a special-purpose processor, such as a field programmable gate array (FPGA) or an application-specific integrated circuit (ASIC)) to perform certain operations. A hardware-implemented module may also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement a hardware-implemented module mechanically, in dedicated and permanently configured circuitry, or in temporarily configured circuitry (e.g., configured by software) may be driven by cost and time considerations.
[0070] Accordingly, the term “hardware-implemented module” should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired) or temporarily or transitorily configured (e.g., programmed) to operate in a certain manner and/or to perform certain operations described herein. Considering embodiments in which hardware-implemented modules are temporarily configured (e.g., programmed), each of the hardware-implemented modules need not be configured or instantiated at any one instance in time. For example, where the hardware-implemented modules comprise a general-purpose processor configured using software, the general-purpose processor may be configured as respective different hardware-implemented modules at different times. Software may accordingly configure a processor, for example, to constitute a particular hardware-implemented module at one instance of time and to constitute a different hardware-implemented module at a different instance of time.
[0071] Hardware-implemented modules can provide information to, and receive information from, other hardware-implemented modules. Accordingly, the described hardware-implemented modules may be regarded as being communicatively coupled. Where multiple of such hardware-implemented modules exist contemporaneously, communications may be achieved through signal transmission (e.g., over appropriate circuits and buses) that connect the hardware-implemented modules. In embodiments in which multiple hardware-implemented modules are configured or instantiated at different times, communications between such hardware-implemented modules may be achieved, for example, through the storage and retrieval of information in memory structures to which the multiple hardware-implemented modules have access. For example, one hardware-implemented module may perform an operation, and store the output of that operation in a memory device to which it is communicatively coupled. A further hardware-implemented module may then, at a later time, access the memory device to retrieve and process the stored output. Hardware-implemented modules may also initiate communications with input or output devices, and can operate on a resource (e.g., a collection of information).
[0072] The various operations of example methods described herein may be performed, at least partially, by one or more processors that are temporarily configured (e.g., by software) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, such processors may constitute processor-implemented modules that operate to perform one or more operations or functions. The modules referred to herein may, in some example embodiments, comprise processor-implemented modules.
[0073] Similarly, the methods described herein may be at least partially processor-implemented. For example, at least some of the operations of a method may be performed by one or processors or processor-implemented modules. The performance of certain of the operations may be distributed among the one or more processors, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processor or processors may be located in a single location (e.g., within a home environment, an office environment or as a server farm), while in other embodiments the processors may be distributed across a number of locations.
[0074] The one or more processors may also operate to support performance of the relevant operations in a “cloud computing” environment or as a “software as a service” (SaaS). For example, at least some of the operations may be performed by a group of computers (as examples of machines including processors), these operations being accessible via a network (e.g., the Internet) and via one or more appropriate interfaces (e.g., Application Program Interfaces (APIs).)
Electronic Apparatus and System
[0075] Example embodiments may be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Example embodiments may be implemented using a computer program product, e.g., a computer program tangibly embodied in an information carrier, e.g., in a machine-readable medium for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers.
[0076] A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
[0077] In example embodiments, operations may be performed by one or more programmable processors executing a computer program to perform functions by operating on input data and generating output. Method operations can also be performed by, and apparatus of example embodiments may be implemented as, special purpose logic circuitry, e.g., a field programmable gate array (FPGA) or an application-specific integrated circuit (ASIC).
[0078] The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. In embodiments deploying a programmable computing system, it will be appreciated that that both hardware and software architectures require consideration. Specifically, it will be appreciated that the choice of whether to implement certain functionality in permanently configured hardware (e.g., an ASIC), in temporarily configured hardware (e.g., a combination of software and a programmable processor), or a combination of permanently and temporarily configured hardware may be a design choice. Below are set out hardware (e.g., machine) and software architectures that may be deployed, in various example embodiments.
Example Machine Architecture and Machine-Readable Medium
[0079] FIG. 19 is a block diagram of machine in the example form of a computer system 1900 within which instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative embodiments, the machine operates as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine may operate in the capacity of a server or a client machine in server-client network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The machine may be a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a network router, switch or bridge, or any machine capable of executing instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
[0080] The example computer system 1900 includes a processor 1902 (e.g., a central processing unit (CPU), a graphics processing unit (GPU) or both), a main memory 1904 and a static memory 1906 , which communicate with each other via a bus 1908 . The computer system 1900 may further include a video display unit 1910 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system 1900 also includes an alphanumeric input device 1912 (e.g., a keyboard), a user interface (UI) navigation device 1914 (e.g., a mouse), a disk drive unit 1916 , a signal generation device 1918 (e.g., a speaker) and a network interface device 1920 .
Machine-Readable Medium
[0081] The disk drive unit 1916 includes a machine-readable medium 1922 on which is stored one or more sets of instructions and data structures (e.g., software) 1924 embodying or utilized by any one or more of the methodologies or functions described herein. The instructions 1924 may also reside, completely or at least partially, within the main memory 1904 and/or within the processor 1902 during execution thereof by the computer system 1900 , the main memory 1904 and the processor 1902 also constituting machine-readable media.
[0082] While the machine-readable medium 1922 is shown in an example embodiment to be a single medium, the term “machine-readable medium” may include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more instructions or data structures. The term “machine-readable medium” shall also be taken to include any tangible medium that is capable of storing, encoding or carrying instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present invention, or that is capable of storing, encoding or carrying data structures utilized by or associated with such instructions. The term “machine-readable medium” shall accordingly be taken to include, but not be limited to, solid-state memories, and optical and magnetic media. Specific examples of machine-readable media include non-volatile memory, including by way of example semiconductor memory devices, e.g., Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks.
Transmission Medium
[0083] The instructions 1924 may further be transmitted or received over a communications network 1926 using a transmission medium. The instructions 1924 may be transmitted using the network interface device 1920 and any one of a number of well-known transfer protocols (e.g., HTTP). Examples of communication networks include a local area network (“LAN”), a wide area network (“WAN”), the Internet, mobile telephone networks, Plain Old Telephone (POTS) networks, and wireless data networks (e.g., WiFi and WiMax networks). The term “transmission medium” shall be taken to include any intangible medium that is capable of storing, encoding or carrying instructions for execution by the machine, and includes digital or analog communications signals or other intangible media to facilitate communication of such software.
[0084] Although an embodiment has been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The accompanying drawings that form a part hereof, show by way of illustration, and not of limitation, specific embodiments in which the subject matter may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. This Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
[0085] Such embodiments of the inventive subject matter may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. | A tool (systems, apparatus, methodology, application, user interface, etc.) for accessing content, such as webpages hosted over a network such as the internet, and more particularly, a tool for accessing the content of a webpage and further displaying a grid view superimposed over the content of the webpage. | 6 |
BACKGROUND OF THE INVENTION
The present invention involves a monoclonal antibody (MAb) with the specificity for a 67,000 dalton cell surface protein of Streptococcus pneumoniae, a cell line that produces said antibody, and the partially purified 67,000 dalton cell surface protein.
S.pneumoniae is the leading cause of community-acquired bacterial pneumonia (pneumococcal disease) with approximately 500,000 cases a year reported in the United States. Bacterial pneumonia is the most prevalent among the very young, the elderly and immuno-compromised persons. In infants and children, pneumococci are the most common bacterial cause of pneumonia, otitis media and bacteremia and a less common cause of meningitis (causing 20-25% of reported cases).
Pneumococci are carried in the respiratory tract of a significant number of healthy individuals. In spite of the high carriage rate, its presence does not necessarily imply infection. However, if one of the highly pathogenic pneumococcal types, such as S.pneumoniae, is isolated from rusty-coloured sputum (also containing a large number of polymorphonuclear leucocytes), body fluids, blood cultures, or specimens collected via transtracheal or lung puncture from the lower respiratory tract, its detection is usually significant.
Detection of this bacteria at an early stage is essential to facilitate treatment of the infection. Thus, it is important to possess the ability to identify whether S.pneumoniae is present in a patient and to be able to follow the effect of antibiotic treatment on the bacteria. As available immunoassays for S.pneumoniae antigen detection have shown lack of specificity and/or sensitivity, there remains the need for an improved method of such detection.
S.pneumoniae is a gram positive bacteria. Proteins located on the cell surface of many gram positive bacteria have, in the past, been used in typing and immunoprotection studies. There are a large number of S.pneumoniae strains, and there are many cell surface proteins associated with S.pneumoniae. This has made the identification of a common but exclusive cell surface antigen difficult. However, MAb technology has provided researchers with tools to reproducible and accurately analyze the cell surface components of S.pneumoniae. In addition, S.pneumoniae proteins are of interest to epidemiologists as they may provide for vaccines against the bacteria.
One such pneumonococcal capsular polysaccharide vaccine has been developed, which incorporates the polysaccharide antigen of 23 serotypes of pneumococci that are responsible for 87% of pneumococcal disease in the United States. This second generation vaccine replaced the 14-valent polysaccharide vaccine licensed in 1977. However, the U.S. Department of Health and Human Services states that a more immunogenic pneumococcal vaccine is needed, particularly for children younger than 2 years of age. This is because the 23-valent vaccine is poorly antigenic in this age group, and its use is not recommended in children with recurrent upper respiratory diseases, such as otitis media and sinusitis. Furthermore, the 23-valent vaccine is only 44-61% efficacious when administered to persons over 65 years old, and revaccination is not advised. Thus, there remains the need for an improved pneumococcal vaccine.
It follows then, that there remains a need for at least two products relating to S.pneumoniae. The first is a rapid, specific, and sensitive diagnostic technique for of all strains of S.pneumoniae, that does not give false positive results. What is optimally desired is a Mab that will recognize a cell surface antigen that is universally present in most, if not all, strains of S.pneumoniae and, at the same time does not recognize other organisms or material which may be found in conjunction with S.pneumoniae. Secondly, it is desirous that the Mab and said 67,000 dalton protein be used in research towards development of an improved vaccine.
SUMMARY OF INVENTION
The present invention involves a Mab that is reactive with an epitope (an antigenic determinant of known structure) of a proteinaceous surface component of the bacterium S.pneumoniae, with said antibody being reactive with said antigen in at least 96% of strains of S.pneumoniae.
It is preferred that such MAb is reactive with an epitope of a proteinaceous cell surface component of the bacterium S.pneumoniae, particularly a protein of approximately 67,000 daltons.
An additional aspect of this invention involves a cell line capable of producing a MAb that is reactive with an epitope of a proteinaceous cell surface component of the bacterium S.pneumoniae, with said epitope being present in at least 96% of strains of said bacterium.
It is preferred that said cell line be capable of generating a MAb that demonstrates specificity for an epitope of a proteinaceous cell surface component of the bacterium S.pneumoniae. It is preferred that said cell line is a hybridoma cell line, specifically a hybrid of a mouse spleen cell and an immortal myeloma cell.
A further aspect of this invention provides a diagnostic method to identify, type, and/or detect the presence of the bacterium S.pneumoniae or its antigens, with such method (a) causing the test sample to come into contact with said MAb; and (b) observing whether cell-labelling or agglutination occurs, indicating the presence of S.pneumoniae or an antigen of S.pneumoniae.
It is preferred that such a method involves a MAb that is reactive with an epitope of a proteinaceous cell surface component that is present in at least 96% of the known strains of S.pneumoniae. It is additionally preferred that the said label is chosen from a radio-label, a fluorescent label, a colloidal gold label, and a biotin label or an enzyme label. This method could also be employed to detect infection of S.pneumoniae in patients.
An additional feature of this invention provides a significantly purified form of the said proteinaceous cell surface component of the bacterium S.pneumoniae, having an epitope present in at least 96% of strains of said bacterium. A preferred embodiment of this feature is a 67,000 dalton protein or fragment thereof containing such an epitope. It is to be preferred that an epitope of said component or part thereof is present in more than 99% of the strains of S.pneumoniae, and is only present in said bacterium.
I have generated a MAb that specifically recognized an epitope of a proteinacous cell surface component of the S.pneumoniae common to more than 96% of all strains of said bacterium. The use of this MAb for immunodiagnosis and typing is disclosed.
DETAILED DESCRIPTION OF THE INVENTION
The production of a monoclonal antibody directed against a common protein of S.pneumoniae.
The strains of bacteria and culture conditions
S.pneumoniae strains were obtained from clinical isolates from Children's Hospital of Eastern Ontario, Ottawa, Laboratoire de la Sante Publique de Quebec, Sainte-Anne de Bellevue, and Trinidad. S.pneumoniae was grown on chocolate agar plates supplemented with 1% ISOVITALEX® (BBL, Cockeysville, Md.) overnight at 37° C., in an atmosphere containing 5% CO 2 . The resulting cultures were stored in
brain heart infusion broth containing 20% glycerol at -70° C.
Protein preparation
The extraction of the proteins from the bacteria was performed using SABCOSYL. Whole cells (from 50 plates) suspended in phosphate buffered saline PBS (45 ml) were heat-killed at 56° C. for 20 minutes and centrifuged at 3600 RPM Sorvall SS-34 rotor with Rmax=10.70 cm for 30 minutes using a fixed angle. The pellet was resuspended in 14 ml of 10 mM Hepes buffered water, pH7.4. The cells were then sonicated using a Vibra Cell sonicator, 4 times ×30 seconds pulse at 50%, 30 seconds between each sonication. The suspension was centrifuged at 3500 RPM in a Sorvall SS-34 rotor with Rmax=10.70 cm for 20 minutes. The supernatant was centrifuged once more to get it more clear. It was then transferred to a rigid wall polycarbonate tube, and ultracentrifuged at 28.8K (28,800 RPM) for 60 minutes, 7° C. using a 50.2 Ti rotor. The supernatant was discarded and the pellet resuspended in 1 ml of 10 mM Hepes buffered water. Fifteen seconds of sonication was necessary to resuspended the pellet. One ml of 2% N-Lauryl Sarcosine (SARCOSYL) in 10 mM hepes buffered water was added to the suspension and the tube was gently shaken for approximately 3 minutes at room temperature to mix. The suspension was ultracentrifuged again, at 28.8 K for 60 minutes at 7° C. The protein content of the supernatant was determined by the BIO-RAD protein assay (Bio-Rad Laboratories, Mississauga, Ontario, Canada).
Immunization of mice
A BALB/c mouse was inoculated sub-cutaneously with 5 μg of S.pneumoniae strain Trinidad 810062 proteins from the sarcosyl extraction, combined with 25 μg of Quil A. Three weeks later, the mouse was reinjected subcutaneously with 5 μg proteins and 25 μg Quil A. Eight days before the hybridoma production, the mouse was given 5 μg proteins and 25 μg Quil A, sub-cutaneously. Six and three days before the fusion, the mouse received 5 μg of the same protein preparation, but without Quil A, and the injection was done intraperitoneally. Serum was obtained from the immunized mouse by cardiac puncture before spleen removal.
Fusion procedure
Hybridomas were produced according to a modification of the methods described by Fazekas De St. Groth and Scheidegger, J. Immunol Methods, vol. 35, 1-21 (1986). Spleen cells from immunized mouse and nonsecreting, HGPRT deficient, mouse myeloma cells P3×63 Ag 8.653 were fused in a ratio 10:1 in Dulbecco modified Eagle's medium (DMEM, Flow Laboratories, Mississauga, Ontario, Canada) containing 50% (w/v) polyethylene glycol 1000 (T.J. Baker Chemical Co., Phillipsburg, N.J.). The fused cells (0.1 ml, 1.5×10 5 cells/ml) were portioned into 96-well tissue culture plates (Costar plastics, Vineland, N.J.) which contained a feeder layer of 4×10 3 murine peritoneal exudate cells (macrophages). The suspensions of cells were grown in DMEM that were supplemented with 20% bovine calf serum (Gibco), 2 mM L-glutamine (Sigma Chemical Co., St. Louis, Mo.), and 50 μg/ml gentamicin (Sigma) in the presence of hypoxanthine, aminopterin, and thymidine (HAT) selection medium. All cultures were checked on day six for the presence of clones and the medium was changed. Supernatants of wells containing growing clones were tested on day twelve by ELISA for MAb directed against S.pneumoniae antigens. The cells that were producing antibody were subcloned through limiting dilution. Subclones that were selected were grown either as ascites according to the method of Brodeur et al, J. Immunol Methods, 71, 265-272 (1984) or in vitro for freezing in liquid nitrogen.
Immunoglobulin class determination
The supernatant from the cells producing antibodies were tested against affinity purified anti-mouse immunoglobulin (Southern Biotech) using the ELISA method.
Enzyme-Linked Immunosorbent Assay (ELISA) Procedure
Screening of resulting supernatants for MAbs directed against S.pneumoniae was performed as described by Brodeur et al, J. Med. Microbiol, vol. 15, 1-9, (1982). The antigen (0.1 ml) containing 0.75 μg protein in 0.05M carbonate buffer at pH 9.6 was portioned into each well of a High-binding microtiter plate (Flow). The plate was incubated overnight at room temperature to permit the adsorption of the antigen. The plate was then washed with PBS containing 0.02% Tween-20 (Sigma) and 150 μl of 0.5% bovine serum albumin (BSA, Sigma) in PBS was added to each well. The plate was incubated at 37° C. for 30 minutes. The BSA was discarded and the plate was washed and the test supernatants were added. The positive control was a standard serum. After a one hour incubation at 37° C., the plate was washed three times. This was followed with the addition of 0.1 ml alkaline phosphatase-conjugated goat anti-mouse immunoglobulins (Miles Laboratories, Elkart, Ind.) diluted 1:1000 in PBS containing 3% BSA. The plate was incubated at 37° C. for an additional 1 hour. The plate was then washed and 0.1 ml of a 10% diethanolamine solution (pH 9.8), containing 1 mg/ml p-nitrophenylphosphate (Sigma) was added. The plate was allowed to stand for sixty minutes. The absorbance was then determined spectrophotometrically using a DYNATECH® microplate reader MR 600 at 410nm. Readings greater than 0.1 were scored as positive, indicating the presence of antibodies directed against S.pneumoniae.
SDS-polyacrylamide gel electrophoresis (PAGE)
Resolution of proteins was achieved through electrophoresis on sodium dodecyl sulfate (SDS) 0.75 mm thick slab mini gels according to the method described by Laemmli, Nature, vol. 227, 680-685 (1970). A 10% acrylamide (Bio-Rad) resolving gel and a 4.0% stacking gel were utilized. Cell lysates used on the gels were prepared by sonication, SARCOSYL extraction or heat-killed whole cell preparation. Lysates were mixed with sample buffer (62.5 mM Tris-HCl) pH 6.8, 1% (v/v) glycerol, 2% (w/v) SDS, 0.5% (v/v) 2-mercaptoethanol and 0.5% (w/v) bromophenol blue) and heated for 5 min. at 100° C. Aliquots of 15 μl containing 7.5 μg of protein were applied to each gel lane. Electrophoresis was carried out at 100 V constant voltage until the bromophenol blue tracking dye entered the separating gel. At this time, the voltage was then increased to 200 V. The gels were stained with Coomassie blue dye and then destained following the method of Weber and Osborn in J.Biol. Chem. vol. 244, 4406-4412 (1969). The protein standards used were: Phosphorylase b (97,000), Bovine serum albumin (66,200), ovalbumin (45,000), carbonic anhydrase (28,000), Soybean Trypsine Inhibitor (20,100), α-lactalbumin (14,200) (Bio-Rad Laboratories, Mississauga, Ontario, Canada).
Immunoblotting procedure
The proteins were transferred electrophoretically from the SDS-PAGE gel to nitrocellulose paper (Bio-Rad) by the method described by Towbin et al., Proc. Nati. Acad. Sci., vol. 76, 4350-4354 (1979). A constant current of 66 mA was applied to the gel-nitrocellulose paper sandwich for 15 minutes. This was done in an electroblot buffer of 25 mM Tris-HCl, 192 mM glycine and 20% (v/v) methanol at pH 8.1. The proteins transferred onto the blot were either stained with amido black or detected by an enzyme immunoassay. The detection of bacterial antigens was performed by soaking the paper in PBS solution containing 1% milk for 30 minutes in order to block non-specific protein binding sites. The paper was then incubated with mouse hyper-immune sera at 37° C. for 1 hour. The sheet was washed three times with PBS followed by a 1 hour incubation at 37° C. with peroxidase-conjugated goat anti-mouse immunoglobulins (Cappel, Cochranville, Pa.) diluted 1:1000 in PBS containing 3% BSA. The sheet was once again washed three times and the blots were soaked in a solution of o-dianisidine prepared as described by Towbin et al (supra).
Dot-enzyme immunoassay
A dot-enzyme immunoassay was used for a quick method of screening several MAbs against a large number of S.pneumoniae strains. The strains were grown on chocolate agar plates overnight and an aliquot of approximately 3×10 9 bacteria/ml was prepared in PBS. A small amount of the suspension, approximately 40 μl was applied to a nitrocellulose paper using a DOT-BLOT apparatus (Bio-Rad Laboratories, Mississauga, Ontario, Canada). The dot nitrocellulose paper was then processed following the procedure described in the immunoblotting procedure.
Enzymatic treatment of proteins
Nitrocellulose paper with transferred proteins (see immunoblotting procedure) was treated with 3 different enzymes before being processed with the MAb. The paper was soaked in a 1.25 ,mg/ml Proteinase K solution for 1/2 hour, a 150 μg/ml Trypsin solution for 2 hours, or in a 1 mg/ml Chymotrypsin solution for 2 hours. The nitrocellulose paper was then processed with the MAb as described in the immunoblotting procedure. These treated papers were observed for the disappearance of the protein band. The normal immunoblot, without enzymatic treatment, was used as a positive control.
Properties of monoclonal antibodies
More than 450 hybrid clones were obtained by fusing sensitized mouse spleen cells with P 3 ×63 Ag8.653 cells. The screening for the MAbs in the hybridoma culture supernatants was performed by ELISA, utilizing the homologous immunizing S.pneumoniae SARCOSYL extract as the coating antigens. Every positive hybrid clone supernatant was further tested against several other strains of S.pneumoniae. Eight hybridoma cell lines that demonstrated different patterns of reactivity in ELISA were obtained (see Table 1).
TABLE 1__________________________________________________________________________Characterization of monoclonal antibodies directed againstS. pneumoniae antigens. Immunoglobulin O.D. at Antigen SpecificityClone Class/subclass 410 mm recognized to S. pneumoniae__________________________________________________________________________1) 1G-4 IgG.sub.1 0.154 protein, few strains only approximately 72 KDa2) 2D-4 IgM >2.000 carbohydrate non-specific3) 2G-1 IgM 0.136 N/A N/A4) 4A-9 IgG.sub.3 >2.000 carbohydrate non-specific5) 6B-5 IgA 0.294 carbohydrate non-specific6) 6E-9 IgM/IgG.sub.1 1.000 proteins, non-specific approximately 67 KDa and 100 KDa carbohydrate7) 11E-1 IgG1 0.124 protein, yes approximately 67 KDa8) 13H-8 IgG2A 0.364 protein, homol. strain approximately only 72 KDa__________________________________________________________________________
MAb 11E-1 was the only clone that was very specific to all the strains of S.pneumoniae. It was also directed against a protein. This MAb was subcloned twice by limiting dilution and the class and subclass were determined using affinity purified anti-mouse immunoglobulikn (Southern Biotech) in an ELISA test. This clone was then identified as 11E-1H-3/F-11 but 11E-1 kept as the official designation.
Clone 11E-1 was deposited with the American Type Culture Collection, 12301 Parklawn Dr., Rockville, Md. on Feb. 4, 1993, under the ATCC accession number HB 11262.
Identification of antibody-specific epitopes on the antigen
The Western immunoblotting technique was used to ascertain the specific antigen to which each MAb binds. The mouse hyperimmune serum that was used as positive control, detected all the major proteins present in strains of S.pneumoniae.
Seven of the eight MAbs reacted with antigens transferred from the SDS-PAGE to nitrocellulose paper. The remaining MAb was too weak to react. Three different proteins were recognized by the MAbs with apparent molecular weights of 100,000, 72,000 and 67,000 daltons. In addition a number of very low molecular weight carbohydrates were recognized.
Binding properties of monoclonal antibody 11E-1
To determine whether clone 11E-1 was directed against the cell surface exposed epitope of the 67,000 dalton protein, or part thereof, hybridoma culture supernatants containing the MAbs were incubated with live intact S.pneumoniae bacterial cells. The bacteria were then washed twice with PBS and incubated with 125 I-labelled goat anti-mouse Ig (Dupont) and pelleted.
The bacterial cell-bound 125 I was counted using a 1282 Compugamma. Fewer than 3000 cpm were obtained using negative controls. These data represent the mean of triplicate determinations.
Supernatant containing the MAb 11E-1 showed counts between 5 to 9 times the negative controls containing no MAb, indicating that the component is surface accessible.
Specificity of monoclonal antibody 11E-1
The initial ELISA characterization showed 11E1 reacted only with S.pneumoniae strains. A dot-enzyme immunoassay was used for a rapid method of screening this MAb against numerous bacterial strains. The MAb 11E-1 reacted specifically with 118 S.pneumoniae strains and only cross reacted with one strain of Streptococcus sanguis type I (Table II)
TABLE II______________________________________Specificity of monoclonal antibody 11E-1Bacterial strains Reactivity by DOT-blot.sup.1______________________________________S. pneumoniae 118/123other Streptococcus sp. .sup. 1/29.sup.2N. meningitidis 0/8other Neisseria sp. 0/7E. coli 0/7S. aureus 0/1H. influenzae 0/1K. pneumoniae 0/1S. epidermidis 0/2______________________________________ .sup.1 Number of positive/Number of Strains .sup.2 Positive strain is S. sanquis I ID 12315 from LSPQ, SteAnne de Bellevue, Quebec Note: Of the 5 strains of S.pneumoniae that are not recognized by DOT-assay, 4 have been tested by immunoblot indicating that the 67KDa.
Preparation of Protein Antigen Extract
Several preparative methods of protein extracts have been utilized, especially for SDS-PAGE gel electrophoresis. The sarcosyl extraction has been described previously. An additional method involved the sonication of the bacteria. Approximately 10" bacteria were suspended in 5ml PBS and heat-killed for 20 minutes at 56° C. Using a SONIFIER CELL DISRUPTOR 350, (pulse was set at 50%), the cells were sonicated 3×5 minutes, being kept on ice during the entire procedure. The suspension was the centrifuged for 20 minutes at 25000 RPM using a 70 Til rotor run at 10° C. The supernatant was kept and the protein content determined by the BIO-RAD protein assay. Whole cell extract was also used, 50 μl of 10% SDS was added to the bacterial suspension, which was then boiled for 20 minutes and centrifuged. | This invention relates to a monoclonal antibody (MAb) directed against a surface protein of Streptococcus pneumoniae, a hybridoma cell line producing said antibody, and the use of such an antibody to detect the bacterium Streptococcus pneumoniae, or to detect antigens of Streptococcus pneumoniae. | 8 |
This application is a continuation of application Ser. No. 07/776,386 filed Nov. 21, 1991, now abandoned, itself a national stage of PCT/GB/90/00429 filed Mar. 20, 1990.
FIELD OF INVENTION
This invention relates to the treatment of aluminium base alloys to enable superplastic deformation thereof to be achieved. It also includes a method of superplastically deforming such alloys.
BACKGROUND
Superplastic behaviour in a number of aluminium alloys is known. It is generally required that the alloy should have a fine, stable, grain size (1 to 10 microns) or be capable of achieving such a grain size during hot deformation; be deformable at a temperature not less than 0.7 Tm (melting temperature) and at strain rates in the range 10 -2 to 10 -5 sec -1 .
In this specification where four figure numbers are used to specify aluminium alloys those are as designated by the Aluminum Association Inc.
It has been found that the two most important routes to achieve superplasticity are as follows:
(1) With alloys which have a composition suitable for superplastic deformation but a grain structure which precludes it. With such alloys the grain structure can frequently be modified by an initial non-superplastic deformation step at a suitable forming temperature to induce dynamic recrystallisation so that a fine recrystallised grain structure is progressively developed and superplastic deformation can then take place. Such alloys may for example include 2004 and its derivatives and the process is described in UK Patent 1456050.
Aluminium/lithium alloys such as 8090 and 8091 appear to possess many of the characteristics of the 2004 type in that they can be made to develop a fine grain structure by dynamic recrystallisation from an original grain structure not suitable for superplastic deformation. (see R. Grimes and W. S. Miller in "Aluminium-Lithium 2, Monterey, Calif. 1984"). We have also shown, in UK Patent 2,139,536 how superplastic deformation of an Al/Li alloy can be achieved by modifying its high temperature deformation characteristics.
(2) with alloys such as 7075 and 7475 that are subjected to a static recrystallisation treatment as their final stage in complex thermomechanical processing to develop a fine, stable, grain structure. Such alloys are then inherently capable of subsequent superplastic deformation. Reference is made to work done by Rockwell International and to the publications "Superplasticity in High Strength Aluminium Alloys" pp. 173 to 189 and "Superplastic Forming of Structural Alloys", AIME New York 1982 (ISBN O-89520-389-8).
More recently it has been shown (J. Wadsworth, C. A. Henshall and T. G. Nieh "Superplastic Aluminium-Lithium alloys" in Aluminium Lithium Alloys 3 ed. C. Baker, P. J. Gregson, S. J. Harris and C. J. Peel, Pub. Inst of Metals 1986 p 199) that this type of processing route can also be applied to a variety of aluminium-lithium based alloys to create a superplastically deformable grain structure.
Aluminium/lithium alloys are therefore unusual in that both processing routes can be applied to the same starting alloy chemistry to achieve superplasticity. Work by Wadsworth et al (see above) has shown that good superplastic performance can be achieved by either process route.
Thus the two most important superplastic deformation routes, as discussed above, can be summarised as follows.
Route 1 (corresponding with paragraph numbered 1 above)
Hot rolled product
Heavy cold deformation
Dynamic recrystallisation
Superplastic deformation
In the case of 2004 and its derivatives it is essential, for Route 1, to cast the ingot in such a way that it is supersaturated with zirconium.
Route 2 (corresponding with paragraph numbered 2 above)
Hot rolled product
Solution treatment
Overageing process
Cold or Warm deformation
Static recrystallisation
Superplastic deformation
It must be emphasised that these two routes have been developed separately in respect of different types of alloys. Apart from each starting from a hot rolled product and ending in a superplastic deformation step they differ considerably in conformity with the differing properties of the alloys to which they have been applied.
In many aluminium base alloys grain control constituents such as zirconium are included and when the Zr content increases above about 0.15% casting to produce a good product becomes progressively (and considerably) more difficult.
SUMMARY OF INVENTION
The basis of the present invention is that we have now unexpectedly found that with many alloys falling in the category of numbered paragraph 2 above, suitable treatment enables them to be dynamically recrystallised as set out in numbered paragraph I above. For example some of the paragraph 2 alloys contain, in well known manner, sufficient Zr (or other similar addition) to act as a grain controlling constituent and/or to prevent static recrystallisation. Others normally contain no such addition.
According to one aspect of the present invention there is provided a method of treating a blank of an aluminium base alloy characterised by a combination of heat treatments and cold forming operations to produce a highly recovered semi-fabricated wrought product that is not statically recrystallised and that is inherently non-superplastic and is capable of superplastic deformation only after an initial non-superplastic deformation to achieve dynamic recrystallisation.
According to another aspect of the present invention there is provided a method of treating a previously hot-rolled blank of an aluminium base alloy to produce a highly recovered semi-fabricated wrought product that is not statically recrystallised and that is inherently non-superplastic and is capable of superplastic deformation only after an initial non-superplastic deformation to achieve dynamic recrystallisation characterised by the sequential steps of:
(1) holding the previously hot-rolled blank at a temperature between 275° C. and 425° C. for between 1 and 24 hours
(2) allowing the blank to cool to a temperature suitable for cold forming
(3) cold forming the blank in at least two stages and
(4) annealing the cold formed blank between each of said stages at a temperature of between 300° C. and 400° C. for no more than 2 hours using a controlled heat-up rate of between 10° C. and 200° C./hour and allowing the annealed product to cool.
The grain controlling additive may be Zr in a quantity no more than 0.3% and preferably less than 0.2%.
Preferably after the last cold forming stage the product is finally annealed at a temperature between 450° C. and 500° C. for no more than 2 hours using a controlled heat-up rate of between 40° C. and 200° C./hour.
The cold forming step is preferably cold rolling.
The highly recovered semi-fabricated wrought product of the present invention may be a cellular dislocation structure with a cell diameter of approximately 10 micrometers. The cells are separated from one another by low angle boundaries and are contained within the grains. These grains may have been derived from the cast ingot from which the blank is derived and their "as cast" diameter is preferably in the range of 75 to 500 micrometers.
BRIEF DESCRIPTION OF DRAWING
The above and other aspects of the present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a graph of hot blank heat treatment temperature against subsequent superplastic deformation for alloys 8090 and 8091,
FIG. 2 is a graph showing the affect of temperature on the superplastic performance of alloys 8090 and 8091,
FIG. 3 is a graph showing the effect of strain rate on the superplastic performance of alloys 8090 and 8091,
FIG. 4 is a graph showing variation in cavitation in the same material processed according to the present invention and by a previously known method,
FIGS. 5 and 5a; 6 and 6a; 7 and 7a and 8 and 8a show grain structure, for different strain rates, in the same material processed according to the present invention and by a previously known method.
FIG. 9 is a graph showing the affect of various treatments on the superplastic performance of 2004,
FIG. 10 is a graph showing the affect on ductility of various strain rates for 2004 treated as in FIG. 9, and
FIGS. 11 and 12 are graphs similar to FIG. 9 respectively for alloys 7010 and 7050.
DETAILED DESCRIPTION OF EMBODIMENTS
Samples of 8090 6 mm sheet which had previously been hot-rolled were subjected to the following processing:
(a) heavily cold rolled as in Route 1 above
(b) heavily cold rolled but annealed at 350° C. during cold rolling
(c) hot blank heat treated and cold rolled
(d) hot blank heat treated and cold rolled but annealed at 350° C. during cold rolling.
In all cases the cumulative cold rolled reduction was 75%.
The samples were then all subjected to the same, known, high temperature deformation step. In each case the samples were pre-heated at 520° C. for 10 minutes prior to deforming at a constant crosshead velocity (ccv) of 1.5 mm/min (an initial strain rate of 2×10 -3 /sec).
The results of deformation were as follows:
______________________________________ Superplastic Deformation (%)Sample L-direction T-direction______________________________________(a) 380 400(b) 370 350(c) 550 420(d) 660 610______________________________________
For (b) and (d) annealing at 350° C. would have been after approximately each 20% of cold reduction (i.e.) 20% cold work--inter-anneal--20% cold work etc.
In sample (a) (identical to Route 1) dynamic recrystallisation occured as it also did in sample (b). If an intermediate anneal is applied to the "known" route 1 alloys" (i.e. 2004) there is a major drop in superplasticity, quite possibly to the point that the sheet is no longer superplastic. The 8090 processed as example (b) behaved very differently from similarly treated 2004 in so far as the intermediate annealing treatment had virtually no effect upon the superplastic behaviour of the sheet.
In sample (c) improved superplastic deformation was obtained. The blank heat treatment procedure used was similar to that of Route 2 and it might have been expected that during the pre-heat for 10 minutes at 520° C. a statically recrystallised grain structure would have developed but optical metallography showed this not to be the case. In addition, in sample (d) annealing during cold rolling gave a further improvement in superplastic deformation. This was unexpected.
As shown in FIG. 1, the curve illustrated is a fair average of samples respectively deformed at cross head velocities of 12.5 mm/minute and 1.5 mm/minute (initial strain rates of 1.5×10 -3 /sec and 2×10 -3 /sec respectively). FIG. 1 shows that 350° C. is an optimum temperature for 8090 to produce maximum subsequent superplasticdeformation for material heat treated for 16 hours. In practice we have found that heat treatment temperatures between 275° C. and 450° C. produce reasonable superplasticity in the alloy. It will beobvious to anyone skilled in the art that the heat treatment process is a diffusion controlled phenomenon and is thus controlled by the conjoint effects of time and temperature. Thus both time and temperature can be varied continuously to produce the necessary degree of microstructural change required to improve the material's subsequent superplastic performance. Treatment at 350° C. for 16 hours has been shown to beoptimum for 8090 and produce similar results in 8091. Other alloys may differ from this practice because of differences in their phase diagram and the diffusion rates of their solute elements.
FIGS. 2 and 3 show curves for alloys 8090 and 8091 treated as for samples (a) and (d). The examples in FIG. 2 were all preheated for 20 minutes at 525° C. and tensile tested at a constant crosshead velocity of 3.4 mm/min (initial strain rate of 4.5×10 -3/ sec). In FIG. 3 there was also a preheat step for 20 mins at 525° C. The benefits of samples (d) are clearly apparant. Furthermore these samples are superplastic at a higher deformation temperature than samples (a) which isalso advantageous.
Specifically in FIG. 1 blank heat treatment improves 8090's superplastic performance by a factor of 21/2 to 2. The improvement in superplastic ductility increases with increasing test temperature. In the case of 8091 the improvement in superplasticity with blank heat treatment is small below 500° C., but is significant above 500° C., i.e. withinthe solution treatment temperature range of the alloy. FIG. 3 shows that when tested at the alloy's solution treatment temperature (525° C.)the improvement in superplasticity with blank heat treatment is maintained over a wide range of crosshead velocities for both alloys.
Further experiments were made with 8090 and 8091 alloys treated as for sample (d) and then subjected to a variety of final annealing treatments prior to superplastic deformation. It should here be noted that the superplastic performances of alloys processed according to the known Routes 1 and 2 would decline if they were subjected to a final annealing process. The results of the final annealing were as follows:
______________________________________ Superplastic Elongation 8090 Alloy 8091 Alloy L- T- L- T-Final Anneal Direction Direction Direction Direction______________________________________none 410 240 500 6001 h at 350° C. 405 270 560 5701 h at 450° C. 515 320 750 650(50° C./h heat-up)20 min at 520° C. 180 130 200 330(50° C./h heat-up)______________________________________Test conditions 10 min preheat to 520° C. constant crosshead velocity test at 3.4 mm/min (initial strain rate 2 × 10.sup.-3 /sec).
These results show that annealing at 350° C. (a temperature which somewhat reduces the stored energy from the cold rolling process) does notsignificantly alter the alloys, superplastic forming capability because sufficient stored energy of cold rolling remains for some static recrystallisation to occur as the metal is subsequently raised to temperature for superplastic forming. Annealing at 450° C. with a controlled heat-up rate improves the superplastic forming capability substantially (at this temperature cold work is removed from the alloy andsubstantial recovery takes place) but almost no static recrystallisation occurs. However if the annealing temperature is increased to 520° C. (the solution treatment temperature) then superplastic forming capability is significantly reduced. We interpret this as being due to complete solutionising of the blank heat treatment precipitates removing obstacles to grain boundary movement allowing partial recrystallisation and some grain coarsening. These latter processes render the structure unsuitable for superplastic forming.
A series of 8 mm and 10 mm sheets which had previously been hot-rolled of 8090 were then processed as follows:
Sample 1--8 mm hot blank: Heat treated for 16 h at 350° C.: cold straight rolled to 4 mm: Annealed during cold rolling at 6 mm for 10 mins at 350° C.
Sample 2--As sample 1 but rolling was at right angles to hot rolling direction (cross-rolled).
Sample 3--As sample 2 with additional interanneal at 5 mm for 10 mins at 350° C.
Sample 4--As sample 2 but with a starting gauge of 10 mm.
Sample 5--As sample 2 but heat treatment was carried out after solution treating the hot blank for 30 mins and slow cooling to the heat treatment temperature.
The following table details the superplastic forming performance of the material with and without a final anneal at 450° C. (15 min soak 50° C./h heat-up).
______________________________________Superplastic DuctilityAs Rolled Annealed at 450° C.Sample L-Direction T-Direction L-Direction T-Direction______________________________________1 160 100 350 2302 170 180 510 6003 170 175 470 4504 200 170 475 4405 150 150 320 345______________________________________Test Condition 10 min preheat to 520° C. Initial Strain Rate 2.0 × 10.sup.-3 sec.sup.-1 (constant crosshead velocity 3.4 mm/min).
CONCLUSIONS
1. The final annealing gives a significant improvement in superplastic forming capability in all cases.
2. Cross rolling gives a significant reduction in anisotropy of superplastic forming capability.
Further optimisation of superplastic forming capability was carried out under various test conditions for samples 2 to 5 with all the material given a final anneal at 450° C. prior to superplastic deformation. The results are as follows:
__________________________________________________________________________Alloy 8090 Preheat InitialTemp Time Strain Sample 2 Sample 3 Sample 4 Sample 5°C. Min Rate sec.sup.-1 L T L T L T L T__________________________________________________________________________505 10 2 × 10.sup.-3 470 480 440 610 430 460 340 300520 10 2 × 10.sup.-3 510 600 470 450 475 440 320 345545 10 2 × 10.sup.-3 430 420 550 560 500 450 340 460530 10 4.5 × 10.sup.-3 310 360 280 350 300 320 195 170530 10 8.6 × 10.sup.-3 240 280 280 300 220 240 195 220530 10 2.0 × 10.sup.-3 480 490 525 460 420 460 330 350__________________________________________________________________________
CONCLUSIONS
1. All material shows superplastic forming capability in the solution treatment temperature range (500° to 545° C.) and at strain rates used commercially).
Sample 5 has the lowest overall superplastic capability. Thus solution treating prior to lower temperature heat treatment is not preferred.
Sample 3 has the better Superplastic capability particularly at the higher strain rates and higher test temperatures.
There is little difference with different starting gauges.
CAVITATION
FIG. 4 shows the cavitation observed in optimised route material compared to that found in the same alloy processed using Route 1 above.
A significant reduction in cavitation is found in the optimum route material.
GRAIN STRUCTURE DEVELOPMENT
FIGS. 5, 5a; 6, 6a; 7, 7a and 8, 8a compare the grain structure observed during superplastic forming of optimised route material compared to material processed via route 1.
The optimised route material develops a fine grain structure (necessary forgood superplastic performance and low flow stress) at a much earlier stage of straining.
Transmission electron microscopy has been carried out on material in the as-rolled+ final anneal state and in undeformed regions of samples held atthe forming temperature prior to straining. We have found that in material processed according to the optimum route of the present invention has an unrecrystallised grain structure with a uniform structure whereas route 1 material is unrecrystallised grain structure with a non-uniform structure.In an undeformed region the optimum route is recovered whereas the route 1 material is un-recrystallised.
Thus it can be stated that in the prior art route 2, the essential is that a fine grain statically recrystallised structure is produced during processing and prior to superplastic deformation. It is not practicable toproduce the fine grain structure in the preheat prior to superplastic deformation since the heating rate is too slow and generally not closely controlled. With route 1, this starts with an un-recrystallised structure which does not change significantly during the preheat to superplastic deformation. It transforms to a fine grain structure under the conjoint effects of strain and temperature to produce dynamic recrystallisation butthe strain required to produce a fully recrystallised fine grained structure can be quite large.
Both these routes can develop superplastically deformable Al/Li alloys. In route 2 this requires complex processing (because of the difficulty in statically recrystallizing to a fine grain structure (see I. G. Palmer, W.S. Miller, D. J. Lloyd, M. J. Bull in Aluminium Lithium 3 P565). In route 1the superplastic performance tends to be variable because of the insufficient quantity of zirconium in the alloy (up to 0.3 wt %).
FLOW STRESS MEASUREMENTS
We have found that the optimised route 8090 material of the above summary shows a flow stress of
5.3 MPa (L-direction) 4.8 MPa (T-direction)
This compares to values of 7.8 MPa (L-direction) and 7.9 MPa (T-direction) measured for the same alloy processed without any annealing steps. All tests showing the above results were carried out at 525° C. at an initial strain rate of 2×10 -3 /sec thus the optimum route processing can reduce flow stress by 33%.
Alloy 2004 is normally produced using the method of Route 1 above and good superplastic behaviour results. However FIGS. 9 and 10 show that alloy 2004 can be processed with advantage in accordance with the present invention. This improves the superplastic forming properties and increasesthe optimum forming temperature thus allowing easier control of cavitation during superplastic forming. The cold rolling operation can also be rendered easier by use of the present invention. With 2004 we have found that the final annealing step generally has little effect because a very efficient grain controlling dispersion of ZrAl 3 particles is normallypresent in the alloy.
We have also found, as shown in FIGS. 11 and 12 that the present invention can be applied with advantage to 7000 series alloys; particularly 7010 and7050, both containing Zr.
In the present invention the essential feature is to develop via the processing a highly recovered wrought product but to avoid static recrystallisation. This highly recovered structure leads to improved superplastic elongations, reduced tendency for the alloy to cavitate during deformation and a lower flow stress. All these features are desirable requirements for an alloy that is to be superplastically deformed.
It will thus be understood that the present invention provides a superplastic forming route for Al base alloys in which the starting material is subjected to heating rates at such temperatures and for such times and to such cold forming operations that static recrystallisation issubstantially avoided both during annealing and during pre-heat for superplastic forming. More specifically we have found the following parameters suitable:
______________________________________Starting Material Hot rolled blank______________________________________Low temperature annealed 16 hour at 350° C.for (See FIG. 1 for range in temp.) (Preferred to anneal directly)Cold roll to final gauge Preferred to cross roll Require approx 50% cold workInterannealing Interanneal during cold rolling At least once during cold rolling (Preferred every 20 to 25% cold reduction) (Preferred temp is 350° C., no soak, 50° C./h heat up)Final Anneal This should be at a temperature of at least 350° C. but below the alloy's solution treatment temperature. A controlled heat-up is necessary to avoid static recrystallisation. Preferably the temperature should be 450° C. (plus/minus 25) with a heat up rate of 50 to 100° C./hour and a soak period of 1 to 15 minutes.______________________________________
The basic superplastic processing route described above was developed from work on alloys 8090 and 2004.
The processing route has also been applied starting from a book-mould casting of nominal composition Al-6Cu-1.3Li-0.4 Mg-0.4Ag-0.14Zr. This involved:
(i) extrusion with a 20:1 extrusion ratio into 55 mm×4.5 mm section
(ii) over-ageing for 16 hours at 350° C.
(iii) cold cross-rolling to 3.5 mm gauge
(iv) annealing for 15 minutes at 350° C.
(v) further cold rolling to 2 mm gauge
(vi) final annealing by heating at 50° C./hour to 450° C.
The sheet has been tested under uni-axial tension whilst subjected to a hydrostatic pressure of 650 psi. At 485° C. using a strain rate of 1×10 -3 s -1 an elongation to failure of 400% was obtained. The flow stresses have been measured as a function of strain rate, and from this the superplasticity index, m, obtained. These values are shown in Table 1.
TABLE I______________________________________Flow Stress and m Value Variationwith Strain Rate at T = 485° C.Strain Rate Flow Stress m(s.sup.-1) (MPa) Value______________________________________2.5 × 10.sup.-5 2.59 0.25 5 × 10.sup.-5 3.16 0.337.5 × 10.sup.-5 3.72 0.37 1 × 10.sup.-4 4.14 0.402.5 × 10.sup.-4 6.04 0.45 5 × 10.sup.-4 8.25 0.477.5 × 10.sup.-4 10.05 0.47 1 × 10.sup.-3 11.69 0.462.5 × 10.sup.-3 17.54 0.43 5 × 10.sup.-3 22.98 0.38______________________________________
These results clearly demonstrate that the process produces genuine superplasticity in this alloy without the need for compostional modifications.
The mechanism by which this occurs has been investigated using optical microscopy at various stages of the process. This has shown that the microstructure of the final superplastically formed sheet has a recovered substructure. During superplastic forming it is recrystallised dynamicallyto produce a fine-grained microstructure typical of superplastic materials.
The highly recovered semi-fabricated wrought product of the present invention may be a cellular dislocation structure with a cell diameter of approximately 10 micrometers. The cells are separated from one another by low angle boundaries and are contained within the grains. These grains mayhave been derived from the cast ingot from which the blank is derived and their "as cast" diameter is preferably in the range of 75 to 500 micrometers. | A method of treating a blank of an aluminium base alloy comprising a combination of heat treatments and cold forming operations to produce a highly recovered semi-fabricated wrought product that is not statically recrystallized and that is inherently non-superplastic and is capable of superplastic deformation only after an initial non-superplastic deformation to achieve dynamic recrystallization. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fibrous products. In particular, the present invention concerns a process for reducing the susceptibility of lignocellulosic material to unwanted brightness reversion, in particular to brightness reversion caused by light or heat.
[0003] 2. Description of Related Art
[0004] It is well-known in the art that light (UV light in particular), heat, moisture and chemicals can give rise to changes in the brightness of cellulose pulps. Usually, such changes result in reduced reflectivity, particularly in blue light. This phenomenon is known as brightness reversion or yellowing and can be caused by various factors depending on which type of pulp is concerned. Heat and damp are the main causes of the brightness reversion of chemical (lignin-free) pulps, whereas mechanical pulps mostly yellow when they are exposed to light. The brightness reversion of mechanical pulps also varies depending on the raw material (type of wood), production method (with or without chemical pretreatment), and after-treatment (bleaching with different reagents) used. Thus, for instance, sulphonation and peroxide bleaching greatly increase the susceptibility of pulp to light-induced yellowing.
[0005] The brightness reversion of lignocellulosic pulps and products made from such pulps can be reduced or even prevented in various ways, for instance by means of impregnation or surface treatment using UV screens, antioxidants, or polymers, or by coating the surface with a coating layer or a layer of non-yellowing chemical pulp. Various additives are described in the patent literature. Thus, U.S. Pat. No. 4,978,363 discloses a composition and method for treating fibers based on a mixture of an organopolysiloxane having at least one amino-substituted hydrocarbon radical directly bonded to a silicon atom and a higher fatty carboxylic acid. The carboxylic acid reacts with the amino radicals to reduce yellowing and oxidation of the fiber treatment. The composition and method provide non-yellowing fibers and a treatment agent that does not gel during use, such as when exposed to carbon dioxide and/or used to treat carbon fibers.
[0006] U.S. Pat. No. 6,599,326 discloses inhibition of pulp and paper yellowing using hydroxylamines and other coadditives. Chemical pulps or papers, especially kraft pulps or papers, which may still contain traces of lignin, have enhanced resistance to yellowing when they contain an effective stabilizing amount of a N,N-dialkylhydroxylamine, an ester, amide or thio substituted N,N-dialkylhydroxylamine or N,N-dibenzylhydroxylamine or an ammonium salt thereof. This performance is often further enhanced by the presence of one or more coadditives selected from the group consisting of UV absorbers, polymeric inhibitors, nitrones, fluorescent whitening agents and metal chelating agents. Combinations of hydroxylamines or their salts, benzotriazole or benzophenone UV absorbers and a metal chelating agent are, according to the cited patent, considered particularly effective. As specific examples, the patent mentions N,N-diethylhydroxylamine and N,N-dibenzyl-hydroxylamine.
[0007] Many of the additives that have been found to prevent yellowing are expensive or problematic from an environmental point of view; others are only effective when introduced in so large amounts that they may have a negative effect on other properties of the product or be uneconomical. Accordingly, there is still a need for methods of preventing yellowing
SUMMARY OF THE INVENTION
[0008] It is an aim of the present invention to eliminate the problems of the prior art and to provide a new method of reducing or preventing yellowing. The method aims at effectively reducing both light- and heat-induced brightness reversion of mechanical pulps and high-yield chemical pulps.
[0009] The invention is based on the finding that the reactions that take place during oxidation, in particular enzymatic oxidation, of lignin appear to be similar to the reactions that cause brightness reversion. Therefore, the initial reaction causing brightness reversion can be activated by enzymatic or chemical means and simultaneously immediately blocked by targeted functionalization, by retarding or stopping the reactions.
[0010] Thus, the present invention provides a method of modifying fibres by bonding of new compounds to the oxidized fibres via radical pathways. In particular, the aim of the bonding of the compounds is to stabilize the structure by forming a colourless lignin derivative unable to participate in yellowing reactions.
[0011] According to the invention, new fibrous products with modified properties are produced by activating the fibres of the matrix with an oxidizing agent capable of oxidizing phenolic or similar structural groups, which may undergo reactions conducive to the formation of coloured sites on the fibres, and attaching to the oxidized sites at least one modifying agent to block the reactivity of the oxidized sites. The activation is preferably carried out enzymatically although it is equally possible to use chemical agents for achieving oxidation/radicalization.
[0012] The modifying agent has at least one functional site or reactive structure, which provides for binding of the modifying compound to the lignocellulosic fibre material, in particular at the oxidized phenolic groups or corresponding chemical structures of the fibres, which have been oxidized during the activation step.
[0013] Based on the above, the present invention provides a process for producing a fibre material having increased resistance to brightness reversion, comprising a lignocellulosic fibrous matrix with phenolic or similar structural groups and a modifying agent reducing the susceptibility of yellowing, including the steps of
reacting the lignocellulosic fibrous matrix with an oxidizing agent in the presence of a catalyst capable of catalyzing the oxidation of phenolic or similar structural groups by said oxidizing agent to provide an oxidized fibre material, and contacting the oxidized fibre material with a modifying agent containing at least one first functional site, which is capable of bonding to oxidized fibre material, said modifying agent being capable of imparting to the lignocellulosic fibre material improved resistance to brightness reversion caused by light or heat or combinations thereof.
[0016] It should be noted that the term “catalyst” is to be given a broad interpretation in the present context, and it covers any agent capable of possibly—but not exclusively—in combination with a separate oxidation agent, of achieving oxidation of the phenolic or similar groups.
[0017] Another embodiment of the invention provides a method of reducing light or heat induced brightness reversion of mechanical or high-yield chemical pulp, comprising the steps of enzymatically or chemically oxidizing phenolic groups of the pulp and bonding to the oxidized phenolic groups a substance capable of forming a colourless lignin derivative unable to participate in yellowing reactions.
[0018] More specifically, the present invention is mainly characterized by what is stated in the characterizing parts of claims 1 and 18 .
[0019] The present invention provides important advantages. Importantly, the invention makes it possible to produce novel kinds of fibrous materials having improved brightness reversion. By means of the process, the modifying agents can be reliable attached to the fibres, and the improved resistance to yellowing will not be significantly impaired by, e.g., extensive washing of the fibres prior to forming the material into a paper or cardboard web.
[0020] Further details and advantages of the invention will become apparent from the following detailed description and the appended working examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depict in graphical form yellowing of spruce TMP samples as function of irradiation energy.
DETAILED DESCRIPTION OF THE INVENTION
[0022] As mentioned above, the invention generally relates to a method of producing fibre compositions with reduced susceptibility to yellowing.
[0023] The fibre matrix comprises fibres containing phenolic or similar structural groups, which are capable of being oxidized by suitable oxidizing agents. Such fibres are typically “lignocellulosic” fibre materials, which include fibre made of annual or perennial plants or wooden raw material by, for example, mechanical, chemimechanical or chemical pulping. During industrial refining of wood by, e.g., refiner mechanical pulping (RMP), pressurized refiner mechanical pulping (PRMP), thermomechanical pulping (TMP), groundwood (GW) or pressurized groundwood (PGW) or chemithermomechanical pulping (CTMP), a woody raw material, derived from different wood species as for example hardwood and softwood species, is refined into fine fibres in processes, which separate the individual fibres from each other. The fibres are typically split between the lamellas along the interlamellar lignin layer, leaving a fibre surface, which is at least partly covered with lignin or lignin-compounds having a phenolic basic structure
[0024] Within the scope of the present invention, also chemical pulps are included if they are susceptible to brightness reversion and have a residual content of lignin sufficient to give at least a minimum amount of phenolic groups necessary for providing binding sites for the modifying agent. Generally, the concentration of lignin in the fibre matrix should be at least 0.1 wt-%, preferably at least about 1.0 wt-%.
[0025] In addition to paper- and paperboard-making pulps of the above kind, also other kinds of fibres of plant origin can be treated, such as bagasse, jute, flax and hemp.
[0026] An essential feature of the invention is to block brightness reversion by modifications of phenolic hydroxyls, alfa-carbonyls and/or alfa-hydroxyls on the fibres. In particular, by subjecting lignin structures to enzymatic oxidation to yield oxidized groups of the aforesaid kind, the normal reactions causing brightness reversion can be attained. These reactions are then stopped by bonding a desired compound to the activated, oxidized groups.
[0027] In the first stage of the present process, the lignocellulosic fibre material is reacted with a substance capable of catalyzing the oxidation of phenolic or similar structural groups to provide an oxidized fibre material. Typically, the substance is an enzyme and the enzymatic reaction is carried out by contacting the lignocellulosic fibre material with an oxidizing agent, which is capable—in the presence of the enzyme—of oxidizing the phenolic or similar structural groups to provide an oxidized fibre material. Such oxidizing agents are selected from the group of oxygen and oxygen-containing gases, such as air, and hydrogen peroxide. Oxygen can be supplied by various means, such as efficient mixing, foaming, gases enriched with oxygen or oxygen supplied by enzymatic or chemical means, such as peroxides to the solution. Peroxides can be added or produced in situ.
[0028] According to an embodiment of the invention, the oxidative enzymes capable of catalyzing oxidation of phenolic groups, are selected from, e.g. the group of phenoloxidases (E.C.1.10.3.2 benzenediol:oxygen oxidoreductase) and catalyzing the oxidation of o- and p-substituted phenolic hydroxyl and amino/amine groups in monomeric and polymeric aromatic compounds. The oxidative reaction leads to the formation of phenoxy radicals. Another groups of enzymes comprise the peroxidases and other oxidases. “Peroxidases” are enzymes, which catalyze oxidative reaction using hydrogen peroxide as their electron acceptor, whereas “oxidases” are enzymes, which catalyze oxidative reactions using molecular oxygen as their electron acceptor.
[0029] In the method of the present invention, the enzyme used may be for example laccase, tyrosinase, peroxidase or oxidase, in particular, the enzyme is selected from the group of laccases (EC 1.10.3.2), catechol oxidases (EC 1.10.3.1), tyrosinases (EC 1.14.18.1), bilirubin oxidases (EC 1.3.3.5), horseradish peroxidase (EC 1.11.1.7), manganese peroxidase (EC 1.11.1.13) and lignin peroxidase (EC 1.11.1.14).
[0030] The amount of the enzyme is selected depending on the activity of the individual enzyme and the desired effect on the fibre. Advantageously, the enzyme is employed in an amount of 0.0001 to 10 mg protein/g of dry matter fiber.
[0031] Different dosages can be used, but advantageously a dosage of about 1 to 100,000 nkat/g, more advantageously 10-500 nkat/g.
[0032] In addition to enzymes, also chemical agents, such as alkali metal persulphates and hydrogen peroxide and other per-compounds, can be used for achieving oxidization of the phenolic groups and for forming phenoxy radicals. The dosage of the chemical agent is, depending on the chemical agent and on the pulp (i.e. on the amount of phenolic groups contained therein), typically in the range of about 0.01 to 100 kg/ton, preferably about 0.1 to about 50 kg/ton, e.g. about 0.5 to 20 kg/ton. In the case of chemical agents, no separate oxidation agent needs to be added. The per-compound will achieve the aimed oxidation of the phonolic groups.
[0033] The activation treatment is carried out in a liquid medium, preferably in an aqueous medium, such as in water or an aqueous solution, at a temperature in the range of 5 to 100° C., typically about 10 to 85° C. Normally, a temperature of 20-80° C. is preferred. The consistency of the pulp is, generally, 0.5 to 95% by weight, typically about 1 to 50% by weight, in particular about 2 to 40% by weight. The pH of the medium is preferably slightly acidic, in particular the pH is about 2 to 10, in the case of phenoloxidases. The chemical agents are usually employed at slightly acidic conditions, such as at pH 3 to 6. Peroxidases are typically employed at pH of about 3 to 12. The reaction mixture is stirred during oxidation. Other enzymes can be used under similar conditions, preferably at pH 2-10.
[0034] In the second step of the process, a modifying agent capable of reducing the susceptibility to yellowing of lignocellulosic fibres is bonded to the oxidized phenolic or similar structural groups of the matrix. Such a modifying agent typically exhibits at least one first functional site, which is compatible with the fibrous matrix, and at least one second functional site or structure providing for the above technical effect, as will be explained in more detail below.
[0035] The first functional site comprises in particular functional groups, which are capable of contacting and binding to the fibre at the oxidized phenolic or similar structural groups or at its vicinity. The bond formed between the oxidized phenolic or similar residue can be covalent or ionic or even based on hydrogen bonding. Typical functionalities of the first functional site include reactive groups, such as hydroxyl (including phenolic hydroxy groups), carboxy, anhydride, aldehyde, ketone, amino, amine, amide, imine, imidine and derivatives and salts thereof, to mention some examples. Also electronegative bonds, such as carbon-to-carbon double bonds, carbon-to-hetero atom (e.g. C═N, C═O) as well as oxo or azo-bridges can provide for bonding to the oxidized residues.
[0036] It is essential that the modifying agent is chemically or physically bonded to the fibre matrix to such an extent that at least an essential part of it cannot be removed. One criterion, which can be applied to test this feature, is washing in aqueous medium, because often the fibrous matrix will be processed in an aqueous environment, and it is important that it retains the new and valuable properties even after such processing. Thus, preferably, at least 10 mol-%, in particular at least 20 mol-%, and preferably at least 30 mol-%, of the modifying agent remains attached to the matrix after washing or leaching in an aqueous medium.
[0037] According to an embodiment of the invention, the modifying agent is activated with an oxidizing agent.
[0038] The interaction of the oxidized lignocellulosic material and the modifying agent, resulting in bonding of the modifying agent to the lignocellulosic material, typically takes place in liquid phase, usually in water or in another aqueous medium. The pulp or other lignocellulosic fibrous matrix is suspended in the medium and it is contacted with the modifying agent or a precursor thereof, which is dissolved or dispersed in the same medium. The conditions can vary freely, although it is preferred to carry out the contacting under mixing or stirring. The temperature is generally between the melting point and the boiling point of the medium; preferably it is about 5 to 100° C. Depending on the modifying agent or its precursor, the pH of the medium can be neutral or weakly alkaline or acidic (pH typically about 2 to 12). It is preferred to avoid strongly alkaline or acidic conditions because they can cause hydrolyzation of the fibrous matrix. Normal pressure (ambient pressure) is also preferred, although it is possible to carry out the process under reduced or elevated pressure in pressure resistant equipment. Generally, the consistency of the fibrous material is about 0.5 to 95% by weight during the contacting stage.
[0039] According to a particularly preferred embodiment, the first and the second stages of the process are carried out in the same reaction medium, without separating the fibrous matrix after the oxidation step. The conditions (consistency, temperature, pH, pressure) can, though, even in this embodiment be different during the various processing stages.
[0040] The first and the second stages of the process are carried out sequentially or simultaneously. However, it should be noted that the first step of the process aims at the formation in the fibrous substrate of phenoxy radicals, which are capable of binding modifying agents. Some modifying agents will form substrates for the oxidative enzymes used in the invention, and in that case, it is preferred to first add the oxidative enzymes and to allow the enzyme interact with the fibrous substrate containing phenolic or similar groups, e.g. for 0.1 to 180 minutes, in particular about 1 to 30 minutes to achieve oxidation of the phenolic groups, and to add the modifying agents after the enzymatic oxidation.
[0041] The same observations are true for the chemical oxidation agents mentioned above. As Example 3 shows, reasonably good results are obtained with the simultaneous application of oxidation agent and modifying agent, although the best results are attained when steps one and two are carried our sequentially.
[0042] According to one preferred embodiment, the modifying agent is an aliphatic or aromatic, monocyclic, bicyclic or tricyclic substance. The aliphatic compound can be an unsaturated carboxylic acid, advantageously a monocarboxylic unsaturated fatty acid, having 4 to 30 carbon atoms. In particular, the modifying agent can be a monocarboxylic, unsaturated fatty acids containing a minimum of two double bonds, preferably two conjugated double bonds. Such fatty acids have an even number of carbon atoms, typically in the range of 16 to 22. It is also possible to use lower alkanols, i.e. alcoholic compounds comprising 1 to 6, in particular 1 to 4 carbon atoms. Examples include n- and i-propanol and n- and t-butanol.
[0043] Examples of particularly suitable compounds are constituted by linoleic and linolenic acid. It would appear that the unsaturated fatty acid bonds to the oxidized groups or structure via one of the double bonds.
[0044] Other suitable compounds include antioxidants, such as tocopherol and beta-carotene.
[0045] The compound can have special properties, such as capability to trap radicals and form colourless substituents.
[0046] The above two steps can be carried sequentially or simultaneously. Also other compounds, such as papermaking chemicals may be present during the reaction steps.
[0047] After the above processing, the modified fibre having new properties is generally separated from the liquid reaction and further used in target applications.
[0048] The following non-limiting examples illustrate the invention:
EXAMPLE 1
[0049] A 5 g portion of bleached spruce TMP was suspended in water. The pH of the suspension was adjusted to pH 4.5 by addition of acid. The suspension was stirred at RT. Laccase dosage was 1000 nkat/g of pulp dry matter and the final pulp consistency was 7.5%. After 30 minutes laccase reaction, 0.15 mmol linoleic acid/g of pulp dry matter was added to the pulp suspension. After 1 h total reaction time, the pulp suspension was filtered and the pulp was washed thoroughly with water. Handsheets were prepared. For comparison purposes, reference treatments were carried out using the same procedure as described above but without addition of laccase or linoleic acid or both. The light-fastness on the pulps was tested with Xenotest 150S light exposure and weathering test instrument using “window glass” filter. The brightness of the handsheets was measured as function of irradiation dosage. The results are presented graphically in FIG. 1 .
[0050] From the results presented in FIG. 1 , it is apparent that the addition of linoleic acid and laccase was found to decrease the yellowing tendency of the pulp. In other words, addition of a modifying agent in the presence of an oxidizing agent and a suitable catalyst, the yellowing tendency of pulp was decreased.
EXAMPLE 2
[0000] Bonding of New Compounds to TMP
[0051] A 5 g portion of spruce TMP was suspended in water. The pH of the suspension was adjusted to pH 4.5 by addition of acid. The suspension was stirred at RT. Laccase dosage was 1000 nkat/g of pulp dry matter and the final pulp consistency was 7.5%. After 30 minutes laccase reaction the new compound was added to the pulp suspension. After 1 h total reaction time, the pulp suspension was filtered and the pulp was washed thoroughly with water. Handsheets were prepared. For comparison purposes, reference treatments were carried out using the same procedure as described above but without addition of laccase or the new compound. The light-fastness on the pulps was tested with Xenotest 150S light exposure and weathering test instrument using “window glass” filter. The changes in the ISO brightnesses after irradiation are summarized in Table 1.
TABLE 1 Δ Brightness Irradation (as ISO- Treatment (Whm 2 ) Brightness) TMP Reference 1260 10 TMP + laccase + ferulic acid (0.15 mmol/g) 1260 3 TMP + laccase + vinyl laurate (0.3 mmol/g) 1260 2
EXAMPLE 3
[0052] Sample A: Peroxide bleached aspen-CTMP-pulp was treated with sodium persulphate (dosage 5 kg/ton of pulp) and linoleic acid (5 kg) at 80° C., at pH 5 for 60 minutes. The treatment was carried out at a consistency of 10%.
[0053] Sample B: The pulp sample was treated in the same way as Sample A except that ammonium persulphate (5 kg) was used instead of Na-persulphate.
[0054] Sample C: The pulp sample was treated in the same way as Samples A and B except that hydrogen peroxide was used instead of persulphate. The pH of the test was 4.
[0055] Sample D: The pulp sample was treated as Sample A but t-butanol (5 kg) was used instead of linoleic acid.
[0056] Sample E: The pulp sample was treated in the same way as Sample A, but no linoleic was added. After the treatment with persulphate, a separate treatment was made with linoleic acid (5 kg) at 80° C. at a consistency of 10%. The duration of the treatment was 30 min, and the pH was 5
[0057] Sample F: The sample was prepared as Sample D, but without using any t-butanol. After the persulphate treatment, a separate treatment (30 min, pH 5) with t-butanol was carried out at a consistency of 10% and a temperature of 80° C., the dosage being 5 kg/ton of pulp.
[0058] Sheets were manufactured from the pulp samples and their brightness stability was tested with a Xenotest S150 using a “window pane” filter. The radiation of the Xenotest-apparatus corresponded to that of sunlight through a window pane, but the intensity of the radiation was much stronger (accelerated test). The brightness of the samples was determined after a 2 h radiation (corresponds to 1260 wh/m 2 )
[0059] The results are indicated in Table 2 below:
TABLE 2 Sample Brightness reduction (Δ Brightness, % ISO) Reference (untreated) 10.4 A 6.9 B 7.2 C 6.8 D 7.2 E 6.1 F 6.1
[0060] As apparent from the above results, the brightness stability of the samples treated by the present invention has been improved by even more than 4 units. | The present invention concerns a process for reducing the susceptibility of lignocellulosic material to unwanted yellowing, particularly yellowing caused by light and heat. According to the invention, the fibres are activated enzymatically or chemically and then contacted with a modifying agent capable of bonding to the oxidized fibre material, rendering the lignocellulosic fibre material improved resistance to brightness reversion. By means of the invention, brightness reversion caused by light or heat or a combination thereof can be retarded and even stopped. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 12/421,379 filed Apr. 9, 2009. The entire contents of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to the field of automatic transmissions for motor vehicles and, more particularly, to a friction element load sensor that directly measures torque transmitted by a friction element of an automatic transmission.
BACKGROUND OF THE INVENTION
[0003] A step-ratio automatic transmission system in a vehicle utilizes multiple friction elements for automatic gear ratio shifting. Broadly speaking, these friction elements may be described as torque establishing elements although more commonly they are referred to as clutches or brakes. The friction elements function to establish power flow paths from an internal combustion engine to vehicle traction wheels. During acceleration of the vehicle, the overall speed ratio, which is the ratio of a transmission input shaft speed to a transmission output shaft speed, is reduced during a ratio upshift as vehicle speed increases for a given engine throttle setting. A downshift to achieve a higher speed ratio occurs as an engine throttle setting increases for any given vehicle speed, or when the vehicle speed decreases as the engine throttle setting is decreased.
[0004] Various planetary gear configurations are found in modern automatic transmissions. However the basic principle of shift kinematics remains similar. Shifting a step-ratio automatic transmission having multiple planetary gearsets is accompanied by applying and/or releasing friction elements to change speed and torque relationships by altering the torque path through the planetary gearsets. Friction elements are usually actuated either hydraulically or mechanically.
[0005] In the case of a synchronous friction element-to-friction element upshift, a first pressure actuated torque establishing element, referred to as an off-going friction element, is released while a second pressure actuated torque establishing element, referred to as an on-coming friction element, engages in order to lower a transmission gear ratio. A typical upshift event is divided into preparatory, torque and inertia phases. During the preparatory phase, an on-coming friction element piston is stroked to prepare for its engagement while an off-going friction element torque-holding capacity is reduced as a step toward its release. During the torque phase, which may be referred to as a torque transfer phase, on-coming friction element torque is raised while the off-going friction element is still engaged. The output shaft torque of the automatic transmission typically drops during the torque phase, creating a so-called torque hole. When the on-coming friction element develops enough torque, the off-going friction element is released, marking the end of the torque phase and the beginning of the inertia phase. During the inertia phase, the on-coming friction element torque is adjusted to reduce its slip speed toward zero. When the on-coming friction element slip speed reaches zero, the shift event is completed.
[0006] In a synchronous shift, the timing of the off-going friction element release must be synchronized with the on-coming friction element torque level to deliver a consistent shift feel. A premature release leads to engine speed flare and a deeper torque hole, causing perceptible shift shock for a vehicle occupant. A delayed release causes a tie-up of gear elements, also resulting in a deep and wide torque hole for inconsistent shift feel. A conventional shift control relies on speed measurements of the powertrain components, such as an engine and a transmission input shaft, to control the off-going friction element release process during the torque phase. A conventional torque phase control method releases the off-going friction element from its locked state through an open-loop control based on a pre-calibrated timing, following a pre-determined off-going friction element actuator force profile. This conventional method does not ensure optimal off-going friction element release timing and therefore results in inconsistent shift feel.
[0007] Alternatively, a controller may utilize speed signals to gauge off-going friction element release timing. That is, the off-going friction element is released if the controller detects a sign of gear tie-up, which may be manifested as a measurable drop in input shaft speed. When a release of the off-going friction element is initiated prematurely before the on-coming friction element develops enough torque, engine speed or automatic transmission input shaft speed may rises rapidly in an uncontrolled manner. If this so-called engine speed flair is detected, the controller may increase off-going friction element control force to quickly bring down automatic transmission input speed or off-going friction element slip speed. This speed-based or slip-based approach often results in a hunting behavior between gear tie-up and engine flair, leading to inconsistent shift feel. Furthermore, off-going friction element slip control is extremely difficult because of its high sensitivity to slip conditions and a discontinuity between static and dynamic frictional forces. A failure to achieve a seamless slip control during the torque phase leads to undesirable shift shock.
[0008] In the case of a non-synchronous automatic transmission, the upshifting event involves engagement control of only an on-coming friction element, while a companion clutching component, typically a one-way coupling, automatically disengages to reduce the speed ratio. The non-synchronous upshift event can also be divided into three phases, which may also be referred to as a preparatory phase, a torque phase and an inertia phase. The preparatory phase for the non-synchronous upshift is a time period prior to the torque phase. The torque phase for the non-synchronous shift is a time period when the on-corning friction element torque is purposely raised for its engagement until the one-way coupling starts slipping or overrunning. This definition differs from that for the synchronous shift because the non-synchronous shift does not involve active control of a one-way coupling or the off-going friction element. The inertia phase for the non-synchronous upshift is a time period when the one-way coupling starts to slip, following the torque phase. According to a conventional upshift control, during the torque phase of the upshifting event for a non-synchronous automatic transmission, the torque transmitted through the oncoming friction element increases as it begins to engage. A kinematic structure of a non-synchronous upshift automatic transmission is designed in such a way that torque transmitted through the one-way coupling automatically decreases in response to increasing oncoming friction element torque. As a result of this interaction, the automatic transmission output shaft torque drops during the torque phase, which again creates a so-called “torque hole.” Before the one-way coupling disengages, as in the case previously described, a large torque hole can be perceived by a vehicle occupant as an unpleasant shift shock. An example of a prior art shift control arrangement can be found in U.S. Pat. No. 7,351,183 hereby incorporated by reference.
[0009] A transmission schematically illustrated at 2 in FIG. 1 is an example of a prior art multiple-ratio transmission with a controller 4 wherein ratio changes are controlled by friction elements acting on individual gear elements. Engine torque from vehicle engine 5 is distributed to torque input element 10 of hydrokinetic torque converter 12 . An impeller 14 of torque converter 12 develops turbine torque on a turbine 16 in a known fashion. Turbine torque is distributed to a turbine shaft, which is also transmission input shaft 18 . Transmission 2 of FIG. 1 includes a simple planetary gearset 20 and a compound planetary gearset 21 . Gearset 20 has a permanently fixed sun gear S 1 , a ring gear R 1 and planetary pinions P 1 rotatably supported on a carrier 22 . Transmission input shaft 18 is drivably connected to ring gear R 1 . Compound planetary gearset 21 , sometimes referred to as a Ravagineaux gearset, has a small pitch diameter sun gear S 3 , a torque output ring gear R 3 , a large pitch diameter sun gear S 2 and compound planetary pinions. The compound planetary pinions include long pinions P 2 / 3 , which drivably engage short planetary pinions P 3 and torque output ring gear R 3 . Long planetary pinions P 2 / 3 also drivably engage short planetary pinions P 3 . Short planetary pinions P 3 further engage sun gear S 3 . Planetary pinions P 2 / 3 , P 3 of gearset 21 are rotatably supported on compound carrier 23 . Ring gear R 3 is drivably connected to a torque output shaft 24 , which is drivably connected to vehicle traction wheels through a differential and axle assembly (not shown). Gearset 20 is an underdrive ratio gearset arranged in series with respect to compound gearset 21 . Typically, transmission 2 preferably includes a lockup or torque converter bypass clutch, as shown at 25 , to directly connect transmission input shaft 18 to engine 5 after a torque converter torque multiplication mode is completed and a hydrokinetic coupling mode begins. FIG. 2 is a chart showing a clutch and brake friction element engagement and release pattern for establishing each of six forward driving ratios and a single reverse ratio for transmission 2 .
[0010] During operation in the first four forward driving ratios, carrier P 1 is drivably connected to sun gear S 3 through shaft 26 and forward friction element A. During operation in the third ratio, fifth ratio and reverse, direct friction element B drivably connects carrier 22 to shaft 27 , which is connected to large pitch diameter sun gear S 2 . During operation in the fourth, fifth and sixth forward driving ratios, overdrive friction element B connects turbine shaft 18 to compound carrier 23 through shaft 28 . Friction element C acts as a reaction brake for sun gear S 2 during operation in second and sixth forward driving ratios. During operation of the third forward driving ratio, direct friction element B is applied together with forward friction element A. The elements of gearset 21 then are locked together to effect a direct driving connection between shaft 28 and output shaft 26 . The torque output side of forward friction element A is connected through torque transfer element 29 to the torque input side of direct friction element B, during forward drive. The torque output side of direct friction element B, during forward drive, is connected to shaft 27 through torque transfer element 30 . Reverse drive is established by applying low-and-reverse brake D and friction element B.
[0011] For the purpose of illustrating one example of a synchronous ratio upshift for the transmission of FIG. 1 , it will be assumed that an upshift will occur between the first ratio and the second ratio. On such a 1-2 upshift, friction element C starts in the released position before the shift and is engaged during the shift while low/reverse friction element D starts in the engaged position before the shift and is released during the shift. Forward friction element A stays engaged while friction element B and overdrive friction element E stay disengaged throughout the shift. More details of this type of transmission arrangement are found in U.S. Pat. No. 7,216,025, which is hereby incorporated by reference.
[0012] FIG. 3 depicts a general process of a synchronous friction element-to-friction element upshift event from a low gear configuration to a high gear configuration for the automatic transmission system of FIG. 1 . For example, the process has been described in relation to a 1-2 synchronous ratio upshift above wherein friction element C is an oncoming friction element and low/reverse friction element D is an off-going friction element, but it is not intended to illustrate a specific control scheme.
[0013] The shift event is divided into three phases: a preparatory phase 31 , a torque phase 32 and an inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked (not shown) to prepare for its engagement. At the same time, off-going friction element control force is reduced as shown at 34 as a step toward its release. In this example, off-going friction element D still retains enough torque capacity shown at 35 to keep it from slipping, maintaining transmission 2 in the low gear configuration. However, increasing on-coming friction element control force shown at 36 reduces net torque flow within gearset 21 . Thus, the output shaft torque drops significantly during torque phase 32 , creating a so-called torque hole 37 . A large torque hole can be perceived by a vehicle occupant as an unpleasant shift shock. Toward the end of torque phase 32 , off-going friction element control force is dropped to zero as shown at 38 while on-coming friction element apply force continues to rise as shown at 39 . Torque phase 32 ends and inertia phase 33 begins when off-going friction element D starts slipping as shown at 40 . During inertia phase 33 , off-going friction element slip speed rises as shown at 41 while on-coming friction element slip speed decreases as shown at 42 toward zero at 43 . The engine speed and transmission input speed 44 drops as the planetary gear configuration changes. During inertia phase 33 , output shaft torque indicated by profile 45 is primarily affected by on-coming friction element C torque capacity indirectly indicated by force profile 46 . When on-coming friction element C completes engagement or when its slip speed becomes zero at 43 , inertia phase 33 ends, completing the shift event.
[0014] FIG. 4 shows a general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element D is released prematurely as shown at 51 compared with the case shown in FIG. 3 . When off-going friction element 1 ) is released, it breaks a path between automatic transmission input shaft 18 and automatic transmission output shaft 24 , depicted in FIG. 1 , no longer transmitting torque to automatic transmission output shaft at the low gear ratio. Since on-coming friction element C is yet to carry enough engagement torque as indicated by a low apply force at 52 , automatic transmission output shaft torque drops largely, creating a deep torque hole 53 which can be felt as a shift shock. At the same time, engine speed or transmission input speed rapidly increases as shown at 54 , causing a condition commonly referred to as engine flare. A large level of engine flare can be audible to a vehicle occupant as unpleasant noise. Once on-coming friction element C develops sufficient engagement torque as indicated by a rising control force at 55 , automatic transmission input speed comes down and the output torque rapidly moves to a level at 56 that corresponds to on-coming friction element control force 55 . Under certain conditions, this may lead to a torque oscillation 57 that can be perceptible to a vehicle occupant as unpleasant shift shock. FIG. 5 shows a general process of a friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element release is delayed as shown at 61 compared with the case shown in FIG. 3 . Off-going friction element D remains engaged even after on-coming friction element C develops a large amount of torque as indicated by a large actual control force at 65 . Thus, transmission input torque continues to be primarily transmitted to output shaft 24 at the low gear ratio. However, large on-coming friction element control force 65 results in a drag torque, lowering automatic transmission output shaft torque, creating a deep and wide torque hole 63 . This condition is commonly referred to as a tie-up of gear elements. A severe tie-up can be felt as a shift shock or loss of power by a vehicle occupant.
[0015] As illustrated in FIGS. 3 , 4 , and 5 a missed synchronization of off-going friction element release timing with respect to on-coming friction element torque capacity leads to engine flare or tie-up. Both conditions lead to varying torque levels and profiles at automatic transmission torque output shaft 24 during shifting. If these conditions are severe, they result in undesirable driving experience such as inconsistent shift feel or perceptible shift shock. The prior art methodology attempts to mitigate the level of missed-synchronization by use of an open loop off-going friction element release control based on speed signal measurements. It also attempts to achieve a consistent on-coming friction element engagement torque by an open-loop approach during a torque phase under dynamically-changing shift conditions.
[0016] FIG. 6 illustrates a prior art methodology for controlling a friction element-to-friction element upshift from a low gear configuration to a high gear configuration for automatic transmission 2 in FIG. 1 . The prior art on-coming control depicted in FIG. 6 applies to a conventional torque phase control utilized for either a synchronous or non-synchronous shift. In this example off-going friction element D remains engaged until the end of torque phase 32 . Although the focus is placed on torque phase control, FIG. 6 depicts the entire shift control process. As shown the shift event is divided into three phases: a preparatory phase 31 , a torque phase 32 and an inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked (not shown) to prepare for its engagement. At the same time, off-going friction element control force is reduced as shown at 34 as a step toward its release. During torque phase 32 controller 4 commands an on-coming friction element actuator to follow a prescribed on-coming friction element control force profile 64 through an open-loop based approach. Actual on-coming friction element control force 65 may differ from prescribed profile 64 due to control system variability. Even if actual control force 65 closely follows prescribed profile 64 , on-coming friction element engagement torque may still vary largely from is shift to shift due to the sensitivity of the on-coming friction element engagement process to engagement conditions such as lubrication oil flow and friction surface temperature. Controller 4 commands enough off-going element control force 61 to keep off-going element D from slipping, maintaining the planetary gearset in the low gear configuration until the end of torque phase 32 . Increasing on-coming friction element control force 65 or engagement torque reduces net torque flow within the low-gear configuration. Thus, output shaft torque 66 drops significantly during torque phase 32 , creating so-called torque hole 63 . If the variability in on-coming friction element engagement torque significantly alters a shape and depth of torque hole 63 , a vehicle occupant may experience inconsistent shift feel. Controller 4 reduces off-going friction element actuator force at 38 , following a pre-calibrated profile, in order to release it at a pre-determined timing 67 . The release timing may be based on a commanded value of on-coming friction element control force 62 . Alternatively, off-going friction element D is released if controller 4 detects a sign of significant gear tie-up, which may be manifested as a detectable drop in input shaft speed 44 . Inertia phase 33 begins when off-going friction element D is released and starts slipping as shown at 67 . During inertia phase 33 , off-going friction element slip speed rises as shown at 68 while on-coming friction element slip speed decreases toward zero as shown at 69 . Transmission input speed 44 drops as the planetary gear configuration changes. During inertia phase 33 , output shaft torque 66 is primarily affected by on-coming friction element torque capacity or control force 65 . The shift event completes when the on-coming friction element comes into a locked or engaged position with no slip as shown at 70 .
[0017] FIG. 7 illustrates another prior art methodology for controlling torque phase 32 of a synchronous upshift process from the low gear configuration to the high gear configuration. In this example, controller 4 allows off-going friction element D to slip during torque phase 32 . Although the focus is placed on torque phase control, FIG. 7 depicts the entire shift event. During preparatory phase 31 , an on-coming friction element piston is stroked to prepare for its engagement. At the same time, off-going friction element control force 86 is reduced as a step toward its slip. During torque phase 32 , on-coming friction element control force is raised in a controlled manner. More specifically, controller 4 commands on-coming friction element actuator to follow a prescribed on-coming friction element control force profile 87 through an open-loop based approach. An actual on-coming friction element control force 88 may differ from the commanded profile 87 due to control system variability. Even if actual control force 88 closely follows commanded profile 87 , on-coming friction element engagement torque may still vary largely from shift to shift due to the sensitivity of on-coming friction element engagement process to engagement conditions such as lubrication oil flow and friction surface temperature. Increasing on-coming friction element control force 88 or on-coming friction element engagement torque reduces net torque flow within the low-gear configuration. This contributes to output shaft torque 99 being reduced during torque phase 32 , creating a so-called torque hole 85 .
[0018] If the variability in on-corning friction element engagement torque significantly alters the shape and depth of torque hole 85 , the vehicle occupant may experience inconsistent shift feel. A deep torque hole may be perceived as an unpleasant shift shock. During torque phase 32 , off-going friction element control force is reduced as shown at 82 to induce an incipient slip 83 . Controller 4 attempts to maintain off-going friction element slip at a target level through a closed-loop control based on off-going friction element speed 96 which may be directly measured or indirectly derived from speed measurements at pre-determined locations. A variability in off-going friction element control force 82 of off-going element slip torque may alter the shape and depth of torque hole 85 , thus affecting shift feel. If controller 4 inadvertently allows a sudden increase in off-going friction element slip level, automatic transmission input speed or engine speed 90 may surge momentarily, causing the so-called engine speed flair or engine flair. The engine flair may be perceived by a vehicle occupant as an unpleasant sound.
[0019] Controller 4 initiates off-going friction element release process at a predetermined timing shown at which may be based on a commanded value of on-corning friction element control force 93 . Controller 4 lowers off-going friction element control force, following a pre-calibrated profile 94 . If a release of off-going friction element D is initiated prematurely before on-coming friction element C develops enough torque, engine speed or input shaft speed may rise rapidly in an uncontrolled manner. If this engine speed flair 90 is detected, controller 4 increases off-going friction element control force to delay off-going friction element release process. Alternatively to the pre-determined off-going friction element release timing, controller 4 may utilize speed signals to determine a final off-going friction element release timing. When a sign of significant gear tie-up, which may be manifested as a measurable drop in input shaft speed, is detected, off-going friction element D is released following a pre-calibrated force profile. Inertia phase 33 begins when off-going friction element torque capacity or control force drops to non-significant level 95 . During inertia phase 33 , off-going friction element slip speed rises 96 while on-coming friction element slip speed decreases 97 toward zero. The transmission input shaft speed drops as shown at 98 as the planetary gear configuration changes. During inertia phase 33 , the output shaft torque 99 is primarily affected by on-coming friction element torque capacity, which is indicated by its control force 100 . When on-coming friction element C becomes securely engaged at 101 , the shift event completes.
[0020] In summary, a prior art methodology, which is based on an open-loop on-coming friction element control during a torque phase, cannot account for control system variability and dynamically-changing shift conditions during the torque phase, resulting in inconsistent shift feel or unpleasant shift shock. A pre-determined off-going friction element release timing with a pre-calibrated control force profile cannot ensure an optimal timing under dynamically changing shift conditions, resulting in inconsistent shift feel or unpleasant shift shock. The alternative approach to gauge off-going friction element release timing based on speed signals often results in a hunting behavior between gear tie-up and engine flair, leading to inconsistent shift feel. Furthermore, off-going friction element slip control is extremely difficult because of its high sensitivity to slip conditions. In addition, a large discontinuity exists between static and dynamic friction coefficients, introducing a large torque disturbance during an incipient slip control. A failure to achieve a seamless off-going friction element slip control during the torque phase leads to undesirable shift shock.
[0021] As can be seen from the above discussion the controllability of both off-going friction element and on-coming friction element is desirable in order to deliver a consistent and seamless shift quality. The prior art does not have a cost effective design solution to the problem of directly measuring torque passing through either a multiple disc clutch or a band brake and therefore is a need in the art for a transmission control system that minimizes shift shock during a gear ratio change that does not rely solely on traditional speed signal measurement or a predetermined open-loop control and instead relies on measuring friction element load level in either a multiple plate clutch or a band brake for consistently controlling its torque level through a closed loop approach.
SUMMARY OF THE INVENTION
[0022] The present invention is directed to a load sensor assembly for measuring an amount of torque transmitted through a torque establishing element of an automatic transmission. The assembly comprises a core mounted on a transmission housing and a load sensor mounted on the core and positioned against a portion of the torque establishing element whereby a portion of the amount of torque transmitted through the torque establishing element travels through the load sensor and is measured by the load sensor assembly. Preferably, a cable is connected to the load sensor for transmitting a signal representative of the amount of torque to a transmission controller. A cover or sleeve extends over the core and the sensor.
[0023] In a preferred embodiment, the torque establishing element is a multiple disk friction element including an end plate and a spline connection between the transmission case and the end plate. The connection has teeth that extend from the transmission case and cooperate with teeth extending from the end plate. The load sensor assembly is mounted on the transmission housing between two spline teeth extending from the end plate and in a location where a spline tooth would normally be located. Preferably, the core is made of metal and the sleeve is made from one of rubber, plastic and metal. The sensor may have several different configurations. In one configuration, a pin is fixed to the end plate and the load sensor is placed against the pin. In another configuration, the force sensor is a load-resistive elastomer deposited on a thin film and the core is a tooth of a friction element plate. An example of such a thin film force sensor can be found in U.S. Pat. No. 6,272,936, which is incorporated herein by reference. In yet another configuration, the core is a metal beam securely anchored to the transmission case and the load sensor is a strain sensor that measures an amount of strain on the beam caused by the torque.
[0024] In another embodiment the torque establishing element is a band brake including an anchor bracket and a band brake strap. The core may engage the strap in many ways. In one configuration, the band brake strap has a block extending therefrom and the core passes through the transmission housing and engages the block. The load sensor is located between the core and the block. In another configuration, the band brake strap has a hook extending therefrom formed by punching a hole in the strap. The core passes through the transmission housing and engages the hook and the load sensor is located between the core and the hook. In yet another configuration, the anchor bracket has a pin extending therefrom. The core passes through the transmission housing and engages the pin. The load sensor is located between the core and the pin. Preferably, a cushion is located between the load sensor and the cover.
[0025] In yet another embodiment, the torque establishing element is a band brake including an anchor bracket and a hand brake strap while the core is an anchor pin, which does not necessarily have a cover, mounted in the transmission case. The anchor pin extends out of the transmission case and engages the anchor bracket. The load sensor is mounted between the anchor pin and the transmission case whereby torque is transferred to the band strap, pushes on the anchor pin and is sensed by the load sensor. Preferably, a cushion is located between the load sensor and the anchor pin. The core includes an anchor pin mounted in the transmission case. The core extends out of the transmission case and is connected to an anchor strut which, in turn, engages the anchor bracket. The load sensor is mounted between the anchor pin and the transmission case. Torque is transferred to the band strap where it pushes on both the anchor strut and pin, with the torque being sensed by the load sensor. Preferably, the transmission housing includes a hole for supporting the anchor pin. A nut is mounted in one end of the hole and secures the anchor pin to the housing. A plug and a support are located between the nut and the anchor pin. With this arrangement, torque passing through the friction elements of a transmission may be directly measured and shift shock and engine flair may be reduced.
[0026] Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings, wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic diagram of a gearing arrangement for an automatic transmission system according to the prior art;
[0028] FIG. 2 is a chart showing a clutch and brake friction element engagement and release pattern for establishing each of six forward driving ratios and a single reverse ratio for the transmission schematically illustrated in FIG. 1 ;
[0029] FIG. 3 is a plot of a general process of a synchronous friction element-to-friction element upshift event from a low gear configuration to a high gear configuration for the prior art automatic transmission system of FIG. 1 ;
[0030] FIG. 4 is a plot of the general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which the off-going friction element is released prematurely compared with the case shown in FIG. 3 ;
[0031] FIG. 5 is a plot of the general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element release is delayed compared with the case shown in FIG. 3 ;
[0032] FIG. 6 is plot of a prior art synchronous friction element-to-friction element upshift control from a low gear configuration to a high gear configuration based on speed measurements of powertrain components for the automatic transmission system in FIG. 1 wherein an off-going friction element remains locked during the torque phase;
[0033] FIG. 7 is plot of a prior art synchronous friction element-to-friction element upshift control from a low gear configuration to a high gear configuration based on speed measurements of powertrain components for the automatic transmission system in FIG. 1 , wherein an off-going friction element is slipped during the torque phase;
[0034] FIG. 8 is a schematic diagram of a gearing arrangement for an automatic transmission system including load sensor locations in accordance with a first preferred embodiment of the invention;
[0035] FIG. 9 is a plot of a synchronous friction element to friction element upshift control from a low gear configuration to a high gear configuration for the automatic control system in FIG. 8 based on direct measurements or estimates of torsional load exerted onto an off-going friction element in accordance with a preferred embodiment of the invention;
[0036] FIG. 10 is a flow chart showing an on-coming friction element control method in accordance with a preferred embodiment of the invention;
[0037] FIG. 11 is a flow chart showing an off-going element release control method in accordance with a preferred embodiment of the invention;
[0038] FIG. 12 is a plot of the process used to determine an ideal release timing of the off-going friction element in accordance with first preferred embodiment of the invention;
[0039] FIG. 13 is a flow chart showing a shift control method in accordance with a preferred embodiment of the invention;
[0040] FIG. 14 is a plot of a synchronous friction element-to-friction element upshift from a low gear configuration to a high gear configuration for the automatic transmission control system in FIG. 8 based on the direct measurements or estimates of torsional load exerted onto an off-going friction element and an on-coming element in accordance with another preferred embodiment of the invention;
[0041] FIG. 15 is a flow chart showing an on-coming friction element shift control method in accordance with another preferred embodiment of the invention;
[0042] FIG. 16A depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed between two teeth of a endplate of a friction element for measuring a relative load level on the friction element;
[0043] FIG. 16B depicts the load sensor assembly of FIG. 16A installed in a transmission case;
[0044] FIG. 17A depicts a load sensor assembly in accordance with another preferred embodiment of the invention placed against a pin extending from an endplate of a friction element for measuring a relative load level on the off-going friction element;
[0045] FIG. 17B depicts the load sensor assembly of FIG. 17A installed in a transmission case;
[0046] FIG. 18 depicts a load sensor in accordance with another preferred embodiment of the invention formed of a thin film-type load sensor and attached to a tooth for measuring a relative load level on the off-going friction element;
[0047] FIG. 19 depicts a load sensor assembly in accordance with another preferred embodiment of the invention formed of a metal beam for measuring a relative load level on the off-going friction element;
[0048] FIG. 20 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0049] FIGS. 21A-21C depict a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0050] FIGS. 22A and 22B depict a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0051] FIG. 23 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0052] FIG. 24 depicts a chart in accordance with another preferred embodiment of the invention;
[0053] FIG. 25 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0054] FIG. 26 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0055] FIG. 27 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0056] FIG. 28 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element; and
[0057] FIG. 29 depicts a chart in accordance with another preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] With initial reference to FIG. 8 , there is shown an automotive transmission employing the invention. As this automatic transmission arrangement is similar to the one schematically illustrated in FIG. 1 all the same parts have been indicated with corresponding reference numbers and therefore a duplicate discussion of these parts will not be made here. Instead, of particular importance is the addition of a torque sensor 120 located in friction element C, a load sensor 130 located in friction element D, and a torque sensor 131 located in transmission output shaft 24 , all connected to controller 4 for controlling various functions of transmission 2 as will be more fully discussed below.
[0059] FIG. 9 shows a torque phase control method according to a preferred embodiment of the invention for a synchronous friction element-to-friction element upshift from a low gear configuration to a high gear configuration for the automatic transmission system in FIG. 8 . The on-coming friction element control method illustrated here is also applicable to non-synchronous shift control. The shift event is divided into 3 phases: preparatory phase 31 , torque phase 32 and inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked to prepare for its engagement. At the same time, off-going friction element control force or its torque capacity is reduced as shown at 404 as a step toward its release. During torque phase 32 , on-coming friction element control force is raised in a controlled manner as shown at 405 . More specifically, controller 4 commands on-coming friction element actuator to follow a target on-coming friction element engagement torque profile 406 through a closed-loop control directly based on the measurements of on-coming friction element engagement torque 407 during torque phase 32 . On-coming friction element torque 407 may be directly measured using a load sensor according to this invention as more fully described below. On-coming friction element engagement torque directly affects transmission output torque that is transmitted to the vehicle wheels. This torque-based close-loop control eliminates or significantly reduces the undesirable effects of on-coming friction element engagement torque sensitivity to hardware variability and shift conditions, achieving a consistent shift feel, regardless of shift conditions.
[0060] Alternatively to the direct measurements, on-coming friction element torque can be determined from the measurements of transmission output shaft torque using torque sensor 131 depicted in FIG. 8 . Mathematically, on-coming friction element torque T OCE can be described as a function of measured output shaft torque T OS as:
[0000] T OCE ( t )= G OCE T OS ( t ) Eq. (1)
[0000] Where G OCE can be readily obtained based on a given gear set geometry.
[0061] Yet alternatively, on-coming friction element torque T OCE can be estimated through the following Eq. (2), based on a slight change in transmission component speeds ω i at pre-determined locations (i=1, 2, . . . , n),
[0000] T OCE ( t )= F trans (ω i ,t ) Eq. (2)
[0000] where t indicates time and F trans represents a mathematical description of a transmission system. More specifically, as on-coming friction element engagement torque rises 407 , torque levels transmitted through various transmission components change. This creates small, but detectable changes in ω i . A transmission model, F trans , can be readily derived to estimate on-coming friction element engagement torque when off-going friction element remains locked during torque phase 32 .
[0062] Controller 4 commands enough off-going friction element control force 408 to keep it from slipping, maintaining the planetary gearset in the low gear configuration during torque phase 32 . As on-coming friction element engagement torque 407 increases, a reaction torque goes against a component that is grounded to a transmission case. More specifically, in this case, torque transmitted through off-going friction element or torsional load 409 exerted onto off-going friction element D decreases proportionally. Off-going friction element load level 409 can be directly monitored using a torque sensor such as is more fully discussed below. Alternatively, off-going friction element load level T OGE 409 can be calculated from measured or estimated on-coming friction element engagement torque T OCE 407 when off-going friction element remains locked during torque phase 32 according to:
[0000] T OGE ( t )= F OCE/OGE ( T OCE ( t )) Eq. (3)
[0000] where F OCE/OGE represents a torque ratio between on-corning friction element C and off-going friction element D at the low gear configuration and can be obtained based on gear set geometry. According to this invention, off-going friction element D is released at an ideal timing when torque load exerted onto off-going friction element D becomes zero or a near-zero level. Transmission controller 4 initiates a release process of off-going friction element D as shown at 410 as off-going friction element load 409 approaches zero at 411 . Off-going friction element torque is dropped quickly as shown at 412 with no slip control. Since no off-going friction element slip control is involved, the method is insensitive to off-going friction element break-away friction coefficient variability. In addition, the quick release of off-going friction element D shown at 412 induces little disruption in output shaft torque at 413 because off-going friction element load level is near zero as shown at 411 at the moment of release. Off-going friction element D starts slipping 411 once its control force reaches a non-significant level. During inertia phase 33 , a conventional control approach may be utilized based on on-coming friction element slip measurements. Off-going friction element slip speed increases as shown at 415 while on-coming friction element slip speed decreases as shown at 416 . The transmission input speed drops as shown at 417 as the planetary gear configuration changes. During inertia phase 33 , output shaft torque 418 is primarily affected by on-coming friction element torque level 419 . Alternatively to the conventional control, a closed loop control that is based on measured or estimated on-corning friction element torque may continue to be employed. When on-coming friction element C completes engagement or when its slip speed becomes zero as shown at 420 , the shift event completes.
[0063] FIG. 10 shows a flow chart of closed-loop on-coming friction element engagement torque control during the torque phase depicted in FIG. 9 . Step 430 is the beginning of torque phase 32 . Controller 4 chooses a desired on-coming element torque at step 431 and measures or estimates an actual torque at step 432 . At step 433 , the on-coming friction element actuator is then adjusted by controller 4 based on the difference between the measured/estimated torque level and the actual torque level. At step 434 , controller 4 determines if torque phase has ended and if so controller 4 starts inertia phase 33 at 436 .
[0064] FIG. 11 shows a flow chart of an off-going friction element torque control process during torque phase 32 depicted in FIG. 9 . The process starts at step 440 at the beginning of torque phase 32 . A load transmitted through locked off-going friction element D is directly measured or estimated at step 441 . At step 442 , when its load level drops below a predetermined level, off-going friction element D is promptly released at step 444 . The control process ends at step 445 at the end of torque phase 32 .
[0065] Alternatively to the measurements or estimates of absolute load levels, FIG. 12 illustrates the process to determine the ideal release timing of off-going friction element D based on relative load measurements or estimates according to this invention. FIG. 12 depicts an actual load profile 451 exerted on off-going friction element D and a relative load profile L(t) 452 measured by torque sensor 130 during the upshift event in FIG. 9 . The preferred embodiment requires only relative load profile L(t) 452 . Relative load profile L(t) 452 is preferably constructed from uncalibrated sensor output that reflects actual load profile 451 , but not its absolute levels. This feature eliminates the need of a full sensor calibration across the entire load range. It also makes the preferred embodiment insensitive to sensor output drift over time. However, the preferred embodiment relies on knowledge of sensor measurement L 0 453 which corresponds to zero off-going friction element load level 454 . Sensor measurement L 0 453 can be readily identified, as often as required, by sampling sensor output while vehicle transmission 2 is in a neutral or a similar condition where no load is exerted onto off-going friction element D. Transmission controller 4 collects relative load data 455 during torque phase 32 to dynamically construct relative load profile L(t) 452 . Then, controller 4 extrapolates L(t) to predict t 0 457 where L(t 0 )=L 0 . Once t 0 457 is obtained in advance, controller 4 predicts when to initiate an off-going friction element release process. Specifically controller 4 starts the release process at a time equal to t 0 −Δt shown at 458 , where Δt is the time required to quickly drop off-going friction element control force to zero. In this way, off-going friction element D starts slipping at or near ideal timing t 0 457 when the actual off-going friction element load level is at or close to zero as shown by reference numeral 454 .
[0066] FIG. 13 presents a flow chart of the new upshift control method according to this invention. During preparatory phase 31 at step 461 of a synchronous upshift event, off-going friction element torque capacity or apply force is reduced to a holding level without allowing any slip at step 462 while on-coming friction element piston is stroked at step 463 . During torque phase 32 , transmission controller 4 measures at step 465 a relative load level exerted onto off-going friction element D at a pre-specified sampling frequency using torque sensor 130 described further below. Controller 4 repeats this measurement step 465 until enough data points are collected at step 466 for dynamically constructing a relative load profile at step 467 that shows load as a function of time L(t). Once relative load profile L(t) is obtained, controller 4 predicts the ideal off-going friction element release timing t 0 at step 468 so that L(t 0 )=L 0 where L 0 corresponds to a substantially zero load level on off-going friction element D. Controller 4 initiates an off-going friction element release process at t 0 −Δt as shown as step 469 where Δt is a pre-specified time required to quickly drop off-going friction element apply force to zero. Alternatively, controller 4 may initiate the off-going friction element release process at t thres such that L(t thres )=L thres where L thres is a predetermined threshold. No slip control is required for off-going friction element D during torque phase 32 . Inertia phase 33 starts when off-going friction element D is released. The control methodology illustrated in FIG. 10 is preferably applied to on-coming friction element C during torque phase 32 . A conventional on-coming friction element control may be applied during inertia phase 33 based on speed signals. When on-coming friction element C becomes securely engaged at step 473 , the shift event completes at step 474 .
[0067] FIG. 14 illustrates another preferred embodiment of the invention relating to a transmission system with an on-coming friction element actuator which may not have a sufficient control bandwidth compared with a sampling time of load measurements. At the beginning of torque phase 32 , a transmission controller raises on-coming friction element actuator force based on a pre-calibrated slope 480 over a time interval Δt between t 0 and t 1 as shown at interval 481 . During interval 481 , on-coming friction element load is either measured or estimated with a sampling time finer than Δt to construct an engagement torque profile 482 . If the measured or estimated torque profile 482 indicates a slow rise compared with a target torque profile 483 , controller 4 increases a slope of commanded on-coming friction element control force for a next interval 485 between t 1 and t 2 . On the other hand, if the actual torque is rising faster than a target profile, controller 4 reduces a slope of commanded on-coming friction element control force. For example, during interval 485 between t 1 and t 2 , on-coming friction element load is either measured or estimated with a sampling time finer than Δt to construct an engagement torque profile 486 . The measured or estimated slope 486 of the engagement torque is compared against a target profile 487 to determine a slope 488 of commanded force profile for the following control interval. This process is repeated until the end of torque phase 32 . The off-going friction element release control remains the same as that shown in FIG. 9 .
[0068] FIG. 15 shows a flow chart of alternative closed-loop on-coming friction element engagement torque control during torque phase depicted in FIG. 14 . The start of torque phase 32 is shown at step 520 . Following path 521 , the off-coming friction element torque is measured or estimated at step 522 and torque profile 482 is created therefrom at step 523 . The method may have to go through several iterations as shown by decision block 524 and return loop 525 . Torque slope profile 486 or an average derivative of torque profile 482 is calculated at 526 and while a desired target slope profile 487 is calculated at 527 and compared with torque slope profile 486 at 528 . The actuator force slope is increased 529 or decreased 530 and the process continues 531 , 532 until the end of torque phase 32 . The process then proceeds to inertia phase 33 at 533 .
[0069] While the shift control has been discussed above, attention is now directed to the structure of the various load sensor assemblies. FIG. 16A , 16 B, 17 A, 17 B, 18 and 19 depict several preferred embodiments of load sensor assemblies for measuring a relative load level exerted on off-going friction element D or on-coming element C according to preferred embodiments of the invention. FIG. 16A shows a cross-sectional view of a load sensor assembly 601 design according to a preferred embodiment. In FIG. 16A , sensor assembly 601 is installed between two teeth 602 , 603 of an end plate 604 of off-going friction element D. Assembly 601 includes a core 605 , a load sensor 606 and a sleeve 607 . Core 605 is preferably made from a metal, such as steel or aluminum, and is securely grounded to a transmission case 608 through anchor bolts 609 . Load sensor 606 is preferably a film-type sensor constructed with a pressure-resistive material. Sensor 606 generates an electrical signal that corresponds to a relative level of loading force 610 . Sleeve 607 , which protects sensor 606 , is preferably made from rubber, plastic or metal. While cover 607 is referred to as either a sleeve or a cover, it is to be understood that the terms are interchangeable. FIG. 16B illustrates an installation of sensor assembly 601 in transmission case 608 . Sensor assembly 601 is securely positioned in a location where a spline tooth is normally located otherwise. When off-going friction element plates are installed, end plate 604 fits snugly around sensor assembly 601 , providing a preload to sensor 606 . That is, sensor 606 preferably indicates non-zero output L 0 even when no load is exerted on off-going friction element D or its end plate 604 . When the torque load is exerted as shown by arrow 610 during a shift event, the output from sensor 601 provides a relative measure of the load on off-going friction element D. When this embodiment is employed to measure relative load exerted onto an off-going friction element such as when torque sensor 130 is used to measure the load on friction element D, it is readily understood that optimal friction element release timing is identified when the sensor output level approaches to L 0 corresponding to zero load level.
[0070] FIGS. 17A and 17B depict another sensor assembly 611 which has a similar structure to assembly 601 in FIG. 16A . Assembly 611 includes a grounded core 612 , a force sensor 613 and a sleeve 614 . However, as illustrated in FIG. 17A , assembly 611 is placed against a pin 615 that is fixed to an end plate 616 of off-going friction element D. Sensor 613 is preloaded against pin 615 , providing non-zero output in the absence of torque load on off-going friction element end plate 616 ( FIG. 17B ). When a torque load is exerted on off-going friction element D, pin 615 is pressed with a force 617 against sensor 613 across sleeve 614 . This enables sensor 613 to provide the relative measure of torque load on off-going friction element D. FIG. 17B shows a view of sensor assembly 611 and off-going friction element end plate 616 with pin 615 in a transmission case 618 .
[0071] FIG. 18 shows another potential embodiment of this invention wherein a thin film-type force sensor 621 is directly attached to a tooth 622 of a friction element plate 623 , covered with a protective sleeve 624 . Sleeve 624 is preferably made from rubber, plastic or metal. When plate 623 is installed into a transmission case 625 , sensor 621 directly measures contact load 626 between friction element tooth 622 and a spline 627 through sleeve layer 624 , providing a relative measure of the load exerted onto off-going friction element D.
[0072] FIG. 19 shows another preferred embodiment of the invention wherein a metal beam 631 , which is securely anchored to a transmission case 632 , is installed and positioned between two teeth 633 , 634 of an off-going friction element plate 635 . As a load level 636 exerted on plate 635 varies, a strain level of beam 631 changes. The level of the strain is detected through a strain sensor 637 , providing a relative measure of is torque load exerted on off-going friction element D. Optionally, a cover may be added to protect strain sensor 637 .
[0073] FIGS. 20 , 21 A, 21 B, 21 C, 22 A, 22 B and 23 - 29 show various preferred embodiments of the invention relating to directly measuring torque in a friction element. More specifically, FIG. 20 shows a partial view of a band brake system 700 with a load sensing assembly 731 . Brake system 700 includes an anchor end of a band strap 732 , a pin or a hook 733 , and an anchor bracket 734 . Band strap 732 is preferably either a single-wrap or double-wrap type. Load sensor assembly 731 includes an assembly core 735 , a load sensing unit 736 and a protective sleeve or cover 737 . Assembly core 735 is made of a metal and securely mounted to a transmission case 738 with a bolt 739 or any other means. Cover 737 may be made of metal, rubber, plastic or any other materials. Cover 737 protects sensor unit 736 from direct contact with pin or hook 733 for reduced sensor material wear. Cover 737 may be made of a thermally-insulated material to protect sensor 736 from heat. Cover 737 also acts as a protective shield against any other hostile conditions that include electro-chemical reaction with transmission oil. Load sensing unit 736 , which may be a pressure resistive film-type, is positioned between core 735 and cover 737 . The tip of sensor 736 is positioned against pin 733 across cover 737 . When a band engagement is commanded, strap 732 is pulled by a hydraulic servo (which is described below) in the direction shown with an arrow 740 . Band strap 732 stretches slightly, pushing pin or hook 733 against load sensor 736 . Load sensor 736 generates an electrical signal according to a magnitude of the contact force. That is, sensor 736 provides a relative measure of band tension at the location of pin 733 . The electrical signal is transmitted to a data acquisition unit (not shown) and then to controller 4 through an electrical cable 741 .
[0074] FIGS. 21A , 21 B and 21 C depict band strap designs in detail. In FIG. 21A , a band strap 732 has a part punched out and bent to form a pin or a hook 753 and a hole 752 . Hole 752 also acts as an oil drain during band engagement. In FIG. 21B , a small pin or a block 754 is riveted, screwed or welded to strap 732 . Alternatively, a pin or a hook 755 can be formed as a part of an anchor bracket 734 as shown in FIG. 21C . A pin 755 is attached to a band anchor bracket 734 instead of a strap 732 . Sensor assembly 731 is positioned against the pin 755 . Since bracket 732 is stiffer than the strap 732 , its strain is smaller under loaded conditions during both holding and engagement. Thus, a level of force exerted onto a load sensor 736 through a micro displacement of pin 755 is reduced significantly. The lower stress level improves the life of the sensor assembly 731 while enabling the use of a sensor 736 rated for a lower maximum force.
[0075] FIG. 22A illustrates sensor functions during a band engagement process. When the engagement is initiated, transmission controller 4 sends an electrical signal I(t) to raise and regulate a hydraulic force 761 applied to a servo piston 762 . As servo piston 762 is stroked, a servo rod 763 pulls one end 764 of band strap 732 . Tension around strap 732 builds up, squeezing out lubrication oil 766 from a band-drum interface. During the engagement, brake torque from strap 732 to a drum 767 is partly transmitted through viscous shear across oil 766 . The brake torque is transmitted through a mechanical frictional force once strap 732 makes physical contact with drum 767 . According to a conventional analysis, the relationships between engagement torque T eng , band tension at a pin F pin 733 and band tension at a servo F servo 769 can be written as follows, assuming a Coulomb friction model as a primary torque transfer mechanism between band strap 732 and drum 767 :
[0000] T eng =F servo R ( e μβ −1) Eq. (4)
[0000] F pin =F servo e μβ Eq. (5)
[0000] where R=drum radius, m=a Coulomb friction coefficient, b=a band wrap angle 770 assuming that pin 733 is positioned sufficiently close to an anchor 734 . Drum 767 rotates in the same direction 772 as the hydraulic force 761 . Substituting Eq. (5) into Eq. (4) yields:
[0000]
T
eng
=
F
pin
R
(
1
-
-
μβ
)
or
F
pin
=
T
eng
R
(
1
-
-
μβ
)
Eq
.
(
6
)
[0076] Since the electrical output signal S pin from the sensor is approximately linear with band tension F pin :
[0000] S pin =kF pin Eq. (7)
[0000] where k is a proportional constant. Substituting Eq. (7) into Eq. (6) yields:
[0000]
S
pin
=
k
R
(
1
-
-
μβ
)
T
eng
=
k
′
T
eng
or
S
pin
t
=
k
′
T
eng
t
where
Eq
.
(
8
)
k
′
=
k
R
(
1
-
-
μβ
)
Eq
.
(
9
)
[0000] According to Eq. (8), the sensor output S pin provides a relative measure of band brake engagement torque T eng .
[0077] This embodiment provides a relative measure of T eng and its derivative (dT eng /dt) that enables a closed loop control of on-coming friction element engagement process during torque phase 32 . It significantly improves band engagement control, mitigating a sudden rise of band brake torque known as “grabbing” behaviors. Alternatively, the sensor signals may be utilized to adaptively optimize open-loop calibration parameters such as a rate of pressure rise as a function of oil temperature in order to achieve a consistent (dT eng /dt). The similar analysis can be applied to the so-called “de-energized” band engagement where the drum spins in the opposite direction of the servo.
[0078] FIG. 22B illustrates sensor functions while band strap 732 is securely engaged around drum 767 under a holding condition without any slippage. In this case, the band tension F pin at pin 733 reflects both the level of the band tension F servo 784 at the servo and the level of torque load T load 785 exerted onto band 732 and drum 767 from the adjoining components (not shown). It is important that one should clearly differentiate T load from T eng which is brake torque exerted from the band to the drum under slipping conditions.
[0079] According to a conventional analysis, the relationships between F pin , F servo and T load can be algebraically written as:
[0000]
F
pin
=
F
servo
+
T
load
R
or
T
load
=
R
(
F
pin
-
F
servo
)
Eq
.
(
10
)
[0000] Substituting Eq. (10) into Eq. (7), the sensor output S pin can be described as a function of F servo and T load as:
[0000]
S
pin
=
kF
pin
=
kF
servo
+
k
R
T
load
Eq
.
(
11
)
[0000] Note that F servo is a function of an electrical signal I commanded to a hydraulic control system from a transmission controller. That is:
[0000] F servo =F servo ( I ) Eq. (12)
[0000] Substituting Eq. (12) into Eq. (11) results in:
[0000]
S
pin
=
kF
pin
=
kF
servo
(
I
)
+
k
R
T
load
Eq
.
(
13
)
[0000] In the absence of T load , Eq. (13) becomes:
[0000] S pin =kF servo ( I )≡ S pin noload ( I ) Eq. (14)
[0000] where S pin noload is defined as the sensor output measured under no load condition for a given level of I. In practice S pin noload can be readily obtained, as required, by sweeping the servo actuator with a varying level of I while a vehicle is in a stationary condition. Substituting Eq. (14) into Eq. (13) yields:
[0000]
S
pin
-
S
pin
noload
(
I
)
=
k
R
T
load
Eq
.
(
15
)
[0000] Thus, S pin −S pin noload (I) provides a relative measure of torque load T load for a given electrical input I. The optimal timing to release off-going friction element during a synchronous shift is when the load exerted onto off-going friction element or T load becomes zero. This can be readily determined by sampling S pin and evaluating S pin −S pin noload (I) for a given electrical signal I. The use of the load sensor assembly according to this embodiment significantly improves band release controllability during a synchronous shift under all the operating conditions.
[0080] FIG. 23 shows a cross-sectional view of another sensor assembly 811 including a cushion element 812 inserted between a load sensor 813 and a pin or a block 814 that is attached to a band strap or an anchor bracket. Cushion element 812 is preferably made of a rubber. Alternatively, cushion element 812 may be made of a metal in the form of a spring such as a disk spring or a conical spring. A protective cover 815 is preferably positioned between cushion element 812 and block 814 . Cover 815 is readily slidable at a nominal force under loaded conditions. The loading force is transmitted from block 814 to load sensor 813 by deformation of cushion element 812 . Accordingly, cushion element stiffness is used to specify a force range at sensor 813 for a given range of loading force at block 814 . The force transmitted to load sensor 813 becomes limited once the cushion element surface becomes flush with surface 817 of the assembly core. This non-linear characteristic indicated at 818 enables high resolution force measurement for a targeted load range 819 as shown in FIG. 24 while protecting sensor 813 from excessive loading.
[0081] FIG. 25 shows an alternative embodiment of this invention. In this design, a load sensor 821 is placed at the bottom of a band anchor pin 822 inside a transmission case 823 . Electrical cable 824 attached to sensor 821 is routed outside through case 823 . The tip of pin 822 is inserted into an anchor bracket 826 , which is attached to band strap 825 . When the band brake system is actuated, strap 825 is hydraulically or mechanically tightened around a drum such that anchor bracket 826 pulls pin 822 in the direction of anchor load 828 as represented by an arrow. Accordingly, load sensor 821 directly measures an anchor load 828 exerted onto pin 822 from the anchor bracket 826 . A cushion element 831 is preferably placed between the bottom of an anchor pin 822 and load sensor 821 . Note that the sensing area of sensor 821 is smaller than the surface area of cushion element 831 . The anchor load supported by pin 822 is distributed over the surface of cushion element 831 . Accordingly, only part of the anchor load is transmitted to load sensor 821 . This enables the use of a sensor rated for a lower maximum force.
[0082] In FIG. 26 , a strut 841 is inserted between an anchor bracket 826 and an anchor pin 843 . Strut 841 enables the flexible placement of anchor pin 843 with respect to band strap 825 and transmission case 823 . Also, an angle 845 between strut 841 and pin 843 may be adjusted to optimize a level of the axial loading that bracket 876 exerts onto pin 843 through strut 841 . Cushion element 831 and the reduced axial loading allow the use of a sensor 821 rated for a lower maximum force. Alternatively, angle 845 may be adjusted to reduce the side loading onto pin 843 to minimize sensor output hysteresis caused by sticky pin displacement under the loaded conditions.
[0083] The embodiment of the invention in FIG. 27 shares many of the same features described in connection with the embodiment in FIG. 26 . First, anchor pin 853 is inserted into an unthreaded hole 852 inside transmission case 823 . Its large head 854 prevents pin 853 from falling through hole 852 . A cushion element 836 and a load sensor 821 are placed against pin head 854 . Cushion element 836 may be made of a rubber and act as a seal to protect the sensor 821 from transmission oil. Behind sensor 821 and cushion element 836 is a sensor support dish 857 , which may be made of a metal. Sensor support dish 857 is backed by a large plug 858 inserted into a threaded hole 859 . The position of plug 858 may be adjusted and locked with a nut 860 in order to set anchor pin 853 to a desirable position with respect to anchor bracket 826 and strut 841 .
[0084] The embodiment of the invention shown in FIG. 28 shares features with the embodiment for FIG. 27 . Specifically, a load sensor 821 is placed behind a cushion element 872 inside support dish 874 with a raised retaining wall 873 . Cushion element 872 is preferably made of rubber. Alternatively, cushion element 872 may be made of metal in the form of a spring such as a disk or a conical spring. Under a no load condition, the surface of cushion element 872 is in contact with that of a pin 875 , while the end of retaining wall 873 is away from the surface of pin 875 . When the anchor load is below a predetermined level, the entire load is transmitted to sensor 821 through the elastic deformation of cushion element 872 . As the anchor load increases, cushion element 872 becomes compressed. Once the surface level of cushion element 872 becomes flush with the end of retaining wall 873 , retaining wall 873 starts supporting the load exerted on pin 875 , limiting the load on sensor 821 .
[0085] As shown in FIG. 29 , cushion element stiffness determines where the sensor output starts leveling off at 876 . This embodiment of the invention enables the sensor performance to be targeted for a specific load range, maximizing a measurement resolution 877 . In addition, sensor output voltage at limiting load level 876 and at zero load level 878 can be used to auto-calibrate sensor 821 for enabling absolute load measurements. That is when the sensor output reaches its maximum plateau, a transfer function between sensor output voltage and load level can be mapped based on two point calibration. This feature is extremely useful, especially if sensor characteristics drift over time or vary under different operating conditions. This load-limiting feature also protects the sensor from overloading, preventing its failure.
[0086] Based on the above, it should be readily apparent that the present invention provides numerous advantages over prior friction element control during a torque phase of gear-ratio changing. The preferred embodiments provide a consistent output shaft torque profile for a powertrain system with a step-ratio automatic transmission system during a synchronous friction element-to-friction element upshift, which reduces shift shock. Also, there is a significant reduction in shift feel variability for a powertrain system with a step-ratio automatic transmission system during a synchronous friction element-to-friction element upshift. The preferred embodiments of the invention permit the use of either absolute or relative load levels which are directly measured or estimated. The use of a relative load profile, instead of absolute load levels, eliminates the need of full-sensor calibration, while the use of a relative load profile only requires one point sensor calibration that corresponds to zero load level and improves robustness against sensor drift over time. The preferred embodiments also provide for reduced output shaft torque oscillation at the beginning of the inertia phase due to the release of the off-going friction element at or near the ideal release timing where its load level is zero or close to zero and robustness against the variability of off-going friction element breakaway friction coefficient by means of a quick release of the off-going friction element at the ideal synchronization timing.
[0087] Further advantages include a consistent output shaft torque profile and significant reduction in shift feel variability for a powertrain system with a step-ratio system during a torque phase of a synchronous friction element-to-friction element upshift and during a torque phase of a non-synchronous upshift with an overrunning coupling element. Further, the system provides robustness against the variability of off-going friction element breakaway friction coefficient by means of a quick release of an off-going friction element at an ideal synchronization timing during a synchronous shift and against the variability of a friction element actuation system for both synchronous and non-synchronous shifts.
[0088] A clutch load sensor assembly provides a relative measure of torque load exerted to the clutch while it is engaged. A band brake load sensor assembly provides a relative measure of engagement torque (brake torque) and its derivative during an engagement process while a band slips against a drum and a relative measure of torque load exerted onto a band and a drum while the band is securely engaged to the drum without slippage. Sensor output may be calibrated with respect to a command signal to a band servo actuator while torque load is zero. Use of a protective cover in the sensor assembly prevents a direct contact between a load sensing material and the pin for reduced sensor material wear; and shields the sensor from hostile conditions that include heat and electro-chemical interaction, such as with transmission oil.
[0089] Although described with reference to preferred embodiments of the invention, it should be understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For example, the invention could be extended to a double-wrap band brake system. In general, the invention is only intended to be limited by the scope of the following claims. | A load sensor assembly for measuring an amount of torque transmitted through a torque establishing element includes a core mounted on a transmission housing and a load sensor mounted on the core. The load sensor is positioned against a portion of the torque establishing element whereby a portion of the amount of torque transmitted through the torque establishing element travels through the load sensor and is measured. A cable is connected to the load sensor for transmitting a signal representative of the amount of torque to a transmission controller. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to collapsible structures, and in particular, to collapsible structures which incorporate the use or delivery of water.
[0003] 2. Description of the Prior Art
[0004] There are presently many collapsible structures that are being provided for use by children and adults in a number of different applications. Examples of these collapsible structures are illustrated in the following patents: U.S. Pat. No. 5,816,954 (Zheng), U.S. Pat. No. 6,006,772 (Zheng), U.S. Pat. No. 5,778,915 (Zheng), U.S. Pat. No. 5,467,794 (Zheng), U.S. Pat. No. 5,975,101 (Zheng), U.S. Pat. No. 5,722,446 (Zheng), U.S. Pat. No. 4,858,634 (McLeese), U.S. Pat. No. 4,825,592 (Norman), U.S. Pat. No. 5,964,533 (Ziglar), U.S. Pat. No. 5,971,188 (Kellogg et al.), U.S. Pat. No. 6,485,344 (Arias), U.S. Pat. No. 6,343,391 (LeGette), U.S. Pub. No. 2004/0139997 (Zheng) and U.S. Pat. No. 5,038,812 (Norman), among others. These collapsible structures are supported by one or more frame members that can be twisted and folded to reduce the overall size of the structure. These collapsible structures can be used in a wide variety of applications, such as containers, tents, play structures, executive toys, shelters, sports structures, and others. As a result, collapsible structures have become very popular.
SUMMARY OF THE DISCLOSURE
[0005] It is an object of the present invention to provide a collapsible structure that incorporates the use or delivery of water.
[0006] In order to accomplish the objects of the present invention, the collapsible structure according to the present invention provides a structure having at least one foldable frame member having a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form at least one panel when the frame member is in the unfolded orientation. A water tube is attached to the fabric material and connected to a water supply, and a water outlet is coupled to the water tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a collapsible structure according to one embodiment of the present invention.
[0008] FIG. 2 is a partial cut-away view of the section A of the structure of FIG. 1 illustrating a frame member retained within a sleeve.
[0009] FIGS. 3A through 3C illustrate how the collapsible structure of FIG. 1 may be twisted and folded for compact storage.
[0010] FIG. 4 is a cross-sectional view of the section 4 -- 4 in FIG. 1 .
[0011] FIGS. 5-6 illustrate other embodiments of collapsible structures according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.
[0013] As shown in FIGS. 1 and 2 , a structure 20 is provided that comprises four panels 22 , 24 , 26 and 28 connected to each other to encircle an enclosed space. Each panel 22 , 24 , 26 , 28 can have four sides, such as a left side 30 , a bottom side 32 , a right side 34 and a top side 36 , although each panel 22 , 24 , 26 , 28 can assume any configuration and have any number of sides. Each panel 22 , 24 , 26 and 28 has a frame retaining sleeve 38 provided along and traversing the four edges of its four sides 22 , 24 , 26 , 28 . A frame member 40 is retained or held within each respective frame retaining sleeve 38 to support each panel 22 , 24 , 26 , 28 . Only the frame member 40 is shown in FIG. 2 ; the other frame members are not shown but are the same as frame member 40 .
[0014] The frame members 40 may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The frame members 40 are preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame members should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each frame member 40 is capable of assuming two positions or orientations, an open or expanded position such as shown in FIG. 1 , or a folded position in which the frame member is collapsed into a size which is much smaller than its open position (see FIG. 3C ).
[0015] Fabric or sheet material 42 extends across each respective panel 22 , 24 , 26 , 28 , and is held taut by the respective frame member 40 when in its open position. The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric should be water-resistant and durable to withstand the wear and tear associated with rough treatment. The frame members 40 may be merely retained within the respective frame retaining sleeves 38 without being connected thereto. Alternatively, the frame retaining sleeves 38 may be mechanically fastened, stitched, fused, or glued to the respective frame members 40 respectively, to retain them in position.
[0016] FIG. 4 illustrates one possible connection for connecting adjacent edges of two panels 22 and 24 . The fabric pieces 42 are stitched at their edges by a stitching 44 to the respective sleeves 38 . Each sleeve 38 may be formed by folding a piece of fabric. The stitching 44 also acts as a hinge for the panels 22 and 24 to be folded upon each other, as explained below. The connections for the three other pairs of adjacent edges may be identical. Thus, the connections on the left side 30 and the right side 34 of each panel 22 , 24 , 26 , 28 act as hinge connections for connecting an adjacent panel.
[0017] At the top side 36 and the bottom side 32 of each panel 22 , 24 , 26 , 28 , where there is no hinge connection to an adjacent panel, the frame retaining sleeve 38 may be formed by merely folding over the corresponding fabric piece and applying a stitching 46 (see FIG. 2 ). The fabric piece 42 for the corresponding panel may then be stitched to the sleeve 38 .
[0018] Openings 48 and 50 may be provided in some or all of the panels 22 , 24 , 26 , 28 . These openings 48 and 50 may be of any shape (e.g., triangular, circular, rectangular, square, diamond, etc.) and size and can be designed to allow an individual to pass through them to enter or to exit the structure 20 (among other functions).
[0019] A plurality of tubes are provided on one or more of the panels 22 , 24 , 26 , 28 via stitching, glue or similar attachment means, or via removable attachment mechanisms such as hooks, straps, ties, VELCRO™ pads and the like. These tubes can be used to form tube systems for delivering water or other liquids to selected locations or outlets. For example, a tube 52 can have a first end 54 that extends away from the structure 20 for connecting to a water supply 56 , such as a water tap or faucet. The intermediate portion of the tube 52 can extend along a bottom side 32 of the panel 24 and then up along the sides 34 and 32 of the panels 22 and 24 , respectively, before traversing a portion of the fabric 42 of the panel 22 to a shower outlet 60 positioned above the opening 50 . The shower outlet 60 can have a plurality of spray holes to allow water to be sprayed like a mist on to any individual passing through the opening 50 . Another tube 58 branches off from the tube 52 along the fabric 42 of the panel 24 , then extends around the circular opening 48 , and then extends along the top sides 36 of the panels 24 and 22 to a shower head 62 . Spray holes 66 can be provided along the circular portion of the tube 58 to allow water to be sprayed like a mist on to any individual passing through the opening 48 . A branch of tubing 64 can connect the tubes 52 and 58 along the fabric 42 of the panel 22 . Thus, water can be delivered from the supply 56 through the tubes 52 , 58 to outlets such as the spray holes 66 , shower outlet 60 and shower head 62 . This water spraying ability can be both functional and for amusement. For example, the structure 20 can be placed around a sandbox or other location where it might be desirable for the individuals exiting that location to be washed or showered.
[0020] The tubes 52 , 58 , 64 can be made from any conventional soft tubular material that allows water to flow therethrough without leaking. Examples include the materials used for garden hoses, among others. The material is preferably soft and flexible so that the tubes can be folded as the structure 20 is twisted and folded in the manner described below.
[0021] While the structure 20 of FIG. 1 is shown and described as having four panels, each having four sides, it will be appreciated that the structure 20 may be made of any number of panels, each having any number of sides, without departing from the spirit and scope of the present invention. For example, each structure may have at least one panel (see FIG. 5 below), and each panel may have three or more sides. Thus, the structures of the present invention may take a variety of external shapes. However, each panel, regardless of its shape, is supported by at least one frame member 40 .
[0022] FIGS. 3A through 3C describe the various steps for folding and collapsing the structure 20 of FIG. 1 for storage. The first step consists of pushing panels 22 and 24 towards panels 28 and 26 , respectively, about their hinged connections so that panel 22 collapses upon panel 28 and panel 24 collapses upon panel 26 . Then, the two panels 22 and 28 are folded so as to be collapsed upon the two panels 24 and 26 to form a stack of four panels, as shown in FIG. 3A . In the second step, the structure 20 is then twisted and folded to collapse the frame members 40 and panels 22 , 24 , 26 , 28 into a smaller shape. In particular, the opposite border 70 of the stack of panels 22 , 24 , 26 , 28 is folded in (see arrow 72 in FIG. 3A ) upon the previous fold to further collapse the frame members 40 with the panels. As shown in FIG. 3B , the folding is continued so that the initial size of the structure 20 is reduced until the frame members 40 and panels are collapsed on each other (see FIG. 3C ) to provide for a small essentially compact configuration having a plurality of concentric frame members 40 and layers of the panels 22 , 24 , 26 , 28 so that the collapsed structure 20 has a size which is a fraction of the size of the initial structure.
[0023] FIG. 5 illustrates a modification of the structure 20 , where the new structure 20 a is essentially comprised of the panel 22 a , and the other panels 24 , 26 , 28 are omitted. The panel 22 a and its fabric 42 a , opening 50 a , tube 52 a , tube 58 a , shower head 62 a and shower outlet 60 a can be the same as the corresponding panel 22 and its fabric 42 , opening 50 , tube 52 , tube 58 , shower head 62 and shower outlet 60 . The structure 20 a further includes another shower outlet 74 a , and two hanging straps 76 a attached to the top side 36 a . The straps 76 a allow the panel 22 a to be suspended from the top edge of an open door, from the branches of a tree, or any other support member that would allow the panel 22 a to be suspended in a vertical manner. The panel 22 a can be folded and collapsed in the same manner as described above in connection with FIGS. 3A-3C . As with the structure 20 , the structure 20 a allows for a collapsible structure to incorporate water use or water play, where the ability of the structure 20 , 20 a to be reduced in size for storage promotes convenience and ease of storage.
[0024] FIG. 6 extends the principles of FIGS. 1-5 to different types of collapsible structures. In FIG. 6 , the structure 100 does not have separate panels 22 , but is instead made up of two crossing frame members 102 , 104 that can be made of the same material as the frame member 40 described above. The frame members 102 , 104 cross at an apex 106 , and their respective ends are secured to the ground or surface, so as to form a domed or apexed configuration for the structure 100 . Fabric material, which is provided in the form of a shell 108 , is removably attached to the frame members 102 , 104 to form an enclosing structure. Frame retaining sleeves 110 and 112 can be stitched to the fabric shell 108 to retain the frame members 102 and 104 , respectively. Openings 116 and 118 similar to the openings 48 , 50 can be provided in the fabric shell 108 , and tubes 114 can be attached to the fabric shell 108 or the sleeves 110 , 112 to form tubing systems. For example, the tube 114 can have an end 120 that is adapted to be connected to a water faucet 122 . The tube 114 can be partially housed in its own sleeve 124 which is attached to (e.g., by stitching) and extends along the sleeve 110 , and then extends along the fabric shell 108 around the opening 116 , then along the bottom edge of the fabric shell 108 where it branches in three directions: towards a tubing section 126 (having spray holes) that encircles the opening 118 , towards a spray ring 128 , and towards a shower head 130 . The tube 114 can be made from the same material as the tube 52 . The structure 100 can be disassembled by removing and separating the frame members 102 and 104 , and then folding the fabric shell 108 . Since the tube 114 is flexible and soft, it can be folded together with the fabric shell 108 .
[0025] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. | A structure has at least one foldable frame member having a folded and an unfolded orientation, with a fabric material covering portions of the frame member to form at least one panel when the frame member is in the unfolded orientation. A water tube is attached to the fabric material and connected to a water supply, and a water outlet is coupled to the water tube. | 4 |
BACKGROUND OF THE INVENTION
It long has been recognized that the control of rodents such as rats and mice and similar agricultural pests is highly desirable, since such animals can increase their populations to quickly deplete food supplies meant for humans or other animals. They also spread disease, contaminate the food or directly injure other animals and children. Rats, are extremely cautious of items new in their surroundings consuming strange food in small quantities. Therefore, until the availability of slow acting but lethal toxicant baits, rats were very difficult to poison. The slow acting toxicants are effective because rats apparently cannot connect illness of themselves and others to the food that they are eating until they have consumed a lethal dose. Also, such toxicant bait when eaten makes a rodent thirsty, so that if the rodent is within a structure it will leave in an attempt to find water before drying. This eliminates the problem of odoriferous decay within a structure. However, effective stations must be provided to supply the toxicant bait in an enticing manner without endangering children or larger animals and so that a large number or rodents per bait fill are killed.
To be effective, a bait station must cope with the nature of the pest and the requirements of the toxicant bait. For example, toxicant baits usually require sufficient quantity to provide several days feeding for multiple animals and the station must be large enough to store the bait. Yet rodents have a propensity to get into the bait and excrete upon or otherwise foul it. This makes it unusable for its intended purpose, since later arriving pests may not enter and feed at the fouled bait station. Therefore, the rodents must not be given access to the bait except for feeding.
Mice, generally are inquisitive, but rats hesitate to enter a device which does not provide a visible exit as they enter, and they are most strongly attracted if the visible exit does not disappear as they finally are drawn in by the aroma of the bait to feed. Also the floor of the station should remain dry since most rodents will not enter a wet bait station. Therefore, the station should also be self draining and resistant to wind blown rain if exposed to such conditions.
There is a need therefore, for rodent and similar pesticidal bait stations which provide access and a visible egress for the rodents, and in which the bait containing area is baffled to such a degree that the pest can feed without being able to get into the bait itself. Also, the bait station should be constructed so that entry or access by other than the target pest for whom the station is intended, will be difficult or impossible. It should further be of the nature that the station cannot be entered by children or such that the children cannot reach into the station easily and disturb or obtain the bait. The bait containing portion of the station should be easily recharged and access to the bait recharging area must be locked securely or otherwise closed against the aforesaid children.
Typical patents pertinent to rodent bait stations include Hedrich, et al, Re. No. 14,782; Mayfield, U.S. Pat. No. 2,764,840; Kelly, U.S. Pat. No. 2,944,364; Starr, U.S. Pat. No. 2,977,711; Freeman, U.S. Pat. No. 3,303,600; Anderson, U.S. Pat. No. 3,352,053; Kare, U.S. Pat. No. 3,466,789; Connelly, U.S. Pat. No. 4,182,070; Clark, Sr. U.S. Pat. No. 4,364,194; and Baker, U.S. Pat. No. 4,400,904. The bait station disclosed in Baker has a general "H" configuration so that upon entry to one of the arms of the "H", the rodent can see a way out. However, when the rodent turns down the center arm, its pathway is blocked by the bait container. A visible escape route can not be seen, so the more cautious rats are hesitant about moving to the bait container for feeding. Also, the bait in the Baker station is enclosed in a upstanding tube which provides attraction and leverage for destructive juveniles.
SUMMARY OF THE INVENTION
The present invention considers the problems of the prior art bait stations and provides means to eliminate these problems. Preferably, the present bait station has an "H" configuration with openings at all ends of the "H" arms and bait containing bins located on either side of the center connecting passageway between the "H" arms. This makes access by children or nontarget animals very difficult as two right angle bends must be made in order to gain access to the bait bins. The floor of the present bait station tapers away from the bait bins so that any water that is blown into the structure during a rain storm and not blocked by entrance baffles, tends to drain therepast. This keeps the bait station dry and attractive to rodents. Since, in its preferred embodiment, a rodent can always see the light of an exit, the odor of the bait proves irresistible and the rodent's natural caution is overcome so that it comes back again and again until a lethal dose of bait has been ingested.
The bait station is constructed with two main components, a bottom which defines the "H" passageways and the bait bins, and a top, which covers the structure and provides access for filling, either by removal thereof or by removal of a central lid screwed or otherwise fastened thereto. The top and the bottom of the station are held together by suitable locking means and the station preferably is tied down in position. Internal bait deflectors allow the bait to be poured into a central region for deflection into the bait bins. These bait deflectors also act along with internal baffles to restrict a rodent's movement so that in most instances only the rodent's head can access a bait bin for feeding. This eliminates rodent fouling of the bins. Substitution of a bait bottle with a large supply of bait for the central lid reduces refill requirements in areas where such is safe and desirable.
In some embodiments, one of the arms of the "H" structure is eliminated so that a "T" type construction results in a more compact bait station for small areas. The bait bins may also be eliminated and replaced by traps with are enclosed within the station to prevent access by children or other animals. Trap embodiments normally are used in areas where a dying rodent may not be able to leave a structure and therefore presents an odoriferous nuisance upon demise if it dies in an inaccessible spot.
It is therefore an object of the present invention to provide a toxicant bait station in which the target animal may enter a low profile opening and see an egress when it is attracted to be toxicant bait and after feeding on the bait, leave the station without fouling the bait or spilling or kicking it out of the bait container.
It is another object of the invention to provide a rodent toxicant bait station wherein baffles permit access to the bait by the rodent while allowing drainage of fluids, such as urine or blow in rain water.
It is another object of the invention to provide a rodent trap or bait station wherein only the head of the rodent is permitted access to the bait, and this is done while the light from egress passageways are still visible.
It is another object to provide a bait station which is attractive to the target animals but whose bait cannot be reached by nontarget animals or children.
These and other object and advantages of the present invention will become apparent to those skilled in the art after considering the following detailed specification together with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bait station constructed according to the present invention in use attracting a rat;
FIG. 2 is a top plan view of the bait station of FIG. 1;
FIG. 3 is a side, cross-sectional view taken on line 3--3 of FIG. 2;
FIG. 4 is a side, cross-sectional view taken at line 4--4 in FIG. 2 showing how a rat is restricted in its access to the toxicant bait;
FIG. 5 is a top plan view of the bait station with its cover and bait deflectors removed showing how rats have restricted access to the toxicant bait in bait bins;
FIG. 6 is a side, cross-sectional view taken on line 6--6 of FIG. 5 showing typical entry baffle heights;
FIG. 7 is an exploded view of the component parts of the bait station of FIGS. 1 through 6;
FIG. 8 is a top plan view of the lower housing of a modified circular embodiment of the bait station;
FIG. 8A is an enlarged detailed view showing a twist lock feature of the bait station of FIGS. 8 and 9;
FIG. 9 is a top plan view of a cover housing for the lower housing of FIG. 8;
FIG. 10 is a side view, partially in cross-sectional of the embodiment of FIG. 8 having a large bait bottle connected thereto;
FIG. 11 is a modified embodiment of the station of FIGS. 1 through 7;
FIG. 12 is a top view of a lower housing of a modified embodiment with a center feed station and dual bait slides;
FIGS. 13 and 14 are top views of modified embodiments of the station of FIGS. 1 through 7 having traps instead of bait bins; and
FIG. 15 is an exploded perspective view of a disposable bait prepackaged bait station similar to the station of FIGS. 1 through 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings more particularly by reference numbers, number 20 in FIG. 1 refers to a bait station constructed according to the present invention. The station 20 includes a base housing 22 mated with a cover housing 24 which includes openings 26 on its opposite side walls 28 and 29 which extend between solid walls 30 and 31. The openings 26 provide access for target animals such as the rat 32, for access to bait placed therein through a screw or snap-on cap 34. The cap 34 is large enough to allow inspection of the interior of the station 20 upon removal. Ties 36 are strung through anchoring tie slots 38 and 40 (FIG. 2) on the base and cover housings 22 and 24 respectively to maintain the staton 20 at its desired location.
As shown in FIG. 3, the cap 34 can be child proofed by means such as a tab 42 which extends downwardly from the cap 34 to engage with a cam rise 44 adjacent the lip 46 of the fill and inspection opening 48 normally closed by the cap 34. A rat 32, entering through an opening 26 can see the opposite opening 26, as it is being lured toward the bait 50 being positioned in one of two bait bins 52 and 54 (FIG. 4). The bait bins 52 and 54 are shielded from direct view through the opening 48 by a pair of removable deflectors 56 and 58. The deflectors 56 and 58 engage at their uppermost portions 60 and 62 and are interlocked by upstanding tabs 64 and 66. The lower side corners 68 of the deflectors 56 and 58 engage slots 70 in slot members 72 along the side walls 74 of the bait bins 52 and 54. The slots 70 are positioned so that central gables 76 of the deflectors 56 and 58 allow a rat 32 to extend its head over the front side wall 78 or 80 of the bait bin 52 or 54, as shown in FIG. 4. The limited access provided by the gables 76 prevent the rat 32 from climbing into a bin 52 or 54 and spoiling the bait 50 for other rats 32. The rat 32 is further discouraged from climbing into a bin 52 or 54 by the abrupt right angle accesses thereto which occur because of the general "H" configuration of the station 20 as shown in FIG. 5. The entrances 26 are at the ends of the "H" arms.
Entrance baffles 82 are provided at each opening 26 to keep liquids, nontarget animals and children from entering the openings 26. It should be noted that the baffles 82 do not extend completely across the floor 84 of the openings 26. This allows the drainage of fluids which might be blown in in a heavy rainstorm. The floor 84 is canted toward the openings 26 so that this drainage is encouraged. The canting of the floor 84 is shown more clearly in FIGS. 6 and 7. Internal baffles 86 are provided across either end 88 and 90 of the central passageway 92 of the "H" passage system 94. These baffles 86 eliminate the possibility that blown in fluids will, in fact, remain adjacent the bait bins 52 and 54, and also further discourage nontarget animals.
The base housing 22 and cover housing 24 are connected together by suitable means such as fasteners 100 shown in FIG. 3 which pass through securing holes 102 in the cover housing 24 to engage with blind nut structures 104 connected to the base housing 22. Other securing holes 106 formed in studs 108 in the base housing 22 can be used as alternative means to anchor the station 20 in a desired location.
FIGS. 8, 8A, 9 and 10 show details of a circular shaped bait station constructed according to the present invention, which with 45° rotation between the base housing 122 and the cover housing 124 thereof can be closed so that its entry openings 126 are either blocked or opened by two large baffles 128 and 130 and the outside walls 132 and 134 of bait bins 136 and 138 respectively. Lock pins 140, as shown in FIG. 9, extend every 90° about the cover housing for engagement of four of eight lock slots 142 formed every 45° in a flange 144 about the base housing 122. When the cover housing 124 is rotated 45° from the position shown in FIG. 9, the openings 126 allow access over baffles 148 so that rodents can pass to the central passageway 150 underneath deflectors 156 and 158 similar to deflectors 56 and 58 for feeding through the gables 160 thereof. In FIG. 10, the normal cap closure 162 similar to cap 34 has been replaced by a large bait bottle 164 which screws in as a replacement. It should be noted that the bottle 164 has external threads 166 whereas the cap 34 was shown to have internal threads. Either is suitable provided the adjacent lip 46 or 168 is suitably oppositely threaded.
FIG. 11 illustrates a bait station 170 similar to bait station 20 except that one arm of the "H" configuration has been eliminated. Otherwise the portions as numbered thereof are identical to that of the bait station 20. The entry pathways are shown by the arrows 172. Another modified embodiment 180 of station 20 is shown in FIG. 12. In station 180, the rodent paths are shown by arrows 182. Since in station 182 there is a central bait bin 184 with suitable baffles 186 and 188, rodents must look across the bait bin 184 to see an exit even though they cannot use it because of the baffles 186 and 188. The central bait bin 184 is fed by a bait slide or by dual bait slides 190 and 192 on the opposite sides thereof so that as bait is eaten out of the central bait bin 184, additional bait stored on the slides becomes accessible to a rodent.
In the station 200, shown in FIG. 13, the bait bins 52 and 54 have been replaced by rodent traps 202 and 204. This allows essentially the same structure without the deflectors 56 and 58 to be used as an enclosed rodent trap. Once a rodent is killed by the trap 202 or 204, it is not accessible to children or pets. FIG. 14 shows a similar structure 210 where the internal bins with their baffles 78 and 80 have been removed allowing a more compact arrangement for placement of the traps 202 and 204.
In FIG. 15 a two-piece bait station 220 is shown with a disposable feed bin structure 222. The station 202 includes a cover housing 224 which nests with the disposable feed bin 222. The back sides 226 and 228 of the disposable feed bin structure 222 extend to the side walls 230 of the housing 224 so that the opposite walls 232 and 234 of the bin structure 222 define with the opposite outer walls 136 of the cover housing 224, the arms of the "H" structure discussed above. Prepackaged bait 50 is provided in the bins 238 and 240 of the structure 222. Suitable means such as the security pin 242 and aligning holes 244 and 246 in the cover housing 224 and the structure 222 respectively are used to lock the two structures together. Notches 248 are provided in the cover housing 224 which align with holes 250 in the walls 228 so that tie anchors 252 can be threaded therethrough for anchoring the station 220 in the desired location.
Thus there has been shown and described novel bait stations which fulfill all of the objects and advantages sought therefore. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this Specification and the accompanying drawings. All such changes, modifications, alterations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | The bait station includes an H-shaped passageway with toxicant bait containers located between the arms of the "H" which can be accessed from the central arm by the target animals. Floor baffles and overhead bait deflectors prevent the target animals from entering the bait containers while restricting access to the station by nontarget animals and children. | 0 |
TECHNOLOGICAL FIELD
The present invention deals with a device to be connected to a network and especially its installation and configuration. Installation is a general concept that covers all the hardware operations needed to connect the device to a network. Similarly configuration is understood to cover all the software operations that enable controlled transmission of data in the network between the device concerned and other devices connected to the network. The invention does not limit the type of network in question: it can be the Internet, an intranet, a Local Area Network (LAN), a Wide Area Network (WAN) or any other network intended for transmission of data between electronic terminals. The physical form of the network may be Ethernet(, Token Ring(, cellular radio network or any other corresponding network known as such.
BACKGROUND OF THE INVENTION
Intelligent network devices, such as routers, VPN (Virtual Private Network) devices, print servers, network printers, network cameras, and telecommunications adapters, require detailed configuration data before they can transmit and receive information through the network in a controlled manner. For instance in an IP (Internet Protocol) network the device needs to know its own IP address and the address of the default gateway, and possibly lots of other configuration data.
Information travels through the network generally in the form of packets. As background information for the invention, two known addressing schemes for IP packets are described, namely the IPv4 (Internet Protocol version 4) and IPv6 (Internet Protocol version 6) packet headers. The layout of an IPv4 packet header is illustrated in FIG. 1, and the layout of an IPv6 packet header is illustrated in FIG. 2 . Column numbers in FIGS. 1 and 2 correspond to bits.
In FIG. 1, the fields of the known IPv4 header are as follows: Version Number 101 , IHL 102 , Type of Service 103 , Total Length 104 , Identification 105 , Flags 106 , Fragment Offset 107 , Time to Live 108 , Protocol 109 , Header Checksum 110 , Source Address 111 , Destination Address 112 , Options 113 and Padding 114 . In FIG. 2, the fields of the known proposed IPv6 header are as follows: Version Number 201 , Traffic Class 202 , Flow Label 203 , Payload Length 204 , Next Header 205 , Hop Limit 206 , Source Address 207 and Destination Address 208 . The use of the fields in the headers is known to the person skilled in the art. An IP packet consists of a header like that of FIG. 1 or 2 accompanied by a data portion. In IPv6, there may be a number of so-called Extension headers between the main header shown in FIG. 2 and the data portion.
In a network where security features are important, an authentication may be performed by computing a Message Authentication Code (MAC) using the contents of the packet and a shared secret key, and sending the computed MAC as a part of the packet in an AH (Authentication Header) or ESP (Encapsulating Security Payload) header. Privacy is typically implemented using encryption, and the ESP header is used. The AH header is illustrated in FIG. 3, where column numbers correspond to bits. The fields of the known AH header are as follows: Next Header 301 , Length 302 , Reserved 303 , Security Parameters 304 and Authentication Data 305 . The length of the last field 305 is a variable number of 32-bit words.
The Encapsulating Security Payload (ESP) may appear anywhere in an IP packet after the IP header and before the final transport-layer protocol. The Internet Assigned Numbers Authority has assigned Protocol Number 50 to ESP. The header immediately preceding an ESP header will always contain the value 50 in its Next Header (IPv6) or Protocol (IPv4) field. ESP consists of an unencrypted header followed by encrypted data. The encrypted data includes both the protected ESP header fields and the protected user data, which is either an entire IP datagram or an upper-layer protocol frame (e.g., TCP or UDP). A high-level diagram of a secure IP datagram is illustrated in FIG. 4 a , where the fields are IP Header 401 , optional other IP headers 402 , ESP header 403 and ecrypted data 404 . FIG. 4 b illustrates the two parts of an ESP header, which are the 32-bit Security Association Identifier (SPI) 405 and the Opaque Transform Data field 406 , whose length is variable.
Several existing solutions are being used to configure newly installed network devices. Some devices have a display and keyboard for entering configuration data. Others may have a serial port in the device so that it can be attached to a separate configuration terminal for configuration. There are also solutions where a broadcast network packet or a ping packet is used to configure the device.
Solutions based on having a display and keyboard are often too costly and cumbersome for users. Likewise, attaching a configuration terminal to the device is an extra burden for the user. Methods based on broadcast packets only work in the local network, and cannot be used to configure the device remotely. Remote configuration is becoming more and more desirable, as the number of installed network devices is growing much faster than the number of people skilled enough to configure them. Finally, methods based on a ping packet can be used to configure the device remotely, but are limited in the amount of configuration data. Also, such methods will not work if the device to be configured is behind a device that is also listening for several other configuration packets or if there are similar identical devices on the same network.
Growing use of networks, especially increasing use of the Internet for electronic commerce and corporate communications is making security ever more important. Attacks against the network infrastructure are increasingly common. One opportunity for performing such attacks is the moment when the network device is being configured. At that time, most devices do not provide any security, and the attacker will be able to load the device with his/her configuration and software. The compromised device can then be instrumental in furthering the attack.
SUMMARY OF THE INVENTION
The existing configuration methods for configuring network devices lack ease of use, robustness, and security. Problems during device configuration are often very. difficult for users to understand and solve. It is therefore desirable to provide a method and apparatus for loading configuration data into the network device in a reliable, easy-to-use manner from a network management station controlled by an employee skilled in configuration of new network devices. This allows physical installation of new network devices to be carried out by employees that are not as skilled in configuration of new network devices. This genus of methods and apparatus will be referred to as the unsecure, remote configuration class. Further, in some networks where security is an issue, it is desirable to be able to configure new network devices remotely and securely from a remote network management station. This allows remote configuration via network packets without fear that an interloper with intent to attack the network will be able to intercept and alter the configuration data or other information such as network address or device identifier. The object of this invention is to provide methods, as well as a network device which can carry out the disclosed methods.
The object of the unsecure, remote configuration methods of the invention is accomplished by installing the network device in a dummy mode, and sending a configuration packet, including a device-specific identifier, to the network device to be configured or reconfigured either by broadcasting a packet containing the new network device's device identifier or sending a configuration packet directly to the network device's network address with the packet containing the device identifier of the device to be configured. The new network device to be remotely configured then either recognizes its device identifier in the broadcast packet or recognizes its device identifier in the packet sent directly to its network address, and uses the data therein to configure itself.
The object of the secure, remote configuration methods of the invention is accomplished by: transmitting the configuration packet from a remote network management station to the network device to be configured or reconfigured either by broadcast or by direct transmission to the network address of the device to be configured, authenticating the configuration packet at the network device to be configured or reconfigured as being from the proper network management station and containing the proper device identifier or by at least verifying that the configuration packet contains the properly encrypted device identifier which could only have been encrypted by the authentic network management station or some other secure information derived from the device identifier which can serve as a reliable indicator of the source of the configuration packet, and then decrypting and using the contents of the authenticated packet to configure the new network device.
It is characteristic of the secure, remote configuration method according to the invention that it comprises the steps of
transmitting from the management station a configuration packet to the network device,
authenticating at the network device the management station as the genuine transmitter of the configuration packet and
decoding the configuration parameters contained in said configuration packet and storing them as the configuration parameters of the network device.
The invention applies as well to a network device, of which it is characteristic that it comprises a computing block arranged to
compute device identifiers from cryptographic keys derived from recognised packets and
compare computed device identifiers against information used to verify known device identifiers for authentication of transmitting parties.
According to the invention, each new network device to be configured has a device identifier used to authenticate the device. There is also a management station connected to the network and used to remotely configure freshly installed network devices. The invention does not limit the nature of the device identifier; on the contrary, it should be understood very generally as something that can be used to identify a network device. According to a first embodiment of the invention, the management station knows the device identifier, IP address, default gateway, and other information needed to configure each new network device. When a new network device has been installed into the network it operates initially in a dummy mode where it only reads device identifiers from the packets it receives but does not otherwise process any data transferred in the network (or processes data in a factory-configured manner). The management station sends a specially formatted packet to the broadcast address of the network in which the new network device resides. The special packet contains an identifying code derived from the device identifier of the new network device and possibly other data. Whenever the new network device receives a packet, it checks whether the packet is a special packet with the identifying code matching its own device identifier. If the code matches, the device decodes the special packet, retrieves the configuration information from it and starts using its new configuration. It may also engage in a further information exchange with the management station to obtain further configuration data and to provide feedback to the management station user. In place of the identifying code derived from the device identifier the packet sent by the management station could also be a factory-configured (or generally preconfigured) address other than IP address, e.g. ethernet address, or some other kind of device identifier that the network will recognize.
According to a second embodiment of the invention the network device has its P address preconfigured manually before it is installed in the network. Thereafter, the management station may send a configuration packet directly to that address; the network device may even send a packet first to a preconfigured management station address to let it know it is there and wants to be configured.
According to a third embodiment of the invention the network device may obtain its IP address automatically from the network, e.g. using DHCP (Dynamic Host Configuration Protocol). According to a fourth embodiment of the invention the network device might respond to an ARP (Address Resolution Protocol) packet for IP addresses of some format, e.g. after a short delay to give a possible real owner of the address time to respond.
Security against any network-level attacks can be provided with the method. The device identifier is most advantageously derived from a cryptographic public key. The device identifier may also be the cryptographic key itself or a certificate accompanying it. Both the new network device and the management station may know the other device's device identifier beforehand so that they may recognise a received packet as coming from the correct sender. Alternatively each device may display the identifier computed from data received from the other party to the user and have the user confirm that the identifier is correct. This is called a (manual) verification of the device identifier. Both the new network device and the management station verifies that the cryptographic public key received from the other side matches the (manually) verified device identifier. Then, they cryptographically generate a shared secret using the authenticated cryptographic public keys. One implementation of this is to have each cryptographic public key be a Diffie-Hellman public value. After the authentication and verification stages the configuration may proceed safely.
The present invention provides a method to remotely configure a network device in a reliable, easy-to-use manner from a separate management station (which can be another network device). Optionally, the method can provide security.
The method enables devices to be installed by fairly unskilled support personnel, and the technically more demanding configuration operation can be performed by an expert from a management station without needing to travel to the installation site.
BRIEF DESCRIPTION OF DRAWINGS
The novel features which are considered as characteristic of 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 drawings. Features well-known as such have not been described in detail so as not to obscure the invention.
FIG. 1 illustrates a known IPv4 packet header,
FIG. 2 illustrates a known IPv6 packet header,
FIGS. 3, 4 a and 4 b illustrate other known packet headers,
FIG. 5 illustrates some features of a network and a network device,
FIG. 6 illustrates a method according to the invention and
FIG. 7 illustrates a network device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention is here described in terms of a network device attached to an IP (Internet Protocol) network. However, the present invention is equally applicable to other network protocols.
A network device 500 in FIG. 5 is a device that has one or more network interfaces 501 . A network interface is a connection to the physical network 502 , such as an Ethernet(network, a mobile radio network or some other network. In most networks, each network interface has one or more network addresses 503 that identify the network interface as the transmitter and/or receiver of packets. Network addresses are character strings; in FIG. 5 the characters are represented generally by X's. In an IP network the network address 503 is an IP address. The network knows how to route packets from a transmitting network address to a receiving network address from anywhere in the network. Such routing may involve travelling through multiple network devices, each device sending the packet down a link that it thinks will bring the packet closer to its final destination.
As a network device comes from the manufacturer, it has normally no information about the network address or other configurable data it will have when it is installed in a network. Such configuration data needs to be entered into the device either before or after the device is physically connected to the network in the appropriate location.
Configuration data is data that the network device needs to know before it can start normal operation. Typically, such data would include an IP address 503 , netmask 504 , default gateway address 505 , and operational parameters 506 for the network device 500 . Configuration data may also include new software to be downloaded to the device.
A management station 507 is a network device that will provide the newly installed device with configuration data. It may, but need not, maintain communications with the new network device also after installation. The management station usually has a user interface (keyboard and display).
Part of the present invention is that each network device 500 (and management station 507 ) can have a device identifier 508 , which is a public character string that could e.g. be printed on a sticker and attached to the bottom of the device.
The device identifier 508 serves two purposes. Firstly it identifies the device to be configured, so that if multiple devices using the same configuration method are attached to the same network, or there are other network devices on the path that the configuration packet needs to travel to reach its destination, the appropriate network device can be identified and other devices can ignore configuration data which is not intended for them. The other, more important purpose of the device identifier is that if it is derived from an appropriate cryptographic key, the device being configured and the management station can use it to authenticate each other, and to exchange cryptographic keys with each other securely. The device identifier is optional, but multiple configurable devices on the same network cannot be distinguished and security cannot be guaranteed without device identifiers.
It is possible to have the device generate its own device identifier (e.g. when it is first powered on) by some method known as such, and e.g. display the device identifier on screen if the device has one. This may be desirable in some cases to make all devices be identical when they leave the factory.
The device identifier is used for identifying the particular network device being configured by having the initial packet(s) sent to it contain either the device identifier directly, or some information derived from the device identifier (such as a hash of it and some other data). All receiving devices can then ignore configuration packets that are not destined to themself by checking the device identifier (or derived information) in each received configuration packet. To ease troubleshooting by users, the network device may display a warning if it sees a configuration packet that is not destined to itself. Device identifiers may also contain parity bits or other data that can be used to validate that a user has typed them in correctly.
To use the device identifier for security, it is a value derived from a cryptographic public key. The public key can be a Diffie-Hellman public value, an RSA (Rivest-Shamir-Adelman) key, a DSA key (Digital Signature Algorithm; U.S. Government Digital Signature Standard), or some other public key. The use of Diffie-Hellman public values is known from patents U.S. Pat. No. 4,218,582 and U.S. Pat. No. 4, 200,770, and the use of RSA keys is known from patent U.S. Pat. No. 4,405,829. For security, the device identifier should be derived from the public key in a way that makes it very hard to come up with another public key that would have the same identifier. One possible method is to use a cryptographic hash function (e.g. SHA1; Secure Hash Algorithm 1) to compress the public key, and then use an appropriate number of bits from the returned hash value. The use of the SHA1 algorithm is known from the publication “NIST, FIPS PUB 180-1, Secure Hash Standard, April 1995”. To make the device identifier easier for users to communicate, it is also possible to further process it for readability, e.g. by converting it to short English words similarly to what is used by some one-time-password methods.
An advantageous embodiment of the method according to the invention will be described below with reference to FIG. 6, where a multitude of possible authentication features are included. Later on it will be mentioned, which steps of the method are optional and not necessarily required by the invention.
To configure a new network device that has been installed in the network, the management station sends at stage 601 a specially formatted configuration packet to the new network device. The packet will be addressed so that the new network device will be able to see it. The exact method of doing this depends on the network protocol that is used and on the embodiment of the invention that is applied. In an IP network, the configuration packet can be addressed to the broadcast address of the network containing the new device. This causes all devices on that physical network to see it, including the hew device. Addressing directly to the new network device's IP address or some address behind it (for routers) will not work in this embodiment of the invention because the new network device has not yet been configured and consequently the ARP address resolving operation would fail. ARP (Address Resolution Protocol) is a known protocol that resolves IP addresses to Ethernet( addresses. Other alternatives than using the broadcast address have been described above in the general description of the invention.
The configuration packet will typically contain the new device's device identifier (or derivation thereof), the device's IP address, netmask, default gateway, and the management station's IP address and device identifier and/or public key. It may also contain information for setting up a shared secret, such as the management station's Diffie-Hellman public value and/or a certificate that will be used to verify that the packet came from the correct management station.
Each party (new network device and management station) needs to be assured that it is communicating directly with the other device and not with some intermediary (man-in-the-middle) that could modify the configuration data as it is transferred. If a single configuration packet is used without a further packet exchange, it may be sufficient to perform one-sided authentication, meaning that the new network device is assured that it receives the configuration packet directly from the management station without any intermediary tampering with the contents of the configuration packet.
To authenticate bidirectionally and to establish security according to FIG. 6, each party will send its public key to the other party. At stage 601 the management station sends its public key to the new network device along with the configuration packet. When a new network device receives the configuration packet labelled with its own device identifier, it computes at stage 602 the transmitting party's device identifier from the public key (and whatever other data might be used in the computation in a particular implementation) included in the configuration packet. It verifies that the device identifier it got by computing matches the known device identifier of the correct management station. The invention does not limit the way how this check is accomplished. There are several possible ways, like the following:
the network device displays the computed device identifier to a user, and the user verifies it using some out-of-band means (e.g. phone call or checking against written notes), and either accepts or rejects the identifier (e.g. by pressing the appropriate button),
the device identifier identifying the correct management station has been entered into the new network device beforehand, or a user types it in on location by using a keyboard, and the new network device compares the typed identifier electronically against the computed one, or
the device identifier is verified using some other means, such as checking a certificate or using a value stored in tamper-resistant memory means to verify that the identifier is acceptable; if a certificate contained in the packet is to be used the network device will most likely have the public key or a certificate of a CA (Certification Authority) in memory.
After checking the identity of the management station at stage 602 , the new network device may compute a shared secret at stage 603 using any method known as such, some of which are listed below, and set up whatever method will be used for further communication with the management station. With IPSEC, for instance, it could set up an AH or ESP security association with the management station. At stage 604 the network device sends a reply packet back to the management station, typically containing its own device identifier, its Diffie-Hellman public value or other public key, and other information depending on the particular application.
Upon receiving the reply packet, the management station will verify at stage 605 that the received public key or corresponding value matches the correct device identifier. Same methods may be applied as the other way round at stage 602 . The management station may compute the shared secret at stage 606 before setting up whatever method will be used for further communication with the management station.
The calculation of a shared secret at stages 603 and 606 corresponds to cryptographic authentication. Almost any authenticating key agreement method from the literature can be used. Examples include the following:
Each public key is a Diffie-Hellman public value, and the device identifiers are derived from the public value (e.g. using the SHA1 hash); effectively, each party authenticates each other's public value, and computes the Diffie-Hellman shared secret. Because both public values were authenticated, the resulting shared secret is also authenticated.
Each public key is a digital signature key (e.g. RSA or DSS), and the device identifiers are derived from the public key (e.g. using the SHA1 hash). The parties first obtain a shared secret (e.g. by a Diffie-Hellman exchange, public key encryption, or some equivalent method), and then digitally sign data used to derive it to prove to the other party that there was no man-in-the-middle.
If the key agreement method uses implicit authentication, it may be necessary to actually use the shared secret to prove its possession to the other party.
Once a shared secret has been established using any method, it can be used to cryptographically authenticate and/or encrypt any further messages. The configuration process may continue with an arbitrary packet exchange 607 protected by the shared secret. A number of well-established methods exist for doing this once the shared secret is available. One possibility is using the IPSEC AH and ESP headers for protecting the rest of the configuration exchange.
It is also conceivable to use symmetric cryptographic keys with tamper-resistant hardware. In this case, the devices typically already have a shared secret key. No explicit authentication is necessary. The parties can directly use their secret key to encrypt or authenticate any messages they send, and the correct key will be needed by the other party to decrypt messages or generate/validate authentication codes. If cryptographic authentication is not required, it may be omitted from stages 603 and 606 altogether.
Appropriate timeouts and recovery mechanisms must be used to cope with packets lost in the network. For instance, a network device may want to disable listening for configuration packets once it has been configured. However, it cannot do so until after it knows the management station has received the reply packet. Alternatively the network device may accept any time a new configuration packet that correctly indicates the management station as the authenticated transmitting party. This way the operation of the network is easy to change online by reconfiguring the appropriate network devices when necessary.
A user's view of the configuration process depends on the method used for verifying the other device's device identifier at stages 602 and 605 . The following installation process alternatives give an idea of the possible variations:
Known peer device identifier is explicitly typed in at both management station and new network device.
Known network device identifier is explicitly typed in at the managemement station but not at the new network device. When the management station has sent the configuration packet to the new network device, the new network device will display the computed device identifier of the management station and wait for user confirmation. The user will need to verify the device identifier out-of-band (e.g. by telephone, or having previously written it on paper).
No device identifier typed in on either side; both sides display it on screen for verification.
FIG. 7 is a schematic block diagram of those parts of a network device or management station 700 that take part in the operation according to the invention. The following explanation of the block diagram refers to a new network device to be configured but the corresponding functions are equal in a management station, although during the remote configuration of a newly added network device they take place in different order in a management station than in the network device to be configured.
Physical network interface 701 may be any prior art network interface known as such, adapted to receive and transmit packets through the network. Device identifier observation block 702 reads device identifiers from received packets to recognise those packets that are meant for this particular network device. A positive recognition occurs when the device identifier of the received packet coincides with the network device's own previously stored device identifier, read from the appropriate nonvolatile device identification memory 703 . A recognised packet will be written into a scratch pad storage 704 so that a computing block 705 may compute the device identifier of the transmitting device from the public key contained in the received and stored packet. To authenticate the transmitting device, the computing block 705 compares the device identifier it has computed against a known correct device identifier inputted by the user through a keypad 707 . Alternately the network device 700 may show the computed device identifier in a display 708 and wait for a positive or negative acknowledgement from the user through a keypad 707 . It is also possible to have the information used in the authentication read from a tamper-resistant memory 706 . A positive comparison or positive acknowledgement causes the configuration parameters contained in the received and stored configuration message to be transferred from the scratch pad storage 704 to a nonvolatile configuration memory 709 . If the result of the comparison or acknowledgement is negative, the temporarily stored configuration message is discarded from the scratch pad storage 704 and the network device 700 returns to its original dummy state where it only reads device identifiers from received packets and waits for its own configuration message without processing any other data received from the network.
After the transmitting management station has been correctly authenticated, a transmitter block 710 assembles a reply packet containing at least the network device's own public key read from the device identification memory 703 and the management station's network address read from the configuration memory 709 as the recipient's address. The reply packet is sent through the network interface 701 through the network to the management station.
Alternatively, the computer 705 may be programmed to use the apparatus already described to carry out any of the various other configuration methods described herein or included within the scope of the claims.
Memory blocks 703 , 704 , 706 and 709 may be any suitable memory circuits known as such. Keypad 707 may be any known keypad or keyboard and display 708 may be a LED display, a LCD screen, a cathode ray tube or any other suitable display known as such. The intelligent blocks 702 , 705 and 710 are most advantageously realised in a microprocessor by programming it to perform the necessary functions, which programming as such is within the normal ability of a person skilled in the art. A network device and a management station may naturally contain many other parts as those shown in FIG. 7 . Also, the configuration of FIG. 7 is exemplary in the sense that other arrangements may as well be used to reduce the invention into practice. | A network device ( 100, 300 ) is connected to a network ( 102 ) having also a management station ( 107 ) connected thereto. The method for configuring the network device comprises the steps of
transmitting from the management station a configuration packet to the network device ( 201 ),
authenticating at the network device the management station as the genuine transmitter of the configuration packet ( 202 ) and
decoding the configuration parameters contained in said configuration packet and storing them as the configuration parameters of the network device ( 203 ). | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to medical devices and more particularly to endoscopes for performing colonoscopy and other medical procedures.
BACKGROUND OF THE INVENTION
[0002] Flexible colonoscopy has been performed for more than 30 years. While significant advances have been made during that time, the procedure is still relatively unpleasant for most patients, and quite painful for others requiring not insignificant amounts of pain sedation. During the procedure, the physician advances a flexible endoscope through the soft and winding colon. During advancement, the physician pushes one end of the endoscope while trying to direct the distal tip (that can be up to four feet away from the physician) through the colon. Since the endoscope is flexible, the force applied to the endoscope at the proximal end is not necessarily transferred to the distal end. Rather, the endoscope tends to form bends and loops as it is being pushed through the colon.
[0003] This inevitably leads to stretching of the colon and of the various points where the colon is tethered inside the body causing discomfort for the patient. As a result, physicians typically need to administer sedation to the patient in order for the patient to remain comfortable through the procedure and reduce the pain created by the stretch. Sedation carries significant risks, particularly when higher doses are used, including depressing the respiratory and cardiac function.
[0004] Recent technical advances in colonoscopies over the past several years include thinner endoscopes, better optics and adjustable stiffness of the scope shaft, which assists in advancing the scope more easily into the colon. However, the basic technique is unchanged and problems of overstretching the colon remain. The procedure still remains unpleasant for the patient and most often requires considerable sedation.
[0005] Improved endoscopes and colonoscopy procedures are therefore desired.
SUMMARY OF THE INVENTION
[0006] One embodiment of the present invention is directed to a sheath for assisting movement of an endoscope within a cavity of a patient's body. The sheath includes an everting shaft having proximal and distal regions and a lumen for receiving the endoscope. An expandable member is positioned along the distal region, which is expandable from a first diameter to a second, larger diameter for engaging a wall of the cavity.
[0007] Another embodiment of the present invention is directed to an endoscope apparatus. The apparatus includes an everting shaft having inner and outer layers and a lumen defined by the inner layer. An endoscope extends along the lumen and is engaged with the inner layer. An expandable member is positioned along a distal region of the outer layer and is expandable from a first diameter at which the expandable member grips the endoscope to a second, larger diameter at which the expandable member releases the endoscope and allows the endoscope to move relative to the expandable member.
[0008] Another embodiment of the present invention is directed to a method of moving an endoscope along an elongated body cavity. The method includes: (a) inserting an endoscope apparatus into the body cavity, the apparatus comprising an endoscope and an everting shaft, which includes inner and outer layers, a lumen through which the endoscope extends, and an expandable member; (b) advancing the apparatus to a curved portion of the body cavity with the expandable member contracted to a first diameter at which the expandable member grips the endoscope; (c) expanding the expandable member from the first diameter toward a second, larger diameter at which the expandable member releases the endoscope and anchors to a wall of the body cavity; (d) applying a withdrawing force on the outer layer when the expandable member is anchored to the wall of the body cavity to thereby reduce curvature of the curved portion of the body cavity; and (e) advancing the endoscope relative to the expandable member such that engagement between the endoscope and the inner layer causes a distal portion of the inner layer to evert to the outer layer during advancement.
[0009] Another embodiment of the present invention is directed to a medical device for insertion into a body cavity. The device includes an elongated sheath. The expandable member is expandable from a first diameter to a second, larger diameter and is mounted to the elongated sheath such that the elongated sheath has an angular position that is rotatable relative to the expandable member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1-1 through 1 - 14 illustrate a colonoscopy procedure according to one embodiment of the present invention.
[0011] FIG. 2 is a side view of an endoscope apparatus in a deflated state according to one embodiment of the present invention.
[0012] FIG. 3 is a side view of the endoscope apparatus in an inflated state according to one embodiment of the present invention.
[0013] FIG. 4 is an enlarged, cross-sectional view of the distal end of the apparatus shown in FIGS. 2-3 within a patient's colon.
[0014] FIG. 5 is an enlarged view of the distal end showing an expandable member in an inflated state.
[0015] FIG. 6 is an enlarged view of the distal end showing the expandable member in a deflated state.
[0016] FIG. 7 is a side view of an endoscope apparatus according to an alternative embodiment of the present invention.
[0017] FIG. 8 is a cross-sectional view of an endoscope apparatus having the inflation cavity of an expandable member coupled to the inflation cavity of an everting sheath according to an alternative embodiment of the present invention.
[0018] FIG. 9 is a cross-sectional view of an endoscope apparatus having a rotatable balloon according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIGS. 1-1 through 1 - 14 illustrate a colonoscopy procedure according to one embodiment of the present invention. During the procedure, an endoscope apparatus 10 is advanced into the colon 12 of a patient. The endoscope apparatus 10 is inserted into the bottom 14 of colon 12 and advanced through each segment to reach the end 16 . For simplicity, the full length of endoscope apparatus 10 is not shown beyond the bottom 14 of colon 12 in FIGS. 1-1 through 1 - 14 .
[0020] As described in more detail below, apparatus 10 includes an endoscope 17 , which extends through an outer everting sheath 18 and has a distal end 17 a and a proximal portion 17 b . Sheath 18 assists in advancing endoscope 17 through colon 12 . In one embodiment, everting sheath 18 has an inner layer that frictionally engages the outer diameter surface of endoscope 17 and an outer layer that carries an expandable member 20 . In one embodiment, expandable member 20 forms a balloon, which can be inflated and deflated. When sheath 18 and expandable member 20 are inflated, the outer layer of the sheath becomes separated from the inner layer. The inner layer is connected to the outer layer at the distal end of sheath 18 to allow the inner layer to evert to the outer layer at the distal end of sheath 18 .
[0021] In FIG. 1-1 , the endoscope apparatus 10 is shown inserted into colon 12 , within the everting sheath 18 , which is fully deflated. When deflated, one or more elastic elements or bands 26 , grip the expandable member 20 and sheath 18 to the outer diameter of endoscope 17 such that the endoscope and sheath can be advanced together along colon 12 .
[0022] At this point in the procedure, the endoscope is used in a normal manner. As the endoscope is advanced further within the colon, the shaft of the endoscope begins to form bends and loops, causing discomfort due to stretching of the colon from its normal configuration. This is usually the first point in the procedure when the patient experiences significant discomfort. As the physician pushes proximal portion 17 b in order to advance distal end 17 a , the bend in endoscope 17 can cause the colon 12 to stretch along area 30 causing pain.
[0023] FIG. 1-2 illustrates everting sheath 18 and expandable member 20 inflated with a fluid such as water. However, any suitable fluid (liquid or gas) can be used for inflating sheath 18 and/or expandable member 20 . Sheath 18 and expandable member 20 can be inflated through a common passage or lumen or can be inflated through separate passages or lumens. When expandable member 20 and sheath are inflated, the water pressure overcomes the grip of the small elastic bands 26 (shown in FIG. 1-1 ) such that expandable member 20 and the outer layer of sheath 18 no longer grip the outer diameter of endoscope 17 . Expandable member 20 is sized and shaped such that, when inflated, the outer diameter surface of expandable member 20 engages the interior surface of colon 12 and can serve to anchor sheath 18 in position relative to the colon. Various shapes and textures of the expandable member can be used to anchor the sheath and expandable member to the colon without applying excessive radial force on the colon, as excessive radial force could cause discomfort in and of itself. When the sheath and expandable member are anchored in position, endoscope 17 is free to move in an axial direction relative to expandable member 20 .
[0024] In FIG. 1-3 , with expandable member 20 anchored to colon 12 , the physician pulls endoscope 17 and sheath 18 from proximal portion 17 b to withdraw slightly the endoscope and sheath from the colon and thereby straighten that section of the colon.
[0025] In FIG. 1-4 , the bottom of colon 12 begins to shorten and the stretch along area 30 is reduced as endoscope 17 and sheath 18 are withdrawn further. Eventually, the curve formed by endoscope 17 is reduced with further withdrawal of endoscope 17 and sheath 18 , creating a relatively straight section of colon 12 for advancement of the endoscope along the colon.
[0026] Referring to FIG. 1-5 , expandable member 20 remains inflated and is fixed against the wall of colon 12 . Endoscope 17 is able to move independently from expandable member 20 because of the action of everting sheath 18 underneath the expandable member. The physician can then push the proximal portion 17 b of the endoscope while maintaining a pulling force on the outer layer of sheath 18 . As shown in FIG. 1-6 , the frictional engagement between the outer diameter surface of endoscope 17 with the inner layer of sheath 18 causes the inner layer of the sheath to evert out of the distal end of the sheath (as shown by everted section 32 ). As sheath 18 everts, more of the distal end 17 a of the endoscope becomes exposed.
[0027] As shown and described in more detail below, everted section 32 represents material along the inner layer of sheath 18 that has advanced relative to the outer layer of the sheath and is therefore exposed out of the distal end of the sheath.
[0028] At this point in the procedure, the distal end 17 a of endoscope 17 has reached a relatively straight section of colon 12 due to the everting action of sheath 18 and the straightening of the bottom portion of the colon. Expandable member 20 and sheath 18 can then be deflated, as shown in FIG. 1-7 . This causes elastic bands 26 to re-grip endoscope 17 at a distance further back from distal end 17 a . Endoscope 17 and sheath 18 can then be advanced together once again in the usual manner, as shown in FIG. 1-8 .
[0029] When the patient starts to feel pain or the endoscope begins to form exaggerated bends once again, expandable member 20 can be re-inflated, as shown in FIG. 1-9 . As shown in FIG. 1-10 , the everting sheath 18 can be withdrawn slightly thereby straightening endoscope 17 between expandable member 20 (which is fixed against colon 12 ) and the rectum. This allows the endoscope 17 to be advanced in a relatively straight line between the rectum and expandable member 20 . Now, most of the force applied by pushing endoscope 17 from proximal portion 17 b is transferred to the level of expandable member 20 . This has the effect of pushing the flexible endoscope 17 from the midshaft rather than at the proximal portion 17 b , providing some mechanical advantage.
[0030] Once endoscope 17 has then been advanced beyond a difficult section and the colon is straightened, expandable member 20 can be deflated as shown in FIG. 1-11 . Note that as sheath 18 becomes further everted, more of endoscope 17 becomes exposed out of the distal end of the sheath, along everted section 32 . When expandable member 20 is deflated, the expandable member re-grips endoscope 17 , this time even further back from distal end 17 a . In FIG. 1-12 , endoscope 17 and sheath 18 are advanced further until another difficult point is reached. In FIG. 1-13 , expandable member 20 can be inflated once again. In FIG. 1-14 , endoscope 17 is advanced to the end 16 of colon 12 . At this point in the procedure, endoscope 17 can image the end 16 of colon 12 .
[0031] If during the procedure the physician wishes to “reload” expandable member 20 to the distal end 17 a of endoscope 17 , the physician can advance endoscope 17 and deflated expandable member 20 to an straight section of colon 12 such that shown in FIG. 1-7 , for example. The expandable member 20 can be inflated to engage the surface of colon 12 and hold the expandable member and sheath in a fixed position relative to the colon. The physician can then pull back and withdraw the endoscope 17 relative to sheath 18 and expandable member 20 until the distal end 17 a of endoscope 17 reaches expandable member 20 . Expandable member 20 and sheath 18 can then be deflated causing elastic bands 26 to re-grip the distal end 17 a of endoscope 17 . The endoscope 17 , sheath 18 and expandable member 20 can then be advanced together through the straight section of colon 12 .
[0032] The everting sheath and expandable member described above can be used with any type of endoscope for any medical procedure. In addition to endoscopes used for colonoscopy, the everting sheath and expandable member can be used with endoscopes for performing an upper endoscopy procedure through the esophagus, for example, to facilitate deeper passage into the small intestine. In addition, the sheath and expandable member can be used in other elongated medical instruments or devices for advancement along a human or other animal body cavity.
[0033] FIG. 2 is a side view of endoscope 17 and sheath 18 , with sheath 18 and expandable member 20 in a deflated state according to one embodiment of the present invention. FIG. 3 is a side view of endoscope 17 and sheath 18 , with sheath 18 and expandable member 20 in an inflated state according to one embodiment of the present invention.
[0034] Referring to FIG. 2 , endoscope 17 has an elongated shaft with a distal end 17 a , a proximal portion 17 b and a handle 17 c . Endoscope 17 is shown inserted within everting sheath 18 . Everting sheath 18 has a distal end 18 a and a proximal end 18 b . Endoscope 17 extends through an internal lumen of sheath 18 , from proximal end 18 b to distal end 18 a . In one embodiment, expandable member 20 is a separate element that is attached to the outer layer of sheath 18 . In another embodiment, expandable member 20 is formed as a single, continuous piece of material with the outer layer of sheath 18 . For example, expandable member 20 can be defined by one or more areas of reduced material thickness relative to the thickness of sheath 18 , or by one or more areas where the sheath material elasticity is increased relative to the elasticity of sheath 18 . The areas of reduced material thickness or increased material elasticity expand to a greater degree than sheath 18 when sheath 18 is inflated. Expandable member 20 can have any number of sections 28 defined by elastic bands 26 .
[0035] Elastic bands 26 extend around the periphery of expandable member 20 and are sized to grip the outer diameter of endoscope 17 when sheath 18 and expandable member 20 are deflated. Similar to expandable member 20 , elastic bands 26 can be formed of any suitable elastic material, which can be separate from expandable member 20 or integral with the expandable member material. For example, bands 26 can be separate rubber bands that are mounted over expandable member 20 . In an alternative embodiment, elastic bands 26 are formed within the material of expandable member 20 , such as one or more bands having increased material thickness than expandable member 20 . Any number of bands can be used. Sheath 18 , expandable member 20 , and bands 26 can be formed of any suitable elastic material, such as elastic polymers.
[0036] Sheath 18 includes an inflation valve or port 40 for inflating sheath 18 through a lumen 42 . In this embodiment, sheath 18 further includes a separate inflation valve or port 44 for inflating expandable member 20 through a separate lumen 46 . Again, sheath 18 and expandable member 20 can be inflated through a common lumen or through separate lumens. As described in more detail below, sheath 18 is formed as a cylindrical tube with sidewalls formed by two layers of material with a space between them. When a fluid is introduced within the space between the two layers, the fluid pressure expands the space, thereby inflating the sheath, as shown in FIG. 3 . The expandable member 20 is attached to the outer layer of material and can be inflated with sheath 18 or separately from sheath 18 in alternative embodiments.
[0037] Inflation valve 40 can include a fitting for attaching a syringe that can be used for inflating the sheath and/or expandable member. In addition, inflation valve 40 can include a chamber for storing extra material of sheath 18 that can be used during eversion.
[0038] In one embodiment, the inner layer of sheath 18 is frictionally attached to the outer diameter of endoscope 17 when sheath 18 is inflated and deflated. This allows the inner layer of sheath 18 to evert out the distal end of the sheath when sheath 18 and expandable member 20 are inflated and endoscope 17 is advanced relative to expandable member 20 . Inflation of sheath 18 provides an area of lubrication between the inner and outer layers of the sheath material to allow expandable member 20 to slide back and forth relative to endoscope 17 , as shown in more detail in FIGS. 4 and 5 .
[0039] FIG. 4 is an enlarged, cross-sectional view of the distal end 18 a of everting sheath 18 when inflated. Endoscope 17 extends through an internal lumen 60 of sheath 18 . Sheath 18 has a cylindrical inner layer 62 and a cylindrical outer layer 64 , which together form an elongated, annular tube. At distal end 18 a , inner layer 62 is attached to outer layer 64 , forming a continuous material, for example. Cavity 66 between inner layer 62 and outer layer 64 is inflated by introducing a pressurized fluid (such as water) within the cavity. Inflation of the space between the inner and outer layers of sheath 18 separates elastic bands 26 and expandable member 20 from endoscope 17 and allows the endoscope to move independently from expandable member 20 .
[0040] When sheath 18 and expandable member 20 are inflated and endoscope 17 is advanced relative to expandable member 20 , as shown by arrow 68 , the frictional engagement between inner layer 62 and the outer diameter of endoscope 17 causes the inner layer 62 to travel with endoscope 17 relative to expandable member 20 and outer layer 64 . As endoscope 17 continues to advance, more of the inner layer material gets everted out of distal end 18 a , as shown by arrows 69 , thereby forming additional outer layer material. This eversion action increases the length of everted section 32 that extends forward beyond expandable member 20 (not shown in FIG. 4 ). As mentioned above, the movement of inner layer 62 relative to outer layer 64 about the fluid in cavity 66 provides an area of lubrication to allow expandable member 20 to slide back and forth relative to endoscope 17 , and the inner layer 62 is able to pass freely under expandable member 20 .
[0041] FIG. 5 is an expanded view of the distal end 18 a of sheath 18 according to one embodiment of the present invention. When sheath 18 and expandable member 20 are inflated, fluid pressure inside the expandable member and the sheath overcomes the grip of elastic bands 26 and allows expandable member 20 to expand from a first diameter to a second, larger diameter. When elastic bands 26 are released from endoscope 17 , the endoscope is free to move relative to the fixed expandable member 20 . Expandable member 20 can have any number of sections. In the embodiment shown in FIG. 5 , expandable member 20 has three sections separated by two elastic bands 26 . When inflated, expandable member 20 engages the inner surface of colon 12 . This allows the location of expandable member 20 and the outer layer 64 of sheath 18 to remain fixed relative to colon 12 .
[0042] As mentioned above, expandable member 20 can be inflated and deflated either separately or with sheath 18 . In the embodiment shown in FIG. 5 , expandable member 20 has an internal cavity 80 , which is coupled to lumen 46 for inflating expandable member 20 separately from sheath 18 .
[0043] FIG. 6 cross-sectional view of the distal end 18 a of sheath 18 when sheath 18 and expandable member 20 are deflated. When deflated, elastic bands 26 collapse expandable member 20 until the bands grip the outer diameter of endoscope 17 through outer layer 64 and inner layer 62 of sheath 18 . In this state, endoscope 17 and sheath 18 can be advanced or withdrawn together through colon 12 .
[0044] FIG. 7 is a side view of endoscope 17 and sheath 18 showing sheath 18 in a partially everted state, relative to FIG. 3 . As endoscope 17 is advanced relative to inflated expandable member 20 , the length of everted section 32 forward of expandable member 20 increases, as can be seen with a comparison to FIG. 3 . Also, more of endoscope 17 becomes exposed beyond the distal end 18 a of sheath 18 .
[0045] FIG. 7 also illustrates an alternative embodiment in which extra sheath material 70 is stored in a housing 72 containing inflation valve 40 . The extra sheath material can be stored in a housing separate from inflation valve 40 in a further alternative embodiment. In one embodiment, the inner layer of sheath 18 forms a continuous piece of material with the outer layer at proximal end 18 b , similar to distal end 18 a . However, the inner and outer layers can be disconnected from one another at proximal end 18 b in an alternative embodiment of the present invention.
[0046] FIG. 7 further illustrates an abutment device 92 fastened to the ridges 56 along the outer layer of sheath 18 . Abutment device 92 can be used to anchor the axial position of the outer layer of sheath 18 relative to the patient's rectum as endoscope 17 is advanced. As described with reference to FIGS. 1-1 through 1 - 14 , the colon can be straightened by inflating expandable member 20 and then pulling back on endoscope 17 and sheath 18 . If the physician desires not to withdraw endoscope 17 while straightening the colon, the physician can pull back on sheath 18 while pushing endoscope 17 forward. This may require the physician to pull back on sheath 18 with one hand while pushing forward on endoscope 17 with the other hand. Abutment device 90 can help to free one of the physician's hands while advancing the endoscope 18 . As sheath 18 is being pulled backward, abutment device 90 can be slid forward along sheath 18 toward the patient's rectum. Abutment device 90 can therefore act as a stopper, which holds the position of sheath 18 relative to the colon to prevent forward movement of the sheath when pushing endoscope 17 forward. This keeps the outer diameter of sheath 18 in place and tension between the sheath and expandable member 20 , thereby maintaining a straightened section of the colon.
[0047] FIG. 8 is a cross-sectional view of the distal end of an endoscope apparatus 100 according to an alternative embodiment of the present invention. The same reference numerals are used in FIG. 8 as were used in the preceding figures for the same or similar elements. In this embodiment, the internal cavity 80 of expandable member 20 is coupled to the cavity 66 between the inner and outer layers 62 and 64 of sheath 18 through one or more openings 102 . Inflation lumen 46 is coupled to cavity 80 of expandable member 20 , but could alternatively be coupled to cavity 66 of sheath 18 . When a pressurized fluid is inserted into cavity 80 through inflation lumen 46 in order to inflate expandable member 20 , excess fluid enters cavity 66 through openings 102 causing sheath 18 also to inflate.
[0048] FIG. 9 is a cross-sectional view of the distal end of an endoscope apparatus 200 according to another alternative embodiment of the present invention. Again, the same reference numerals are used for the same or similar elements. In FIG. 9 , endoscope apparatus 200 has an angular position that is rotatable relative to expandable member 20 , as indicated by arrow 201 . Expandable member 20 is mounted to the outer layer 64 of sheath 18 through a sliding interface or fitting 202 . In this example, expandable member 20 has a base 204 , which is mounted in a channel 206 on outer layer 64 to form the sliding interface 202 . Channel 206 has an annular shape, which extends around the circumference of outer layer 64 . Other methods and structures for mounting expandable member 20 to apparatus 10 that allow for relative rotational movement can be used in alternative embodiments of the present invention.
[0049] During some procedures, it may be desirable to apply a rotational torque on the endoscope 17 in order to direct the endoscope 17 around difficult turns or to fine-tune the position of the endoscope 17 when taking a biopsy or removing a polyp, for example. By making exapandable member 20 completely separate from sheath 18 , endoscope 17 can rotate while expandable member 20 remains anchored to the colon in a fixed position.
[0050] A rotatable expandable member or balloon, as shown in FIG. 9 can be implemented on any elongated medical device, such as an endoscope, endoscope sheath or catheter, for example. If a sheath is used, the sheath can be everting or non-everting.
[0051] Various shapes and configurations of the expandable member can be used to improve the longitudinal traction between the colon and the expandable member without creating excessive radial force against the colon. One such configuration is shown in FIG. 10 . Endoscope apparatus 250 includes an endoscope 17 and an everting sheath 18 , which are similar to the embodiments discussed above. In this embodiment, sheath 18 includes an expandable member 252 having a shape that allows for the expandable member to catch or grab on to areas of the colon when withdrawn as in the action of an anchor, but would not require excessive inflation and over-expand the colon. When expanded, expandable member 252 forms three anchor fins 254 , which project radially outward from sheath 18 for engaging the colon wall. Fins 254 can extend around all or part of the circumference and can have any suitable cross-sectional shape, such as triangular.
[0052] FIG. 11 illustrates a further embodiment of an endoscope apparatus 275 having an expandable member 280 attached to everting sheath 18 . In this embodiment, expandable member 280 has a conical shape. Elastic band 26 biases expandable member 280 to the smaller diameter when not inflated.
[0053] In a further embodiment, the expandable member can be formed of a mechanical anchor attached to the sheath, which could be made of plastic or other suitable material. The mechanical anchor could be activated (expanded and/or contracted) by means of a wire-triggered (or other) mechanism, rather than by inflation with a fluid or gas.
[0054] With the embodiments shown in the above-described figures, an everting sheath can be preloaded on any standard or specialized endoscope. The sheath carries an expandable member, which can either be fixed to the endoscope by elastic bands (for example) when deflated, or detached from the endoscope when inflated and anchored to the colon. This allows the endoscope and expandable member to be moved either together as a single unit or independently. This device also may remove the need to invest in complicated and expensive endoscopes with special features to allow the endoscope to be advanced easily through the colon. Rather, a standard endoscope can be preloaded with an everting sheath as described above. This can significantly reduce the expense associated with colonoscopy procedures.
[0055] Also, the use of this device may allow the endoscope to be advanced to the end of the colon much faster than endoscopes of the prior art. This significantly reduces the time required for a colonoscopy procedure and reduces the duration of patient discomfort. In addition, the ability to straighten certain difficult sections of the colon allows the endoscope to be advanced with reduced pain to the patient. As a result, physicians may find that colonoscopy procedures can be performed more safely and with less sedation.
[0056] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention. | A sheath and a method of operating the sheath are provided for assisting movement of an endoscope within a cavity of a patient's body. The sheath includes an everting shaft having an internal and external lining with an inflatable lumen between them, proximal and distal regions and a lumen for receiving the endoscope. An expandable member is positioned along the distal region, which is expandable from a first diameter, at which the expandable member grips the endoscope to a second, larger diameter at which the expandable member engages a wall of the cavity. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to games of skill and in particular to games using playing pieces representing persons of power having different functions as to movement and capturing of an opponent's pieces.
Similar games of the prior art include checkers and chess in which the playing pieces represent individuals having certain powers to move about on the playing board and capture the opponent's pieces.
SUMMARY OF THE INVENTION
The game apparatus of the present invention comprises, basically, a playing board having a playing field of one hundred squares arranged in ten rows and ten columns in an ordered array of rows, columns and diagonals, plus two extra rows, one for each opposing player, of squares or "cells" containing indicia for placement of captured pieces, with two sets of twenty-two player pieces each moving according to individual rules along the rows and columns and in diagonal directions, with the first piece for moving one square in any direction, a second piece for moving any number of squares in any unobstructed direction and also a combined move of moving one square along a row or column in any obstructed (or unobstructed) direction and then one square diagonally away from the beginning square of said move for landing on an unobstructed square or for capture of an opponent's piece in the last square of the move, two pieces for moving in any unobstructed row, column or diagonal direction, two pieces for a two step move, first one square along a column or row in any obstructed (or unobstructed) direction, and then one square diagonally away from the beginning square of said move and landing on an unobstructed square or for capture of an opponent's piece in that last square of the move, two pieces for moving in any unobstructed direction along rows and columns, two pieces for moving in any unobstructed direction along diagonals, two pieces for moving only one square in any direction and ten pieces for moving along a column in one direction toward the opponent's side and for capturing an opponent's piece by moving diagonally forward one square.
Two extra columns, one on each side of the board, are provided for the purpose of extending the capture rows or "cells" for an additional two playing pieces.
It is, therefore, an object of the present invention to provide a game of skill.
It is a further object of the present invention to provide a game of skill having individual playing pieces which function as individuals having various powers to move in various directions on said playing board.
It is another object of the present invention to provide a game of skill in which a row of "cells" is provided for each opponent having inidicia thereon for placement of captured pieces.
These and other objects of the present invention will be manifest upon study of the following detailed description when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the game board of the present invention, showing the initial positions of the playing pieces.
FIGS. 2 A through 2 H are elevational views of the typical playing pieces with their identifying names.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, there is illustrated a plan view of the game board 10 of the present invention showing the position of each of the playing pieces at the beginning of play. The object of the game is to win by capturing the opponent's Maharaja 14. This capture is never consumated. Instead, the game is considered won when the opponent's Maharaja 14 is attacked and he finds no escape.
The game of the present invention comprises, basically, a game board 10 comprising a playing field 11 of one hundred squares arranged in ten rows 15a through 15j and ten columns 17a through 17j which also form diagonals as indicated by arrows 19. A capture row 21a and 21b is provided for each opponent, which row contains indicia in each square or "cell" showing where the captured piece must be placed. In order to provide a square game board 10, two extra columns of squares 23a and 23b are provided on each side of the board. The intersections of columns 23a and 23b with rows 21a and 21b are squares or "cells" which contain indicia for placing a captured Goli (special attendant to the Maharaja and Rani) 26a or 26b which is not released by any Sapahi 28. The squares may be colored alternately light and dark or they may be all one color as desired. Two sets of 22 playing pieces are used, each set being of a different distinguishing color.
Each set of 22 pieces comprises one Maharaja 14, one Rani (wife of the Maharaja) 16, two Shahzadas (sons of the Maharaja) 18a and 18g, two Swars (Lancers of the Maharaja) 22a and 22b, two Jotshis (Astrologers of the Maharaja) 20a and 20b, two Rathwans (Maharaja's palace cart drivers) 24a and 24b, two Golis (special attendants of the Maharaja and Rani) 26a and 26b, and ten Sapahis (Soldiers of the Maharaja) 28a through 28j. Each piece represents an individual having a particular ability to move about the playing board in a particular manner to afford capture of an opponent's pieces and escape from an opponent's pursuit.
The Maharaja 14, or head of state, is represented by an arbitrary symbol as shown in FIG. 2A comprising a base portion 30, curved upper portion 32 having sharp protrusions 34 capped with a symbolic crown 36. This piece representing the Maharaja 14 has the power to move only one square in any direction. The Maharaja 14 is also permitted to move in an obstructed direction first one square along a row or column and then one square to an unobstructed square diagonally away from the point of beginning. However, this move is limited to only one per game and it may not capture an opponent's piece by that move. The Maharaja 14 or head of state is the piece which must be captured or be in a position where its capture is inevitable for one side to win.
The Rani (wife of the Maharaja) 16, or next in line to become head of state, is represented by the arbitrary symbol as shown in FIG. 2B, and comprises a base 38 having a curved portion 40 having sharp protrusions 42 capped by a lesser distinct crown 44. The Rani (wife of the Maharaja) 16, because of her standing in the power structure, has the power to move in any direction, either along a column, row or diagonal, which is not obstructed by an opposing player's piece. She further has the ability to move along an obstructed path in which the first step is one square along either a column or a row, which may be obstructed by an opponent's piece, and then diagonally one square in a direction away from the beginning square of that move, which square may be either occupied or not occupied by an oponent's piece. If the end square is occupied by an opponent's piece, a capture results. A capture will also result if an opponent's piece occupies the square at the end of the move along any row, column or diagonal.
The Shahzada (son of the Maharaja) 18a or 18b, who also may ascend to become head of state, is represented by the arbitrary symbol as shown in FIG. 2C, being an object having a base portion 46 with various curves and protrusions 48 capped by a smaller crown 50 symbolizing an individual having somewhat lesser power. The Shahzada (son of the Maharaja) has the power to move in any unobstructed direction for any number of squares along either a column, a row or a diagonal, and can capture an opponent's piece when it occupies the end square of such a move.
The Jotshi (astrologer of the Maharaja) 20a or 20b, who also has great influence over the Maharaja 14, is represented by the arbitrary symbol as shown in FIG. 2D, having a lesser number of curves and protrusions 52 to symbolize his lesser importance. The Jotshi (astrologer of the Maharaja) 20 has the ability to move in any unobstructed direction along a diagonal and capture an opposing piece in the square at the end of such a move.
The Swar (lancer of the Maharaja) 22, having the ability to influence and protect the Maharaja 14 and his family, is represented by the arbitrary symbol as shown in FIG. 2E being somewhat smaller in size and less eleborate than the other pieces of greater power. The Swar (lancer of the Maharaja) has the ability to move in two steps over an obstructed path or unobstructed path in that, for the first step of the move, it can move one square along any row or column, which may be either obstructed or unobstructed, and then for the remaining step of the move, it can move one square diagonally away from the beginning square of the move, which, if the end square is occupied, will result in a capture of an opponent's piece.
The Rathwan (Maharaja's palace cart driver) 24a or 24b, or other state official, is represented by the arbitrary symbol as illustrated in FIG. 2F and is also somewhat smaller and less elaborate than the members of state of higher rank. The Rathwan (Maharaja's palace cart driver) 24a or 24b has the ability to move in any direction along either a column or a row that is unobstructed and may capture an opponent's piece in the last square of that move.
The Goli (special attendant to the Maharaja and Rani) 26a or 26b, whose essential function is to protect the head of state and his family, is represented by the arbitrary symbol as shown in FIG. 2G. Each Goli (special attendant to the Maharaja and Rani) 26 has the ability to move one square in any direction and capture an opponent's piece if occupying that square.
The Sapahi (soldier) 28, which is the lowest rank playing piece in the game, is represented by the symbol as shown in FIG. 2H. It has the ability to move only in one unobstructed direction one square along a column toward the opponent's side of the board and can capture an opponent's piece only by moving diagonally forward one square occupied by the opponent's piece.
The Sapahi (soldier) 28 has several peculiarities. It moves only forward one square at a time and never two, and when not capturing, advances only one square along the column. If it reaches the tenth row 15a or 15j, it will effect a release of a captured piece occupying the immediately adjacent square of row 21a or 21b, respectively. The released piece is then placed to occupy the square in row 15a or 15j reached by the Sapahi (soldier) and the Sapahi (soldier) is retired from the game. Thus a player cannot exceed the limit on the number of pieces he had at the start of the game. The Sapahi (soldier) 28 alone captures differently from its non-capturing move. It captures to either square that is diagonally adjacent in the direction of the opponent's side.
There is no castling in "Maharaja" chess. However, the Maharaja 14 is also allowed to move only once in the game, like a Swar (lancer of the Maharaja) 22, provided the Maharaja 14 did not yet move from its original position, and had not been in check before or at that time. However, by such a move, he is not allowed to capture any of the opponent's pieces.
To play the game, the pieces are initially arranged on the board as shown in FIG. 1 in which each of the two Rathwans (Maharaja's palace cart drivers) 24a and 24b are placed on the intersections of columns 17a and 17j with rows 15a and 15j near each opponent, each of the two Swars (lancers of the Maharaja) 22a and 22b is placed on the next inner square of row 15a or 15j where they intersect columns 17b and 17i near each opponent, each of the two Jotshis (Astrologers of the Maharaja) 20a and 20b is placed on the next inner square from each end in row 15a or 15j near each opponent, each of the two Shahzadas (sons of the Maharaja) 18a and 18b is placed on the next inner square on row 15a or 15j nearest each opponent, the Rani (wife of the Maharaja) 16 is placed on the next empty square to the right of the left Shahzada (son of the Maharaja) on row 15a or 15j near each opponent, and the Maharaja 14 is placed on the next empty square to the left of the right Shahzada (son of the Maharaja) on row 15a or 15j near each opponent. Each of the Golis (special attendants to the Maharaja and Rani) 26a and 26b is placed one in front of the Rani (wife of the Maharaja) 16, and one in front of the Maharaja 14 in row 15b or 15i near each opponent while each of the Sapahis (soldiers of the Maharaja) is placed in front of one of the remaining pieces. The game is commenced by one opponent moving his playing piece, such as a Sapahi (soldier) or Swar (lancer of the Maharaja), one move, which is then countered by a move by the other opponent.
As soon as a playing piece whose home position is in row 15a or 15b is captured, the captured piece is then placed in its appropriate "cell" in row 21a or 21b on the opposite side of the playing board from its home position. If a Sapahi 28 (soldier) from the opposite side of the board is able to traverse the playing board without being captured and reaches the tenth row, it then perfects a release of the captured piece it faces and the Saphai (soldier) and the released playing piece reverse positions with the Sapahi (soldier) now occupying the "cell" and the released piece occupying the square in front of the "cell". A captured Jotshi must occupy the same color "cell" as it did in the playing field. The released piece is then able to resume its maneuvers on the playing board.
At no time can a player have a greater number of playing pieces than he started with nor can he have a greater number of types of playing pieces than he started with. For example, he can have no more than one Rani, 2 Rathwans, 2 Swars, etc., nor can he have 2 Jotshis occupying the same color square.
For the twin playing pieces (Rathwan, Swar, Jotshi and Shahzada) the opponent capturing the piece decides in which of the two "cells" he will initially place the captured piece. If a release by the opponent's Sapahi (soldier) appears imminent, the captured piece cannot be moved to another "cell". If a Sapahi (soldier reaches the tenth row square in front of a vacant cell he cannot remain in front of the vacant cell but is lost from the game and must be removed from the board. | A game of skill between two opponents uses a playing board having a playing field divided into one hundred squares arranged in rows, columns and diagonals in which two sets of twenty-two playing pieces each are moved along the squares in row, column and diagonal directions, and with individual pieces of a distinctive shape, each for moving in a particular manner on the game board apparatus to capture the opponent's pieces. An extra row of squares or "cells" is provided for each of the two opponents on which are indicia indicating the position and placement of captured pieces which are freed by Sapahis (soldiers of the Maharaja) reaching the opposite side of the board. | 0 |
RELATED APPLICATIONS
This application is a Divisional of U.S. patent application Ser. No. 11/111,834, filed Apr. 22, 2005, now U.S. Pat. No. 7,469,862, whose contents are incorporated by reference.
This application is also related to U.S. patent application Ser. No. 11/111,835, “Aircraft Engine Nacelle Inlet Having Electrical Ice Protection System”, filed Apr. 22, 2005 by the same inventors as the present application, and having substantially the same specification.
BACKGROUND
The invention relates to ice protection systems for aircraft, and more specifically relates to an aircraft equipped with a low power high efficiency electrical ice protection system.
The accumulation of ice on aircraft wings and other structural members in flight is a danger that is well known. Such “structural members” include any aircraft surface susceptible to icing during flight, including wings, stabilizers, rotors, and so forth. Ice accumulation on aircraft engine nacelle inlets also can be problematic. Attempts have been made since the earliest days of flight to overcome the problem of ice accumulation. While a variety of techniques have been proposed for removing ice from aircraft during flight, these techniques have had various drawbacks that have stimulated continued research activities. One approach that has been used is so-called thermal ice protection. In thermal ice protection, the leading edges, that is, the portions of the aircraft that meet and break the airstream impinging on the aircraft, are heated to prevent the formation of ice or to loosen accumulated ice. The loosened ice is blown from the structural members by the airstream passing over the aircraft.
In one form of thermal ice protection, heating is accomplished by placing an electrothermal pad(s), including heating elements, over the leading edges of the aircraft, or by incorporating the heating elements into the structural members of the aircraft. Electrical energy for each heating element is derived from a generating source driven by one or more of the aircraft engines. The electrical energy is intermittently or continuously supplied to provide heat sufficient to prevent the formation of ice or to loosen accumulating ice.
With some commonly employed thermal ice protection systems, the heating elements may be configured as ribbons, i.e. interconnected conductive segments that are mounted on a flexible backing. When applied to a wing or other airfoil surface, the segments are arranged in strips or zones extending spanwise or chordwise along the aircraft wing or airfoil. When applied to the engine inlet the heating elements can be applied either in the circumferential or radial orientation. One of these strips, known as a spanwise parting strip, is disposed along a spanwise axis which commonly coincides with a stagnation line that develops during flight. Other strips, known as chordwise parting strips, are disposed at the ends of the spanwise parting strip and are aligned along chordwise axes. Other zones, known as spanwise shedding zones, typically are positioned on either side of the spanwise parting strip at a location intermediate the chordwise parting strips.
In one preferred form of ice protection, an electrical current is transmitted continuously through the parting strips so that the parting strips are heated continuously to a temperature above 32 degrees Fahrenheit. In the spanwise shedding zones, on the other hand, current is transmitted intermittently so that the spanwise shedding zones are heated intermittently to a temperature above about 32 degrees Fahrenheit.
One problem associated with providing such electrothermal ice protection systems on the nacelle inlets of aircraft engines involves providing sufficient numbers of access openings in the inner or outer barrels of the engine inlet for accessing and servicing the heating equipment such as heater elements and associated components. Providing such access openings proximate to the leading edge of the nacelle inlet can create non-smooth interruptions or protuberances along the otherwise smooth aerodynamic surface of the engine inlet. These interruptions or protuberances can interfere with the desired natural laminar airflow into and around the engine inlets, and may contribute to the creation of unwanted noise and drag.
Therefore, there is a need for a thermal ice protection system for the nacelle inlet of an aircraft engine that provides effective ice protection action, that includes a plurality of conveniently positioned service access openings for use in servicing and maintaining the ice protection system components, and that maintains a smooth aerodynamic inlet shape that results in substantially natural laminar airflow along the critical surfaces of the inlet.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to an aircraft engine nacelle comprising an inner support comprising an outer barrel portion and an inner barrel portion connected to the outer barrel portion; and a removable inlet cowling attachable to the inner support, the removable inlet cowling having an outer lip, an inner lip, and a leading edge extending between the outer and inner lips, and at least one ice protection electrical heater associated with the leading edge of the removable inlet cowling; wherein: the outer barrel portion has at least one service access opening therein, and the outer lip covers the service access opening, when the inlet cowling is attached to the inner and outer barrel portions.
In another aspect, the present invention is directed to a method for servicing ice protection electrical heating equipment located between an inner barrel and an outer barrel of a nacelle. The inventive method comprises removing an inlet cowling having an outer lip that normally covers at least one service access opening formed in the outer barrel to thereby uncover said at least one service access opening, said inlet cowling having been previously provided with at least one ice protection electrical heater that is connected to said ice protection electrical heating equipment; and accessing the ice protection electrical heating equipment through the at least one service access opening to thereby service the same.
In yet another aspect, the present invention is directed to a nacelle inlet for an aircraft engine nacelle having an outer barrel, the nacelle inlet comprising electrical heating means for selectively heating at least a portion of a nacelle inlet surface, and access means for selectively accessing the electrical heating means, the access means being configured to promote laminar airflow over the nacelle inlet surface. The access means may comprise at least one service access opening in the outer barrel, and a removable cowling covering the service access opening to thereby promote laminar airflow over the nacelle inlet surface.
In still another aspect, the present invention is directed to an electric ice protection system for an aircraft engine nacelle having an inner barrel and an outer barrel. The ice protection system comprises an engine inlet cowling having an outer lip configured for engagement with at least a portion of the outer barrel, an inner lip configured for engagement with at least a portion of the inner barrel, and a leading edge extending between the outer and inner lips; at least one parting strip electrical heater attached to the cowling proximate to the leading edge; and a plurality of shed zone electrical heaters arranged side by side on either side of the parting strip electrical heater, wherein the outer barrel has at least one service access opening therein, and the outer lip is configured to cover said at least one service access opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of an aircraft engine having a nacelle inlet thermal ice protection system according to the invention;
FIG. 2 is a perspective view of the aircraft engine of FIG. 1 with the inlet cowling detached;
FIG. 3 is an enlarged perspective view of a forward portion of the aircraft engine of FIGS. 1 and 2 ;
FIG. 4 is a cross-sectional view of a nacelle inlet for an aircraft engine according to the invention;
FIG. 5 is an exploded cross-sectional view of the nacelle inlet of FIG. 4 with the inlet cowling detached;
FIG. 6 is a rear perspective view of a portion of an aircraft engine showing an ice protection electrical heater arrangement on the inner surface of an inlet cowling;
FIG. 7 is a front perspective view an inlet cowling showing the ice protection electrical heater arrangement of FIG. 6 ;
FIG. 8 is a rear perspective view of the inlet cowling of FIG. 7 showing placement of ice protection electrical heaters on an inner surface of the inlet;
FIG. 9 a shows a cross-sectional view of a cowling in which the heater is part of an inner layer of the cowling; and
FIG. 9 b shows a cross-sectional view of a cowling in which the heater is part of an outer layer of the cowling.
DETAILED DESCRIPTION
FIG. 1 shows a portion of an aircraft engine nacelle 100 equipped with one embodiment of a nacelle inlet thermal ice protection assembly 10 according to the invention. The engine nacelle 100 includes a substantially cylindrical inner barrel 102 and a concentric outer barrel 104 . The nacelle inlet assembly 10 is disposed on the forward edges of the engine's nacelle inner and outer barrels 102 , 104 . The nacelle inlet assembly 10 has a smooth aerodynamic shape that substantially promotes natural laminar airflow along the forwardmost surfaces of the engine nacelle 100 .
As shown in FIG. 2 , the nacelle inlet assembly 10 includes a removable inlet cowling 40 . The inlet cowling 40 includes an inner lip 16 , an outer lip 14 , and a leading edge portion 12 connecting the two. The aft edge 18 of the outer lip 14 mates with the nacelle inlet assembly 10 along a split line 60 . The aft edge 18 and split line 60 are positioned a substantial distance downstream of the leading edge portion 12 , thereby providing a smooth, aerodynamic surface on the outer lip 14 between the leading edge 12 and the split line 60 . The lip cowling 40 may be a single continuous 360° airfoil that covers an entire engine inlet, or may comprise a plurality of separable, arcuate cowling segments placed in a circumferential arrangement. In one embodiment, the separable cowling segments have airfoil cross-sections that are placed side by side in a circumferential arrangement.
As shown in FIGS. 2 and 3 , the nacelle inlet assembly 10 further includes a forward support 30 . The support 30 may be substantially permanently connected to the inner and outer barrels 102 , 104 of the aircraft engine nacelle 100 , or may be integrally constructed therewith. The forward support 30 provides strength and rigidity to the nacelle inlet assembly 10 . As shown in FIG. 3 , the forward support 30 includes an inner barrel portion 32 , an outer barrel portion 36 and a forward wall portion 34 connecting the inner and outer barrel portions. The forward support 30 may house a plurality of spaced ice protection electrical heater switch boxes 28 for relaying electric power to the ice protection system's heaters, which are described in detail below. As shown in FIG. 6 , electric power from a pylon electrical junction box 20 may be supplied to one or more control boxes 26 via power feeder harness 24 , and may be supplied from the control box 26 to the heater switch boxes 28 via power supply harnesses 27 .
As shown in FIGS. 2 and 3 , the outer barrel portion 36 of the forward support 30 includes a plurality of circumferentially spaced service access openings 38 therethrough. Each of the service access openings 38 is located proximate to one or more associated heater switch boxes 28 , and provides access to at least one of the heater switch boxes 28 from outside the outer barrel portion 36 .
As shown in FIGS. 1 and 4 , when the inlet cowling 40 is installed on the forward support 30 , the outer lip 14 covers each of the respective service access openings 38 in the outer barrel portion 36 of the forward support 30 . Therefore, this arrangement precludes the need for an individual cover for each service access opening 38 . This arrangement also provides a continuous smooth aerodynamic lip surface 14 proximate to the leading edge 12 that helps promote natural laminar airflow across the nacelle during flight.
As shown in FIGS. 1 , 2 and 3 , the inlet cowling 40 is connected to the forward support 30 along both aft edges 18 , 19 by pluralities of suitable removable fasteners 50 . For example, the fasteners 50 may include bolts, rivets, or other suitable fasteners having substantially flush profiles. Preferably, the fasteners are of a type that is easily installed and removed by service personnel.
Further details of the nacelle inlet assembly 10 are shown in FIGS. 4 and 5 . As shown in FIG. 4 , the inlet cowling 40 substantially conforms to the shape of the forward support 30 except for a ice protection electrical heater pocket 80 formed between the leading edge 12 of the cowling 40 and the forward wall 34 of the forward support 30 . The pocket 80 provides space for a plurality of ice protection ribbon heaters 70 a , 70 b , 70 c , 72 mounted on the inner surface of the leading edge 12 of the inlet cowling 40 , as well as for an electrical connector 76 which connects to electrical connector 74 mounted on the forward wall 34 .
The first and second electrical connectors 74 , 76 automatically connect to one another, making a plug and socket-type connection, when the inlet cowling 40 is adjusted from a first position in which it is separated from the inner and outer barrel portions to a second position in which it covers the inner and outer barrel portions. Alternatively, connectors 74 and 76 may be electrically connected (or disconnected) by manually attaching (or detaching) a cable extending between the two. Electric power is supplied to the heaters 70 a , 70 b , 70 c , 72 from the heater switch boxes 28 via heater supply harness 29 and electrical connectors 74 . In the embodiment shown, the electrical connectors 74 are mounted on the forward wall 34 of the forward support 30 .
As shown in FIG. 4 , the inner barrel portion 32 of the forward support 30 may include an acoustic portion 33 , known to those skilled in the act, for attenuating engine noise. In the arrangement shown, the aft edge 19 of the inner lip 16 adjoins the forward support 30 at a position that is immediately forward (or upstream of) of the acoustic portion 33 .
FIGS. 4 and 5 show the maintenance and service access features of the nacelle inlet assembly 10 . With the inlet cowling 40 removed, the service access openings 38 are uncovered, and various ice protection electrical heating equipment such as the heater switch boxes 28 , heater supply harnesses 29 , power supply harnesses 27 , and electrical connectors 74 can be easily accessed by service personnel extending his or her hand 150 through the service access openings 38 . In addition, the removed inlet cowling 40 provides ready access to the ice protection electrical heaters 70 a , 70 b , 70 c , 72 , and associated electrical connectors 76 mounted on the inside surfaces of the cowling 40 . If required, the removable inlet cowling 40 can be easily replaced with a second inlet cowling 40 , and can be separated from an associated engine nacelle 100 for remote service or repair.
FIGS. 6 and 7 show one possible arrangement for the ice protection electrical heaters 70 a , 70 b , 70 c , and 72 . First, one or more parting strip heaters 72 are provided along an inner surface of the leading edge 12 of the removable cowling 40 . Preferably, each parting strip heater 72 is positioned to be substantially coincident with an airflow stagnation line along the engine inlet's leading edge 12 . Second, a plurality of shed zone heaters 70 a , 70 b , 70 c are provided in substantially side by side relation along the inside surface of the leading edge 12 , thereby substantially covering the entire inside surface of the leading edge 12 . Although adjacent shed zone heaters may abut one another if they are electrically isolated from each other, more preferably, they are spaced apart from one another by a gap of between about 0.04″ to about 0.5″; other gap spacings may also be employed. In this arrangement, power can be supplied substantially constantly to the parting strip heater(s) 72 to provide more or less continuous ice protection along the airflow stagnation line.
Power also can be intermittently supplied to the shed zone heaters 70 a , 70 b , and 70 c to shed accumulated ice on either side of the stagnation line. In the arrangement shown, for example, pulses of electrical power may be supplied in sequence to shed zone heaters 70 a , to shed zone heaters 70 b , to shed zone heaters 70 c , again to shed zone heaters 70 a , etc. The distribution of electric power to the various heaters 70 a , 70 b , 70 c , and 72 is controlled by one or more electrical supply control boxes 26 . This cyclic rationing of electric power between the various shed zone heaters 70 a , 70 b , 70 c acts to minimize the amount of electric power that must be derived from an aircraft's finite electrical generation capacity, while effectively providing ice protection to the engine inlet's leading edge 12 .
It is understood that one may operate the heating system such that all shed zone heaters designated 70 a are active for a first period of time, then all shed zone heaters designated 70 b are active for a second period of time and finally all shed zone heater designated 70 c are active during a third period of time. It is further understood that these three periods of time need not necessarily be of equal duration and that they need not necessarily be contiguous—i.e., there may be some intervening periods during which none of these three sets of shed zone heaters is on. It is also understood that other numbers of sets of heaters may be provided—for instance, two sets, four sets, or five sets, etc.
FIG. 8 shows one possible arrangement for installing the heaters 70 a , 70 b , 70 c , 72 on the inner surface of the inlet cowling 40 . In this arrangement, a parting strip heater 72 is mounted on the inner surface of the lip cowling 40 proximate to the underside of the airflow stagnation line at the leading edge 12 . Next, a plurality of shed zone heating pads 70 a , 70 b , 70 c are applied over the parting strip heater 72 such that the heater pads 70 a , 70 b , 70 c cover substantial portions of the inside surface of the leading edge 12 on each side of the parting strip heater 72 . The heaters 70 a , 70 b , 70 c , 72 may be any type of substantially flat, foil, or ribbon heater capable of supplying sufficient heat energy to the cowling 40 to effectively de-ice the cowling 40 while in service. The heating elements 70 a , 70 b , 70 c , 72 may be configured as “ribbons”, i.e. interconnected conductive sections, that are mounted on a flexible backing. For example, the low-power electric heaters 70 a , 70 b , 70 c , 72 may be like the ice protection electrical heaters described in U.S. Pat. No. 5,475,204, assigned to Goodrich Corporation. Alternatively, the ice protection electrical heaters 70 a , 70 b , 70 c , 72 may be like those described in U.S. patent application Ser. No. 10/840,736, filed on May 6, 2004. The disclosures of U.S. Pat. No. 5,475,204 and U.S. patent application Ser. No. 10/840,736 are hereby incorporated by reference in their entireties. And so, when in use, adjacent portions of the inlet cowling may be sequentially heated by alternatingly supplying current to the plurality of electrical ribbon heaters. Suitable electric wiring 74 supplies electric power to the ice protection electrical heaters 70 a , 70 b , 70 c , 72 from one or more heater switch boxes 28 .
FIG. 9 a shows a cross-section of an inlet cowling 40 a in which the ice protection electrical heater is spaced apart from the ice 950 by one or more layers. The structural skin 904 of the cowling 40 a provides support for the layers above. These layers include a first insulation layer 906 , a heater layer 908 atop the first insulation layer, a second insulation layer 910 atop the heater layer 908 , and an erosion shield 912 atop the second insulation layer 910 . Heat from the heater layer 908 passes through the second insulation layer 910 and the erosion shield to melt the ice 950 .
In one embodiment, the thickness of the inlet cowling is on the order of 0.1″-0.2″. The structural skin 904 is formed of a metallic or composite material having a thickness between about 0.02″ and 0.10″; the first insulation layer 906 is formed of an electrically inert (i.e., electrically insulative) material having a thickness between about 0.01″ and 0.04″; the heater layer 908 comprises electrical heaters formed of a metallic or conductive material on a nonconductive plastic film or other substrate and having a thickness between about 0.005″ and 0.020″; the second insulation layer 910 is formed of an electrically inert (i.e., electrically insulative) but thermally conductive material having a thickness between about 0.01″ and 0.04″; and the erosion shield 912 comprises a thermally conductive metallic skin or coating having a thickness between about 0.002″ and 0.020″.
Instead of being mounted on the inner surface of the inlet cowling 40 as shown in FIGS. 4-6 , the ice protection electrical heaters 908 may be mounted on the outer surface. When positioned on the outer surface, the ice protection electrical heaters are more directly exposed to the ice and so the energy efficiency of the system may improve. Through holes may be formed in some of the underlying layers of the cowling 40 at spaced apart intervals to accommodate wires and other connections to deliver current to the ice protection electrical heaters. FIG. 9 b shows a cross-section of an inlet cowling 40 b in which the heater forms the outer surface of the cowling 40 b . Again, the structural skin 924 of the cowling 40 b provides support for the layers above. These layers include a first insulation layer 926 , and a heater layer 928 atop the first insulation layer 924 , all having substantially the same composition and thickness ranges discussed above with respect to FIG. 9 a . In this instance, however, the heater layer 928 is exposed to the elements and so must also serve as the erosion shield.
In both FIGS. 9 a and 9 b , a wire or cable 930 provides current to the heater layers 908 , 928 . preferably, the wire is connected to the heater via an electrical solder connection 932 , as seen in these figures. It is understood in these figures that each of the heater layers may comprise multiple individual ice protection electrical heaters.
Engine inlets in accordance with the present invention may realize efficient ice protection with lower weight inlet structure, as compared to a conventional hot air thermal anti-ice (TAI) system. Furthermore, eliminating the pressures and temperatures associated with a traditional TAI system simplifies certain aspects of nacelle design. For instance, traditional split lines between the inlet major components are driven by the thermal anti-ice system and the acoustic requirements. The electrical system of the present invention generally does not rely upon these limitations and may therefore allow for these locations to be optimized for other design criteria. As an example, moving the traditional split line between the inlet lip and the outer barrel aft improves the aerodynamic performance of the inlet and allows the lip to be incorporated into a design that promotes natural laminar flow while also covering an access opening.
The above description of various embodiments of the invention is intended to describe and illustrate various aspects of the invention, and is not intended to limit the invention thereto. Persons of ordinary skill in the art will understand that certain modifications may be made to the described embodiments without departing from the invention. All such modifications are intended to be within the scope of the appended claims. | An aircraft engine nacelle inlet is provided with an inlet cowling. The inlet cowling includes an inner lip, an outer lip, and a leading edge portion connecting the inner and outer lips. Heating elements are provided proximate the leading edge, either on an inside surface of the cowling or on an outside surface. An inner barrel portion and an outer barrel portion of the nacelle inlet define a space therebetween. Ice protection-related equipment such as controllers, cables, switches, connectors, and the like, may reside in this space. One or more access openings are formed in the outer barrel to enable an operator to gain access to this equipment. The inlet cowling attaches to the inner and outer barrels with its outer lip extending sufficiently far in the aft direction to cover the access opening. When the cowling is removed, the access opening is uncovered, thereby permitting access to the equipment. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/600,183, filed Aug. 10, 2004, the inventors being Randolph A. Busch and Harold H. Palmer.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is reciprocating pump polished rod packing seals.
2. Description of Related Art
Over 75 percent of artificially lifted producing oil wells are being produced with sucker rod pumping systems, with the sucker rod string terminating in a polished rod that extends from the well head to the atmosphere. Stuffing boxes, having packing seals about the polished rod, are utilized to prevent well fluids from escaping around the polished rod. Well fluids include corrosive hydrocarbons including salt water and natural gas.
Due to the wear and tear of the moving polished rod, the corrosiveness of some well fluids, and the pressure drop across the packing seal in the stuffing box, all stuffing boxes on sucker rod pumping systems will leak at some time, requiring the primary packing seals in conventional stuffing boxes to be replaced periodically.
What is needed is a more simplified, unique, flexible, pressure-regulating secondary packing arrangement in a unitized assembly, readily adapted to any manufacturer's stuffing box in the field or on new installations.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of the prior art by providing apparatus for a secondary packing arrangement that, when used with a conventional stuffing box on a reciprocating plunger type pump having a polished rod, provides a pressure transmitter to create opposing pressures across a packing seal, the pressure being equal to or greater than the corresponding well fluid pressure at any given time during the pumping cycle. In some exemplary embodiments, the secondary packing arrangement includes a first chamber separated by a packing seal from a second chamber formed between the packing seal and the primary packing seal of the conventional stuffing box. The first chamber accepts well fluids, that in some exemplary embodiments are then routed to a pressure transmitter, which transmits the well fluids pressure to a more environmentally acceptable barrier fluid in the second chamber, such that when leakage occurs from the primary packing seal in the stuffing box, the leakage will be barrier fluid. Regulating the opposing pressures across the packing seal in this secondary packing arrangement provides the optimum operating condition for the packing seal elements, thus increasing the life of the elements.
In the case of the previously described secondary seal arrangement, i.e. the primary and secondary seals, the barrier fluid is sealed from the atmosphere, in some exemplary embodiments, by the primary seal in the conventional stuffing box. The consumption of the barrier fluid will be due mainly to leakage past the primary seal and evaporation of the barrier fluid film from the surface of the polished rod. Leakage past the primary seal is a function of the seal load and wear rate, for a given pressure. Increased seal load improves sealing, but also increases wear rate due to increased friction. The load, or squeeze, of the primary seal is adjusted by threaded bolts, and manually set by the operator. In order to reduce this operator induced uncertainty with respect to the rate of barrier fluid consumption, an alternative seal arrangement has been devised.
In such an exemplary embodiment (See FIG. 11 ), an intermediate seal is placed in the lower housing, above the secondary seal, so as to reside between the primary and secondary seals. The load, or squeeze, of the intermediate seal is automatically set upon assembly and is not adjustable. The barrier fluid will then fill the area between the secondary and intermediate seals, and act to regulate the pressure across the secondary seal, just as in the previous seal arrangement. The intermediate seal, although exposed to a pressure differential at least equal to the well fluids pressure, will only come in contact with the clean barrier fluid. The primary seal will remain in place to contain the barrier fluid in the event of intermediate seal wear to the point of leakage. Since the primary seal will not need to be highly loaded, the decreased friction should result in less wear and reduced horsepower requirements.
The concept of hydro-balancing the pressure across the secondary seal of a stuffing box is the subject of Harold Palmour's U.S. Pat. No. 5,209,495 and U.S. Pat. No. 6,302,401. However, the present invention is a more simplified, unique, flexible pressure-balancing/regulating secondary packing arrangement in a unitized assembly, readily adapted to any manufacturer's stuffing box in the field or on new installations.
Additionally, the secondary packing arrangement of our invention prevents corrosive well fluids from contacting the packing seal elements in the conventional stuffing box, thus increasing the life of the packing seal elements in the stuffing box.
The application of this technology to sucker rod pumping systems will overcome the universal problem of losing production and polluting the area around the well head.
For a well producing at least first and second quantities of well fluids, and in combination with a reciprocating plunger type pump having a polished rod, and a stuffing box through which the polished rod moves, the stuffing box having a stuffing box packing seal, we have provided a secondary packing arrangement, through which the polished rod moves, the secondary packing arrangement, comprising: a housing having a top member and a chamber; a packing assembly, positioned within the housing chamber, through which the polished rod moves, the packing assembly having: a cylinder, the cylinder having an outer wall sealed against the housing; a packing seal, having at least one packing seal element, the packing seal having a top and a bottom, the packing seal and the cylinder dividing the housing chamber into a first chamber and a second chamber, the first chamber containing the first well fluid quantity, the second chamber in fluidic communication with the stuffing box packing seal; a retaining member supporting the packing seal, such that the first well fluid pressures the packing seal bottom; and a cap on the cylinder, the cap having fluid passages; a barrier fluid in the housing second chamber, the barrier fluid pressurably engaging the packing seal top through the cap fluid passages; and a pressure transmitter having a cylinder and a piston within the cylinder, the cylinder having a well fluid communication end, the well fluid communication end fluidically communicating with the second well fluid quantity such that the second well fluid quantity pressures the piston, the cylinder having a barrier fluid communication end, the barrier fluid communication end fluidically communicating with the housing second chamber, such that the barrier fluid pressurably engages the piston; the piston being sized such that the pressure from the second well fluid quantity on the piston is transmitted to the barrier fluid, the barrier fluid pressure opposing the first well fluid quantity pressure exerted by the first well fluid quantity on the packing assembly packing seal bottom. In some exemplary embodiments the barrier fluid pressure and the first well fluid quantity pressure are substantially balanced across the packing assembly packing seal.
In some exemplary embodiments the barrier fluid pressure is not less than the first well fluid quantity pressure, across the packing assembly packing seal.
In some exemplary embodiments the second well fluid quantity is routed from the housing first chamber to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a flow line transporting produced well fluids, and further wherein the second well fluid quantity is routed from the well flow line to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a casing, the well accumulating pressured gas in the casing, and further wherein the second well fluid quantity is routed from the casing to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the packing assembly cylinder has a top portion and bottom portion, the bottom portion being sealed against the housing and against the top portion and affixed within the housing chamber for no movement, the top portion being free for lateral movement, the packing seal being positioned within the cylinder top portion.
In some exemplary embodiments the housing top member bears upon the packing assembly cap, the barrier fluid passing laterally through the cap.
In some exemplary embodiments the secondary packing arrangement the packing assembly cylinder has an upper and lower portion, the upper portion having a groove, and further comprises an o-ring positioned within the groove for sealing the cylinder upper portion against the cylinder lower portion, and further comprises a wave spring positioned between the housing top member and the packing assembly cap, such that the housing top member bears upon the packing assembly cap through the wave spring, thereby maintaining a load on the cylinder upper portion and the o-ring.
In some exemplary embodiments the stuffing box threadably attaches to the housing top member.
In some embodiments, the barrier fluid is selected from the group consisting of hydrocarbon based, vegetable based, and animal fat based fluids.
In some exemplary embodiments the retaining member comprises a washer and a snap ring, the washer being sized for a clearance between the washer and the polished rod, the snap ring expanding against the cylinder and supporting the washer, the washer supporting the packing seal.
In some exemplary embodiments the pressure transmitter comprises means for adding additional barrier fluid.
In some exemplary embodiments the pressure transmitter cylinder well fluid communication end has a hole, and further comprising a rod attached to the pressure transmitter cylinder piston, the rod extruding through the cylinder well fluid communication end hole, such that, as the amount of barrier fluid in the cylinder barrier fluid communication end and the housing second chamber decreases, the rod extrusion from the cylinder is decreased.
In some exemplary embodiments the rod includes indicia related to the amount of barrier fluid.
In some exemplary embodiments the pressure transmitter cylinder barrier fluid communication end has a hole, and further comprising a rod attached to the pressure transmitter cylinder piston, the rod extruding through the cylinder barrier fluid communication end hole, such that, as the amount of barrier fluid in the cylinder barrier fluid communication end and the housing second chamber decreases, the rod extrusion from the cylinder is increased.
In some exemplary embodiments the rod includes indicia related to the amount of barrier fluid.
In some exemplary embodiments the well fluid is within the group consisting of water, oil, and hydrocarbon gas.
For a well producing at least first and second quantities of well fluids, and in combination with a reciprocating plunger type pump having a polished rod, and a stuffing box through which the polished rod moves, the stuffing box providing a stuffing box packing seal, we have provided a secondary packing arrangement through which the polished rod moves, the secondary packing arrangement comprising: a housing having a top member and a chamber; a packing assembly, positioned within the housing chamber, through which the polished rod moves, the packing assembly having: a cylinder, the cylinder having an outer wall sealed against the housing; a lower packing seal, having at least one packing seal element, the packing seal having a top and a bottom, the packing seal and the cylinder dividing the housing chamber into a first chamber and a second chamber, the first chamber containing the first well fluid quantity; a retaining member supporting the packing seal, such that the first well fluid quantity pressures the lower packing seal bottom; and a cap on the cylinder, the cap having: a first member and a second member, the polished rod moving through the first and second members, the first member having fluid passages; an intermediate packing seal, the intermediate packing seal being positioned adjacent the polished rod by the first and second members; the cap first member being sealed against the housing and against the second member, the cap defining a third chamber between the cap and the stuffing box packing seal; a barrier fluid in the housing second chamber, the barrier fluid pressurably engaging both the lower and intermediate packing seals through the cap second member fluid passages; and a pressure transmitter having a cylinder and a piston within the cylinder, the cylinder having a well fluid communication end, the well fluid communication end fluidically communicating with the second well fluid quantity such that the second well fluid quantity pressures the piston, the cylinder having a barrier fluid communication end, the barrier fluid communication end fluidically communicating with the housing second chamber, such that the barrier fluid pressurably engages the piston; the piston being sized such that the pressure from the second well fluid quantity on the piston is transmitted to the barrier fluid, the barrier fluid pressure opposing the first well fluid quantity pressure exerted by the first well fluid quantity on the packing assembly packing seal bottom.
In some exemplary embodiments barrier fluid pressure and the first well fluid quantity pressure are substantially balanced across the packing assembly packing seal.
In some exemplary embodiments the barrier fluid pressure is not less than the first well fluid quantity pressure, across the packing assembly packing seal.
In some exemplary embodiments the second well fluid quantity is routed from the housing first chamber to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a flow line transporting produced well fluids, and further wherein the second well fluid quantity is routed from the well flow line to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a casing, the well accumulating pressured gas in the casing, and further wherein the second well fluid quantity is routed from the casing to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the secondary packing arrangement further comprises a fitting for introducing a fluid into the third chamber.
In some exemplary embodiments the secondary packing arrangement further comprises a wick material positioned about the polished rod in the third chamber, for absorbing the introduced fluid in the third chamber and applying the fluid to the polished rod.
In some exemplary embodiments the introduced fluid is the same as the barrier fluid.
In some exemplary embodiments the fitting is a grease fitting.
For a well producing at least first and second quantities of well fluids, and in combination with a reciprocating plunger type pump having a polished rod, and a stuffing box through which the polished rod moves, the stuffing box having a stuffing box packing seal, we have provided a secondary packing arrangement through which the polished rod moves, the secondary packing arrangement comprising: a housing having a top member and a chamber; a packing assembly, positioned within the housing chamber, through which the polished rod moves, the packing assembly having: a packing seal, having at least one packing seal element; a packing seal compression member positioned within the lower housing above the at least one packing seal element, the packing seal being positioned to divide the housing chamber into a first chamber and a second chamber, the first chamber containing the first well fluid quantity, the second chamber in fluidic communication with the stuffing box packing seal, such that the first well fluid quantity pressures, the packing seal; and a compression member displacement mechanism for forcing the packing seal compression member toward the packing seal and compressing the packing seal; a barrier fluid in the housing second chamber, the barrier fluid pressurably engaging the packing assembly; and a pressure transmitter having a cylinder and a piston within the cylinder, the cylinder having a well fluid communication end, the well fluid communication end fluidically communicating with the second well fluid quantity such that the second well fluid quantity pressures the piston, the cylinder having a barrier fluid communication end, the barrier fluid communication end fluidically communicating with the housing second chamber, such that the barrier fluid pressurably engages the piston; the piston being sized such that the pressure from the second well fluid quantity on the piston is transmitted to the barrier fluid, the barrier fluid pressure opposing the first well fluid quantity pressure exerted by the first well fluid quantity on the packing assembly packing seal. In some exemplary embodiments the barrier fluid pressure and the first well fluid quantity pressure are substantially balanced across the packing assembly packing seal.
In some exemplary embodiments the barrier fluid pressure is not less than the first well fluid quantity pressure, across the packing assembly packing seal.
In some exemplary embodiments the second well fluid quantity is routed from the housing first chamber to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a flow line transporting produced well fluids, and further wherein the second well fluid quantity is routed from the well flow line to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a casing, the well accumulating pressured gas in the casing, and further wherein the second well fluid quantity is routed from the casing to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the compression member displacement mechanism extends through the housing top member.
For a well producing at least first and second quantities of well fluids, and in combination with a reciprocating plunger type pump having a polished rod, and a stuffing box through which the polished rod moves, we have provided a secondary packing arrangement through which the polished rod moves, the secondary packing arrangement comprising: the stuffing box, the stuffing box having: a top member and a lower housing forming a chamber; an upper packing seal positioned within the top member; a lower packing seal, the upper and lower packing seals each having at least one packing seal element; a lower packing seal compression member, the lower packing seal and compression member being positioned within the lower housing such that the lower packing seal divides the chamber into a first and second chamber, the first containing the first well fluid quantity, the second chamber in fluidic communication with the upper packing seal, such that the first well fluid quantity pressures the lower packing seal; and a compression member displacement mechanism for forcing the packing seal compression member toward the lower packing seal and compressing the lower packing seal; a barrier fluid in the housing second chamber between the upper packing seal and the lower packing seal, the barrier fluid pressurably engaging the lower packing seal; and a pressure transmitter having a cylinder and a piston within the cylinder, the cylinder having a well fluid communication end, the well fluid communication end fluidically communicating with the second well fluid quantity such that the second well fluid quantity pressures the piston, the cylinder having a barrier fluid communication end, the barrier fluid communication end fluidically communicating with the housing second chamber, such that the barrier fluid pressurably engages the piston; the piston being sized such that the pressure from the second well fluid quantity on the piston is transmitted to the barrier fluid, the barrier fluid pressure opposing the first well fluid quantity pressure exerted by the first well fluid quantity on the lower packing seal.
In some exemplary embodiments the barrier fluid pressure and the first well fluid quantity pressure are substantially balanced across the packing assembly packing seal.
In some exemplary embodiments the barrier fluid pressure is not less than the first well fluid quantity pressure, across the packing assembly packing seal.
In some exemplary embodiments the second well fluid quantity is routed from the housing first chamber to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a flow line transporting produced well fluids, and further wherein the second well fluid quantity is routed from the well flow line to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the well has a casing, the well accumulating pressured gas in the casing, and further wherein the second well fluid quantity is routed from the casing to the pressure transmitter cylinder well fluid communication end.
In some exemplary embodiments the compression member displacement mechanism extends through the housing top member.
For a well producing at least first and second quantities of well fluids, and in combination with a reciprocating plunger type pump having a polished rod, and a stuffing box through which the polished rod moves, the stuffing box having a stuffing box packing seal, we have provided a secondary packing arrangement, through which the polished rod moves, the secondary packing arrangement, comprising: a housing having a top member and a chamber; a packing assembly, positioned within the housing chamber, through which the polished rod moves, the packing assembly further comprising means for dividing the housing chamber into a first chamber and a second chamber, the first chamber containing the first well fluid quantity, the second chamber in fluidic communication with the stuffing box packing seal; a barrier fluid in the housing second chamber, and means for pressuring the barrier fluid such that the barrier fluid pressure on the packing assembly opposes the pressure exerted by the first well fluid quantity on the packing assembly.
In some exemplary embodiments, the secondary packing arrangement further comprises means for routing fluids from the housing first chamber for pressuring the barrier fluid.
In some exemplary embodiments the well has a flow line transporting well fluids, and the secondary packing arrangement further comprises means for routing fluids from the well flow line for pressuring the barrier fluid.
In some exemplary embodiments the well has a casing, the casing accumulating pressured hydrocarbon gas, and the secondary packing arrangement further comprises means for routing pressured gas from the well casing for pressuring the barrier fluid.
The foregoing features and advantages of our invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated, in some embodiments, in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a conventional double pack stuffing box.
FIG. 2 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 3 is a sectional view of the lower housing in an exemplary embodiment of the present invention.
FIG. 4 is an enlargement of a portion of FIG. 2 .
FIG. 5 is a sectional view of the packing assembly upper portion in an exemplary embodiment of the present invention.
FIG. 6 is a top view of the packing assembly upper portion in FIG. 5 .
FIG. 7 is a sectional view of the packing assembly lower portion in an exemplary embodiment of the present invention.
FIG. 8 is a bottom view of the packing assembly lower portion in FIG. 7 .
FIG. 9 is a sectional view of the packing assembly cap in an exemplary embodiment of the present invention.
FIG. 10 is a top view of the packing assembly cap in FIG. 9 .
FIG. 11 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 12 is an enlargement of a portion of FIG. 11 .
FIG. 13 is a bottom view of a packing assembly cap first member in an exemplary embodiment of the present invention.
FIG. 14 is a sectional view of the packing assembly cap first member in FIG. 13 .
FIG. 15 is a sectional view of a packing assembly cap second member in an exemplary embodiment of the present invention.
FIG. 16 is a top view of the packing assembly cap second member in FIG. 15 .
FIG. 17 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 18 is an enlargement of a portion of FIG. 17 .
FIG. 19 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 20 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 21 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 22 is a partially sectional view of an exemplary embodiment of the present invention.
FIG. 23 is a sectional view of a conventional double pack stuffing box packing seal.
FIG. 24 is a sectional view of a conventional double pack stuffing box compression ring.
FIG. 25 is a partially sectional view of an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The following discussion describes exemplary embodiments of the invention in detail. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well. For a definition of the complete scope of the invention, the reader is directed to the appended claims.
Referring now to FIG. 1 . A typical polished rod 10 extends from the well head and through a conventional double pack stuffing box 12 . This stuffing box has two packing seal 13 , 14 with each seal having at least two packing seal elements. The packing seal is commercially available and typically referred to as cone or dome packing. Tightening the bolts 15 presses the packing seal 14 against the polished rod by being turned against a packing seal compression ring 14 a . The stuffing box has a lower housing 16 with a threaded end 17 for connecting to the well head, such that well fluids will enter the annulus 18 about the polished rod, from the well head fluid outlet below. The stuffing box also has an upper housing 19 , encompassing the packing seal 13 . A typical well will have a flow line leading from the well head for transporting well fluids, the well fluids typically including oil, salt water, and/or hydrocarbon gas. Such a flow line is in fluid communication with the well head fluid outlet to which the stuffing box is attached. Furthermore, a typical well will have a casing, in which well fluids, in the form of hydrocarbon gas, are accumulated under pressure.
Referring now to FIG. 2 , an exemplary embodiment of the secondary packing arrangement device 30 of the present invention is illustrated in combination with a conventional single pack stuffing box 20 having a packing seal 21 with four packing seal elements. In the conventional single pack stuffing box, when bolts 22 are tightened the packing seal is pressed against the polished rod 10 . The stuffing box has a lower housing 23 with a threaded end 24 that, in a conventional installation, attaches to the well head such that an annulus 25 is formed about the polished rod.
In the exemplary embodiment shown in FIG. 2 and in a closer view in FIG. 14 , the secondary packing arrangement 30 has a housing including a lower housing 32 that can readily be adapted from the lower housing 16 of the conventional double pack stuffing box shown in FIG. 1 , with only slight resizing of the interior. The lower housing is shown in more detail in FIG. 3 . The lower housing has a lower end 33 that threadably attaches to the wellhead at a well fluid outlet such that well fluids enter the lower housing. Bolted to the lower housing 32 is a top member 34 with an adapter 36 for threadably receiving the conventional single pack stuffing box lower housing end 24 . The secondary packing arrangement housing forms a chamber 38 that is in fluid communication with the stuffing box packing seal 21 . The lower housing 32 has three threaded outlets 40 , 42 , 44 , a first shoulder 46 and a second shoulder 48 . The bolted joinder of the housing top member 34 to the lower housing 32 is sealed by a conventional O-ring 49 adjacent the second shoulder 48 .
As further illustrated in FIG. 2 and FIG. 4 , this exemplary embodiment of the secondary packing arrangement 30 includes a packing assembly 50 , positioned within the housing chamber 38 , through which the polished rod 10 moves. In this exemplary embodiment, the packing assembly includes a cylinder having a top portion 52 , shown in more detail in FIG. 5 and FIG. 6 . As shown therein, the top portion is shown to have an open bottom 54 , a groove 56 for accepting an O-ring 58 , and a groove 60 for accepting a conventional snap ring 62 . The snap ring supports a conventional washer 64 , the washer sized to create a clearance 66 between the washer and the polished rod 10 . The snap ring and washer retain a packing seal, which includes three conventional packing seal elements 68 positioned within the cylinder upper portion. These packing seal elements seal against the polished rod, preventing well fluid passage through the packing assembly cylinder upper portion.
In the exemplary embodiment illustrated in FIG. 4 , the packing assembly cylinder also includes a bottom portion 70 , shown in more detail in FIG. 7 and FIG. 8 . The cylinder bottom portion has an opening 72 , eight fluid passages 74 , and a groove 76 in its outer wall 78 for positioning an O-ring 80 against the lower housing interior, thus sealing the annulus around the cylinder bottom portion 70 to prevent well fluids from passing to the annulus about the cylinder upper portion 52 . The cylinder bottom portion also includes an upper surface 82 against which the cylinder upper portion 52 seals using the O-ring 58 . These two seals, along with the seal between the polished rod and the packing seal elements 68 , effectively divide the housing chamber 38 into a first chamber 84 and a second chamber 86 , well fluids being present in the first chamber only.
In this exemplary embodiment of FIG. 2 and FIG. 4 , the packing assembly 50 also includes a cap 90 , shown in more detail in FIG. 9 and FIG. 10 . The cap has an opening 92 and eight fluid passages 94 . The cap fits on the top of the cylinder upper portion 52 , and a conventional wave spring 96 is positioned between the cap and the cylinder upper portion. During installation of the secondary packing arrangement 30 , the cap and the cylinder upper portion are free to simultaneously move along the top surface of the cylinder bottom portion 70 without breaking the seal between the cylinder upper and bottom portions. This allows optimum positioning of the packing seal elements 68 with respect to the polished rod 10 . The housing top portion bears upon the cap as it is tightened, compressing wave spring 96 , thereby loading O-ring 58 and maintaining a seal between cylinder upper and bottom portions.
In the exemplary embodiment of the present invention depicted in FIG. 2 and FIG. 4 , the second chamber 86 is filled with a barrier fluid, which moves in the second chamber and through the cap 90 fluid passages 94 such that the barrier fluid contacts the packing seal, and any pressure within the second chamber acts on the packing seal elements.
A pressure transmitter 100 is provided in the exemplary embodiment of the present invention shown in FIG. 2 . The transmitter sits in a base 101 that is attached to the housing top portion 34 using a bracket 102 . The transmitter includes a cylinder 104 and a piston 106 within the cylinder. Attached to the piston is a rod 108 that screws into a nut 110 mounted in the piston. The rod extends from the cylinder through hole 112 with an elastomer seal. A hose 114 with a valve 116 extends from one of the lower housing outlets in the housing first chamber 84 , and enters a well fluid communication end of the cylinder through inlet 118 , establishing communication of well fluids and well fluids pressure from the well fluid outlet, through the housing first chamber, into the cylinder, and to the top of the piston. During installation the grease fitting 120 allows the operator to fill the housing second chamber 86 and the barrier fluid communication end of the cylinder below the piston with barrier fluid. A hose 122 extends from a cylinder barrier fluid communication end outlet 124 to one of the lower housing outlets 40 , thus establishing barrier fluid communication between the housing second chamber and the cylinder below the piston.
In the exemplary embodiment illustrated in FIG. 2 , the pressure transmitter piston 110 is sized such that the pressure from the well fluid on the piston is transmitted to the barrier fluid, resulting in the desired regulation of pressure across the packing assembly packing seal.
The rod 108 extruding from the cylinder 104 in the exemplary embodiment illustrated in FIG. 2 provides an indication as to the amount of barrier fluid. The greater the extended length, the more barrier fluid is present. In some exemplary embodiments, appropriate indicia are provided on the rod to provide information to the operator as to required addition of barrier fluid. In some exemplary embodiments, the rod is of sufficient size that it can be viewed by the operator from a distance.
In some exemplary embodiments, and as shown in FIG. 2 , a pressure gauge 126 , with valve 128 and related attachment fittings 130 , is attached to the housing through one of the lower housing outlets 44 , allowing the operator to determine the pressure in the housing second chamber 86 , the pressure being then comparable by the operator to conventional well head pressure gauges (reflecting pressure in the housing first chamber 84 ) to confirm the proper regulation of pressure across the packing seal 50 .
In another exemplary embodiment of the present invention, depicted in FIG. 11 and in more detail in FIG. 12 , a different packing assembly cylinder upper portion 202 and cap 204 are provided. The cylinder upper portion 202 is reduced in height and encloses two packing seal elements 205 . The snap ring 62 and the washer 64 are unchanged and support the packing seal elements as in the previously described exemplary embodiment. The cylinder upper portion 202 is free for sealed lateral movement and positioning during installation. Similarly, the packing assembly lower portion 70 seals against the housing to divide the housing into the first chamber 84 and the second chamber 86 .
In the exemplary embodiment shown in FIG. 12 , the cap 204 includes a first member 206 , shown in more detail in FIG. 13 and FIG. 14 . The first member includes an opening 208 sized to create the clearance 210 between the first member opening and the polished rod 10 . The first member has eight fluid passages 212 and a groove 214 for positioning an O-ring 216 . The packing assembly cap second member 220 , shown in more detail in FIG. 15 and FIG. 16 , includes an opening 222 for the polished rod and a groove 224 for positioning an O-ring 226 .
In this exemplary embodiment 200 , the O-ring 216 seals the packing assembly cap first member 206 against the second member 220 , and the O-ring 226 seals the second member against the housing top portion 34 . The first and second members mate to form a space for positioning an intermediate packing seal member 228 about the polished rod, the intermediate packing seal member integrating an O-ring 230 for energizing the seal member against the polished rod 10 . Unlike the cap 90 of the previous embodiment, the cap 204 in this exemplary embodiment does not have a fluid passage for allowing barrier fluid to contact the packing seal 21 of the conventional stuffing box 20 . Instead, the cap 204 cooperates with the opening in the housing top member 34 to form a third chamber 232 between the cap second member, the intermediate packing seal member and the packing seal 21 of the stuffing box. The intermediate packing seal prevents barrier fluid from the second chamber from entering the third chamber. The intermediate packing seal load is automatically set upon installation and is not adjustable.
In another exemplary embodiment, of the type depicted in FIG. 17 and shown in more detail in FIG. 18 , the housing top portion 302 is modified to include an outlet 304 from the third chamber 232 , the outlet being adapted to receive a grease fitting 306 . During installation the operator fills the third chamber with a barrier fluid, such as grease, and also positions a wick-type material about the polished rod 10 in the third chamber for soaking in the fluid and lubricating the polished rod.
Refer again to the exemplary embodiment depicted in FIG. 2 and FIG. 4 , and the pressure transmitter 100 , the hose 114 , with valve 116 , connected to inlet 118 on the well fluid communication end of the transmitter cylinder 104 , the hose 122 connected to outlet 124 on the barrier fluid communication end of the transmitter cylinder 104 , and the grease fitting 120 . In another exemplary embodiment 30 a , of the type depicted in FIG. 19 , a hose 114 a connects to outlet 124 a on what is now the well fluid communication end of the transmitter 100 a cylinder 104 a , a hose 122 a connects to inlet 118 a on what is now the barrier fluid communication end of the transmitter cylinder 104 a , and the grease fitting 120 a is positioned on the barrier fluid communication end of the transmitter cylinder 104 a . This reversal of hoses to the transmitter results in the barrier fluid, such as grease, being present in the top (barrier fluid communication end) of the transmitter where the seal about the indicator rod 108 a is located at the hole 112 (see FIG. 2 ) in the transmitter cylinder 104 a . Should this seal leak, the leaked fluid will be the relatively clean barrier fluid, instead of well fluids.
Similarly, refer again to the exemplary embodiment depicted in FIG. 11 and FIG. 12 , having corresponding pressure transmitter components with the exemplary embodiment of FIG. 2 , i.e. the pressure transmitter 100 , the hose 114 , with valve 116 , connected to inlet 118 on the well fluid communication end of the transmitter cylinder 104 , the hose 122 connected to outlet 124 on the barrier fluid communication end of the transmitter cylinder 104 , and the grease fitting 120 . In another exemplary embodiment 200 a , of the type depicted in FIG. 20 , a hose 114 a connects to outlet 124 a on what is now the well fluid communication end of the transmitter 100 a cylinder 104 a , a hose 122 a connects to inlet 118 a on what is now the barrier fluid end of the transmitter cylinder 104 a , and the grease fitting 120 a is positioned on the barrier fluid communication end of the transmitter cylinder 104 a . This reversal of hoses to the transmitter results in the barrier fluid, such as grease, being present in the top (barrier fluid communication end) of the transmitter where the seal about the indicator rod 108 a is located at the hole 112 (see FIG. 2 ) in the transmitter cylinder 104 a . Again, should this seal leak, the leaked fluid will be the relatively clean barrier fluid, instead of well fluids.
Similarly, refer again to the exemplary embodiment depicted in FIG. 17 and FIG. 18 , having corresponding pressure transmitter components with the exemplary embodiment of FIG. 2 , i.e. the pressure transmitter 100 , the hose 114 , with valve 116 , connected to inlet 118 on the well fluid communication end of the transmitter cylinder 104 , the hose 122 connected to outlet 124 on the barrier fluid communication end of the transmitter cylinder 104 , and the grease fitting 120 . In another exemplary embodiment 300 a , of the type depicted in FIG. 21 , a hose 114 a connects to outlet 124 a on what is now the well fluid communication end of the transmitter 100 a cylinder 104 a , a hose 122 a connects to inlet 118 a on what is now the barrier fluid communication end of the transmitter cylinder 104 a , and the grease fitting 120 a is positioned on the barrier fluid communication end of the transmitter cylinder 104 a . This reversal of hoses to the transmitter results in the barrier fluid, such as grease, being present in the top (barrier fluid communication end) of the transmitter where the seal about the indicator rod 108 a is located at the hole 112 (see FIG. 2 ) in the transmitter cylinder 104 a . Again, should this seal leak, the leaked fluid will be the relatively clean barrier fluid, instead of well fluids.
In exemplary embodiments of the type depicted in FIGS. 19-21 , the reversal of the hoses 114 a , 122 a results in barrier fluid being in the end of the pressure transmitter cylinder 104 through which the indicator rod 108 a extends. As a result, a decrease in the amount of barrier fluid causes the indicator rod to extend further from the cylinder.
Turning to FIG. 22 , an additional exemplary embodiment of a secondary packing arrangement 400 is illustrated in combination with a conventional single pack stuffing box 20 having a packing seal 21 with four packing seal elements. In the conventional single pack stuffing box, when bolts 22 are tightened the packing seal is pressed against the polished rod 10 . The stuffing box has a lower housing 23 with a threaded end 24 that, in a conventional installation, attaches to the well head such that an annulus 25 is formed about the polished rod.
In exemplary embodiments of the type shown in FIG. 22 , the secondary packing arrangement 400 has a housing 402 including a lower housing 404 that can readily be adapted from the lower housing 16 of the conventional double pack stuffing box shown in FIG. 1 , with only slight modification. The lower housing 404 has a lower end 406 that threadably attaches to the wellhead at a well fluid outlet such that well fluids enter the lower housing. Bolted to the lower housing 404 is an upper housing 408 with an adapter 410 for threadably receiving the conventional single pack stuffing box lower housing end 24 . Bolts 411 (one shown) are provided for bolting the upper housing 408 to the lower housing 404 . As part of a packing assembly 412 , two bolts 414 (one shown) are positioned by the upper housing 408 in a manner similar to the two bolts 15 shown in the conventional double pack stuffing box 12 depicted in FIG. 1 . The housing 402 forms a chamber 416 , and within the housing chamber, and as part of the packing assembly 412 , is a packing seal 418 and a packing seal compression ring 420 . The packing seal and compression ring 418 , 420 are, in some exemplary embodiments, the same as the packing seal 14 and compression ring 14 a , shown in FIG. 1 . Additional, sectional views of the packing seal 14 and the compression ring 14 a , are provided in FIG. 23 and FIG. 24 , respectively.
In exemplary embodiments of the type illustrated in FIG. 22 , the bolts 414 turn against the compression ring 420 forcing the packing seal 418 to seal against the polished rod 10 . The bolted joinder of the upper housing 408 to the lower housing 404 is sealed by a conventional O-ring 422 positioned on a shoulder 424 of the lower housing. Although the upper housing 408 positions bolts 414 in a manner similar to the positioning of bolts 15 in the upper housing 19 of the conventional double pack stuffing box 12 , the upper housing 408 no longer is configured to contain a packing seal such as the packing seal 13 positioned with the upper housing of the conventional stuffing box.
Refer again to the FIG. 19 and the hoses 114 a , 122 a . A hose 122 a is provided in exemplary embodiments of the type illustrated in FIG. 22 and is similarly routed as the hose 122 a in FIG. 19 . However, in some such exemplary embodiments, a hose 426 communicates well fluids using a conventional connection to another well fluid outlet on a flow line (not shown), instead of routing such well fluids from the chamber 428 below the packing assembly 412 , as was the manner utilized in the exemplary embodiment of FIG. 19 , using the hose 114 a . This configuration continues to use the pressure transmitter 100 to regulate the pressures between the well fluids and the barrier fluid on either side of the packing assembly 412 .
Similarly, in some exemplary embodiments of the type illustrated in FIG. 22 , the hose 426 communicates well fluids using a conventional connection to another well fluid outlet on the casing (not shown).
In some exemplary embodiments of the kind depicted in FIG. 22 , a pressure gauge 126 , valve 128 , and related attachment fittings 130 are provided, in a similar fashion to the pressure gauge 126 , valve 128 , and related attachment fittings 130 depicted in FIG. 19 .
Turning now to FIG. 25 , an exemplary embodiment of the secondary packing arrangement of the present invention is depicted, and is shown in combination with a conventional double pack stuffing box 502 of the type depicted in FIG. 1 . In exemplary embodiments of the type shown in FIG. 25 , the device has a housing 502 , the housing having an upper housing 504 and a lower housing 506 , the lower housing forming a chamber 508 . The lower housing 506 has a lower end 510 that threadably attaches to the wellhead at a well fluid outlet such that well fluids enter the lower housing. Bolts 512 (one shown) are provided for bolting the upper housing 504 to the lower housing 506 . As part of a packing assembly 514 , two bolts 516 (one shown) are positioned by the upper housing in a manner similar to the two bolts 15 shown in the conventional double pack stuffing box 12 depicted in FIG. 1 . Within the housing chamber 508 , and as part of the packing assembly 514 , is a packing seal 518 and a packing seal compression ring 520 . The packing seal and compression ring 518 , 520 are, in some exemplary embodiments, the same as the packing seal 14 and compression ring 14 a , shown in FIG. 1 .
In exemplary embodiments of the type illustrated in FIG. 25 , the bolts 516 turn against the compression ring 520 forcing the packing seal 518 to seal against the polished rod 10 . The bolted joinder of the upper housing 504 to the lower housing 506 is sealed by a conventional O-ring 522 positioned on a shoulder 524 of the lower housing. The upper housing 504 positions bolts 516 in a manner similar to the positioning of bolts 15 in the upper housing 19 of the conventional double pack stuffing box 12 , and the upper housing 504 is configured to contain a packing seal such as the packing seal 13 positioned with the upper housing of the conventional stuffing box.
Refer again to the FIG. 19 and the hoses 114 a , 122 a . A hose 122 a is provided in exemplary embodiments of the type illustrated in FIG. 25 and is similarly routed as the hose 122 a in FIG. 19 . However, in some such exemplary embodiments, a hose 426 communicates well fluids using a conventional connection to another well fluid outlet on a flow line (not shown), instead of routing such well fluids from the chamber 508 below the packing assembly 514 , as was the manner utilized in the exemplary embodiment of FIG. 19 , using the hose 114 a . This configuration continues to use the pressure transmitter 100 to balance the pressures exerted by the well fluids and the barrier fluid on either side of the packing assembly 514 .
Similarly, in some exemplary embodiments of the type illustrated in FIG. 22 , the hose 426 communicates well fluids using a conventional connection to another well fluid outlet on the casing (not shown).
In some exemplary embodiments of the kind depicted in FIG. 25 , a pressure gauge 126 , valve 128 , and related attachment fittings 130 are provided, in a similar fashion to the pressure gauge 126 , valve 128 , and related attachment fittings 130 depicted in FIG. 19 .
In some exemplary embodiments of the kind illustrated in FIG. 2 , FIG. 11 , FIG. 17 , FIG. 19 , FIG. 20 , and FIG. 21 , a quantity of well fluids is routed to the pressure transmitter cylinder well fluid communication end from a well fluid outlet on a well flow line or from a well fluid outlet on a well fluid outlet from the well casing, eliminating the need for the hose leading from the housing first chamber.
In some exemplary embodiments of the kind illustrated in FIG. 22 and FIG. 25 , a quantity of well fluids is routed to the pressure transmitter cylinder well fluid communication end from the housing first chamber.
In some exemplary embodiments and applications of the present invention the barrier fluid is either hydrocarbon based, a hydrocarbon based grease, non-hydrocarbon based, vegetable based, or animal fat based. In some exemplary embodiments and applications, the well fluid includes hydrocarbons, oil, hydrocarbon gas, and/or water.
With respect to the above description then, it is to be realized that the optimum apparatus for a particular application, will include elastomer seals, piping, fittings, hoses, barrier fluids, and other seal materials, which will occur to those skilled in the art upon review of the present disclosure.
All equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
The descriptions in this specification are for purposes of illustration only and are not to be construed in a limiting sense. The scope of the present invention is limited only by the language of the following claims. | A secondary packing arrangement is provided for use with a well having a reciprocating pump and polished rod, and in combination with a stuffing box, the stuffing box being modified. Packing seals, a barrier fluid and a pressure transmitter cooperate with modified stuffing box components to regulate the pressure on either side of a packing seal. The barrier fluid is contained above the packing seal, with well fluids and accompanying pressures being contained below the packing seal, such that if leakage occurs, relatively clean barrier fluids are leaked instead of well fluids. The pressure across the packing seal is substantially balanced across the packing seal, or the well fluid side pressure is less than the barrier fluid side, thus reducing the occurrence of leakage and extending the life of the packing seal. Sources for the well fluids cooperating with the pressure transmitter include the well's flow line and casing. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 09/750,040, filed Dec. 29, 2000; now U.S. Pat. No. 6,359,812 which is a continuation of application Ser. No. 09/428,925, filed Oct. 28, 1999, now U.S. Pat. No. 6,198,665; which is a continuation of application Ser. No. 09/303,442, filed May 3, 1999, now U.S. Pat. No. 6,028,795; which is a continuation of Ser. No. 09/055,327, filed Apr. 6, 1998, now U.S. Pat. No. 5,923,591; which is a continuation of Ser. No. 08/853,713, filed May 9, 1997, now U.S. Pat. No. 5,781,479; which is a continuation of application Ser. No. 08/694,599, filed Aug. 9, 1996, now U.S. Pat. No. 5,719,809; which is a continuation of application Ser. No. 08/582,906, filed Jan. 4, 1996, now U.S. Pat. No. 5,615,155; which is a continuation of application Ser. No. 08/435,959, filed May 5, 1995, now U.S. Pat. No. 5,493,528; which is a continuation of application Ser. No. 08/294,407, filed Aug. 23, 1994, now U.S. Pat. No. 5,448,519; which is a continuation of application Ser. No. 07/855,843, filed Mar. 20, 1992, now U.S. Pat. No. 5,450,342; which is a continuation-in-part of application Ser. No. 07/349,403, filed May 8, 1989, now U.S. Pat. No. 5,175,838; which is a continuation of application Ser. No. 07/240,380, filed Aug. 29, 1988, now U.S. Pat. No. 4,868,781; which is a continuation of application Ser. No. 06/779,676, filed Sep. 24, 1985, now abandoned; said U.S. Pat. No. 4,868,781 being reissued by application Ser. No. 07/542,028, filed Jun. 21, 1990 now Pat. No. Re. 33,922; said application Ser. No. 07/855,843, filed Mar. 20, 1992, now U.S. Pat. No. 5,450,342 also being a continuation-in-part of Ser. No. 07/816,583, filed Jan. 3, 1992, now abandoned; which is a continuation of application Ser. No. 07/314,238, filed Feb. 22, 1989 now U.S. Pat. No. 5,113,487; which is a continuation of application Ser. No. 06/864,502, filed May 19, 1986, now abandoned, said application Ser. No. 07/816,583, filed Jan. 3, 1992, now abandoned, also being a continuation-in-part of application Ser. No. 07/349,403, filed May 8, 1989 now U.S. Pat. No. 5,175,383; which is a continuation of application Ser. No. 06/779,676, filed Sep. 24, 1985, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a memory device, and in particular, to a memory device suitable for a graphic memory to be utilized in high-speed image processing.
The prior art technique will be described by referring to graphic processing depicted as an example in FIGS. 1-2. For example, the system of FIG. 1 comprises a graphic area M 1 having a one-to-one correspondence with a cathode ray tube (CRT) screen, a store area M 2 storing graphic data to be combined, and a modify section FC for combining the data in the graphic area M 1 with the data in the store area M 2 . in FIG. 2, a processing flowchart includes a processing step S 1 for reading data from the graphic area M 1 , a processing step S 2 for reading data from the store area M 2 , a processing step S 3 for combining the data read from the graphic area M 1 and the data read from the store area M 2 , and a processing step S 4 for writing the composite data generated in the step S 3 in the graphic area M 1 .
In the graphic processing example, the processing step S 3 of FIG. 2 performs a logical OR operation only to combine the data of the graphic area M 1 with that of the store area M 2 .
On the other hand, the graphic area M 1 to be subjected to the graphic processing must have a large memory capacity ranging from 100 kilobytes to several megabytes in ordinary cases. Consequently, in a series of graphic processing steps as shown in FIG. 2, the number of processing iterations to be executed is on the order of 10 6 or greater even if the processing is conducted on each byte one at a time.
Similarly referring to FIGS. 2-3, graphic processing will be described in which the areas M 1 and M 2 store multivalued data such as color data for which a pixel is represented by the use of a plurality of bits.
Referring now to FIG. 3, a graphic processing arrangement comprises a memory area M 1 for storing original multivalued graphic data and a memory area M 2 containing multivalued graphic data to be combined therewith.
For the processing of multivalued graphic data shown in FIG. 3, addition is adopted as the operation to ordinarily generate composite graphic data. As a result, the values of data in the overlapped portion become larger, and hence a thicker picture is displayed as indicated by the crosshatching. in this case, the memory area must have a large memory capacity. The number of iterations of processing from the step S 1 to the step S 4 becomes on the order of 10 6 or greater, as depicted in FIG. 2 . Due to the large iteration count, most of the graphic data processing time is occupied by the processing time to be elapsed to process the loop of FIG. 2 . In graphic data processing, therefore, the period of time utilized for the memory access becomes greater than the time elapsed for the data processing. Among the steps S 1 -S 4 of FIG. 2, three steps S 1 , S 2 , and S 4 are associated with the memory access. As described above, in such processing as graphic data processing in which memory having a large capacity is accessed, even if the operation speed is improved, the memory access time becomes a bottleneck of the processing, which restricts the processing speed and does not permit improving the effective processing speed of the graphic data processing system.
In the prior art examples, the following disadvantages take place.
(1) In the graphic processing as shown by-use of the flowchart of FIG. 2, most of the processing is occupied by the steps S 1 , S 2 , and S 4 which use a bus for memory read/write operations consequently, the bus utilization ratio is increased and a higher load is imposed on the bus.
(2) The graphic processing time is further increased, for example, because the bus has a low transfer speed, or the overhead becomes greater due to the operation such as the bus control to dedicatedly allocate the bus to CRT display operation and to memory access.
(3) Moreover, although the flowchart of FIG. 2 includes only four static processing steps, a quite large volume of data must be processed as described before. That is, the number of dynamic processing steps which may elapse the effective processing time becomes very large, and hence a considerably long processing time is necessary.
Consequently, it is desirable to implement a graphic processing by use of a lower number of processing steps.
A memory circuit for executing the processing described above is found in the Japanese Patent Unexamined Publication No. 55-129387, for example.
Recent enhanced resolution of graphic display units is now demanding a large-capacity memory for use as a frame buffer for holding display information. In displaying a frame of graphic data, a large number of access operations to a capacious frame buffer take place, and therefore high-speed memory read/write operations are required. A conventional method for coping with this requirement is the distribution of processings.
An example of the distributed process is to carry out part of the process with a frame buffer. FIG. 26 shows, as an example, the arrangement of the frame buffer memory circuit, used in the method. The circuit includes an operation unit 1 , a memory 2 , an operational function control register 23 , and a write mask register 26 . The frame buffer writes data in bit units regardless of the word length of the memory device. On this account, the frame buffer writing process necessitates to implement operation and writing both in bit units. In the example of FIG. 26 , bit operation is implemented by the operation unit I and operational function control register 23 , while bit writing is implemented by the mask register 6 only to bits effective for writing. This frame buffer is designed to implement the memory read-modify-write operation in the write cycle for data D from the data processor, eliminating the need for the reading of data DO out of the memory, which the usual memory necessitates in such operation, whereby speedup of the frame buffer operation is made possible.
FIG. 27 shows another example of distributed processing which is applied to a graphic display system consisting of two data processors 20 and 20 ′, linked through a common bus 21 with a frame buffer memory 9 ″. The frame buffer memory 9 ″ is divided into two areas a and b which are operated for display by the data processors 20 and 20 ′, respectively. FIG. 28 shows an example of a display made by this graphic system. The content of the frame buffer memory 9 ″ is displayed on the CRT screen, which is divided into upper and lower sections in correspondence with the divided memory areas a and b as shown in FIG. 28 . When it is intended to set up the memory 9 ″ for displaying a circle, for example, the data processor 20 produces an arc aa′a″ and the data processor 20 ′, produces a remaining arc bb′b″ concurrently. The circular display process falls into two major processings of calculating the coordinates of the circle and writing the result into the frame buffer. In case the calculation process takes a longer time than the writing process, the use of the two processors 20 and 201 for the process is effective for the speedup of display. If, on the other hand, the writing process takes a longer time, the two processors conflict over the access to the frame buffer memory 9 ″, resulting in a limited effectiveness of the dual processor system. The recent advanced LSI technology has significantly reduced the computation time of data processors relative to the memory write access time, which fosters the use of a frame buffer memory requiring less access operations such as one 9 ′ shown in FIG. 26 .
In application of the frame buffer memory 9 ′ shown in FIG. 26 to the display system shown in FIG. 27, when both processors share in the same display process as shown in FIG. 28, the memory modification function is consistent for both processors and no problem will arise. In another case, however, if one processor draws graphic display a′ and another processor draws character display b′ as shown in FIG. 29, the system is no longer uneventful. In general, different kinds of display are accompanied by different memory modification operations, and if two processors make access to the frame buffer memory alternately, the setting for the modification operation and the read-modify-write operation need to take place in each display process. Setting for modification operation is identical to memory access when seen from the processor, and such double memory access ruins the attempt of speedup.
A conceivable scheme for reducing the number of computational settings is the memory access control in which one processor makes access to the frame buffer several times and then hands over the access right to another processor, instead of the alternate memory access control. However, this method requires additional time for the process of handing over the access right between the processors as compared with the display process using a common memory modification function. Namely, the conventional scheme of sharing in the same process among more than one data processor as shown in FIG. 28 is recently shifting to the implementation of separate processes as shown in FIG. 29 with a plurality of data processors as represented by the multi-window system, and the memory circuit is not designed in consideration of this regard.
An example of the frame buffer using the read-modify-write operation is disclosed, for example, in an article entitled “Designing a 1280-by-1024 pixel graphic display frame buffer in a 64K RAM with nibble mode”, Nikkei electronics, pp. 227-245, published on Aug. 27, 1984.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to-provide a method for storing graphic data and a circuit using the method which enables a higher-speed execution of dyadic and arithmetic operations on graphic data.
Another object of the present invention is to provide a memory circuit which performs read, modify, and write operations in a write cycle so that the number of dynamic steps is greatly reduced in the software section of the graphic processing.
Still another object of the present invention is to provide a memory circuit comprising a function to perform the dyadic and arithmetic operations so as to considerably lower the load imposed on the bus.
Further another object of the present invention is to provide a memory circuit which enables easily to implement a priority processing to be effected when graphic images are overlapped.
Further another object of the present invention is to provide a memory circuit with logical functions for use in constructing a frame buffer suitable for the multiple processors, parallel operations with the intention of realizing a high-speed graphic display system.
According to the present invention, there is provided a memory circuit having the following three functions to effect a higher-speed execution of processing to generate composite graphic data.
(1) A function to write external data in memory elements.
(2) A function to execute a logical operation between data previously stored in memory elements and external data, and to write the resultant data in the memory elements.
(3) A function to execute an arithmetic operation between data previously stored in memory elements and external data and to write the resultant data, in the memory elements.
A memory circuit which has these functions and which achieves a portion of the operation has been, implemented with emphasis placed on the previous points.
Also, many operations other than processing to generate composite multivalued graphic data as described above, a dyadic logic operation is required in which two operands are used. That is, the operation format is as follows in such cases.
D—D op s; where op stands for operator. On the other hand, the polynomial operation and multioperand operation as shown below are less frequently used.
D−S i opS z op . . . opS n
when the dyadic and two-operand operation is conducted between data in a central processing unit (CPU) an data in the memory elements, memory elements need be accessed only once if the operation result is to be stored in a register of the CPU (in a case where the D is a register and the S is a unit of memory elements) Contrarily, if the D indicates the memory elements unit and the S represents a register, the memory elements unit must be accessed two times. In most cases of data Processing including the multivalued graphic data processing, the number of data items is greater than the number of registers in the CPU; and hence the operation of the latter case where the D is the data element unit is frequently used; furthermore, each of two operands is stored in a memory element unit in many cases. Although the operation to access the S is indispensable to read the data, the D is accessed twice for read and write operations, that is, the same memory element unit is accessed two times for an operation.
To avoid this disadvantageous feature, the Read-Modify-Write adopted in the operation to access a dynamic random access memory (DRAM) is utilized so as to provide the memory circuit with an operation circuit so that the read and logic operations are carried out in the memory circuit, whereby the same memory element unit is accessed only once for an operation. The graphic data is modified in this fashion, which unnecessitates the operation to read the graphic data to be stored in the CPU and reduces the load imposed on the bus.
In accordance with the present invention there is provided a unit of memory elements which enables arbitrary operations to read, write, and store data characterized by including a control circuit which can operate in an ordinary write mode for storing in the memory elements unit a first data supplied externally based on first data and second data in the memory elements unit, a logic operation mode for storing an operation result obtained from a logic operation executed between the first and second data, and an arithmetic operation mode for storing in the memory element unit result data obtained from an arithmetic operation executed between the first data and the second data.
In general, when it is intended to share a resource by a plurality of processors, the resource access arbitration control is necessary, and when it is intended for a plurality of processors to share in a process for the purpose of speedup, they are required to operate and use resources in unison. These controls are generally implemented by the program of each processor, and it takes some processing time. Resources used commonly among processors include peripheral units and a storage unit. A peripheral unit is used exclusively for a time period once a processor has begun its use, while the storage unit is accessed by processors on a priority basis. The reason for the different utilization modes of the resources is that a peripheral unit has internal sequential operating modes and it is difficult for the unit to suspend the process in an intermediate mode once the operation has commenced, while the storage unit completes the data read or write operation within the duration of access by a processor and its internal operational mode does not last after the access terminates.
When it is intended to categorize the aforementioned memory implementing the read-modify-write operation in the above resource classification, the memory is a peripheral unit having the internal modification function, but the internal operating mode does not last beyond the access period, and operates faster than the processor. Accordingly, the memory access arbitration control by the program of the low-speed processor results in an increased system overhead for the switching operation, and therefore such control must be done within the memory circuit. The memory circuit implementing the read-modify-write operation does not necessitate internal operating modes dictated externally and it can switch the internal states to meet any processor solely by the memory internal operation.
The present invention resides in a memory circuit including a memory device operative to read, write and hold data, an operator which performs computation between first data supplied from outside and second data read out of the memory device, means for specifying an operational function from outside, and means for controlling bit writing from outside, wherein the operational function specifying means issues a selection control signal to a selector which selects one of a plurality of operational function specifying data supplied from outside, and wherein the bit writing control means issues a selection control signal to a selector which selects one of a plurality of bit writing control data supplied from outside, so that a frame buffer memory which implements the read-modify-write operation can be used commonly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram for explaining an operation to generate a composite graphic image in a graphic data processing system.
FIG. 2 is a flowchart of processing applied to the prior art technique to generate composite graphic data.
FIG. 3 is a schematic block diagram for explaining multivalued graphic data processing.
FIG. 4 is a timing chart illustrating the ordinary operation of a memory.
FIG. 5 is an explanatory diagram of a memory having a logic function.
FIG. 6 is a table for explaining the operation modes of the memory of FIG. 5 .
FIG. 7 is schematic circuit diagram for implementing the logic function.
FIGS. 8-9 are tables for explaining truth values in detail.
FIG. 10 is a block diagram depicting the configuration of a memory having a logic function.
FIG. 11 is a flowchart of processing to generate composite graphic data by use of the memory of FIG. 10 .
FIG. 12 is an explanatory diagram of processing to generate composite graphic data by use of an EOR logic function.
FIGS. 13-14 are schematic diagrams for explaining the processing to generate composite graphic data according to the present invention.
FIG. 15 is an explanatory diagram of an embodiment of the present invention.
FIG. 16 is a table for explaining in detail the operation logic or the present invention.
FIG. 17 is a schematic circuit diagram of an embodiment of the present invention.
FIG. 18 is a circuit block diagram for explaining an embodiment applied to color data processing.
FIG. 19 is a block diagram illustrating a memory circuit of an embodiment of the present invention.
FIG. 20 is a table for explaining the operation modes of a control circuit.
FIG. 21 is a schematic diagram illustrating an example of the control circuit configuration.
FIG. 22 is a circuit block diagram depicting an example of a 4-bit operational memory configuration.
FIGS. 23 a to 23 c are-diagrams for explaining an application example of an embodiment.
FIG. 24 is a schematic diagram for explaining processing to delete multivalued graphic data.
FIG. 25 is a block diagram showing the memory circuit embodying the present invention;
FIG. 26 is a block diagram showing the conventional memory circuit;
FIG. 27 is a block diagram showing the conventional graphic display system;
FIG. 28 is a diagram explaining a two processor graphic display;
FIG. 29 is a diagram showing a graphic display by one processor a character display by another processor;
FIG. 30 is a block diagram showing the multi-processor graphic display system embodying the present invention;
FIG. 31 is a table used to explain the operational function of the embodiment shown in FIG. 30;
FIG. 32 is a block diagram showing the arrangement of the conventional frame buffer memory;
FIG. 33 is a block diagram showing the arrangement of the memory circuit embodying the present invention;
FIG. 34 is a schematic logic diagram showing the write mask circuit in FIG. 33;
FIG. 35 is a diagram used to explain the frame buffer constructed using the memory circuit shown in FIG. 33;
FIG. 36 is a block diagram showing the arrangement of the graphic display system for explaining operation code setting according to this embodiment;
FIG. 37 is a timing chart showing the memory access timing relationship according to this embodiment;
FIG. 38 is a timing chart showing the generation of the selection signal and operation code setting signal based on the memory access timing relationship; and
FIG. 39 is a timing chart showing the memory write timing relationship derived from FIG. 37, but with the addition of the selection signal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings, the following paragraphs describe embodiments of the present invention in detail.
FIG. 4 is a timing chart of a DRAM. First, the operation to access the memory will be briefly described in conjunction with FIG. 4 . In this timing chart, ADR is an address signal supplied from an external device and WR indicates a write request signal. These two signals (ADR and WR) are fed from a microprocessor, for example. In addition, RAS is a row address strobe signal, CAS is a column address strobe signal, A indicates an address signal representing a column or row address generated in the timesharing fashion, WE stands for a write enable signal, and Z is a data item supplied from an external device (microprocessor). Excepting the Z signal, they are control signals generated by a DRAM controller, for example. The memory access outlined in FIG. 4 can be summarized as follows.
(i) As shown in FIG. 4, a memory access in a read/write cycle generally commences with a read cycle (I) and ends with a write cycle (III) due to a write enable signal, WE.
(ii) Between the read cycle (I) and the write cycle (III), there appears an interval (II) in which a read data Do and an external data Z (to be written) exist-simultaneously.
(iii) This interval (ii) is referred to as the operation enabled interval.
As described above, the store data Do and the external write data Z exist simultaneously in the interval (II). As a consequence, the store data Do and the external data Z can be subjected to an operation during a memory cycle in this interval by use of the memory circuit having an operation function, thereby enabling the operation result to be written in the memory circuit.
FIG. 5 is a block diagram illustrating a first embodiment of the present invention, FIG. 6 is an explanatory diagram of the operation principle of the embodiment shown in FIG. 5, FIG. 7 is a circuit example implementing the operation principle of FIG. 6, and FIG. 8 is a table for explaining in detail the operation of the circuit shown in FIG. 7 .
The circuit configuration of FIG. 5 comprises a control logic circuit 1 , a unit of memory elements 2 , a DRAM controller 3 , external data X and Y, a write data Z to the memory elements unit 2 , a read data Do from the memory elements unit 2 , and signals A, CAS, RAST ADR, and WR which are the same as those described in conjunction with FIG. 4 . The external data Z of FIG. 4 is replaced with the write data Z delivered via the control circuit to the memory elements unit 2 in FIG. 5 .
In accordance with an aspect of the present invention as shown in FIG. 5, the control circuit I controls the read data Do by use of the external data signals X and Y, and the modified read data is written in the memory elements unit 2 . FIG. 6 is a table for explaining the control operation. In this table, mode I is provided to set the external data Y as the write data Z, whereas mode II is provided to set the read data Do as the write data Z. As shown in FIG. 6, the external data signals X and Y, namely, the external control is used to control two modes, that is, the read data of the memory elements unit 2 is altered and written (mode II), or the external data Y is written (mode I). For the control of two modes, (i) mode I or II is specified by the external data X and (ii) the modification specification to invert or not to invert the read data Do is made by use of an external data.
The control and modification are effected in the interval (II) described in conjunction with FIG. 4 .
A specific circuit example implementing the operation described above is shown in FIG. 7 .
The control logic circuit comprises an AND gate 10 and an EOR gate 11 and operates according to the truth table of FIG. 8, which illustrates the relationships among two external data signals X and Y, store data Do, -and output Z from the control circuit 1 .
As can be seen from FIG. 8, the control circuit 1 operates primarily in the following two operation modes depending on the external data X.
(i) When the external data X is ‘0’, it operates in the operation mode I in which the external data Y is processed as the write data Z.
(ii) When the external data X is ‘1’, it operates in the operation mode II in which the data obtained by modifying the read data Do based on the external data Y is used as the write data Z.
As already shown in FIG. 4, the operation above is executed during a memory cycle.
Consequently, the principle of the present invention is described as follows.
(i) The output Do from the memory elements unit 2 is fed back as an input signal to the control circuit as described in conjunction with FIG. 4; and
(ii) The write data to, the memory elements unit 2 is controlled by use of the input data signals X and Y (generated from the write data from the CPU) as shown in FIG. 5 .
These operations (i) and (ii) are executed during a, memory cycle. That is, a data item in the memory elements is modified with an external input data (namely, an operation is conducted between these two data items) during a memory cycle by use of three data items including (i) feedback data from the memory elements, (ii) data inputted from an external device, and (iii) control data from an external device (a portion of external input data is also used as the control data). These operations imply that an external device (for example, a graphic processing system, a CPU available at present, or the like) can execute a logic operation only by use of a write operation.
The operation of the circuit shown in FIG. 7, on the other hand, is expressed as follows
Z=X·Do Y+X·Do·Y=Do·Y+X·Y+X·Do·Y =( X+Y )· Do·Y+X·Y+X·DO·Y=X·Y+X ·( YÅDo ) (1)
Substituting the externally controllable data items X and Y with the applicable values of a signal “O”, a signal “1”, the bus data Di fed from the microprocessor, and the reversed data thereof appropriately Di, the operation results of the dyadic logic operations as shown in FIG. 9 will be obtained. FIG. 10 . is a circuit diagram implemented by combining the dyadic operations of FIG. 9 with the processing system of the FIG. 5 embodiment. The system of FIG. 10 comprises four-input selectors SELf and SEL 1 , input select signals SO and S 1 to the selector SELf, input select signals S 2 and S 3 to the selector SEL 1 , and an inverter element INV.
Referring now to FIG. 1, and FIGS. 9-11, an operation example of a logic operation will be specifically described.
As shown in FIG. 9, the input select signals SO and S 1 are used as the select signals of the selector SELf to determine the value of data X. Similarly, the input select signals S 2 and S 3 are used to determine the value of data Y. The values that can be set to these data items X and Y include a signal “O”, a signal “1”, the bus data Di, and the inverted data thereof Di as described before. The selectors SELf and SEL 1 each select one of these four signal values depending on the input select signals S 0 to S 3 as shown in FIG. 10 . FIG. 9 is a table illustrating the relationships between the input select signals SO to S 3 and the data items X and Y outputted from the selectors SELf and SEL 1 , respectively, as well as the write data Z outputted from the control circuit 1 . In graphic processing as shown in FIG. 1 (OR operation: Case 1 ), for example, the data items X and Y are selected as Di and Di, respectively when the input select signals are set as follows: SO, SI=(11) and S z , S 3 =(10). Substituting these values of X and Y in the expression (1) representing the operation of the control circuit 1 , the OR operation, namely, Z=Di+Di Do=Di·(1+Do)+Di Do=Di+(Di+Di) Do=Di+Do is executed. In accordance with an aspect of the present invention, therefore, the graphic processing of FIG. 1 can be performed as shown in FIG. 11 in which the input select signals S 0 to S 1 are specified in the first step (function specification), a graphic data item to be combined is thereafter read from the storage area M 2 , and the obtained data item is stored in the graphic area only by use of a write operation.
Various logic functions can be effected by changing the values of SO to S 3 as depicted in FIG. 9 . Consequently, an operation to draw a picture, for example, by use of a mouse cursor which is arbitrarily moved can be readily executed as shown in FIG. 12 . Even when the mouse cursor (M 2 ) overlaps with a graphic image in the graphic area M 1 as illustrated in FIG. 12, the cursor must be displayed, and hence a function of the EOR operation is necessary. In this cursor display, when the input select signals are set as SO, S 1 =(10) and S 2 , S 3 =(01), the processing can be achieved as depicted in FIG. 11 in the same manner as the case of—the composite graphic 7 c data generation described before. The various logic functions as listed in the table of FIG. 9 can be therefore easily implemented; furthermore, the Read-Modify-Write operation on the memory element unit 2 can—be accomplished only by a write operation.
By use of the circuit configuration of FIG. 10, the dyadic logic operations of FIG. 9 can be executed as a modify operation to be conducted between the data Di from the microprocessor and the read data Do from the memory elements unit 2 . Incidentally, the input select signals are used to specify a dyadic logic operation.
In accordance with the embodiment described above, the prior art processing to generate a composite graphic image can be simplified as depicted by the flowchart of FIG. 11 .
The embodiment of the present invention described above comprises three functions as shown in FIG. 10, namely, a memory section including memory elements unit 2 , a control section having the control circuit 1 , and a selector section including the selectors SEIA and SELI. However, the function implemented by a combination of the control and selector sections is identical to the dyadic logic operation function described in conjunction with FIG. 9 . Although this function can be easily achieved by use of other means, the embodiment above is preferable to simplify the circuit configuration.
On the other hand, graphic processing is required to include processing in which graphic images and the like are overlapped as illustrated in FIGS. 13 14 . In the first case, the graphic image in the store area M 2 takes precedence over the graphic image in the graphic image area M 1 when they are displayed as depicted in FIG. 13 . In the second case, the graphic image in the graphic image area M 1 takes precedence over the graphic image in the store area M 2 as shown in FIG. 14 .
The priority processing to determine the priority of graphic data as illustrated in FIGS. 13-14 cannot be achieved only by the logical function implemented by the FC section of FIG. 10) described above.
This function, however, can be early implemented by use of the memory circuit in an embodiment of the present invention namely, only simple logic and selector circuits need by added to the graphic processing system. An embodiment for realizing such a function will be described by referring to FIGS. 15-17. The FC section of FIG. 15 corresponds to a combination of the control circuit and the selectors SELf and SEL 1 . In this embodiment, the logic operation function (FC) section operates in the pass mode with the input select signals so to S 3 of the selectors SELf and SEL 1 set as (0, 0, 1, 0), for example.
The circuit block diagram of FIG. 15 includes a priority control section 4 , a two-input selector SEL 2 , a priority specification signal P, an input select signal S 4 to-the selector SEL 2 , a graphic data signal Di′ from the store area M 2 , a graphic image area M 1 , a selected signal Di from selector SEL 2 , a graphic data signal Do from the graphic image area M 1 (identical to the read data signal from the memory elements unit 2 shown in FIG. 10 ), and an output signal Z from the FC section (identical to the output signal from the control circuit I of FIG. 4 ). For the convenience of explanation, the graphic area is set to a logic value “1” and the background area is set to a logic value “O” as shown in FIG. 15 . In this processing, the priority control section 4 and the selector SEL 2 operate according to the contents of the truth table of FIG. 16 . The relation-ships between the input select signal S 4 and the input data Di to the logic operation function (FC) section are outlined in FIG. 16, where the signal S 4 is determined by a combination of the priority specification signal P, the data Di′ in the area M 2 , and the data Do from the area M 1 , and the input data Di is set by the signal S 4 .
In other words, the truth table of FIG. 16 determines an operation as follows. For example, assume that the graphic area to be used as the background is Mi. If the data items Do and Di′ in the areas M 1 and M 2 , respectively, are set to the effective data (“1”), the priority specification signal P is used to deter-mine whether the data Do of the background area M 1 takes precedence (P=1), or the data Di′ of the area M 2 takes precedence (P=0).
That is, if a graphic image in the store area M 2 is desired to be displayed over the graphic image of the graphic area M 1 , as illustrated in FIG. 13, the priority specification signal P is set to “0”. Then, if the graphic data items Di′ and Do, are in the graphic areas (“1”) as depicted in FIG. 15, the data Di′ of the store area M 2 is preferentially selected by the selector SEL 2 . If the priority specification signal P is set to “1”, the graphic processing is similarly executed according to the truth table of FIG. 16 as shown in FIG. 14 .
In FIG. 16, if the graphic areas (“1”) are overlapped, the graphic area of the graphic area M 1 , or the store area M 2 , is selected depending on the priority specification signal P, and the data of the graphic area M 1 is selected as the background for the area in which the graphic area does not exist.
FIG. 17 is a specific circuit diagram of the priority control section 4 depicted in FIG. 15 . In this circuit diagram, reference numerals 40 and 41 indicate a three-input NAND circuit and a two-input NAND circuit respectively.
In order to apply the principle of priority decision to color data in which each pixel comprises a plurality of bits, the circuit must be modified as illustrated in FIG. 18 .
The circuit of FIG. 18 includes a compare and determine section 5 for determining the graphic area (COL 3 ) of the graphic area M 1 and a compare and determine section 6 for determining the graphic area (COL 1 ) of the store area M 1 . As described above, the priority comprises a plurality of bits, it is different from the circuit for processing information for which a pixel comprises a bit as shown in FIG. 15 in that the priority determination between significant data items is achieved by use of the code information (COLf to COL 3 ) because the graphic data is expressed by the code information.
Consequently, in the case of color data, the overlapped graphic images can be easily processed by adding the compare and determine sections which determine the priority by comparing the code information.
The preceding paragraphs have described the priority determine circuit applied to an embodiment of the memory circuit having an operation function, however, it is clear that such embodiment can be applied to a simple memory circuit, or a memory circuit which has integrated shift register and serial outputs.
In accordance with this embodiment, the following effect is developed.
(1) When executing the processing as shown in FIG. 1, the processing flowchart of FIG. 11 can be utilized, and hence the memory cycle can be minimized.
(2) Three kinds of processing including the read, modify, and write operations can be executed only during a write cycle, which enables an increase in the processing speed.
(3) As depicted in FIGS. 16-18, the priority processing to be conducted when the graphic images are overlapped can be effected by the use of a plurality of simple logic gates.
(4) The graphic processing of color data can be also easily implemented by externally adding the compare and determine circuits for determining the graphic areas (code data comprising at least two bits).
(5) The size of the circuit configuration necessary for implementing the memory circuit according to the invention is quite small as compared with that of a group of memory elements, which is considerably advantageous to manufacture a large scale integration circuit in the same memory chip.
Next, another embodiment will be described in which processing to generate a composite graphic data represented as the multivalued data of FIG. 3 is executed.
FIG. 19 is a circuit block diagram of a memory circuit applied to a case in which multivalued data is processed. This circuit is different from the memory circuit of FIG. 5 in the configuration of a control circuit 1 ′.
The configuration of FIG. 19 is adopted because the processing to generate a composite graphic data from the multivalued data indispensably necessitates an arithmetic operation, not a simple logic operation. As shown in FIG. 19, however, the basic operation is the same as depicted in FIG. 5 .
In the following paragraphs, although the arithmetic operation is described, the circuit configuration includes the sections associated with the logic operation because the logic operation is also used for the multivalued graphic data processing. The circuit arrangement of FIG. 19 includes a control circuit 11 , memory elements unit 2 , a DRAM controller 3 , external control signals CNT and Cr, data Y supplied from an external device, write data Z to the memory elements unit 2 , read data Do from the memory elements unit 2 , and signals A, WE, CAS, RAS, ADR, and WR which are the same as those shown in FIG. 5 .
In the embodiment as shown in FIG. 19, the control circuit 11 performs an operation on the read data Do and the external data Y according to the external control signals CRT and Cr; and the operation result, write data Z is written in the memory elements 2 . FIG. 20 is a table illustrating the control operation modes of the control circuit 1 ′. When the external control signals CRT and Cr are set to f, the control circuit 1 ′ operates in a mode where the external data Y is used as a control signal to determine whether or not the read data Do is subjected to an inversion before it is outputted; when the signals CRT and Cr are set to 0 and 1, respectively, the control circuit 1 ′ operates in a mode where the external data Y is outputted without change; and when the signals are set to 1, the control circuit 1 ′ operates in a mode where the read data Do, the external data Y, and the external control signal Cr are arithmetically added.
FIG. 21 is a specific circuit diagram of a circuit implementing the control operation modes. In this circuit arrangement, the arithmetic operation is achieved by use of the ENOR gates G 1 and G 2 , and the condition that the external control signals CRT and Cr are f and 1 , respectively is detected by the gates G 6 to G 8 , and the output from the ENOR gate or the external data Y is selected by use of a selector constituted from the gates G 3 to G 5 . This circuit configuration further includes a NAND gate G 9 for outputting a generate signal associated with the carry lookahead function provided to minimize the propagation delay of the carry and an AND gate GIO for generating a propagate signal similarly associated with the carry lookahead function. The logical expressions of the output signals Z, P, and G from the control circuit I′ are as listed in FIG. 21, where the carry lookahead signals P and G each are set to fixed values (P=0, G=1) if the external control signal CNT is f.
FIG. 22 is the configuration of a four-bit operation memory utilizing four memory circuits for the embodiment. For simplification of explanation, only the sections primarily associated with the arithmetic operation mode are depicted in FIG. 22 . The circuit diagram includes the memory circuits 11 - 14 shown in FIG. 19, gates G 11 to G 28 constituting a carry lookahead circuit for achieving a carry operation, and a register F for storing the result of a carry caused by an arithmetic operation. The memory circuits 11 and 14 are associated with the least and most-significant bits, respectively.
Although not shown in this circuit configuration to simplify the circuit arrangement, the register F is connected to an external circuit which sets the content to f or 1 . The logical expression of the carry result, namely, the output from the gate G 29 is as follows.
G 4 +G 3 ·P 4 +G 2 ·P 3 ·P 4 +G 1 ·P 2 ·P 3 ·P 4 +Cr·P 1 ·P 2 ·P 3 ·P 4
When the external control signal CNT is f, Pi and Gi are set to 1 and f, respectively (where, i indicates an integer ranging from one to four), and hence the logical expression includes only the signal Cr, which means that the value of the register F is not changed by a write operation. Since the intermediate carry signals Gr 2 to Gr 4 are also set to the value of the signal Cr, three operation states are not changed by a write operation when the external control signal CNT is f. If the external control signal CNT is 1, the carry control signals P 1 to P 4 and G 1 to G 4 of the memory circuits 11 - 14 , respectively function as the carry lookahead signals, so an ordinary addition can be conducted.
As shown in FIG. 20, although the control circuit has a small number of operation modes, the operation functions can be increased by selecting the logic value f, the logic value 1, the write data D to a microprocessor or the like, and the inverted data D of the write data D as the inputs Of the external control signal Cr and the external data Y.
FIGS. 23 a to 23 c illustrate an example in which the above-mentioned circuits are combined. FIG. 23 a is a specific representation of a circuit for the least significant bit, whereas FIG. 22 b is a table outlining the operation functions of the circuit of FIG. 23 a.
In the following paragraphs, the circuit operation will be described only in the arithmetic operation mode with the external control signal CNT set to 1.
Gates G 29 -G 33 constitute a selector (SEL 3 ) for the external control signal Cr, while gates G 34 -G 37 configure a selector (SEL 4 ) for the external data Y. The circuit arrangement of FIG. 23 a comprises select control signals Sf and S 1 for selecting the external control signal Cr and select control signals S 2 and S 3 for selecting the external data Y. FIG. 23 c depicts a circuit for the most-significant bit. This circuit is different from that of FIG. 23 a in that the selector for the signal Cr is constituted from the gates G 38 -G 44 so that a carry signal Cri-I from the lower-order bit is inputted to the external control signal Cr when the external control signal CNT is 1. The selector for the external data Y is of the same configuration of that of FIG. 23 a. In the circuit configuration of FIG. 23 c, the memory circuit arrangement enables to achieve 16 kinds of logical operations and six kinds of arithmetic operations by executing a memory write access. For example, the processing to overlap multivalued graphic data as shown in FIG. 3 is carried out as follows. First, the select signals SO to S 3 are set to 0, 0, 0, and 1, respectively and the write data Z is specified for an arithmetic operation of Do Plus 1. A data item is read from the multivalued graphic data memory M 2 and the obtained data item is written in the destination multivalued graphic data area M 1 , which causes each data to be added and the multivalued graphic data items are overlapped at a higher speed. Similarly, if the select signals Sf to S 3 are set to 1 and the write data Z is specified for a subtraction of Do Minus Di, the unnecessary portion (such as the noise) of the multivalued graphic data can be deleted as depicted in FIG. 24 . Like the case of the overlap processing, this processing can be implemented only by executing a read operation on the data memory M 3 containing the data from which the unnecessary portion is subtracted and by repeating a write operation thereafter on the destination data memory M 3 , which enables higher-speed graphic processing.
According to the above embodiments,
(1) The multivalued graphic data processing is effected by repeating memory access two times, and hence the processing such as the graphic data overlap processing and subtraction can be achieved at a higher speed;
(2) Since the data operation conducted between memory units is implemented on the memory side, the multivalued graphic processing can be implemented not only in a device such as a microprocessor which has an operation function but also in a device such as a direct memory access (DMA) controller which has not an operation function; and
(3) The carry processing is conducted when a memory write access is executed by use of the circuit configuration as shown in FIG. 22, so the multiple-precision arithmetic operation can be implemented only by using a memory write operation, thereby enabling a multiple-precision arithmetic operation to be achieved at a higher speed.
It is also possible to perform the dyadic operation and the arithmetic operation on graphic data at a higher speed. Moreover, the priority processing to be utilized when graphic images overlap and processing for color data can be readily implemented.
FIG. 25 shows a frame buffer memory circuit including an operation unit (LU) 1 for implementing the modification functions for the read-modify-write operation, a data memory 2 , operational function specifying registers 23 and 24 for specifying an operational function of the operation unit, an operational function selector 25 for selecting an operational function, write mask registers 26 and 27 for holding write mask data, and a write mask selector 28 for selecting write mask data. Symbol D denotes write data sent over the common bus, and symbol C denotes a selection signal for controlling the operational function selector 5 and write mask selector 28 .
FIG. 30 is a block diagram showing the application of the inventive frame buffer memory circuit 9 shown in FIG. 25 to the multi-processor system, in which are included data processors 20 and 20 ′, a common bus 21 and an address decoder 22 .
The following describes, as an example, the operation of this embodiment. For clarification purposes, FIGS. 25 and 30 do not show the memory read data bus, memory block address decoder and read-modify-write control circuit, all of which are not essential for the explanation of this invention In this embodiment, the memory circuit 9 is addressed from 800000H to 9FFFFFH. The memory circuit 9 itself has a 1M byte capacity in a physical sense, but it is addressed double in the range 800000H-9FFFFFH to provide a virtual 2M byte address space. The method of double addressing is such that address 800000H and address 900000H contain the same byte data, and so on, and finally address 8FFFFFH and address 9FFFFFH contain the same byte data. Accordingly, data read by the processor 20 at address 8 xxxxxH is equal to data read at address 9 xxxxxH, provided that the address—section xxxxx is common. The reason for double addressing the memory circuit 9 beginning with address 800000H and address 900000H is to distinguish accesses by the data processors 20 and 201 . Namely, the data processor 20 is accessible to a 1M byte area starting with 800000H, while the-processor 20 , is accessible to a 1M byte area starting with 900000H. The address decoder 22 serves to control the double addressing system, and it produces a “O” output in response to an address signal having an even (8H) highest digit, while producing a “1” output in response to an address signal having an odd (9H) highest digit.
The operation unit I has a function set of 16 logical operations as listed in FIG. 31 . In order to specify one of the 16 kinds of operations, the operation code data FC is formatted in 4 bits, and the operational function specifying registers 23 and 24 and operational function selector 25 are all arranged in 4 bits. Since the memory 2 is of the 16-bit word length, the write mask registers 26 and 27 and mask selector 28 also have 16 bits.
Next, the operation of the data processor 20 in FIG. 30 in making write access to the frame buffer memory 9 will be described. The data processor 20 has a preset of function code FO in the operational function specifying register 23 and mask data MO in the write mask register 26 . When the data processor 20 makes write access to address 800000H, for example. the memory access operation takes place in the order of reading, modifying and writing in the timing relationship as shown in FIG. 39 . In response to the output of address 800000H onto the address bus by the data processor 20 , the address decoder 22 produces a “O” output, the operational function selector 25 selects the operational function specifying register 23 , and the operation unit 1 receives F 0 as operation code data FC. At this time, the write mask selector 28 selects the write mask register 26 , and it outputs MO as WE to the memory 2 . In FIG. 39, data in address SOOOOOH is read out in the read period, which is subjected to calculation with write data D from the data processor 20 by the operation unit 1 in accordance with the calculation code data FO in the modification period, and the result is written in accordance with data MO in the write period. The write mask data inhibits writing at “O” and enables writing at “1”, and the data MO is given value FFH for the usual write operation.
When another data processor 20 ′ makes-access to the frame buffer 9 , function code F 1 is preset in the operational function specifying register 24 and mask data M 1 is preset in the write mask register 27 . In order for the data processor 201 to access the same data as one in address 800000H for the data processor 20 , it makes write access to address 900000H. The write access timing relationship for the data processor 201 is similar to that shown in FIG. 39, but differs in that the output signal C of the address decoder 22 is “1” during the access, the function code for modification is F 1 , and the write mask is M 1 in this case.
Accordingly, by making the data processors 20 and 20 ′ access different addresses, the calculation and mask data can be different, and the operational functions need not be set at each time even when the processors implement different display operations as shown in FIG. 29 .
Next, the arrangement of the frame buffer memory 9 and the method of setting the operational function according to this embodiment will be described.
FIG. 32 shows a typical arrangement of the frame buffer. Conventionally, a memory has been constructed using a plurality of memory IC (Integrated Circuit) components with external accompaniments of an operation unit 1 , operational function specifying register 23 and write mask register 26 . The reason for the arrangement of the memory using a plurality of memory IC components is that the memory capacity is too large to be constructed by a single component. The memory is constructed divisionally, each division constituting 1, 3 or 4 bits or the like of data words (16-bit word in this embodiment). For example, when each division forms a bit of data words, at least 16 memory IC components are used. For the same reason when it is intended to integrate the whole frame buffer shown in FIG. 32, it needs to be divided into several IC components.
The following describes the method of this embodiment for setting the operational function and write mask data for the sliced memory structure. The setting method will be described on the assumption that a single operational function specifying register and write mask register are provided, since the plurality of these register sets is not significant for the explanation.
Currently used graphic display units are mostly arranged to have operational functions of logical bit operations, and therefore it is possible to divide the operation unit into bit groups of operation data. It is also possible in principle to divide the operation unit on a bit slicing basis also for the case of implementing arithmetic operations, through the additional provision of a carry control circuit. The write mask register 26 is a circuit controlling the write operation in bit units, and therefore it can obviously be divided into bit units. The operational function specifying register 23 stores a number in a word length determined from the type of operational function of the operation unit 1 , which is independent of the word length of operation data (16 bits in this embodiment), and therefore it cannot be divided into bit groups of operation data. On this account, the operational function specifying register 23 needs to be provided for each divided bit group. Although it seems inefficient to have the same functional circuit for each divided bit group, the number of elements used for the peripheral circuits is less than 1% of the memory elements, and the yearly increasing circuit integration density makes this matter insignificant. However, in contrast to the case of slicing the operational function specifying register 23 into bit groups, partition of the frame buffer-shown in FIG. 32 into bit groups of data is questionable. The reason is that the operational function specifying register 23 is designed to receive data signals D 15 -DO. When the frame buffer is simply sliced into 1-bit groups, the operational function specifying register 23 can receive 1-bit data and it cannot receive a 4-bit specification code listed in FIG. 31 . If, on the other hand, it is designed to supply a necessary number of 1-bit signals to the operational function specifying register 23 , the frame buffer must have terminals effective solely for the specification of operational functions, and this will result in an increased package size when the whole circuit is integrated. If it is designed to specify the operational function using the data bus, the number of operational functions becomes dependent on bit slicing of data, and to avoid this the frame memory of this embodiment is intended to specify operational functions using the address but which is independent of bit slicing.
FIG. 33 shows, as an example, the arrangement of the frame buffer memory which uses part of the address signals for specifying operational functions. Symbol Dj denotes a 1-bit signal in the 16-bit data signals to the graphic display data processor, A 23 -A 1 are address signals to the data processor, WE is the write control signal to the data processor, FS is the data setting control signal for the operational function specifying register 3 and write mask register 26 , DOj is a bit of data read out of the memory device 2 , DIj is a bit of data produced by the operation unit 1 , and Wj is the write control signal to the memory device 2 .
FIG. 34 shows, as an example, the arrangement of the write mask register, which includes a write mask data register 61 and a gate 62 for disabling the write control signal WE.
FIG. 35 shows the arrangement of the frame buffer constructed by using the memory circuit shown in FIG. 33 . The figure shows a 4-bit arrangement for clarifying the connection to each memory circuit.
FIG. 36 shows the memory circuit of this embodiment applied to a graphic display system, with the intention of explaining the setting of the operation code. Reference number 20 denotes a data processor, and 23 denotes a decoder for producing the set signal FS.
The following describes the operation of the memory circuit. In this embodiment, an address range 800000H-9FFFFFH is assigned to the memory circuit 9 . The decoder 23 produces the set signal FS in response to addresses AOOOOOH-AOOOIFH. The operation unit 1 has the 16 operational functions as listed in FIG. 31 .
When the data processor 20 operates to write data FOFFH in address A00014H, for example, the decoder 23 produces the set signal FS to load the address bit signals A 4 -A 1 , i.e., 0101B (B signifies binary), in the operational function specifying register 3 . Consequently, the operation unit 2 selects the logical-sum operation in compliance with the table in FIG. 31 . In the write mask register 26 , a bit of 16-bit data OFOOH from the data processor 20 , the bit position being the same as the bit position of the memory device, is set in the write mask data register 61 . As a result, FOFFH is set as write mask data.
Next, the operation of the data processor 20 for writing F3FFH in address 800000H will be described. It is assumed that the address BOOOOOH has the contents of 0512H in advance. FIG. 37 shows the timing relation-ship of memory access by the data processor 10 . The write access to the memory circuit 9 by the data processor 20 is the read-modify-write operation as shown in FIG. 37 . In the read period of this operation, data 0512H is read out onto the DO bus, and the D bus. receives F3FFH. In the subsequent modification period, the operation unit 1 implements the operation between data on the D bus and DO bus and outputs the operation result onto the DI bus. In this example, the D bus carries F3FFH and the DO bus carries 0512H, and the DI bus will have data F7FFH as a result of the logical-sum operation which has been selected for the operation unit 1 . Finally, in the write period of the read-modify-write operation, data F7FFH on the DI bus is written in the memory device. In this case, FOFFH has been set as write mask data by the aforementioned setting operation, and a “O” bit of mask data enables the gate 62 , while “1” bit disables the gate 62 as shown in FIG. 34, causing only 4 bits (D 11 -D 8 ) to undergo the actual write operation, with the remaining 12 bits being left out of the write operation. Consequently, data in address 800000H is altered to 0712H.
The foregoing embodiment of this invention provides the following effectiveness. Owing to the provision of the operation specifying registers 23 and 24 and the write mask registers 26 and 27 in correspondence to the data processors 20 and 20 ′, specification of a modification function for the read-modify-write operation and mask write specification are done for each data processor even in the case of write access to the frame buffer memory 9 by the data processors 20 and 20 ′ asynchronously and independently, which eliminates the need for arbitration control between the data processors, whereby both processors can implement display processings without interference from each other except for an access delay caused by conflicting accesses to the frame buffer memory 9 .
The above embodiment is a frame buffer memory for a graphic display system, and the data processors 20 and 20 ′ mainly perform the coordinate calculations for pixels. The two data processors can share in the coordinate calculation and other processes in case they consume too much time, thereby reducing the processing time and thus minimizing the display wait time. For the case of a time-consuming frame buffer write processing, the use of the read-modify-write operation reduces the frequency of memory access, whereby a high-speed graphic display system operative with a minimal display wait time can be realized.
The above embodiment uses part of the address signal for the control signal, and in consequence a memory-circuit operative in read-modify-write mode with the ability of specifying the operational function independent of data slicing methods can be realized. On this account, when all functional blocks are integrated in a circuit component, the arrangement of the memory section can be determined independently of the read-modify-write function.
Although in the foregoing embodiment two data processors are used, it is needless to say that a system including three or more data processors can be constructed in the same principle. The present invention is obviously applicable to a system in which a single data processor initiates several tasks and separate addresses are assigned to the individual tasks for implementing parallel display processings. The memory circuit of the above embodiment differs from the usual memory IC component in that the set signal FS for setting the operational function and w-rite-mask data and the signal C for selecting an operational function and write mask are involved. These signals may be provided from outside at the expense of two additional IC pins as compared with the usual memory device, or may be substituted by the aforementioned signals by utilization of the memory access timing relationship for the purpose of minimizing the package size. FIG. 38 shows the memory access timing relation-ship for the latter method, in which a timing unused in the operation of a usual dynamic RAM is used to distinguish processors (the falling edge of RAS causes the WE signal to go low) and to set the operation code and write mask data (the rising edge of RAS causes CAS and WE signals to go low), thereby producing the FS and C signals equivalently. Although in the above embodiment a 16-bit data word is sliced into 1-bit groups, these values can obviously be altered. Although in the above embodiment the operational function and write mask are specified concurrently, they may be specified separately.
It is obvious that the word length for operational function specification may be other than 4 bits. The above embodiment can also be applied to a memory with a serial output port by incorporating a shift register. According to the above embodiments, the coordinate calculation process in the display process is shared by a plurality of processors so that the calculation time is reduced, and the frame buffer memory operative in a read-modify-write mode can be shared among the processors without the need of arbitration control so that the number of memory accesses is reduced, whereby a high-speed graphic display system can be constructed. Moreover, the modification operation for the read-modify-write operation is specified independently of the word length of write data, and this realizes a memory circuit incorporating a circuit which implements the read-modify-write operation in arbitrary word lengths, whereby a frame buffer used in a high-speed graphic display system, for example, can be made compact. | A memory device which includes dynamic random access memories for effecting data read and write operations, first and second data terminals for receiving data, and a controller having a first data input connected to receive first data, a second data input connected to receive second data, a third data input connected to receive a function mode signal, and operation unit for executing operations between the first data and the second data. The operation unit includes a function setting unit for setting a function indicated by a function mode signal prior to receipt of the first data. The second data is read out of a selected part of the storage locations. The operation corresponding to the set function is executed for the first and second data. The operation result is written into the selected part of the storage locations during one memory cycle. | 6 |
BACKGROUND OF THE INVENTION:
The invention relates generally to heat-exchange arrangements.
Heat-exchangers are known which include a housing and a nest or bundle of tubes arranged interiorly of the same. A cooling medium flows through the tubes whereas a fluid to be cooled flows through the housing and impinges the tubes exteriorly thereof. Baffles are arranged inside the housing for changing the direction of flow of the fluid to be cooled. By virtue of the impingement of the fluid to be cooled upon the outside surfaces of the conduits or tubes, the cooling medium flowing in the conduits may undergo vaporization.
Heat-exchangers of this type are utilized in cooling circuits which include a vaporizer, a compressor, a condenser and a pressure-reducing valve. Here, the cooling medium flows along a closed path. The cooling medium enters the heat-exchanger in liquid form and is vaporized therein by virtue of the heat-exchange which it undergoes with a fluid to be cooled, that is, the heat-exchanger serves as a vaporizer. After leaving the heat-exchanger, the cooling medium is compressed, condensed and subjected to a pressure reduction. In this manner, the cooling medium is returned to its original liquid state. The liquid cooling medium is then re-admitted into the heat-exchanger.
The introduction of the cooling medium into a heat-exchanger of the type described above is generally controlled by means of a thermostatic expansion valve located upstream of the inlet for the liquid cooling medium and the opening and closing of which are effected by means of external pressure equalization. The open and closed phases of the expansion valve are regulated in dependence upon the output from a pressostat and a thermostat arranged downstream of the outlet opening for the vaporized cooling medium. This regulation resides in that liquid cooling medium is permitted to enter the heat-exchanger only when the pressostat and the thermostat register a completely gaseous condition for the cooling medium at the outlet of the heat-exchanger. This design serves not only as a means for controlling the operation of the heat-exchanger but serves also as a safety measure for the compressor arranged downstream of the outlet opening for the cooling medium. Thus, impingement of the compressor by drops of liquid cooling medium sucked in by the compressor may cause severe damage to the latter.
The efficiency of a heat-exchanger of the above type with respect to the cooling circuit has been found to be no better than that of the tube which exhibits the poorest heat transfer and which, concomitantly, provides for the poorest vaporization of cooling medium within the nest of tubes. The reason is that the cooling medium flowing in the tube having the poorest heat transfer characteristics passes through the tube in liquid form and causes the thermostat and pressostat to close the expansion valve located in the region of the inlet of the heat-exchanger. The result is that the remaining tubes of the nest, which provide for better vaporization, contain less cooling medium than they are capable of vaporizing on the basis of their design. In practice, the gaseous phase of the cooling medium is then disadvantageously shifted towards the inlet of the heat-exchanger, that is, complete vaporization of the cooling medium occurs closer to the inlet of the heat-exchanger than would be the case otherwise. As a consequence, the efficiency of the heat-exchanger and, concomitantly, the efficiency of the entire cooling circuit, is substantially decreased.
In order to alleviate these disadvantages to some extent, it has been necessary in the past to either construct larger heat-exchangers or to arrange a number of smaller heat-exchangers in series. However, this not only results in large space requirements and high costs but also requires the performance of more work at the suction side of the compressor.
A heat-exchanger of the type under consideration which has become known from the DT-AS 1,077,681 attempted to overcome the foregoing disadvantages by conveying the cooling medium through the nest of tubes progresively along a plurality of paths. Here, covers are provided at the opposite ends of the nest of conduits, the cover serving as baffles which cause the cooling medium exiting from one of the conduits to flow into another of the conduits. The covers are provided with separating webs and connecting members on their inner sides. On the one hand, the separating webs and connecting members are arranged so that the cooling medium is initially introduced into the conduits constituting the uppermost horizontal row of the nest and into the conduits constituting the lowermost horizontal row of the nest. On the other hand, the separating webs and connecting members are arranged so that the cooling medium is each time deflected only from one horizontal row of conduits to the immediately adjacent overlying or underlying row of conduits. The separating webs and connecting members are further arranged in such a manner that the cooling medium exits from the heat-exchanger via one of the covers and at a level of the latter corresponding approximately to the horizontal symmetry axis thereof. Moreover, provision is made for a progressive increase in the volume interiorly of the conduits so as to adjust for the increase in volume of the cooling medium as it vaporizes. The preceding measures are intended to achieve a better vaporizing effect and an accompanying improved efficiency. Nevertheless, even with this heat-exchanger it is not possible to avoid the passsage of cooling medium through the nest in liquid phase. One of the reasons for this resides in that the housing in which the nest of tubes is accommodated has an internal cross-section which is of circular configuration. Thus, on the one hand, despite the provision of baffles, the fluid to be cooled impinges the external surfaces of the tubes with varying flow velocities due to the circular configuration of the housing. On the other hand, so-called "dead edges" exist in the housing and the tubes arranged in these dead edges can be only partially impinged by the fluid to be cooled. Particularly dangerous conditions exist here in view of the danger that the cooling medium will pass through the nest of tubes in liquid phase.
It may be seen, therefore, that improvements in the state of the art are desirable.
SUMMARY OF THE INVENTION
A general object of the invention is to provide a novel heat-exchange arrangement.
Another object of the invention is to provide a heat-exchange arrangement which enables a more uniform heat transfer than was possible heretofore to be achieved.
A further object of the invention is to provide a heat-exchange arrangement which enables higher efficiencies than were obtainable heretofore to be realized.
An additional object of the invention is to provide a heat-exchange arrangement which is of a more compact construction than the heat-exchangers of the prior art.
A concomitant object of the invention is to provide a heat-exchanger of the type outlined above which enables the disadvantages described previously to be avoided and which, while having a compact construction, enables a completely uniform quantity of cooling medium to be vaporized in each conduit of the conduit nest and also enables the completely vaporized cooling medium to be superheated with respect to the vaporization temperature in the final portions of the flow paths defined by the conduits.
These objects, as well as others which will become apparent as the description proceeds, are achieved in acccordance with the invention. According to one aspect of the invention, there is provided a heat-exchange arrangement which comprises a housing having an inner surface defining a first flow path for a fluid to undergo heat-exchange. The inner surface of the housing includes a pair of substantially parallel surface portions which bound the first flow path along the flow direction so that the first flow path is of substantially constant width along the flow direction. A plurality of spaced conduits is arranged in the first flow path and defines a series of second flow paths for a medium to undergo heat-exchange with a fluid flowing in the first flow path. The conduits are arranged such that substantially the same predetermined minimum distance separates the most closely spaced ones of the conduits. A plurality of baffles is provided in the first flow path for regulating the flow pattern of a fluid flowing therein. The baffles are arranged in such a manner that, in the region between two adjacent ones of the baffles, the projected free flow cross-section of the first flow path as determined in a plane substantially paralleling the conduits is substantially equal to the projected free flow cross-section of the first flow path as determined in a plane substantially normal to the conduits.
Of particular interest to the invention is a heat-exchange arrangement or heat-exchanger of the type wherein a cooling medium is vaporized. The preferred form of heat-exchanger according to the invention has a nest of conduits, and a cooling medium flows through the interiors of the conduits whereas a fluid to be cooled impinges the external surfaces of the conduit nest interiorly of a housing. The preferred form of heat-exchanger in accordance with the invention also includes baffles arranged interiorly of the housing and which are provided for the fluid to be cooled. For the sake of simplification, the description herein will be primarily with reference to the preferred arrangement just outlined.
A particularly favorable embodiment of the invention contemplates for the housing, or at least the interior thereof, to have a substantially rectangular cross-sectional configuration. As indicated previously, the distance of separation of the conduits from one another, that is, the minimum distance separating the most closely spaced ones of the conduits, is advantageously constant. Moreover, it is preferred for the conduits to be spaced from the inner surface or wall of the housing and for the spacing between the inner wall of the housing and the conduits most closely adjacent thereto to substantially equal the minimum distance of separation of the conduits. Also, as pointed out earlier, the ratio of the projected free flow cross-section of the fluid to be cooled in directions parallel and perpendicular to the conduits is preferably approximately 1:1 in the region between two adjacent baffles.
It has been surprisingly determined that, by virtue of the combination of these characteristics, each conduit is, on the average, completely uniformly impinged by the fluid to be cooled while so-called "dead zones" are eliminated. Consequently, due to the resulting completely uniform heat transfer from the outer sides to the inner sides of the conduits, a completely uniform vaporization of the cooling medium in the interiors of the conduits is achieved. Noteworthy here is that, by virtue of the ratio of about 1:1, in the region intermediate two adjacent baffles, between the projected free flow cross-sections parallel and perpendicular to the conduits of the fluid to be cooled, the flow velocities perpendicular and parallel to the conduits may be maintained substantially the same. For water, the optimum value of the flow velocity lies between about 1 and 1.2 meters per second.
It has also been surprisingly found that the length of the conduit nest according to the invention need be only about one-half of the optimum length, as calculated from the appropriate literature sources, for conventional heat-exchangers having housings of circular configuration or cross-section. Moreover, it has been further found that, despite the relatively small dimensions of the conduit nest in accordance with the invention, the conduit nest is still capable of possessing a super-heating stretch, that is, a portion along which the cooling medium is heated above its vaporization temperature, which is of the order of 5 to 10% of the total length of the conduit nest. Here, the flow direction of the fluid to be cooled is advantageously transverse and countercurrent to the flow direction of the cooling medium, that is, the fluid to be cooled advantageously includes a flow component which is transverse to the direction of flow of the cooling medium as well as a flow component which is countercurrent to the direction of flow of the cooling medium.
By virtue of the above characteristics, it is possible, for example, to design a heat-exchanger having a heat transfer capacity per unit area of approximately 25,000 to 30,000 kilocalories per square meter per hour in the following manner: The conduits are arranged so as to define a grid pattern having a grid spacing of substantially 10 millimeters. The grid pattern has four-by-nine conduits, that is, a shorter side of the grid pattern is defined by a row of four conduits and a longer side of the grid pattern is defined by a row of nine conduits. The conduits have outer diameters of substantially 8 millimeters, wall thicknesses of substantially 0.5 millimeter and lengths of substantially 1250 millimeters.
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 drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a cooling circuit having a heat-exchanger interposed therein;
FIG. 2 schematically illustrates a heat-exchanger according to the invention and indicates a vaporizing portion and a super-heating portion of the heat-exchanger;
FIG. 3 is a side view of a practical embodiment of a heat-exchanger in accordance with the invention;
FIG. 4 is a plan view of the embodiment of FIG. 3;
FIG. 5 is an enlarged vertical sectional view of the portion of the heat-exchanger indicated at V in FIG. 3; and
FIG. 6 is a sectional view in the direction of the arrows VI--VI of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing in detail, it is pointed out that FIG. 1 thereof is presented so as to provide a better understanding of the invention and so as to illustrate one application of a heat-exchanger in accordance with the invention. FIG. 1 illustrates a cooling circuit which is here assumed to be in communication with a heat pump circuit.
The cooling circuit of FIG. 1 includes a heat-exchanger or vaporizer 11, a compressor 2, a condenser 3 and a pressure-reducing valve 4. It may be seen that the heat-exchanger 11 is of the type having a nest of conduits arranged in a housing. The heat-exchanger 11 is provided with an inlet pipe connection or inlet 11' and an outlet pipe connection or outlet 11". A fluid to be cooled such as, for instance, water, flows into the heat-exchanger 11 through the inlet 11'. In the heat-exchanger 11, the fluid to be cooled gives up a portion of its heat content (enthalpy) to the cooling medium present in the conduits. Thereafter, the fluid to be cooled leaves the heat-exchanger 11 via the outlet 11".
The heat transfer between the fluid to be cooled and the cooling medium causes vaporization of the latter. The cooling medium vaporized in the heat-exchanger 11 is sucked in by the compressor 2, brought to a higher pressure and temperature level and then forced into the condenser 3. In the condenser 3, the cooling medium condenses and gives up a portion of its heat content during the condensation period. This heat may be given up to a suitable heat-removing arrangement such as, for example, an underfloor heating arrangement, a ventilating system or the like, which is arranged in heat-exchange relationship with the condenser 3. Subsequently, the cooling medium flows out of the condenser 3 and through the pressure-reducing valve 4. In the later, the cooling medium is subjected to a quasi-adiabatic expansion and is thereby further cooled. By virtue of the pressure-reducing valve 4, the cooling medium achieves approximately the same temperature and pressure values which it possessed when it originally entered the heat-exchanger 11.
The introduction of the cooling medium into the heat-exchanger 11 is regulated by means of a thermostatic expansion valve 5 the opening and closing of which are effected via external pressure equalization as schematically represented by the membrane shown in FIG. 1. It may be seen that the expansion valve 5 is arranged upstream of the inlet which is provided in the heat-exchanger 11 for the cooling medium. The open and closed phases of the expansion valve 5 are controlled in dependence upon a pressostat 6 and a thermostat 7 which are arranged downstream of the outlet provided for the cooling medium in the heat-exchanger 11. It may be seen that the pressostat 6 and the thermostat 7 are connected with the membrane which serves to provide external pressure equalization. The pressostat 6 and the thermostat 7 control the expansion valve 5 in that the latter is maintained in its closed position so long as the pressostat 6 and the thermostat 7 detect cooling medium in liquid phase leaving the heat-exchanger 11. It is only when the pressostat 6 and the thermostat 7 register a totally gaseous phase for the cooling medium in the region of the outlet end provided for the latter in the heat-exchanger 11 that the thermostatic expansion valve 5 is opened with external pressure equalization and liquid cooling medium is again permitted to enter the heat-exchanger 11 for vaporization.
Referring still to FIG. 1, it may be seen that the individual conduits of the heat-exchanger 11 have been identified with the reference characters a, b, c, d and e. For the prior art heat-exchangers of the type represented by the heat-exchanger 11, it has been found in the past that the efficiency of such a heat-exchanger with respect to the cooling circuit is only so good as that of the conduit which possesses the poorest heat transfer characteristics and which, concomitantly, provides the poorest vaporization of cooling medium interiorly of the conduit nest. In the present instance, let it be assumed that the conduit a provides the best heat transfer effect. This has the result that the cooling medium entering the conduit a is already completely vaporized after having passed through only a relatively short section of the conduit a. On the other hand, let it be assumed that the conduit e provides the poorest heat transfer effect so that the cooling medium leaves this conduit in liquid phase. The conduits b, c and d are assumed to provide vaporizing effects which lie between the extreme values represented by the conduits a and e.
Considering now the consequences of the foregoing, it may be seen that the cooling medium which passes through the conduit e in liquid phase causes the pressostat 6 and the thermostat 7 to maintain the thermostatic expansion valve 5 is a closed position. In fact, the expansion valve 5 will be maintained in a closed position until such time as, by virtue of corresponding pressure and temperature conditions, the presence of exclusively cooling medium vapor at the outlet end of the heat-exchanger 11 which is provided for the cooling medium is indicated to the pressostat 6 and the thermostat 7. This leads to the result that the conduit e providing the poorest heat transfer effect determines the quantity of cooling medium which is vaporized in the heat-exchanger 11 per unit of time and, thereby, determines the efficiency of the heat-exchanger 11 as well as of the overall cooling circuit.
In contrast, the schematically illustrated heat-exchanger 1 according to the invention shown in FIG. 2 provides a completely uniform vaporizing effect in its conduits f-o. The heat-exchanger 1 is provided with an inlet conduit 1 IV for the introduction of a cooling medium into the conduits f-o and is also provided with an outlet conduit 1 V for the withdrawal of the cooling medium from the conduits f-o. The heat-exchanger 1 further includes a housing 1'" in which the conduits f-o are arranged. The housing 1'" is provided with an inlet pipe connection or inlet 1' for the introduction therein of a fluid to be cooled and is further provided with an outlet pipe connection or outlet 1" for the withdrawal of the fluid.
The fluid to be cooled enters the housing 1'" via the inlet 1' and, through the conduits f-o, gives up a portion of its content to the cooling medium. Thereafter, the fluid leaves the housing 1'" via the outlet 1". Meanwhile, the cooling medium enters the heat-exchanger 1 through the inlet 1 IV in predominantly liquid phase. The cooling medium is completely converted into the vapor phase along the stretch or section identified by V s . In a subsequent super-heating stretch or section identified by U s , the cooling medium is slightly super-heated with respect to its vaporization temperature. Thereafter, the cooling medium leaves the heat-exchanger 1 via the outlet 1 V and is sucked in by a compressor such as the compressor 2 of FIG. 1.
Due to the fact that, in accordance with the invention, the tendency of the cooling medium to pass through the conduits in liquid phase may be eliminated, it is possible to shorten the vaporizing conduits f-o according to the invention by about one-half as opposed to the vaporizing conduits of the prior-art constructions. Consequently, the pressure drop of the cooling fluid when it passes through the heat-exchanger 1 in accordance with the invention may also be decreased as opposed to the pressure drops observed in the prior-art constructions. As a result, for otherwise identical conditions, a higher pressure than in the prior art exists at the suction intake of the compressor in accordance with the invention. According to the laws governing gas compressors, this higher pressure has the effect of increasing the conveying capacity of the compressor. This, in turn, leads to an increase in cooling capacity. For a pressure increase of 0.1 atmospheres at the compressor inlet, an increase in cooling capacity of about 4 to 5% may be achieved.
Referring now to FIGS. 3-6, it is pointed out that these illustrate a practical embodiment of the invention. Where appropriate, the same reference characters as in FIG. 2 have been used in FIGS. 3-6.
The heat-exchanger 1 of FIGS. 3-6 is provided with tube plates or support member 9 for supporting the conduits (such as the conduits f-o of FIG. 2) of the conduit nest. As best illustrated in FIG. 5, the tube plates 9 are arranged in the regions of the respective longitudinal ends of the conduit nest. The conduits are connected with the tube plates 9 and this may be accomplished in known manner such as, for instance, by expanding the conduits into the tube plates 9 or by welding or soldering the conduits to the tube plates 9.
The heat-exchanger 1 is further provided with caps 8 and 8' one of which is arranged in the region of each of the longitudinal ends of the conduit nest. The caps 8 and 8' are welded to the respective tube plates 9. In the interior of the housing 1'" of the heat-exchanger 1, there are provided baffles 10 and 10' for regulating the flow pattern of a fluid to be cooled. The arrangement of the baffles 10 and 10' is particularly evident from FIGS. 5 and 6.
As is most readily apparent from FIG. 6, the housing 1'" has a rectangular cross-sectional configuration. It may also be seen that the minimum distance of separation of the conduits from one another, as well as the distance between the inner wall of the housing 1'" and the conduits adjacent thereto, is constant. In other words, the distance of separation between conduits is the same for all most closely adjacent pairs of conduits whereas the distance between the inner wall of the housing 1'" and the conduits most closely adjacent thereto equals the minimum distance of separation of the conduits from one another. The minimum distance of separation of the conduits from one another and, concomitantly, the distance between the inner wall of the housing 1'" and the conduits most closely adjacent thereto, is also referred to here as the grid spacing r which is indicated in FIG. 6.
According to an advantageous embodiment of the invention, the grid spacing r is 10 millimeters. Here, the conduits, which are favorably composed of corrosion-resistant or stainless steel, have outer diameters of 8 millimeters, wall thicknesses of 0.5 millimeter and lengths of 1250 millimeters. Although a heat-exchanger designed in this manner is of compact construction, it is nevertheless surprisingly possible to achieve a heat transfer capacity per unit area of 25,000 to 30,000 kilocalories per square meter per hour.
Although certain principles of the invention have been detailed to this point, there is, however, another important factor in the solution of the prior-art problems in accordance with the invention. This resides in the arrangement of the baffles 10 and 10'. The baffles 10 and 10' are arranged in such a manner that, intermediate two adjacent baffles, e.g. intermediate the baffle 10' shown in FIGS. 3 and 6 and the baffle 10 immediately to the right or the left thereof shown in FIG. 3, as well as intermediate the terminal baffles 10 and the respective tube plates 9, the ratio of the projected free flow cross-sectional areas F p and F s of the fluid to be cooled parallel and perpendicular to the conduits, respectively, is approximately 1:1. The shading in FIG. 6 indicates what is to be understood here by the projected free flow cross-sectional areas F s and F p .
The ratio of approximately 1:1 between the areas F s and F p has the result that the flow velocity V km of the fluid to be cooled is completely constant from the inlet 1' to the outlet 1" of the heat-exchanger 1 as is indicated by appropriate curved arrows in FIG. 3. The rectangular cross-sectional configuration of the housing 1'", as well as the constant grid spacing r of the conduits from one another and from the inner wall of the housing 1'", have the additional effect of providing for a completely uniform impingement of the conduits by the fluid to be cooled. Consequently, a completely uniform heat transfer from the fluid to be cooled to the cooling medium to be vaporized occurs, and as a result, a highly effective and uniform vaporizing effect is achieved. When the fluid to be cooled was water, the flow velocity was of the order of 1-1.2 meters per second and a super-heating stretch U s (see FIG. 2) of 5 to 10% of the total length L of the conduit nest resulted (see FIG. 2).
It may be pointed out here that, in accordance with the invention, the conduits and the housing 1'" are advantageously composed of copper or corrosion-resistant steel.
It will be self-understood that the principles of the invention may also be extended to other conduit dimensions when the rectangular cross-sectional configuration of the housing 1'" and a constant grid spacing r for the conduits are maintained, and when, in dependence upon the aforementioned dimensions, the baffles 10 and 10' are so arranged interiorly of the housing 1'" that, in the region between two adjacent baffles 10 and 10', as well as in the region between a terminal baffle 10 and 10' and the respective tube plate 9, the ratio of the projected free flow cross-sectional areas F p and F s of the fluid to be cooled parallel and perpendicular to the conduits is approximately 1:1. It is further pointed out that, in view of the increase in volume of the cooling medium during vaporization of the same, it is possible to connect the conduits in a progressive and uniform manner instead of providing an arrangement such as illustrated for the embodiment of FIGS. 3-6. In other words, it is possible to connect the conduits so that the cooling medium flows progressively and uniformly from one conduit to another. This may be accomplished in known manner by providing suitable baffle members at the longitudinal ends of the conduit nest.
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 constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a heat-exchanger for cooling circuits, 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 heat-exchange arrangement includes a housing which has an inner surface defining a first flow path for a fluid to undergo heat-exchange. The inner surface of the housing comprises a pair of substantially parallel surface portions which bound the first flow path along the flow direction so that the first flow path is of substantially constant width along the flow direction. A plurality of spaced conduits is arranged in the first flow path and defines a series of second flow paths for a medium to undergo heat-exchange with a fluid flowing in the first flow path. The conduits are arranged such that substantially the same predetermined minimum distance separates the most closely spaced ones of the conduits. A plurality of baffles in the first flow path serves to regulate the flow pattern of a fluid flowing in the first flow path. The baffles are arranged in such a manner that, in the region between two adjacent ones of the baffles, the projected free flow cross-section of the first flow path as determined in a plane substantially paralleling the conduits is substantially equal to the projected free flow cross-section of the first flow path as determined in a plane substantially normal to the conduits. The arrangement outlined permits a more uniform heat-exchange than was possible heretofore to be achieved. In particular, the arrangement makes it possible to insure that the heat-exchange effect for any one of the conduits is approximately the same as for any other conduit. | 5 |
RELATED APPLICATIONS
This application is a continuation-in-part application of my application Ser. No. 649,530 filed Jan. 15, 1976 for Pressure Relief Device now abandoned.
PROBLEM AND PRIOR ART
Storage elevators and silos, e.g., for grain and various other granular like materials, comprise relatively large structures, frequently having diameters of ten, twenty or more feet and often being a hundred or more feet high. As a result when such grain or storage elevators are filled, the contents thereof exert a considerable lateral pressure on the walls of such elevators. Generally, the lateral pressure exerted on the walls of the elevator is a static pressure. However, when the discharge opening of the elevator is opened, and the material therein begins to flow during a discharging operation, it has been observed that the lateral pressures exerted on the walls of the elevator are substantially increased. The considerable increase in lateral pressure on the walls of the elevator has been attributed to the dynamic pressure of the material flow during a discharging operation. Such dynamic pressure increase was greatest in the upper and intermediate areas of the storage elevator and which decreases only toward the bottom of the elevator.
Heretofore, to compensate for such increase in pressure acting on the walls of a storage elevator or silo, the walls of the silo were reinforced in order to withstand such pressure. However, because of the considerable size of such silo or storage elevator, the cost of reinforcing such walls presented considerable design problems and initial high costs. Unless the walls of such elevators were properly designed to withstand the increased dynamic pressure imparted on such walls, the upper walls of the elevator would tend to fail within a given limited time frame, then would otherwise occur, if not for the dynamic pressure action thereon.
OBJECTS
It is therefore an object of this invention to provide a storage elevator or silo with a pressure relief device which will substantially minimize the dynamic pressure build-up on the walls of the elevator during a discharging operation.
Another object is to provide a pressure relief device which by relieving the dynamic pressure acting on the walls of the elevator, the flow of material through the discharge opening is enhanced during a material discharging operation.
Another object is to provide a pressure relief device for a storage elevator which is relatively simple and positive in operation.
BRIEF SUMMARY OF THE INVENTION
The foregoing objects and other features and advantages are obtained by a storage elevator or silo, e.g., a grain elevator having longitudinally disposed therein a pressure relief device in the form of a screw which has a blade diameter which is relatively small in comparison to the cross-sectional diameter of the storage elevator. The screw is vertically disposed and of rigid construction, whereby the pitch, diameter and blade shape may be of uniform or variable in configuration along the longitudinal axis of the screw. The screw could be extended for the entire length of the storage elevator or for a portion of the elevator height. Also, the screw may be fixed or may be rotatably mounted within the elevator or silo.
FEATURES
A feature of this invention resides in the provision of an elongated screw disposed within the storage elevator in spaced relationship to the circumscribing walls of the elevator which functions to minimize the lateral build-up of pressure on the walls of the elevator during a discharging operation.
Another feature resides in the provision whereby the screw can be either fixed or mounted for rotation within the storage elevator.
Another feature resides in the provision whereby the screw further facilitates the discharge of the material from the elevator.
Another feature resides in the provision whereby the incorporation of the screw pressure relief device results in the provision that the walls reinforcements heretofore required to withstand the increase lateral forces resulting from the dynamic pressures can be minimized.
Other features will become more readily apparent when considered in view of the drawings and specification wherein:
FIG. 1 illustrates a cross-section view of a storage elevator or silo embodying the present invention.
FIG. 1A is a section view taken along line lA--1A on FIG. 1.
FIG. 2 is a fragmentary showing of a modified embodiment.
FIG. 3 is a fragmentary showing of another modified embodiment
FIG. 4 is a sectional view of another modified form of the invention.
DETAILED DESCRIPTION
Referring to the drawings there is shown in FIG. 1 a storage elevator or silo 10 embodying the present invention. It comprises a building structure having a diameter which may be as large as ten, twenty or more feet, and having a height of fifty, sixty or more feet. Frequently, the height of such storage elevators may exceed one hundred or more feet. Such elevators generally have upwardly extending circumscribing side walls 11 which converge into a hopper like section 12 adjacent the bottom end of the elevator 10. The hopper section 12 generally terminates at a discharge opening 13 which is suitably controlled by a closure 14. The dotted line showing illustrates the closure in the opened position.
In accordance with this invention there is disposed within the bin portion 16 of the elevator a pressure relief device 17. The pressure relief device 17 comprises an elongated central axle 18 to which there is connected a helical screw blade 19. The diameter of the screw blade 19 is substantially smaller than the cross-section or diameter of the bin portion 16. In the embodiment of FIG. 1, the axle or axis 18 of the pressure relief device is rigidly fixed. Thus the screw is not free to turn. It will be understood that the pitch, diameter and shape of the blade portion 19 may vary depending upon the nature or properties of the stored material, the dimensions of the elevator, the magnitude of the lateral pressures and the required discharge rate. In the illustrated embodiment, the axis of the pressure relief device is disposed in alignment with the discharge opening 13. As shown, the axle 18 is fixed between an upper and lower supports; the lower support being secured by a brace or spider 26.
In operation, with the elevator 10 filled with granular material, e.g., grain, and with the opening 13 closed, the weight of the grain exerts a lateral static pressure on the walls 11 of the elevator.
Referring to FIG. 1, the solid line showing M 1 illustrates the lay of the material M when the opening 13 is normally closed. Upon the opening of the discharge opening, the central movement of the material, which tends to follow the curvature of the screw blades, causes the material to be removed from the central or internal portion of the mass which will cave the material M inwardly as indicated at M 2 , which occurs along the entire length of the screw, thereby relieving the walls of any dynamic pressure build-up which would otherwise normally occur.
By relieving the lateral forces by minimizing the dynamic pressures on material discharge, the need for reinforcing the elevator walls 11 can be greatly reduced.
FIG. 2 illustrates a fragmentary portion of a storage elevator 19A in which the pressure relief device 18A is rotatably journalled in a suitable end bearing 20 for rotation. In the illustrated form, the screw 18A is mounted to idle, i.e., to rotate under the influence of the falling material adjacent the screw 18A when the discharge opening is opened. In all other respects the structure of FIG. 2 is similar to that hereinbefore described.
FIG. 3 illustrates another embodiment. In this arrangement, the screw 18C is rotatably mounted as described in FIG. 2, but differs therefrom in that the screw 18C is positively driven by a suitable power source, e.g., motor 22. The actuation of the motor 22 is timed to the opening of the discharge opening, so that the screw 18C rotates only when the discharge opening of the storage elevator 10C is opened. A means may be provided to control the speed of the screw 18C relative to the material resistance acting on the screw and rate of flow. This is attained by providing a suitable automatic speed controller 24 and sensing device 24a connected in circuit with the motor that will function to speed up or slow down the motor according to the resistance forces imposed on the screw and rate of flow during a discharging operation.
FIG. 4 illustrates another modified embodiment. In this form of the invention, the storage elevator 25 is provided with a pressure relief screw 18D which has a central axle 27 having a helical screw blade 28 in which the shape and pitch of the blades varies along the length of the axle 27. In all other respects the invention of FIG. 4 is similar to that hereinbefore described. It will be understood that the pressure relief screw 18D may be fixed, as herein described, or mounted for rotation to either idle or to be positively driven as described with respect to FIGS. 2 and 3.
In each of the described embodiments, the dynamic pressure build up on the elevator walls is substantially reduced. Also, the rate of discharge is enhanced since the dynamic pressure is relieved.
While the invention has been described with respect to several embodiments thereof, it will be appreciated and understood that variations and modifications may be made without departing from the spirit or scope of the invention. | A pressure relief device for use in a storage elevator for reducing the dynamic pressure imposed on the walls of a storage elevator during a discharging operation which includes a screw which extends longitudinally along the interior of the storage elevator and in spaced relationship to the vertically extending side walls of the elevator. The screw may be fixed or rotatably mounted. | 1 |
BACKGROUND
The present disclosure relates, in general, to a seal assembly and method and, more particularly, to a segmented labyrinth seal assembly and method for sealing against the leakage of fluid.
Segmented labyrinth seal assemblies are often used to seal against the leakage of fluid in applications involving a rotating shaft that penetrates a fixed casing such as in turbo machine, centrifugal compressor, and the like. These type of seal assemblies usually include a series of arcuate labyrinth segments disposed in an end-to-end relationship and together extending around the rotating shaft with minimal clearance. The segments are adapted to expand during light loads or sudden loss of load to minimize rubbing damage caused by misalignment, vibration and thermal distortion.
However, these assemblies are often difficult to assemble, do not necessarily provide uniform loading on all segments, and are difficult or impossible to adjust.
Therefore, what is needed is a segmented seal assembly of the above type that is relatively easy to assembly, provides uniform loading on all segments of the assembly and can easily be adjusted.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial elevation-partial sectional view of a segmented labyrinth seal assembly according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view taken along the line 2 — 2 of FIG. 1 .
FIG. 3 is a partial cross-sectional view, depicting a component of the seal assembly of FIGS. 1 and 2.
FIG. 4 is a view, similar to FIG. 3 but depicting an alternate embodiment of the component of FIG. 3 .
DETAILED DESCRIPTION
An embodiment of the present invention is shown in FIG. 1 in connection with a shaft 10 forming a portion of a turbo machine, centrifugal compressor, or the like. An annular labyrinth seal assembly 12 extends around the shaft to seal against the leakage of fluid in an axial direction along the shaft from a high pressure area to a low pressure of the turbo machine. The seal assembly 12 consists of four arcuate segments 14 , 16 , 18 and 20 disposed in an end-to-end relationship with each segment extending for approximately ninety degrees to form a ring. A portion of the outer surfaces of the segments 14 , 16 , 18 , and 20 are machined to form flat surface portions 14 a , 16 a , 18 a , and 20 a , midway between the respective ends of each segment.
A spring-loaded assembly 24 is mounted in one end portion of the segment 14 and engages the corresponding end of the segment 20 ; a spring-loaded assembly 26 is mounted in one end portion of the segment 16 and engages the corresponding end of the segment 14 ; a spring-loaded assembly 28 is mounted in one end portion of the segment 18 and engages the corresponding end of the segment 16 ; and a spring-loaded assembly 30 is mounted in one end portion of the segment 20 and engages the corresponding end of the segment 18 . The assemblies 24 , 26 , 28 , and 30 will be described in detail later.
With reference to FIG. 2, the seal assembly 12 is mounted in a casing 32 , and although shown partially, it is understood that the casing extends completely around the shaft 10 and supports it for rotation in a conventional manner. The casing 32 has an internal cylindrical bore 32 a which receives the shaft 10 , and an inner annular cavity, or enlarged groove, 32 b formed in the inner surface portion of the casing that defines the bore 32 1 , for receiving the seal assembly 12 . Although FIG. 2 depicts only the seal assembly segment 18 extending in the cavity 32 b , it is understood that the other segments 14 , 16 , and 20 also extend in other portions of the cavity.
The outer surface of the shaft 10 is radially spaced from the corresponding inner surface of the casing 32 to form an annular chamber 34 . The segment 18 has an annular inside labyrinth surface 18 b extending through a corresponding portion of the chamber 34 and into a sealing engagement with the outer surface of the shaft 10 . The labyrinth surface 18 b thus divides the chamber 34 into a relatively high pressure portion 34 a located upstream of the labyrinth surface 18 b and a relatively low pressure portion 34 b located downstream of the labyrinth surface. In the event the casing 32 forms part of a turbo machine or a compressor, the high pressure chamber portion 34 typically would be in pressure communication with the high pressure discharge gas from the impeller (not shown) of the turbo machine or compressor.
The inner surface of the segment 18 is spaced from the inner wall of the cavity 32 a to form a annular space, and a passage 36 connects the space with the chamber portion 34 a . Thus, the relatively high pressure in the chamber portion 34 a is transmitted to the latter space so that as the pressure increases, the segment 18 , and therefore its labyrinth surface 18 b , is forced into sealing engagement with the outer surface of the shaft 10 . This establishes a seal against the movement of the high pressure gas in an axial direction along the shaft 10 from the chamber portion 34 a to the chamber portion 34 b.
It is understood that the other segments 14 , 16 , and 20 of the seal assembly are identical to the segment 18 , extend in the cavity 32 a of the casing in the same manner, and, together with the segment 18 , surround the entire outer surface of the shaft 10 . Also, each of the other segments 14 , 16 , and 20 has a labyrinth surface that also sealing engages the outer surface of the shaft 10 in the same manner as described above.
Since the specific arrangement of the segments 14 , 16 , 18 and 20 , the labyrinth surface 18 b and the corresponding labyrinth surfaces of the segments 14 , 16 , and 20 , as well as their engagement with the shaft 10 , do not, per se, form a part of any embodiment of the present invention, they will not be described in any further detail. However, they are fully disclosed in U.S. Pat. No. 5,403,019, assigned to the present assignee, and the disclosure of this patent is incorporated by reference.
Although the casing 32 is not shown in FIG. 1 for the convenience of presentation, it is provided with two stops 38 a and 38 b in its upper half, which are shown in FIG. 1 . The labyrinth segments 14 , 16 , 18 , and 20 slide into the cavity 32 a of the casing 30 and are retained by the stops 38 a and 38 b extending in corresponding grooves formed in the end portions of the segments 14 and 20 .
Referring to FIGS. 1 and 3, a through bore 20 b is formed through the segment 20 and extends from an outer surface of the segment to the end thereof adjacent the corresponding end of the segment 18 . The spring-loaded assembly 30 is located in the bore 20 b and includes a spring 40 extending in the bore between a spring plate 42 and a ball 44 . A portion of the ball 44 extends outwardly from the bore 20 b under the force of the spring 40 , and the remaining portion of the ball rides in a retainer sleeve 46 disposed in the end portion of the bore. The spring 40 thus urges the ball 44 outwardly from the bore 20 b against the corresponding end of the adjacent segment 18 .
A portion of the bore 20 b extending from the surface of the segment 20 is of a smaller diameter than the remaining portion of the bore to form a shoulder for receiving the spring plate 42 . The smaller-diameter portion of the bore 20 b is internally threaded, and an externally threaded set-screw 48 is in threaded engagement with this bore portion. Thus, rotation of the set-screw 48 causes corresponding axial movement of same in the bore 28 b and thus adjusts the compression on the spring 40 , and therefore the force applied by the spring to the ball 44 . This creates an adjustable separation force between the end of the segment 20 and the corresponding end of the segment 18 .
The connection assemblies 24 , 26 and 28 are identical to the assembly 30 and are mounted in the seal assembly segments 14 , 16 , and 18 , respectively, in an identical manner.
In operation, the set-screw 48 is adjusted to apply a predetermined separation force between the segments 18 and 20 as discussed above, and the set-screws associated with the segments 14 , 16 , and 20 are adjusted in the same manner. Thus, the segments 14 , 16 , 18 , and 20 are spring loaded into a slightly expanded position, with the corresponding ends of adjacent segments being in a slightly spaced condition, as shown in FIG. 1 . As the pressure in the chamber portion 34 a pressure increases, the labyrinth surface 18 a of the segment 18 , as well as the labyrinth surfaces of the segments 14 , 16 , and 20 will be forced into a sealing engagement with the shaft 10 as described above.
The seal assembly 10 has several advantages. For example, it is relatively easy to assemble, provides uniform loading on all segments of the assembly and can easily be adjusted. Also, the flat surface portions 14 a , 16 a , 18 a , and 20 a make the segments 14 , 16 , 18 , and 20 , respectively, more stable when retracted and ensures that the upstream pressurized steam gets into the cavity 32 a and into the annular space between the inner wall of the cavity and the corresponding outer surface of each segment 14 , 16 , 18 , and 20 .
According to the embodiment of FIG. 4 the ball 44 of the previous embodiment is replaced by a solid cylindrical plunger 50 . Since the remaining components of the embodiment of FIG. 4 are identical to the embodiment of FIGS. 1-3, they are referred to by the same reference numerals.
An annular flange 50 is formed on the plunger near one end thereof which receives the corresponding end of the spring 40 . A portion of the plunger 50 extends outwardly from the bore 20 b under the force of the spring 40 , and the spring extends around another portion of the plunger in the bore 20 b . The spring 40 thus urges the plunger 50 outwardly from the bore 20 b against the corresponding end of the adjacent segment 18 . It is understood that a plunger, identical to the plunger 50 , are provided on the connection assemblies 24 , 26 and 28 and function in an identical manner. The embodiment of FIG. 4 thus enjoys all of the advantages of the embodiment of FIGS. 1-3.
It is understood that several variations may be made in the foregoing without departing from the scope of the invention. For example, number of segments forming the ring around the shaft can vary within the scope of the invention. Also, the spatial references, such as “above”, etc. is for the purpose of example only, are not intended to limit the structure disclosed to a particular orientation. Moreover, the embodiment described above is not limited to turbo machines or compressors, but is equally applicable to other equipment requiring a seal.
Other modifications, changes and substitutions are intended in the foregoing disclosure and in some instances some features of the disclosure will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure. | A segmented labyrinth seal assembly and method according to which a plurality of arcuate segments extend around a rotating shaft with the shaft being engaged by a sealing portion of each segment, thus sealing against the movement of fluid in an axial direction along the shaft. An engagement member extends from one end of at least one segment and is adapted to engage the corresponding end of the adjacent segment. The engagement member is urged in a direction towards the corresponding end to apply a separation force between the ends, and the separation force is adjustable. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Application Ser. No. 60/990,341 entitled “FLOATING CONNECTOR FOR MICROWAVE SURGICAL DEVICES” filed Nov. 27, 2007 by Gene H. Arts et al which is incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to microwave surgical devices used in tissue ablation procedures. More particularly, the present disclosure is directed to a floating connector assembly for coupling a microwave ablation antenna to a microwave generator.
[0004] 2. Background of Related Art
[0005] Microwave ablation of biological tissue is a well-known surgical technique used routinely in the treatment of certain diseases which require destruction of malignant tumors or other necrotic lesions. Typically, microwave surgical apparatus used for ablation procedures includes a microwave generator which functions as a source of surgical radiofrequency energy, and a microwave surgical instrument having a microwave antenna for directing the radiofrequency energy to the operative site. Additionally, the instrument and generator are operatively coupled by a cable having a plurality of conductors for transmitting the microwave energy from the generator to the instrument, and for communicating control, feedback and identification signals between the instrument and the generator. The cable assembly may also include one or more conduits for transferring fluids.
[0006] Commonly, the microwave instrument and the cable are integrated into a single unit wherein the cable extends from the proximal end of the instrument and terminates at a multi-contact plug connector, which mates with a corresponding receptacle connector at the generator. Separate contact configurations are typically included within the multi-contact connector to accommodate the different electrical properties of microwave and non-microwave signals. Specifically, coaxial contacts are used to couple the microwave signal, while non-coaxial contacts in a circular or other arrangement are used to couple the remaining signals and/or fluids. Suitable coaxial and non-coaxial connectors are commercially available “off the shelf” that can be used side-by-side within a single housing in the construction of a cost-effective multi-contact connector for microwave ablation systems.
[0007] The use of two disparate connectors within a single housing may have drawbacks. Specifically, the coaxial and non-coaxial connectors assembled within the cable-end plug must be precisely aligned with their mating connectors on the microwave generator receptacle to avoid interference or binding when coupling or uncoupling the connectors. The need for such precise alignment dictates the connectors be manufactured to very high tolerances, which, in turn, increases manufacturing costs and reduces production yields. This is particularly undesirable with respect to the microwave surgical instrument, which is typically discarded after a single use and thus subject to price pressure.
SUMMARY
[0008] The present disclosure provides a floating connector apparatus having at least two connectors, such as a coaxial and a non-coaxial connector, within a single supporting housing. At least one of the connectors is floatably mounted to the housing. By using a floating rather than a rigid mounting, the floating connector is afforded a range of movement sufficient to compensate for spacing variations between and among the corresponding mating connectors. In this manner, commonly-available connectors can be used in a single supporting housing without requiring exacting manufacturing tolerances and the associated costs thereof.
[0009] In one embodiment, a plug (i.e., male) housing and a corresponding mating receptacle (i.e., female) housing are provided. The male housing includes a fixedly inputted male coaxial connector, such as a QN connector, that is mounted in spaced relation relative to a fixedly mounted male circular connector, such as an Odu™ Medi-Snap™ connector. The counterpart female housing includes a female coaxial connector that is fixedly mounted to the receptacle housing in spaced relation relative to a female circular connector that is floatably mounted to the receptacle housing. The floating female circular connector has at least one degree of freedom of movement, for example, the floatably mounted connector can move along the X-axis (i.e. left-right); the Y-axis (up-down); the Z-axis (in-out); or it can rotate, pitch, or yaw about the longitudinal axis of the circular connector, or any combination thereof. A positive stop can be included for limiting inward movement of the floating connector along its Z-axis to enable sufficient coupling force to be generated when mating the connectors. When the plug and receptacle are coupled, the floatably mounted connector is able to adjust to spacing and angular variations between it and the fixed connectors. This eliminates binding and interference among the connectors, establishes and maintains electrical continuity, provides tactile feedback to the user, and permits multiple connectors to be included within a single housing without the expense of precision manufacturing and high production tolerances.
[0010] According to another embodiment, the floating connector is mounted to a plate-like mounting assembly that includes a stationary rim concentrically disposed around a suspended inner member. The stationary rim is rigidly coupled to, or is integral to, the receptacle housing. The connector is rigidly coupled to the suspended inner member. The stationary rim and suspended inner member are resiliently coupled along the substantially annular interstice between the rim and the member. It is contemplated the interstitial edges of the stationary rim and suspended inner member can abut or overlap. The resilient coupling can include one or more elastomeric materials or springs as further described herein. In an embodiment, the resilient coupling can be a captured o-ring. The floating connector may include a floating member having a connector fixedly disposed therethrough, the connector including a mating end adapted to couple to a mating connector and a mounting end which mounts to the floating member. The floating connector may further include a support member having an opening defined therein, the opening including an internal dimension greater than the mounting end of the connector to define a clearance between the opening and the mounting end of the connector, the floating member and the connector being positioned in substantial concentric alignment with the opening. The floating connector also includes an elastomeric coupling fixedly disposed between the floating member and the support member.
[0011] According to a further embodiment of the present disclosure, the floating connector assembly may include a resilient spring mounting plate, which further includes an outer stationary rim and suspended inner member that are coupled by at least one thin resilient beam. The beam is attached at one end to the stationary rim and at the other end to the suspended inner member. The rim, the member and the resilient beams can be a single piece formed by, for example, stamping, injection molding, laser cutting, water jet machining, chemical machining, blanking, fine blanking, compression molding, or extrusion with secondary machining. The spring plate can include at least one slot defining a floating region concentrically disposed within a fixed region, the slots further defining the spring beam. The spring beam couples the floating region and the fixed region. The spring plate further includes a connector fixedly disposed therethrough. The connector includes a mating end adapted to couple to a mating connector and a mounting end which mounts to the floating region of the spring plate.
[0012] The mounting assembly may include a support member having an opening defined therein, the opening including an internal dimension greater than the mounting end of the connector to define a clearance between the opening and the mounting end of the connector, the spring plate and the connector being positioned in substantial concentric alignment with the opening. The floating connector includes a collar for securing the spring plate to the support member, the collar further including an aperture defined therein having an internal dimension greater than the mating end of the connector to define a second clearance between the aperture and the mating end of the connector, and at least one coupling device which attaches the collar and the spring plate to the support member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which:
[0014] FIG. 1 is an oblique view of an embodiment of a floating connector in accordance with the present disclosure;
[0015] FIG. 2 is an exploded view of an embodiment of the floating connector of FIG. 1 having a resilient mounting plate, circular connector, and coaxial connector;
[0016] FIG. 3 is an enlarged view of the resilient spring mounting plate of FIG. 2 ;
[0017] FIG. 4 is an enlarged view of a circular connector mounted atop the resilient spring mounting plate of FIG. 3 ;
[0018] FIG. 5A is a side cross sectional view of one embodiment of the floating connector in accordance with the present disclosure;
[0019] FIG. 5B is a top view of one embodiment of the floating connector in accordance with the present disclosure;
[0020] FIG. 6A is a side cross sectional view of another embodiment of the floating connector in accordance with the present disclosure showing a floating member resiliently coupled to a support member in a substantially overlapping configuration;
[0021] FIG. 6B is a top view of the embodiment of the floating connector shown in FIG. 6A in accordance with the present disclosure;
[0022] FIG. 7A is a side view of still another embodiment of the floating connector in accordance with the present disclosure showing a floating member resiliently coupled to a support member and configured to limit movement to a single axis of motion;
[0023] FIG. 7B is a top view of the embodiment of the floating connector shown in FIG. 7A in accordance with the present disclosure;
[0024] FIG. 8A is a side view of yet another embodiment of the floating connector in accordance with the present disclosure showing a floating member and support member in a substantially abutting configuration having a positive stop member;
[0025] FIG. 8B is a top view of the embodiment of the floating connector shown in FIG. 8A in accordance with the present disclosure;
[0026] FIG. 8C is a bottom view of the embodiment of the floating connector shown in FIG. 8A in accordance with the present disclosure;
[0027] FIG. 9 is a side view of still another embodiment of the floating connector in accordance with the present disclosure showing a floating member resiliently coupled to a support member by a captured o-ring, and having a positive stop member; and
[0028] FIGS. 10A-10C are side views illustrating the coupling and uncoupling of the floating connector with a connector assembly.
DETAILED DESCRIPTION
[0029] Particular embodiments of the present disclosure will be described herein with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure with unnecessary detail. References to connector gender presented herein are for illustrative purposes only, and embodiments are envisioned wherein the various components described can be any of male, female, hermaphroditic, or sexless gender. Likewise, references to circular and coaxial connectors are illustrative in nature, and other connector types, shapes and configurations are contemplated within the present disclosure.
[0030] Referring to FIG. 1 , there is disclosed a floating connector assembly 100 that includes support member 110 having an outer surface 111 and an inner surface 112 . Support member 110 further includes a coaxial connector 160 fixedly mounted thereto in spaced relation relative to floating connector 120 . Floating connector 120 is fixedly mounted to support member 110 by a coupling device 150 , as will be described in detail below. Coaxial connector 160 may be mounted to support member 110 by any suitable means such as by a nut or a clip (not shown) as is well-known in the art. The spaced relationship of floating connector 120 to coaxial connector 160 substantially mirrors the spaced relationship of a corresponding mating connector assembly 790 , shown by example in FIGS. 10A-C , wherein male circular connector 780 is configured to matingly engage female circular connector 740 and coaxial connector 785 is configured to matingly engage coaxial connector 760 .
[0031] With reference to FIG. 2 , floating connector 120 includes a collar 130 and a female circular connector 140 which is configured to floatably mount within floating connector 120 as will be further described herein. Female circular connector 140 can be of a keyed type such as an Odu™ or LEMO™ connector as will be familiar to the skilled artisan. Support member 110 and collar 130 further include openings 115 and 135 , defined therein respectively, dimensioned to permit floating movement of and accommodate electrical and/or fluidic connections to, female circular connector 140 .
[0032] Floating connector 120 further includes a spring plate 200 having an arrangement of slots 250 , 250 ′, 270 , 270 ′ defined thereon which, in turn, are arranged to define a fixed region 210 and a floating region 220 having spring beams 280 disposed therebetween (see FIG. 3 ). Spring plate 200 can be constructed of any material having spring-like properties, such a spring steel or a resilient polymer, and can be formed by any suitable means, such as stamping, injection molding, laser machining, water jet machining, or chemical machining. A recess 114 is disposed upon outer surface 111 and located around the perimeter of opening 115 , and is dimensioned to provide floating movement of spring plate 200 sufficient to enable proper coupling of connector 140 with a mating connector. As can be readily appreciated, recess 114 also prevents excessive inward movement of spring plate 200 to enable sufficient mating forces to be generated during coupling, and also to prevent exceeding the elastic limits of spring plate 200 .
[0033] As best seen in FIG. 3 , floating region 220 further includes a centrally disposed mounting hole 260 defined therein dimensioned to receive a mounting boss 142 of female circular connector 140 . In one embodiment, mounting hole 260 is substantially circular and includes opposing flat areas 265 dimensioned to accept mounting boss 142 having corresponding opposing flat areas (not shown) to inhibit unintended rotation of female circular connector 140 within mounting hole 260 , as is well-known in the art. Female circular connector 140 can be retained to spring plate 200 by a nut 145 , as shown in FIGS. 5A and 5B , or may be retained by any suitable means such as integral clip, external clip, or adhesive. Slots 250 , 250 ′ further describe stops 240 , 240 ′ for limiting the range of motion of floating member 220 along the X-axis, the Y-axis, the Z-axis, and/or rotationally about the Z-axis (i.e. longitudinal axis) of female circular connector 140 .
[0034] With reference now to FIGS. 4 , 5 A, and 5 B, female circular connector 140 of spring plate 200 is sandwiched between collar 130 and support member 110 in substantial coaxial alignment with opening 115 and opening 135 . Collar 130 and spring plate 200 are affixed to support member 110 by a coupling devices 150 which can be threaded fasteners, rivets, adhesive, bonding, or other suitable coupling devices. By this configuration, spring beams 280 and/or the overall resilient properties of spring plate 200 afford circular connector 140 a range of movement within openings 115 and 135 and recess 114 , for example, along the X-axis (left-right), the Y-axis (up-down), the Z-axis (in-out), and/or rotationally about the Z-axis (roll).
[0035] By way of example, FIGS. 10A-10C show a schematic illustration of the coupling and uncoupling of the connector assembly with floating connector assembly 700 . In particular, FIG. 10A shows male circular connector 780 poised to mate with female circular connector 740 , wherein the longitudinal axis of male circular connector 780 is misaligned by an illustrative angle 750 with respect to longitudinal axis Z of circular connector 740 . In FIG. 10B , as the connector assemblies are joined, coaxial connectors 785 and 760 , which are fixed to their respective support members, couple normally, while male circular connector 780 , which is imprecisely aligned with circular connector 740 , causes spring beams 720 (see FIG. 3 ) and/or spring plate 710 to deflect in response to the coupling forces applied by male circular connector 780 to circular connector 740 . This permits female circular connector 740 to move into substantial alignment with male circular connector 780 as the connectors are brought into a fully-coupled state. In this manner, the desired coupling of two connectors 740 and 780 , which were originally misaligned, is achieved without the interference or binding which would normally be encountered with such initial misalignment and/or imprecise alignment. Turning now to FIG. 10C , as the connector assemblies are decoupled, male circular connector 780 parts from circular connector 740 , enabling spring beams 720 and/or the overall resilient properties of spring plate 710 to bias circular connector 740 back to its original position, i.e., into substantially orthogonal alignment with support member 705 .
[0036] Other embodiments contemplated by the present disclosure are shown with reference to FIG. 6A-FIG . 9 . FIGS. 6A and 6B show one embodiment of a floating connector having a floating assembly 305 which includes a female circular connector 340 that is fixedly mounted to a floating member 300 though an opening 302 provided therein. The opening 302 is dimensioned to accept a mounting boss 342 of circular connector 340 as previously described herein. Floating member 300 is concentrically aligned with an opening 315 defined in a support member 310 , and is further dimensioned to extend at the perimeter thereof beyond the edge of opening 315 . An elastomeric coupling 320 is adhesively disposed between floating member 300 and support member 310 along the perimetric interstice defined by the overlap therebetween. Elastomeric coupling 320 may be formed from any suitable resilient material, such as rubber, neoprene, nitrite, silicone, foam rubber, or polyurethane foam. Additionally or optionally, elastomeric coupling 320 can include bellows-like corrugations to alter the resilient properties thereof.
[0037] FIGS. 7A and 7B show another embodiment of a floating connector in accordance with the present disclosure wherein the motion of a floating assembly 405 is substantially limited to a single axis of motion. A plurality of bar-shaped elastomeric couplings 420 are adhesively disposed between a floating member 400 and a support member 410 , and are arranged in mutually parallel configuration and generally orthogonal to the desired axis of motion. The range of motion of floating assembly 405 is dictated by the shape and arrangement of at least one bar-shaped coupling 420 . Other embodiments are envisioned which include, for example, elastomeric couplings of other shapes and arrangements, including without limitation square-shaped or dot-shaped elastomeric couplings in a lattice arrangement.
[0038] Turning now to FIGS. 8A , 8 B, and 8 C, another embodiment in accordance with the present disclosure is provided wherein a floating member 520 is concentrically disposed within an opening 525 defined in a support member 510 , the opening having a stationary rim 528 that is rigidly coupled to, or is integral to, support member 510 . A floating assembly 505 includes a connector 540 that is rigidly coupled to the floating member 520 . Stationary rim 528 and floating member 520 are resiliently coupled along their annular interstice by an elastomeric coupling 530 that is adhesively disposed between stationary rim 528 and floating member 520 . The overall resilient properties of elastomeric coupling 530 afford floating assembly 505 , and particularly, circular connector 540 , a range of movement to permit coupling with a misaligned mating connector, such as connector 780 , as previously described herein. Optionally, a positive stop 560 is included for limiting the inward excursion of floating assembly 505 along the Z-axis during coupling to allow sufficient mating force to be generated when coupling the connectors 540 with, for example, connector 780 . In one embodiment, positive stop 560 has an annular shape and is fixedly disposed in concentric relation to floating assembly 505 at an inner surface 512 of support member 510 along the perimeter of opening 525 . Positive stop 560 can also include a standoff 562 which can be formed integrally with positive stop 560 for dictating the maximum inward displacement of floating assembly 505 .
[0039] In another embodiment as illustrated in FIG. 9 , a stationary rim 628 and a floating member 620 are joined along their annular interstice by a captured o-ring 650 . A floating assembly 605 includes a connector 640 that is rigidly coupled to the floating member 620 . The captured o-ring 650 may be formed from any suitable resilient material, such as rubber, neoprene, nitrile, or silicone, and is compressively retained within opposing semicircular saddles 624 and 626 formed in the circumferential edges of opening 625 and floating member 620 , respectively. Upon coupling, the captured o-ring 650 can deform and/or partially roll in response to the mating forces applied to connector 640 , and in this manner, permit connector 640 to move into substantial alignment a misaligned mating connector, for example, connector 780 , as the connectors are brought into a fully-coupled state.
[0040] The described embodiments of the present disclosure are intended to be illustrative rather than restrictive, and are not intended to represent every embodiment of the present disclosure. Further variations of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be made or desirably combined into many other different systems or applications without departing from the spirit or scope of the disclosure as set forth in the following claims both literally and in equivalents recognized in law. | A floating connector adapted for use with microwave surgical instruments is presented. The disclosure provides for the use of cost-effective and readily available non-floating connectors in a floating housing which can compensate for dimensional variations and misalignments between the connectors. Multiple connectors of varying types can therefore be used within a single support housing without requiring the costly precision manufacturing processes normally associated with such multiple connector assemblies. The floating connector is suitable for use with electrical connections as well as fluidic connections. | 7 |
FIELD OF THE INVENTION
[0001] Various embodiments of the invention pertain to the prevention and/or elimination of shoreline erosion and/or scour beneath marine structures. More particularly, at least one embodiment of the invention relates to a bulkhead system of interlocking carbon-reinforced panels with improved strength.
DESCRIPTION OF RELATED ART
[0002] Currently, the most common methods for stabilizing earth materials or earth materials beneath structures in a marine environment are either the placement of rock protection or constructing a bulkhead by the driving of steel, fiberglass, aluminum or vinyl sheet pile adjacent to the material to be protected. Though these methods can be adequate, each has inherent disadvantages.
[0003] Placement of rock may require encroachment into properties owned by others or areas sensitive with environmental constraints. Conventional steel sheet or aluminum pile may also experience the same encroachment problems and the metallic pile, in a marine condition, is highly subject to corrosion. Additionally, placement of steel sheet pile or rock protection requires the use of heavy equipment along with adequate access. Vinyl and fiberglass sheet pile have very little structural value and are generally utilized in conjunction with rock protection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIGS. 1 and 2 illustrate a reinforced retention panel according to one embodiment of one aspect of the invention.
[0005] [0005]FIG. 3 illustrates a method of manufacturing fiber-reinforced panels according to one aspect of one embodiment of the invention.
[0006] [0006]FIG. 4 illustrates how a plurality of fiber-reinforced panels, according to one embodiment of the invention, may be joined using various interlocks, according to various embodiments of the invention, in one implementation of the invention.
[0007] [0007]FIG. 5 illustrates how seawall support pilings may be protected according to one implementation of the fiber-reinforced panels and interlocking system of one embodiment of the present invention.
[0008] [0008]FIG. 6 illustrates a top view of two fiber-reinforced panels joined by an interlock according to one embodiment of the invention.
[0009] [0009]FIG. 7 illustrates yet another embodiment of the invention where each fiber-reinforced panel has a lug along each longitudinal side of the panel.
[0010] [0010]FIG. 8 illustrates a perspective view of an interlock according to one embodiment of the invention.
[0011] [0011]FIG. 9 illustrates a method of assembling an erosion control barrier according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In the following description numerous specific details are set forth in order to provide a thorough understanding of the invention. However, one skilled in the art would recognize that the invention may be practiced without these specific details. In other instances, well known methods, procedures, and/or components have not been described in detail so as not to unnecessarily obscure aspects of the invention.
[0013] Various aspects of the invention provide a novel bulkhead wall including an interlocking system of reinforced panels that may be employed, for example, to stabilize or protect structures along a shoreline. A bulkhead wall of fiber-reinforced panels, having structural values directly related to the thickness of the panel core and the amount of reinforcing fiber incorporated therein may be use in marine conditions to resist scour or erosion while retaining soil materials behind the panel and resisting hydrostatic loads.
[0014] [0014]FIGS. 1 and 2 illustrate a reinforced retention panel 100 according to one embodiment of one aspect of the invention. The panel 100 includes a core 102 reinforced by one or more layers of reinforcing fiber 104 . The reinforcing fiber 104 may be carbon fiber or any other material which serves to reinforce and/or strengthen the panel 100 . In one implementation, the layers of reinforcing carbon fiber 104 may be arranged near the faces of the panel 100 .
[0015] According to one embodiment of the invention, the reinforcing layers of carbon fiber 104 include unidirectional fiber 106 running substantially parallel to the longitudinal axis of the panel 100 . The longitudinal axis of the panel 100 being substantially parallel to direction in which the panels are to be driven into the ground. In another embodiment, the reinforcing carbon fiber may be weaved or arranged in various other configurations are directions, relative to the longitudinal axis of the panel, (e.g., perpendicular, diagonal, etc.) to strengthen the panel 100 .
[0016] According to one embodiment of the invention, the core 102 may be a fiberglass core. In other embodiments, other materials may be used which provide stiffness and strength to the panel 100 .
[0017] In one embodiment of the invention, the panel 100 includes a lug or blockhead 108 on one edge of the panel 100 along the longitudinal axis of the panel 100 . As described below, this lug or blockhead 108 permits longitudinal movement of a panel while interlocked to other panels. For example, the panel 100 may be driven to a specified depth without affecting other interlocked panels. In another embodiment of the invention, the panel 100 may include lugs or blockheads 108 , along the longitudinal sides of the panel 100 . The lug or blockhead 108 may be attached to the panel using epoxy, or any other conventional method. In another embodiment, the lug or blockhead 108 is manufactured as an integral part of the panel 100 .
[0018] [0018]FIG. 3 illustrates a method of manufacturing fiber-reinforced panels according to one aspect of one embodiment of the invention. One or more layers of resin-impregnated carbon fiber sheets 300 are coupled to one or both sides of a fiberglass core 302 . The structural strength of the panel having structural values directly related to the thickness of the fiberglass core, the amount of carbon fiber incorporated therein, and/or the type of resin used to bind the carbon fiber sheet(s) to the fiberglass core.
[0019] In one embodiment of the invention, the carbon fiber sheet(s) is impregnated with polyester resin. In another embodiment of the invention, a vinyl ester resin is employed to impregnate and bind the carbon fiber sheet(s) to the fiberglass core. In one implementation, each layer of carbon-fiber and resin may total approximately {fraction (1/16)} of an inch in thickness to the reinforced panel.
[0020] A lug is attached or created along the length and edge of the panel 304 . Thus, the panels have increased strength, are relatively lightweight, and are inert to environmental conditions, such as corrosion.
[0021] The carbon fiber reinforced panels disclosed by this invention are unexpectedly strong in comparison to mere fiberglass panels. Tables 1, below, illustrates the result of load tests performed on polyester resin-impregnated carbon fiber panels with a fiberglass core. The overall thickness of the panels are about ⅝ of an inch, including the fiberglass core. The testing involved samples approximately 2 inches by 9 inches long with the carbon fibers positioned perpendicular to the load. As seen from the Maximum Load results, the carbon fiber reinforced panel samples were able to withstand maximum loads in the 3600 pound range representing an average modulus of rupture of 41162 pounds per square inch.
TABLE 1 Carbon Fiber-Reinforced Fiberglass Panels Polyester Resin Max. Load Thickness Width Span Modulus of Sample # (lbs) (in.) (in.) (in.) Rupture(p.s.i.) 1 3744 0.6395 2.0515 9.00 40163 2 3606 0.6115 2.1535 9.00 40302 3 3658 0.6015 2.1390 9.00 42541 4 3478 0.5915 2.1485 9.00 41642
[0022] Table 2, below, illustrates the result of load tests performed on reinforced fiberglass panels similar to those show in Table 1, above, but reinforced with carbon fiber impregnated with vinyl ester resin. The testing involved samples approximately 2 inches by 9 inches long with the carbon fibers positioned perpendicular to the load. As seen from the Maximum Load results, the carbon fiber reinforced panel samples were able to withstand maximum loads in the 3900 pound range representing an average modulus of rupture of 47747 pounds per square inch. These tests show that for panel samples of similar dimensions, the use of vinyl ester resin to impregnate or bond the carbon fiber to the panels increases the strength of the panels more than the use of polyester resin for the same purpose.
[0023] The panels in Samples #2-12, in Table 2, were submerged in saturated salt water over several months prior to the test to determine if the marine environment degrades the panels' structural properties. As the results indicate, the salt water conditions did not affect the strength of the reinforced panels.
TABLE 2 Carbon Fiber-Reinforced Fiberglass Panels Vinyl Ester Resin Max. Load Thickness Width Span Modulus of Sample # (lbs) (in.) (in.) (in.) Rupture(p.s.i.) 1 (Dry) 4100 0.6285 2.0084 9.00 46512 2 (Wet) 4006 0.6250 2.0004 9.00 46140 3 (Wet) 3960 0.6265 2.0083 9.00 45210 4 (Wet) 4456 0.6205 1.9954 9.00 52201 5 (Wet) 4310 0.6265 2.0015 9.00 49376 6 (Wet) 4092 0.6225 1.9874 9.00 47821 7 (Wet) 3928 0.6125 1.9874 9.00 47414 8 (Wet) 3930 0.6115 1.9818 9.00 47730 9 (Wet) 3830 0.6050 1.9764 9.00 47645 10 (Wet) 3870 0.6045 1.9957 9.00 47760 11 (Wet) 3910 0.6095 1.9915 9.00 47566 12 (Wet) 3795 0.6025 1.9730 9.00 47588
[0024] Table 3, below, illustrates the same load test illustrated above, with respect to Tables 1 and 2, but performed on a fiberglass samples ranging from {fraction (7/16)} to nearly {fraction (1/2)} inch thick. As with the above test, fiberglass samples are approximately 2 inches by 9 inches. As can be seen from these tests, the unreinforced fiberglass has much lower maximum loads, in the 600 to 718 lbs. range representing an average modulus of rupture of 14400 pounds per square inch. Although the fiberglass cores used in the two tests were of slightly different thicknesses, the fiberglass cores in Table 1 and 2 were approximately {fraction (1/2)} inch thick while the core in Table 3 was {fraction (7/16)} to {fraction ( 1 / 2 )} inch thick, the increased maximum load strength exhibited by the carbon fiber reinforced panels was still significantly greater than would have been expected.
TABLE 3 Fiberglass Panels Max. Load Thickness Width Span Modulus of Sample # (lbs) (in.) (in.) (in.) Rupture(p.s.i.) 1 660 0.4355 2.0050 9.00 15621 2 714 0.4930 2.0000 9.00 13220 3 608 0.4380 1.9950 9.00 14297 4 718 0.4715 2.0100 9.00 14461
[0025] [0025]FIG. 4 illustrates how a plurality of carbon fiber-reinforced panels 401 - 405 , according to one embodiment of the invention, may be joined using various interlocks 410 - 413 , according to various embodiments of the invention, to create a continuous bulkhead wall in one implementation of the invention. The plurality of carbon fiber-reinforced panels 401 - 405 are joined with sliding interlocks 410 - 413 along their edges. Each individual panel 401 - 405 may be driven into the ground 416 to a specified vertical depth along the outboard face of the structure or material whose sub-grade 420 is to be stabilized or protected. The panels 401 may include one or more lugs to permit the panels to slide up and down, with relation to the interlocks 410 - 413 , while preventing the panels from separating from the interlock and/or an adjoining panel. The tops of the panels may be anchored with bolts, tieback anchors, or a wailer system as necessary to provide support to resist all lateral loads.
[0026] Because the carbon fiber-reinforced panels are relatively strong and are lightweight, the bulkhead or reinforcing wall is easy to assemble, capable of withstanding heavier loads, and provides for flexible field modifications.
[0027] As illustrated in FIG. 4, various types of interlock arrangements may be used depending on the implementation. In one embodiment of the invention, a single interlock 410 may be used to join to fiber-reinforced panels 401 - 402 while filling any gaps between the panels 401 - 402 . The interlock 410 may run from, approximately, the surface of the ground to, approximately, the top of the panels 401 - 402 . In another implementation, the interlocks 411 may be of sectioned into multiple interlocks 411 that can be stacked to join or couple the panels 402 - 403 while filling any gaps between the panels 402 - 403 .
[0028] In yet other implementations, the interlocks 412 and 413 need not run continuously from the ground to the top of the fiber-reinforced panels 403 - 405 . Instead, the interlocks may be arranged to create a gap between interlocks. This gap may be as large or small as the implementation requires. For example, a small gap or gaps 418 may be created to permit water to drain out while still preventing erosion of the sub-grade 420 being protected.
[0029] In yet other implementations, the interlock 422 may run below the ground 420 level to provide greater protection against erosion.
[0030] [0030]FIG. 5 illustrates how seawall support pilings 500 may be protected according to one implementation of the fiber-reinforced panels and interlocking system of one embodiment of the present invention. The timber piling 500 that support the seawall 502 are subject to attack by marine borers when the sea bottom 508 scours below the footing 504 and exposes these piles 500 . A carbon fiber-reinforced panel 504 may be driven into the sea bottom 508 and then secured to the seawall footing 504 with stainless steel bolts 510 .
[0031] In one implementation of the invention, if voids 512 exist beneath the structure being stabilized or protected, these voids 512 can be filled with pressurized grout utilizing holes drilled through the panel 506 . Sealing of these holes is unnecessary since they are completely filled when the grouting operation is completed.
[0032] [0032]FIG. 6 illustrates a top view of two fiber-reinforced panels joined by an interlock according to one embodiment of the invention. In one embodiment of the invention, the interlock system 602 may be composed of high-density polyethylene (HDPE). The interlock 602 serves to join two fiber-reinforced panels 604 and 606 .
[0033] A first panel 604 is secured to the interlock 602 with one or more fasteners or bolts 608 . In one implementation, the one or more bolts may be stainless steel bolts or fasteners. In other implementation, the bolts or fasteners may be of other materials which are resistant to corrosion or which have characteristics desirable for a particular implementation.
[0034] A second panel 606 has a continuous lug 610 , along one edge of the panel 606 . In various implementations of the invention, the lug 610 may be integral with the panel 606 or a separate component which is attached to the panel 606 . In one embodiment of the invention, the lug 610 is made of fiberglass and integral with the panel 606 . The lug 610 slides longitudinally along a groove in the interlock 602 . This interlocking groove allows longitudinal movement of the panel to accommodate driving of each individual panel into the ground while restraining from undesired movement along the other two axes. That is, the interlocking grooves permit the panels to slide up or down but prevents two panels from separating.
[0035] In one implementation of the invention, every panel has a lug 610 along one side in the longitudinal direction. The fiber-reinforced panels 604 and 606 may be cut to size in the field or during installation as conditions dictate. When using panels with a single lug along one longitudinal side or edge, the panels may be cut to the desired width along the non-lug side or edge. The cut panel (e.g., 604 ) can still be joined to other panels by using interlock 602 .
[0036] In one implementation of the invention, the thickness 612 of the fiber-reinforced panels 604 and 606 is uniform, except for the lug portion 610 . For example, in one implementation the panels are half an inch thick. Other fiber-reinforced panels may be manufactured thicker or thinner according to the desired strength for a given implementation.
[0037] [0037]FIG. 7 illustrates yet another embodiment of the invention where each fiber-reinforced panel 702 - 703 has a lug 705 along each longitudinal side of the panel. The interlocks 706 - 708 each have interlocking grooves 710 which join the panels 702 - 703 while permitting the panels to slide in the longitudinal direction so that they may be driven into the ground. According to one implementation of the invention the interlocks may be designed to provide for some clearance (e.g., one-sixteenth of an inch) with the panels.
[0038] The system of interlocks illustrated in FIG. 7 may also be interconnected with a panel 704 which has been cut to size, thereby removing one of the lugs along one edge of the panel 704 . The edge without a lug can still be inserted into the groove or channel and, once it has been driven into the ground, may be secured to interlock 708 by bolts or fasteners. In other embodiments of the invention, interlock 708 may be replaced by an interlock 602 as shown in FIG. 6.
[0039] [0039]FIG. 8 illustrates a perspective view of an interlock 802 according to one embodiment of the invention. The interlock 802 includes two channels 804 and 806 for joining two panels. A first channel 804 permits a panel to slide in and out and up and down. When conditions dictate, a panel may be cut to a desired width, along a longitudinal side, and inserted into the first channel 804 . A second channel 806 includes an interlocking groove 808 that permits a panel to slide up and down but not in and out.
[0040] [0040]FIG. 9 illustrates a method of assembling an erosion control barrier according to one embodiment of the invention. A first fiber-reinforced panel is partially driven into the ground 902 . An interlock (e.g., 802 ) is joined or coupled along one longitudinal side of the first panel 904 . For example, in one implementation the interlock channel 804 (FIG. 8) is joined to the non-lug side of the first panel and attached to the first panel using bolts or other fasteners. In a second implementation the interlock channel 806 (FIG. 8) may be slid over the lug side of the first panel and held in place by the interlocking groove 808 . A second fiber-reinforced panel is joined to the interlock 806 , 906 , either in channel 804 or 806 , and partially driven into the ground 808 , 907 . If joined to channel 804 of the interlock, then it is secured to the interlock 908 after the second fiber-reinforced panel has been driven into the ground. In one implementation, the top portion of one or more panels may be attached to the structure being protected 910 .
[0041] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications are possible. Those skilled, in the art will appreciate that various adaptations and modifications of the just described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein. | A system of composite panels comprised of resin impregnated carbon fiber sheets, on opposing sides of a fiberglass core, having structural values directly related to the thickness of the core and the amount of carbon fiber incorporated, to be used in marine conditions to resist scour or erosion while retaining soil materials behind the panel and resisting hydrostatic loads. Each panel will have high-density polyethylene (HDPE) interlocks on opposite edges allowing the panels to slide together allowing a series of joined panels to form a continuous wall. Additionally the preformed HDPE interlocks may be field-installed and removed allowing the carbon fiber panels to be cut to a specific dimension as necessary. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a blender, especially to a blender that mixes and stirs foodstuffs without crushing solids in the foodstuffs.
2. Description of the Prior Art(s)
A blender is a common household or beverage shop appliance used to mix, puree or emulsify fruits or foodstuffs. With improvements of the blenders, conventional blenders are capable of grinding soybeans with water to produce soymilk, crushing ice to make smoothies or milling grains with other foodstuffs to make sauces by using suitable blade assemblies. Moreover, the conventional blender is also capable of turning liquid milk into milk froth by using a milk-frothing disk in substitution for the blade assembly.
However, whenever the conventional blender operates, the blade assembly of the conventional blender crushes solid foodstuffs, such as ice, fruits, grains and so on. The conventional blender is neither able to merely mix and stir the liquid and the solid foodstuffs to result in a “shaking” effect, nor able to brew tea by pouring water and putting tealeaves into the conventional blender.
To overcome the shortcomings, the present invention provides a blender to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
The main objective of the present invention is to provide a blender. The blender has a base, an axle assembly mounted on the base, a container securely attached to an axle housing of the axle assembly and a stirring disk securely mounted on an axle of the axle assembly.
A user puts foodstuffs such as powder material, syrup, liquid material, ice cubes and so on, into the container, and then drives the axle assembly and the stirring disk to rotate. Thus, stirring ribs of the stirring disk stir and mix the foodstuffs without crushing the foodstuffs. Moreover, when the user puts tealeaves and pours water into the container, the stirring ribs stir the tealeaves and the water to brew tea and to extract nutrition from the tealeaves. The blender is simple, easy and safe, especially for a person or a household to use.
Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged exploded perspective view of a blender in accordance with the present invention, showing a first embodiment of a stirring disk mounted in the blender;
FIG. 2 is a perspective view of the blender in FIG. 1 ;
FIG. 3 is an enlarged exploded perspective view of the blender in FIG. 1 , showing the first embodiment of the stirring disk and an axle assembly;
FIG. 4 is a perspective view of the first embodiment of the stirring disk in FIG. 1 ;
FIG. 5 is a perspective view of a second embodiment of a stirring disk;
FIG. 6 is another perspective view of the second embodiment of the stirring disk in FIG. 5 ;
FIG. 7 is a cross-sectional side view of the second embodiment of the stirring disk in FIG. 5 ;
FIG. 8 is a perspective view of a third embodiment of a stirring disk;
FIG. 9 is an enlarged exploded perspective view of a blender in accordance with the present invention, showing a fourth embodiment of a stirring disk mounted in the blender;
FIG. 10 is a perspective view of the fourth embodiment of the stirring disk in FIG. 9 ;
FIG. 11 is a cross-sectional side view of the fourth embodiment of the stirring disk in FIG. 9 ; and
FIG. 12 is a perspective view of a fifth embodiment of the stirring disk.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 , 2 , 5 , 8 , 9 and 12 , a blender in accordance with the present invention comprises a base 10 , an axle assembly 20 , a container 30 , a stirring disk 40 A, 40 B, 40 C, 40 D, 40 E and a lid 50 .
The base 10 has a base housing 11 and a driving device. The driving device may be a motor, is mounted in the base housing 11 and has a driving member 12 protruding through a top of the base housing 11 .
With further reference to FIG. 3 , the axle assembly 20 is detachably mounted on the top of the base housing 11 and has an axle housing 21 , an axle 22 and a nut 23 . The axle 22 is axially mounted through the axle housing 21 and has an upper end 222 , a lower end 221 and an outer thread. The lower end 221 of the axle 22 is connected to the driving member 12 of the driving device of the base 10 to allow the driving device to rotate the axle 22 . The outer thread is formed on the upper end 222 of the axle 22 . The nut 23 may be a hexagon nut, is mounted on the upper end 222 of the axle 22 and engages the outer thread of the axle 22 .
The container 30 is mounted on the top of the base housing 11 , is securely attached to the axle housing 21 and has an upper opening and a pivot hole 31 . The upper opening of the container 30 allows a user to put foodstuffs into the container 30 . The pivot hole 31 is formed through a bottom of the container 30 for the axle housing 21 to be mounted through the pivot hole 31 .
With further reference to FIGS. 4 and 10 , the stirring disk 40 A, 40 B, 40 C, 40 D, 40 E is securely mounted on the upper end 222 of the axle 22 and has a panel 41 A, 41 B, 41 C, 41 D, 41 E, a lower sidewall 42 A, 42 B, 42 C, 42 D, 42 E and multiple stirring ribs 43 A, 43 B, 43 D, 43 E.
The panel 41 A, 41 B, 41 C, 41 D, 41 E is securely mounted on the upper end 222 of the axle 22 , is securely mounted on the nut 23 of the axle 22 and has multiple through holes 411 A, 411 B, 411 C, 411 D, 411 E and a mounting portion 44 A, 44 E. The through holes 411 A, 411 B, 411 C, 411 D, 411 E are formed through the panel 41 A, 41 B, 41 C, 41 D, 41 E. The mounting portion 44 A, 44 E is formed on a center of the panel 41 A, 41 E, is hollow, is securely mounted on the nut 23 of the axle 22 and has a lower opening for the mounting portion 44 A to be mounted around the nut 23 of the axle 22 .
The lower sidewall 42 A, 42 B, 42 C, 42 D, 42 E is formed around an outer peripheral edge of the panel 41 A, 41 B, 41 C, 41 D, 41 E, protrudes toward a lower surface of the panel 41 A, 41 B, 41 C, 41 D, 41 E, is disposed around the axle housing 21 and has multiple lower through holes 421 A, 421 B, 421 C, 421 D, 421 E. The lower through holes 421 A, 421 B, 421 C, 421 D, 421 E are separately formed through and are arranged around the lower sidewall 42 A, 42 B, 42 C, 42 D, 42 E. Each lower through hole 421 A, 421 B, 421 C, 421 D, 421 E extends longitudinally.
The stirring ribs 43 A, 43 B, 43 D, 43 E are separately formed on the panel 41 A, 41 B, 41 D, 41 E. Each stirring rib 43 A, 43 B, 43 D, 43 E extends radially on the panel 41 A, 41 B, 41 D, 41 E.
With reference to FIGS. 3 and 4 , in a first embodiment of the stirring disk 40 A, the through holes 411 A of the panel 41 A are radially arranged on the panel 41 A. The lower sidewall 42 A has an annular frame 422 A and multiple connecting frames 423 A. The annular frame 422 A is disposed below and around the panel 41 A. The connecting frames 423 A are separately arranged around and are disposed between the annular frame 422 A and the panel 41 A. Each connecting frame 423 A is arc-shaped and has two ends respectively connecting to the annular frame 422 A and the panel 41 A. Each lower through hole 421 A is defined between two adjacent connecting frames 423 A. The stirring ribs 43 A are formed on the lower surface of the panel 41 A.
With reference to FIGS. 5 to 7 , in a second embodiment of the stirring disk 40 B, each through hole 411 B of the panel 41 B is elongated and extends radially on the panel 41 B. The lower sidewall 42 B is perpendicular to the panel 41 B. The lower through holes 421 B of the lower sidewall 42 B are formed through the lower sidewall 42 B. The stirring ribs 43 B are formed on the lower surface of the panel 41 B. Each stirring rib 43 B is a sheet. The stirring disk 40 B further has multiple nets 45 B respectively mounted in the through holes 411 B of the panel 41 B and the lower through holes 421 B of the lower sidewall 42 B.
With further reference to FIG. 8 , in a third embodiment of the stirring disk 40 C, the lower sidewall 42 C obliquely protrudes outwardly toward the lower surface of the panel 41 C. Each through hole 411 C of the panel 41 C is elongated and extends radially on the panel 41 C. The lower through holes 421 C of the lower sidewall 42 C are formed through the lower sidewall 42 C.
With reference to FIGS. 9 to 11 , in a fourth embodiment of the stirring disk 40 D, the stirring disk 40 D further has an upper sidewall 46 D formed around the outer peripheral edge of the panel 41 D, protruding toward an upper surface of the panel 41 D and having multiple upper through holes 461 D. The upper through hoes 461 D are separately formed through and are arranged around the upper sidewall 46 D. The nets 45 D are respectively mounted in the through holes 411 D of the panel 41 D, the lower through holes 421 D of the lower sidewall 42 D and the upper through holes 461 D of the upper sidewall 46 D.
With further reference to FIG. 12 , in a fifth embodiment of the stirring disk 40 E, each through hole 411 E of the panel 41 E is elongated and extends radially on the panel 41 E. The lower through holes 421 E of the lower sidewall 42 E are formed through a distal peripheral edge of the lower sidewall 42 E. The stirring ribs 43 E are formed on the upper surface of the panel 41 E. The mounting portion 44 E further has a holding portion 441 E. The holding portion 441 E is formed on an outer surface of the mounting portion 44 E and may have multiple protrusions or may be a rough surface so allows the user to stably hold the stirring disk 40 E by the mounting portion 44 E.
The lid 50 is mounted on and covers the upper opening of the container 30 .
The blender as described has the following advantages. The user puts the foodstuffs such as powder material, syrup, liquid material, ice cubes and so on, into the container 30 , and then switches on the driving device of the base 10 to drive the driving member 12 , the axle 22 of the axle assembly 20 and the stirring disk 40 A, 40 B, 40 C, 40 D, 40 E to rotate. Thus, the stirring ribs 43 A, 43 B, 43 D, 43 E are capable of stirring and mixing the foodstuffs in the container 30 without crushing the foodstuffs. Moreover, when the user puts tealeaves and pours water into the container 30 , the stirring ribs 43 A, 43 B, 43 D, 43 E stir the tealeaves and the water to brew tea and to extract nutrition from the tealeaves. The through holes 411 A, 411 B, 411 C, 411 D, 411 E, the lower through holes 421 A, 421 B, 421 C, 421 D, 421 E, the upper through holes 461 D and the nets 45 B, 45 D of the stirring disk 40 A, 40 B, 40 C, 40 D, 40 E allow passage of the liquid foodstuffs and split bubbles in the liquid foodstuffs into foams to improve taste of the mixed foodstuffs.
Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A blender has a base, an axle assembly mounted on the base, a container securely attached to an axle housing of the axle assembly, and a stirring disk securely mounted on an axle of the axle assembly. A user puts foodstuffs, such as powder material, syrup, liquid material, ice cubes and so on, or tea leaves and water, into the container, and then drives the axle assembly and the stirring disk to rotate. Thus, stirring ribs of the stirring disk stir and mix the foodstuffs without crushing the foodstuffs, or the tealeaves and the water are brewed into tea. The blender is simple, easy and safe, especially for a person or a household to use. | 0 |
FIELD OF THE INVENTION
This invention relates to a method of electrolytic coating of magnesium and its alloys. In one aspect, the present invention relates to an electrolytic coating of magnesium and its alloys to provide a corrosion-resistant, hard, durable, smooth and adherent coating thereon. In another aspect, the present invention is concerned with such coated articles of magnesium and magnesium alloys which are useful for decorative purposes. In still another aspect, this invention relates to an electrolytic bath which is uniquely suited for providing the surfaces of magnesium and its alloys with coatings having the aforementioned properties and characteristics.
BACKGROUND OF THE INVENTION
Magnesium and its alloys have found a variety of industrial applications. However, because of the reactivity of magnesium and its alloys, and their tendency toward corrosition and environmental degradation, it is necessary to provide the surfaces of this metal with an adequate corrosion-resistant and protective coating. Where articles of magnesium or its alloys are used for decorative purposes, the protective coatings applied thereto must be both decorative and corrosion resistant.
The protection of metallic surfaces, including magnesium and its alloys, against corrosion and actions of the elements, has received considerable attention over the years. Some protection has been afforded the metal by coating its surfaces with paint or enamel. Although such coatings are fairly resistant to chemical attack, they are subject to degradation at high temperatures and adhere poorly to the metal surface particularly when experiencing temperature variations.
In order to provide a more effective and permanent protective coating on magnesium and its alloys, the metal has been anodized in a variety of electrolytic solutions. While anodization of magnesium and its alloys imparts a more effective coating than painting or enameling, still the resulting coated metal has not been entirely satisfactory for its intended applications. The coatings often lack the desired degree of hardness, smoothness, durability, adherence and/or imperviousness required to meet the ever-increasing industrial and household demands.
There is a plethora of prior art patents which deal with anodizing magnesium and its alloys. The following is a list of patents which is representative of the efforts of the prior art workers in this field: U.S. Pat. Nos. 1,574,289; 1,574,290; 2,196,161; 2,197,611; 2,203,670; 2,261,960; 2,276,286; 2,305,669; 2,313,753; 2,313,754; 2,313,756; 2,314,341; 2,321,948; 2,322,205; 2,322,208; 2,322,487; 2,338,924; 2,348,826; 2,414,090; 2,426,254; 2,456,931; 2,766,199; 2,778,789; 2,880,148; 3,477,921; 3,620,939; 3,732,152; 3,791,942; 4,184,926; and 4,227,976. While this list is by no means exhaustive, a review of these patents highlights the significant role which the electrolytic solution plays in the anodizing process and in providing the surface of magnesium and its alloys with the desired coating. Thus, in general, the nature and properties of the coating which is formed on aluminum and its alloys depends, to a great extent, on the composition of the anodic bath (electrolytic solution) used in anodizing the metal. Other parameters such as the process conditions used during the electrodeposition process also contribute to the nature and quality of the coating.
In one early patent, i.e., U.S. Pat. No. 1,574,289, a protective coating for magnesium was provided by immersing the metal, which served as the anode, in a solution of hydrofluoric acid and passing a current therethrough at an applied voltage of about 110 volts or higher. The coating formed on the surface of the metal was believed to be magnesium fluoride or oxy-fluoride.
Later, as disclosed in U.S. Pat. No. 2,313,753, it was found that the coatings produced by treatment with hydrofluoric acid alone as aforesaid are unsatisfactory because they are subject to considerable deterioration when exposed to either the atmosphere or aqueous salt solutions. Accordingly, the latter patent recommended that after subjecting the magnesium article to the action of the fluoride, the resulting coated article must be further treated by subjecting it to the action of a bath containing an arsenic compound in order to alter the fluoride-formed coating to increase its corrosion resistance. The dangers of working with arsenic, however, is well known. Besides, this method requires two separate baths and two separate treatments.
A two-step method of providing a protective coating for magnesium and its alloys is also described in U.S. Pat. No. 2,322,208. According to this patent, the magnesium article is first subjected to the action of a fluoride solution and, in a next step, the coated article is immersed in an aqueous solution of a salt of an oxy-acid of an element selected from the group consisting of chromium, molybdemum, phosphorus, selenium, titanium, tugnsten, vanadium, especially the alkali metal and ammonium salts of such oxy-acids.
U.S. Pat. No. 2,322,487 also discloses that when magnesium or its alloys are treated with acid fluoride solution, the resulting coating is subject to deterioration. This patent, too, requires a post-treatment of the fluoride-treated magnesium or its alloys. According to this patent, after treating the metal with an acid fluoride solution, the coated metal is treated, in a separate step, with an aqueous solution of a soluble alkali, or alkali earth metals, such as sodium hydroxide, potassium hydroxide, calcium hydroxide, sodium carbonate, barium hydroxide, and the like.
Even as recently as U.S. Pat. No. 4,184,926 which issued on Jan. 22, 1980 to Otto Kozak (the inventor of the present application), the protective coating on magnesuim and its alloys was formed by separate treatments of the metal; first in a solution of hydrofluoric acid to form a fluoro-magnesium layer on the metal, and then, in a spearate step, by immersing the coated metal in an aqueous solution of an alkali metal silicate, and applying 150 to 350 volts between said coated metal, serving as the anode, and a second metal which serves as a cathode.
While the coating produced by the said Kozak patent exhibits decided advantages with respect to the coatings theretofore obtained by the prior art methods, the resulting coatings are nevertheless not entirely satisfactory. Moreover, the process is rather cumbersome in that it requires two separate baths and the time required to obtain the desired coating is relatively long by industrial standards.
Accordingly, it is an object of this invention to protect the surface of magnesium and its alloys from corrosion and environmental attacks and consequent degradation.
It is a further object of this invention to protect the surfaces of magnesium with hard, uniform, adherent, smooth, impervious and corrosion-resistant coating.
It is yet another object of this invention to provide such coated articles of magnesium and its alloys which can be used for decorative applications.
It is also an object of this invention to provide an improved method for anodic coating of magnesium and its alloys.
It is still another object of this invention to provide such an improved method whereby the protective coating on the surfaces of magnesium and its alloys is achieved in a single bath.
It is yet another object of this invention to provide a unique electrolytic solution for anodic coating of magnesium and magnesium alloys.
It is still another object of this invention to provide an electrolytic solution which is a stable composition under the electrodeposition conditions, and which facilitate the formation of the desired coating without the necessity for a prior fluoride treatment of the metal.
The forgoing and other unique features of the electrolytic solution and the process of this invention will be further described, and more fully appreciated, from the ensuing detailed description.
SUMMARY OF THE INVENTION
The objects of this invention are achieved by providing a unique electrolytic solution comprising certain specified ingredients designed to form a stable anodic bath and facilitate the coating process in a single bath. When used in the process of this invention, the anodic bath is capable of imparting a hard, smooth, uniform, highly adherent and corrosion-resistant coating on magnesium and magnesium alloys which predominate in magnesium. The anodic bath comprises alkali metal silicate, alkali metal, hydroxide and a fluoride compound, notably hydrofluoric acid as essential ingredients. These compounds react synergistically to produce the unique anodic bath and coating of the present invention.
The electrolytic process comprises immersing the magnesium metal or its alloy in the bath, in which the magnesium serves as the anode. A second metal which is cathodic relative to magnesium is also immersed in the bath. Alternatively, the bath is placed in a container which itself is cathodic relative to the magnesium anode. A voltage potential of from about 150 to about 400 volts is then impressed across the electrodes until a visible spark is discharged across the surface of the magnesium, and this voltage is maintained until the desired coating thickness is formed.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, there is provided a unique electrolytic solution, sometimes referred to as an electrolytic bath or anodic bath, which is, inter alia, stable, particularly at the high voltages employed during the electrodeposition process, and which imparts the desired coatings to the surfaces of magnesium and its alloys, by treatment in a single bath. As used herein, the terms "magnesium" is intended to denote not only the magnesium metal but also the alloys thereof which predominate in magnesium.
As it was previously noted, there is a plethora of electrolytic solutions or anodic baths which have heretofore been employed for anodic coating of magnesium. The different baths frequently differ from one another with respect to only one or two ingredients. Nevertheless, and in view of the often unpredictable behavior of some chemicals, particularly when they are in admixture with other chemicals, the resulting electrolytic solutions exhibit marked differences in properties and abilities to impart coatings on metal surfaces. Frequently, too, the coatings imparted to the metal surfaces will exhibit significant differences in properties or constitution which reflect the differences in compositions of the electrolytic solution. Therefore, the selection of the ingredients used to form the electrolytic solution is of paramount significance in the anodic treatment of metals.
A. The Electrolytic Solution: It has been discovered that an electrolytic solution having the composition hereinafter described is uniquely suitable for coating magnesium articles with a coating having the properties mentioned previously. In addition, it has been discovered that this electrolytic solution permits coating the magnesium article in a single operation, using a single anodic bath, without the necessity for a prior and separate treatment with hydrogen fluoride as required in the method described in the aforementioned Kozak patents and the other patents which were previously discussed.
A typical electrolytic solution which is especially useful in the practice of this invention contains potassium silicate (K 2 SiO 3 ), sodium hydroxide (NaOH), hydrofluoric acid (HF.H 2 O) and water. Certain other compounds may be used in lieu of, or together with, any of the aforementioned ingredients.
While potassium silicate is the silicate of choice in forming the electrolytic solution, other alkali metal silicates or alkali earth metal silicates can be used, including sodium silicate (Na 2 SiO 3 ), lithium silicate (Li 2 SiO 3 ), potassium tetrasilicate (K 2 SiO 4 ) and potassium fluosilicate (K 2 SiF 6 ). Also, hydrofluosilicic acid may be used alone or in conjunction with any of the aforementioned silicates.
Both sodium hydroxide and potassium hydroxide can be used as the alkali metal hydroxide ingredient of the bath. Lithium hydroxide and other alkali metal hydroxides and alkali earth metal hydroxide may be substituted for, or used in admixture with, potassium hydroxide or sodium dydroxide, but the latter two hydroxides are the preferred hydroxide ingredients in preparing the electrolytic solution of the present invention.
An essential feature of the electrolytic solution of this invention is the inclusion therein of hydrofluoric acid. It is believed that the synergistic reaction between hydrofluoric acid and the silicate component of the bath results in a more stable bath, superior coatings on the magnesium article and marked reduction in the time required to provide the desired coating. In lieu of the hydrofluoric acid, or in admixutre therewith, one could use fluosilic acid (H 2 SiF 6 ), alkali metal fluoride such as potassium fluoride (KF) and sodium fluoride (NaF).
B. Preparation of the Electrolytic Solution: In preparing the electrolytic bath, the silicate is first added to water, usually at about room temperature. In general, however, the bath temperature is between about 5° C. and about 70° C., but is preferably between about 20° C. and about 40° C. The silicate constitutes the dominant ingredient of the bath and the resulting coating as well. The silicate is added as a 30 Be' solution and various industrial grades silicates are available in this strength. For example, potassium silicate may be used as 30 Be' KASIL 88 solution available from Philadelphia Quartz Co., Philadelphia, Pa. Next, the hydroxide is added, followed by the addition of the hydrofluoric acid.
The relative amounts of the electrolytic bath components may be varied over a wide range with substantially the same effecacious results. Thus, the amount of silicates can vary from about 1 to about 200 cubic centimeters per liter; the hydroxide quantity can be from about 5 to about 50 grams per liter, and the amount of hydrofluoric acid can vary from about 5 to about 30 cm 3 per liter.
It must be mentioned that the anodic bath must be highly alkaline and maintained at a pH of from about 12 to about 14. Accordingly, the amounts of the hydrofluoric acid, or the fluoride compound should not be so excessive as to reduce the pH of the bath significantly below about 12.
It must further be mentioned that while the relative amounts of the bath ingredients have been specified with respect to specific components, where the equivalents of any of the aforementioned ingredients are employed, the relative amounts thereof can be selected based on the aforementioned concentration ranges.
The following examples are typical anodic baths which are suitable in the practice of this invention:
EXAMPLE 1
______________________________________K.sub.2 SiO.sub.3 (30 Be') 75 cm.sup.3NaOH (granular) 25 gramsHF.H.sub.2 O (10% conc.) 10 cm.sup.3H.sub.2 O 1000 cm.sup.3______________________________________
EXAMPLE 2
______________________________________K.sub.2 SiO.sub.3 (30 Be') 50 cm.sup.3NaOH (granular) 25 gramsH.sub.2 SiF.sub.6 10 gramsH.sub.2 O 1000 cm.sup.3______________________________________
EXAMPLE 3
______________________________________K.sub.2 SiO.sub.3 (30 Be') 75 cm.sup.3NaOH (granular) 20 gramsNaF 10 gramsKF 3 gramsH.sub.2 O 1000 cm.sup.3______________________________________
EXAMPLE 4
______________________________________Na.sub.2 SiO.sub.3 (25 Be') 50 cm.sup.3NaOH (granular) 30 gramsH.sub.2 SiF.sub.6 7 gramsH.sub.2 O 1000 cm.sup.3______________________________________
EXAMPLE 5
______________________________________H.sub.2 SiF.sub.6 30 gramsNaOH (granular) 20 gramsHF.H.sub.2 O (10% conc.) 5 cm.sup.3H.sub.2 O 1000 cm.sup.3______________________________________
EXAMPLE 6
______________________________________H.sub.2 SiF.sub.6 30 gramsKF 5 gramsNaOH (granular) 15 gramsHF.H.sub.2 O (10% conc.) 5 cm.sup.3H.sub.2 O 1000 cm.sup.3______________________________________
C. The Coating Process: the magnesium article to be coated is immersed in the electrolytic solution, maintained at a temperature of from about 20° C. to about 40° C., and is made anodic with respect to said bath. A second metal serving as a cathode is also immersed in the bath. Alternatively, the container containing the bath may itself be made cathodic with respect to the magnesium anode. Thereafter, an electric voltage potential of from about 150 volts to about 400 volts is applied between the two electrodes. At such voltage, a visible spark is discharged across the magnesium surface which creates a thermal environment in which the constituents of the bath unite chemically with magnesium to form highly adherent fluoromagnesium-silicate coating. As the aforementioned voltage level is attained, direct current is passed through the electrolytic system at the current density rate of from about 10 mA to about 3 amperes for about 1 to about 5 minutes to form the desired coating.
As it can be seen, the process of this invention does not require pretreatment of the magnesium and the entire operation may be carried out in a single bath. Moreover, the time required to form the desired coating is considerably reduced and is usually about 1/3 to about 1/5 of the time required to form the coating described in the aforementioned Kozak Patent.
While the invention was heretofore described and illustrated with certain degree of specificity, it is apparent to those skilled in the art that some obvious changes and modifications may be made therein, either in the bath or in the electrodeposition process. Such changes and modifications are nevertheless within the scope of this invention and are suggested by the present disclosure. | An electrolytic bath for coating articles of magnesium and its alloys consists essentially of an aqueous solution containing an alkali metal silicate (e.g., potassium silicate), an alkali metal hydroxide (e.g., potassium hydroxide) and a fluoride (e.g., hydrofluoric acid). In the process, the magnesium article is immersed in the bath and an electrical potential is applied between the magnesium article serving as the anode, and a cathode immersed in the bath until a visible spark is discharged on the surface of the metal. The potential difference is maintained for a few minutes until the desired coating thickness is formed. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates generally to steam traps used in steam distribution systems. More particularly, the invention relates to a steam trap adapted to control the escape of latent heat.
Steam traps, which are essentially automatic valves used to discharge condensate, are widely used in steam distribution systems. In operation, flash steam within the trap chamber of such devices functions to keep the valve closed. As the trap cools, the steam condenses and fluid pressure in the inlet passage forces the valve element off its seat. Condensate then passes through the trap, which eventually causes the valve element to again engage the seat.
The useful life of a steam trap is directly related to its cycle rate. Cycle rate is, in turn, related to latent heat loss. Accordingly, it is often desirable to control loss of such heat in a steam trap. While various configurations have been proposed to limit such heat loss, room exists in the art for novel constructions.
SUMMARY OF THE INVENTION
In accordance with one aspect, the present invention provides a steam trap comprising a trap body defining a seating face. A cap is fitted to the trap body and has a stop face. The trap body and the cap thus define a trap chamber. A thermally insulative element is juxtaposed to the cap. A valve element is located in the trap chamber and is displaceable between limit positions defined by the stop face and the seating face.
In some exemplary embodiments, the thermally insulative element substantially covers a top surface of the cap. Often, the thermally insulative element may comprise a disc of thermally insulative material such as a ceramic material. Preferably, the cap may define a wrenchable portion having a plurality of flats for engagement by a wrench.
Often, the cap may include a pin extending from the top surface thereof. In such embodiments, the insulative disc may define a central bore in which the pin is received. In addition, embodiments are contemplated in which a cover is received over the insulative disc. The cover may be attached to the pin so as to be securely maintained in position. In some embodiments, the cover may be configured having a top portion from which a circumferential skirt depends.
A further aspect of the present invention provides a steam trap comprising a trap body having an inlet and an outlet each defining inner threads. The trap body further includes a spigot defining external threads. Also provided is a cap defining internal threads for engaging the external threads of the spigot of the trap body. The cap defines a top surface on which a disc of thermally insulative material is juxtaposed. The disc substantially covers the top surface of the cap in this aspect of the invention.
Still further aspects of the present invention are achieved by an assembly for use with a steam trap body. The assembly comprises a cap defining internal threads for engaging external threads of a spigot of the steam trap body. The cap further defines a top surface on which a disc of ceramic material is juxtaposed. The disc substantially covers the top surface of the cap. A cover, configured having a top portion from which a circumferential skirt depends, is received over the insulative disc.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a steam trap constructed in accordance with the present invention;
FIG. 2 is cross-sectional view of the steam trap of FIG. 1 ;
FIG. 3 is a view similar to FIG. 1 with components of the cap separated for purposes of illustration; and
FIG. 4 is a cross-sectional view similar to FIG. 2 but showing an alternative nameplate added to the top of the cap.
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, such broader aspects being embodied in the exemplary constructions.
FIG. 1 illustrates a novel steam trap 10 constructed in accordance with the present invention. Steam trap 10 has a trap body 12 to which a cap assembly 14 is attached. Referring now also to FIG. 2 , trap body 12 defines an inlet 16 and an outlet 18 through which the condensate flows. In this embodiment, inlet 16 and outlet 18 define internal threads for connection to a pipeline.
Inlet 16 is connected to an inlet passage 20 , whereas outlet 18 is connected to outlet passages 22 . Inlet passage 20 and outlet passage 22 emerge at a seating face 24 located at the end of a spigot 26 . As can be seen, cap assembly 14 includes a cap 28 having internal threads engaging outer threads on spigot 26 .
As can be seen most clearly in FIG. 1 , cap 28 preferably defines a series of flats 30 about its periphery for engagement by a wrench.
Along with seating face 24 , cap 28 defines a trap chamber 32 in which a valve element in the form of a metal disc 34 is located. Disc 34 is movable upwardly and downwardly within chamber 32 , its movement being limited by seating face 24 and an opposed stop face 36 on the interior of cap 28 . Typically, body 12 and cap 28 are made from metal such as stainless steel. As a result, these components have a relatively high thermal conductivity. As noted above, latent heat loss from a steam trap causes the valve to cycle at a higher rate than otherwise desired.
In accordance with the present invention, it has been found that much of this heat loss occurs at the top surface 38 of the cap. Thus, a thermally insulated element, such as insulative disc 40 , may be juxtaposed to top surface 38 in order to substantially reduce the heat loss. In the illustrated embodiment, for example, disc 40 is configured to substantially cover the entirety of top surface 38 . Preferably, for example, disc 40 will have a diameter that just fits inside the hexagon of the cap to provide maximum coverage.
Although disc 40 may be made of any suitable insulative material (such as an insulating fiber with a low “R” value), it is often formed of a hard ceramic disc in presently preferred embodiments. In this regard, the disc may preferably have a thickness of ⅜ inch. While being more expensive than some alternatives, ceramic provides a very stable and uniform material with very consistent insulation properties. Any industrial grade ceramic is believed suitable, and it does not need to be alloyed with anything.
It is contemplated that disc 40 may be attached to top surface 38 of cap 28 by any suitable means. In the illustrated embodiment, however, cap 28 includes a vertical pin 42 which is received in a central bore 44 defined in disc 40 . Preferably, pin 42 and bore 44 are dimensioned to form a tight fit between these two components. As a result, disc 40 will be maintained securely in proximity to top surface 38 of cap 28 , without rotating.
In presently preferred embodiments, cap assembly 14 further includes a cover 46 fitted over insulative disc 40 . In this case, cover 46 is configured having a top portion 48 from which a circumferential skirt 50 integrally depends. As a result, cover 46 forms a cup shaped element in which insulative disc 40 is received.
Top portion 48 defines a hole 52 in which an end portion of pin 42 is received. Preferably, the length of pin 42 will be such that its end surface will be substantially flush with top portion 48 of cover 46 when the entire assembly is put together ( FIG. 2 ). Alternatively, hole 52 can be eliminated in which case the length of pin 42 will preferably be equal to the thickness of disc 40 . Either way, a small spot weld may be made between pin 42 and cover 46 to maintain it and disc 40 securely in position.
In presently preferred embodiments, cover 46 may be stamped from thin metal. For example, in some preferred embodiments, metal having a thickness of generally about 30 thousandths of an inch may be used for this purpose. Preferably, skirt 50 is dimensioned to leave a slight air gap 54 between it and top surface 38 of cap 28 . This has been found desirable to reduce thermal conduction which could cause cover 46 to undesirably function as a heat exchanger.
Advantageously, various indicia, such as manufacturer name, part number and the like, may be applied on the top portion 48 of cover 46 for both aesthetic and identification reasons. Alternatively, a separate plate 56 ( FIG. 4 ) with this information may be attached to the top portion of cover 46 . In this embodiment, plate 56 can be spot welded to pin 42 to maintain disc 40 and cover 46 in place. Although plate 56 is depicted with a diameter approximately equal to that of top portion 48 , embodiments are contemplated in which the diameter of plate 56 is either greater or less.
In operation, condensate reaches trap 10 at inlet 16 . The condensate flows through inlet passage 20 , lifting disc 34 off of seating face 24 . The condensate continues through outlet passages 22 and leaves trap 10 through outlet 18 .
As steam approaches the trap, the temperature of the condensate increases. When the hot condensate passes between disc 34 and seating face 24 , a portion of it evaporates and forms flash steam. The resulting expansion causes an increase in volume of the flowing mixture of flash steam and condensate, thus increasing the velocity. This causes a local reduction in pressure between disc 34 and seating face 24 , which pushes disc 34 into engagement with seating face 24 .
A steam bubble within chamber 32 retains disc 34 against seating face 24 , thus resisting the pressure in the upstream pipeline. It will be appreciated, however, that loss of latent heat will cause this steam bubble to collapse prematurely which results in excessive cycling of steam trap 10 . The presence of insulative disc 40 has been found to reduce the cycle rate by between 25% to 30%, which facilitates a possible increase in the useful life of the steam trap. In addition, disc 40 has been found to reduce the temperature of the condensate before discharge making steam 10 trap more energy efficient.
It can thus be seen that the present invention provides a steam trap having a novel configuration. While preferred embodiments of the invention have been shown and described, modifications and variations may be made thereto by those of skill in the art without departing from the spirit and scope of the present invention. It should also be understood that aspects of those embodiments may be interchangeable in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to be limitative of the invention described herein. | A steam trap comprises a trap body having an inlet and an outlet each defining inner threads. The trap body further includes a spigot defining external threads. Also provided is a cap defining internal threads for engaging the external threads of the spigot of the trap body. A valve element freely moves inside a trap chamber defined between an inner surface of the cap and the valve seat of the spigot. The cap defines a top surface on which a disc of thermally insulative material is juxtaposed. A cup-shaped cover, which may carry indicia such as manufacturer name and model number, is received over the thermally insulative disc. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to the improvement of an agricultural harvester. More specifically it relates to an improvement for the attachment and removal of windguard or guide assembly tines on a windguard guide assembly.
BACKGROUND OF THE INVENTION
[0002] Crop gathering devices for collecting crops arranged in windrows can include a belt positioned along the front of the device. The belt is driven to rotate between opposed pairs of roller assemblies to convey the crops into a header that is secured to an agricultural harvester, such as a combine which is directed along the windrow. One or more wheels is located near the belt opposite the header to maintain a spacing between the belt and the ground that most effectively conveys crops onto the belt.
[0003] Positioned above the crop gathering device, also referred to as a windrow pickup, is a guide assembly, also referred to as a windguard assembly. The guide assembly tines ensure that the crop material is properly conveyed into the header in spite of any wind or varying crop conditions. Typically, the guide assembly consists of a pipe and a series of tines held in position above and in front of the pickup. Affixed to the pipe are a series of tines. The pipe may be raised or lowered by activating hydraulic cylinders on each end by the operator from the combine cab. Tine angular adjustment may also be performed manually at the end of the pipe. These tines frequently break off or are damaged during the life of the crop gathering device. The guide or windguard tines are typically wrapped, welded or bolted onto the pipe making replacement difficult. The prior art shows a variety of means to attach the windguard tines to the pipe, however these methods have not been entirely successful.
[0004] What is needed are replaceable guide assembly tines that can be easily removed for servicing or replacement with a minimum or complete absence of tools.
SUMMARY OF THE INVENTION
[0005] The present invention relates to an agricultural harvester including a frame carrying a structure movable about an endless path to deliver a crop to a header. The frame includes a guide assembly further including a guide member supported by the frame. The frame includes at least one tine secured to the guide member without extending through the guide member, and the at least one tine extending from the guide member above the structure to guide the crop between the at least one tine and the structure to the header. The at least one tine is installable and removable from the guide member without disconnecting the guide member from the frame. The at least one tine is installable and removable from the guide member without tools.
[0006] The present invention further relates to a guide assembly for use with an agricultural harvester having a frame carrying a structure movable about an endless path to deliver a crop to a header. The guide assembly includes a guide member supportable by the frame. At least one tine is securable over an exterior surface of the guide member without extending through the guide member, and is configured to extend from the guide member above the structure to guide the crop between the at least one tine and the structure to the header. The at least one tine is removable from the guide member without disconnecting the guide member from the frame. The at least one tine is removable from the guide member substantially without tools.
[0007] The present invention yet further relates to an agricultural harvester including a frame carrying a structure movable about an endless path to deliver a crop to a header. The frame includes a guide assembly further including a guide member supported by the frame. The frame also includes at least one tine secured over an exterior surface of the guide member without extending through the guide member, and extending from the guide member above the structure to guide the crop between the at least one tine and the structure to the header. The at least one tine is installable and removable from the guide member without disconnecting the guide member from the frame. The at least one tine is installable and removable from the guide member substantially without tools.
[0008] An advantage of the present invention is the installation/replacement of a guide or windrow tine with minimal or no tools.
[0009] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a top perspective view of an embodiment of a crop gathering device and harvesting header of the present invention.
[0011] FIG. 2 is a top perspective view of an embodiment of a guide or windguard tine construction of the crop gathering device of FIG. 1 of the present invention.
[0012] FIG. 3 is an enlarged, partial perspective view of the guide or windguard tine construction of FIG. 1 assembled to the frame of the crop gathering device of the present invention.
[0013] FIG. 4 is a cross section taken along line 4 - 4 of FIG. 3 of the guide or windguard tine construction of FIG. 1 assembled to the frame of the crop gathering device of the present invention.
[0014] FIG. 5 is an enlarged, partial plan view of the guide or windguard tine construction of FIG. 1 assembled to the frame of the crop gathering device of the present invention.
[0015] FIG. 6 is an enlarged, partial perspective view of an alternate guide or windguard tine construction partially assembled to the frame of the crop gathering device of the present invention.
[0016] FIG. 7 is an partially enlarged, partial plan view of an alternate guide or windguard tine construction partially assembled to the frame of the crop gathering device of the present invention.
[0017] FIG. 8 is a cross section taken along line 8 - 8 of FIG. 6 of an alternate guide or windguard tine construction assembled to the frame of the crop gathering device of the present invention.
[0018] FIG. 9 is an enlarged, partial perspective view of a further alternate guide or windguard tine construction partially assembled to the frame of the crop gathering device of the present invention.
[0019] FIG. 10 is an enlarged, partial plan view of a further alternate guide or windguard tine construction partially assembled to the frame of the crop gathering device of the present invention.
[0020] FIG. 11 is a cross section taken along line 11 - 11 of FIG. 9 of a further alternate guide or windguard tine construction assembled to the frame of the crop gathering device of the present invention.
[0021] FIG. 12 is a top perspective view of an embodiment of a guide or windguard tine construction of the present invention.
[0022] FIG. 13 is a cross section taken along line 13 - 13 of FIG. 12 of the guide or windguard tine construction of the present invention.
[0023] FIGS. 14 and 15 are respective top perspective and plan views of an alternate arrangement of the embodiment of the guide or windguard tine construction of the present invention.
[0024] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a crop gathering device 12 for use with a harvesting header 10 . Harvesting header 10 may be secured to an agricultural harvester such as a combine (not shown) as is known in the art and not further discussed. A frame 14 carries a structure 22 movable about an endless path to deliver a crop to harvesting header 10 . In one embodiment, structure 22 is a belt, or multiple belts, that extends from one end 18 of frame 14 toward another end 20 of frame 14 . Structure 22 may be driven about a set of parallel rollers (not shown) by a power source such as a hydraulic motor 34 . Structure 22 may include a plurality of prongs 24 or fork-like components extending outwardly from the structure to assist with collecting crops arranged in a windrow. Wheels 26 may be rotatably secured to or near respective ends 18 , 20 of frame 14 opposite header 10 to maintain one end of structure 22 near the ground 36 to permit prongs 24 of structure 22 to gather or collect crops arranged in the windrow. A guide member 28 equipped with tines 30 , collectively defining a guide assembly 32 , may be positioned over structure 22 to more effectively feed or deliver crops from structure 22 to header 10 especially during windy conditions.
[0026] Referring to FIG. 2 , an exemplary embodiment of tine 30 includes an elongated first leg 36 extending to a first transition portion 38 and then further extending to a second transition portion 40 . As further shown in FIG. 2 , second transition portion 40 bridges first transition portion 38 with a third transition portion 42 . Tine 30 then further extends from third transition portion 42 to any elongated second leg 44 . Shown in FIG. 2 , dividing the embodiment of tine 30 into two pieces along a midpoint 41 of second transition portion 40 provides two mirror-image components. That is, legs 36 and 44 may be identical and/or symmetric with each other, while first transition portion 38 continuously extending to one half of second transition portion 40 may symmetrically correspond to the other one half of second transition portion 40 contiguously extending to third transition portion 42 . In one embodiment, tine 30 is composed of metal, although nonmetal materials may be used, such as fiberglass, polymerics or other suitable materials.
[0027] Referring to FIGS. 3-5 , the exemplary embodiment of tine 30 is assembled to guide member 28 , forming guide assembly 32 . In one embodiment, an angular adjustment mechanism 58 may be positioned at opposed ends of guide assembly 32 , permitting angular adjustment of guides assembly 32 with respect to structure 22 ( FIG. 1 ) to accommodate operating conditions, such as the amount of wind and the relative size of the crop being harvested. That is, by pivoting angular adjustment mechanism 58 about an axis 43 , the angular orientation and relative distance between legs 36 and 44 and structure 22 may be selectively varied. An alternate version could use only one adjustment mechanism on one end of the guide assembly.
[0028] Further referring to FIGS. 3-5 , tine 30 is secured to guide member 28 . In one embodiment, guide member 28 , shown having a circular cross section ( FIG. 4 ) includes an overlay member 46 that may be welded, adhered, mechanically fastened or otherwise secured to guide member 28 . In one embodiment, overlay member 46 extends over a substantial portion of the length of guide member 28 , although in other embodiments, numerous overlay members 46 may be aligned and secured to guide member 28 . As shown, overlay member 46 defines an angle member having legs 53 , 55 secured to guide member 28 so that corner 57 of overlay member 46 joining legs 53 , 55 extends outwardly from guide member 28 . Overlay member 46 includes a tab 52 extending from an end of legs 55 opposite corner 57 , defining a second mating feature 50 corresponding with second transition portion 40 of tine 30 when brought into engagement with each other. In an alternate embodiment, tab 52 may be formed from a flap formed in guide member 28 so that the flap is of unitary construction with guide member 28 .
[0029] Once second transition portion 40 and second mating feature 50 have been brought and assembled together, tine 30 may be rotated about the axis defined by second mating feature 50 in a rotational direction 70 ( FIG. 3 ) until the junction between third transition portion 42 and second leg 44 is brought into proximity with third mating feature 66 , and similarly the junction between first transition portion 38 and first leg 36 is brought into proximity with first mating feature 48 . As shown, first mating feature 48 and third mating feature 66 define slots formed in an end of leg 53 of overlay member 46 opposite corner 57 . Since a distance 64 , which separates legs 36 and 44 is greater than a distance 62 between first mating feature 48 and third mating feature 66 , legs 36 and 44 may not be brought into mating engagement with their respective mating features 48 , 66 . However, by application of sufficient opposed forces 68 applied to legs 36 , 44 , distance 64 between legs 36 and 44 is reduced until distance 64 is less than distance 62 , permitting legs 36 , 44 to be brought into proximity with respective mating features 48 , 66 by further rotation of tines 30 about the axis defined by second mating feature 50 in rotational direction 70 . That is, as shown in FIG. 4 , tines 30 are rotated about the axis defined by second mating feature 50 until third transition portion 42 and first transition portion 38 are each brought into abutting contact with surfaces 54 , 56 of respective legs 53 , 55 of overlay member 46 . However, in an alternate embodiment, surfaces 54 , 56 of respective legs 53 , 55 of overlay member are not brought into abutting contact with each other in response to legs 36 , 44 being brought into proximity with respective mating features 48 , 66 . Once opposed forces 68 are no longer applied to legs 36 and 44 , elastic restorative retention forces applied by tines 30 increase the distance between legs 36 and 44 and permitting mating engagement with respective mating features 48 , 66 .
[0030] It is to be understood that although mating features 48 , 66 may be parallel with the axis defined by second mating feature 50 , as in the exemplary embodiment, such alignment is not required. That is, a combination of opposed forces such as opposed forces 68 in addition with twisting court portion will forces (not shown) may be required to achieve mating engagement between the corresponding portions of tines 30 and guide member 28 , which includes overlay member 46 .
[0031] It is to be understood that in other embodiments, different profiles of overlay member and corresponding transition portions of times may be used. Optionally, mating features may be formed directly in guide member without use of an overlay member. In a further embodiment, a portion of the mating features may be formed directly in the guide member with the remaining portion of mating features formed in the overlay member.
[0032] Referring to FIGS. 6-8 , tine 130 is secured to guide member 28 in a manner similar with that associated with FIGS. 3-5 . A difference between tine 130 and tine 30 is that tine 130 is configured for use with shorter crops and utilizes legs 136 , 144 instead of legs 36 , 44 used with tine 30 .
[0033] Referring to FIGS. 9-11 , tine 230 is secured to guide member 28 in a manner similar with that associated with securing tine 30 in FIGS. 3-5 , with the exception that only two mating engagements are required to secure tine 230 instead of the three mating engagement required to secure tine 30 . Such circumstances would occur, for example with a tine embodiment containing a single leg, instead of a pair of legs. As further shown in FIGS. 9-11 , tine 230 includes a first leg 236 extending to a first transition portion 238 and then further extending to a second transition portion 240 . Overlay member 246 is similar to overlay member 46 . Once second transition portion 240 and second mating feature 250 associated with a tab 252 formed in overlay member 246 have been brought and assembled together, tine 230 may be rotated about the axis defined by second mating feature 250 in a rotational direction 70 ( FIG. 9 ) until the junction between first transition portion 238 and first leg 236 is brought into proximity with first mating feature 48 . As further shown in FIGS. 9 and 10 , first mating feature 48 defines a slot formed in an end of leg 53 of overlay member 246 opposite corner 57 . Leg 236 is configured so that leg 236 may not be brought into mating engagement with its corresponding first mating feature 48 . However, application of sufficient force 270 that is parallel to the axis defined by second mating feature 250 and directed away from first mating feature 48 and applied to legs 236 , permits leg 236 to be brought into proximity with first mating feature 48 when accompanied by further rotation of tine 230 about the axis defined by second mating feature 250 in rotational direction 70 . Also, as shown in FIG. 9 , tine 230 is rotated about the axis defined by second mating feature 250 until first transition portion 238 is brought into abutting contact with surfaces 54 , 56 of respective legs 53 , 55 of overlay member 246 . Once force 270 is no longer applied to leg 236 , elastic restorative retention forces applied by tines 230 permits mating engagement with first mating feature 48 .
[0034] It is to be understood that second transition portion 240 may permit rotation about the axis defined by second mating feature 250 , but may further include a protrusion 242 or other feature that permits second transition portion 240 to remain in mating engagement with second mating feature 250 when leg 236 is in mating engagement with first mating feature 48 .
[0035] It is to be understood that while second mating feature 50 and 250 face in opposite directions and that mating features 48 , 66 are shown perpendicular to mating features 50 and 250 in the exemplary embodiments, the present invention is not so limited, and that alternative embodiments may have mating features that are neither parallel nor perpendicular to each other.
[0036] Referring to FIGS. 12-15 is an arrangement of alternating tines 30 , 130 of the present invention. Fasteners 72 extending through a recess 80 formed in tab 252 of overlay member 46 secure tines 130 to overlay member 46 . A spanner/support 74 utilizes notches 78 to maintain legs 136 , 144 at a predetermined spacing from each other. FIGS. 14-15 further show an alternate arrangement in which legs 136 , 144 of tines 130 are rotated out of the way. To maintain legs 136 , 144 of tines 130 in its rotated position, notched ends of a spanner/support 74 engage corresponding legs of adjacent tines 30 . Tines 130 should be rotated upward, or removed, when harvesting normal sized windrows rather than short, light crops Tines 130 could be in either position for road travel, but when raised, the tines will be less susceptible to “bouncing”, resulting in reduced noise. In an alternate embodiment, overlay member 46 may include mating features to secure one or more legs of tines 130 .
[0037] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | An agricultural harvester is provided that Includes a frame carrying a structure movable about an endless path to deliver a crop to a header. The frame includes a guide assembly including a guide member supported by the frame. The frame also includes at least one tine secured to the guide member without extending through the guide member, and the at least one tine extending from the guide member above the structure to guide the crop between the at least one tine and the structure to the header. The at least one tine is installable and removable from the guide member without disconnecting the guide member from the frame. At least one tine is installable and removable from the guide member substantially without tools. | 0 |
This is a continuation-in-part application of U.S. application Ser. No. 08/345,682, filed Nov. 21, 1994, now U.S. Pat. No. 5,508,970 which is a divisional application of U.S. application Ser. No. 08/111,046, filed Aug. 24, 1993 U.S. Pat. No. 5,392,254.
FIELD OF THE INVENTION
The present invention relates to a semiconductor memory device, and more specifically to a semiconductor memory device suitable for a clock-synchronous random access memory which can output data at high speed and at random. Further, the present invention relates to a data transfer system for a memory device provided with high speed characteristics and a certain random access function such as synchronous DRAM.
BACKGROUND OF THE INVENTION
With the recent advance of higher processing speed, a microprocessor is provided with a primary memory device of a large capacity. In accompany with the large capacity primary memory device, there has been proposed a memory device capable of accessing data at high speed at the sacrifice of random characteristics of data access, in order to solve a bottleneck with respect to low processing speed due of the low access speed of the external memory device.
An example of the memory device as described above has been proposed (not yet published) by the same inventors in Japanese Patent Application No. 3-255354, in which an address is acquired within a predetermined number of cycles of a basic clock supplied to the system and further data input and output starts a predetermined cycles after the cycle at which the address is acquired. In addition, Japanese Patent Application No. 4-638135 (not yet published) discloses a memory device provided with internal data registers, which operates as follows: a group of access data are stored in the internal registers temporarily for data access between the outside and the memory cells. The data to be stored in the registers are selected by scrambler circuits; that is, a scrambler control circuit controls the scrambler circuits so that access data can be stored cyclically in the respective registers at predetermined sequence for each cycle of a clock signal. Further, the data are inputted and outputted between the outside and the registers via an input/output buffer. In response to a head address indicative of data access start, a predetermined selection sequence of the scrambler circuits is determined.
The above-mentioned semiconductor memory device will be described in more detail with reference to FIG. 4. In FIG. 4, a column decoder 1 selects one of cell blocks CB1 to CB5 of a memory core 2. Each of the cell blocks CB1 to CB5 includes 4 columns CM1 to CM4. Data stored in the four columns CM1 to CM4 of one of the cell blocks CB1 to CB5 (selected by the column decoder 1) are outputted to data lines DLN simultaneously. The data on the data lines DLN are transferred to read/write data lines RWD via a data buffer 4. The read/write data lines RWD are connected to data registers 51 and 52 via scrambler circuits 61 and 62, respectively. A scrambler control circuit 7 controls the two scrambler circuits 61 and 62 so that the data on the read/write data line RWD can be selectively stored 2 bits by 2 bits in data areas R1, R2, R3 and R4 of the data registers 51 and 52, respectively. The data stored in the data registers 51 and 52 are selected by a data selection section 9 and then outputted through a data output buffer 8 as data output.
The operation of the memory device as shown in FIG. 4 will be described hereinbelow.
One block of the five cell blocks CB1 to CB5 of the memory cell 2 is selected by the column decoder 1. Data of the four columns CM1 to CM4 of the selected block are read simultaneously to the data lines DLN, and then transferred to the read/write data lines RWD via the data buffer 4. The four bit data are selectively stored 2 bits by 2 bits in the data areas R1, R2, R3 and R4 of the data registers 51 and 52, respectively via the scrambler circuits 61 and 62 controlled by the scrambler control circuit 7. For instance, the access sequence of the data areas R1, R2, R3 and R4 of the data registers 51 and 52 is as follows: R1, R2, R3 and R4. The data stored in the data areas R1, R2, R3 and R4 are selected by the data selector section 9, transferred to the data output buffer 8, and then outputted therefrom as the data output.
In the semiconductor memory device as described above, however, there exists a problem in that it is impossible to start data access beginning from any given bit of the columns CM1 to CM4, when data more than 4 bits (the number of data areas) are required to be outputted from the data areas R1, R2, R3 and R4 of the data registers 51 and 52. The reason is as follows: since the columns CM1 to CM4 selected by the column decoder 1 are fixed, when 8-bit data are accessed, it is impossible to constitute 8-bit data by simply combining 2 sets of 4-bit data. In other words, it is impossible to obtain an 8-bit continuous access. For example, if the access sequence as "3"-"4"-"5"-"6"-"7"-"8"-"1"-"2" is required, the access sequence is inevitably determined as "3"-"4"-"1"-"2"-"5"-"6"-"7"-"8" or "3"-"4"-"1"-"2"-"7"-"8"-"5"-"6". Although this problem can be solved by using more larger-scale registers or by scarifying the access speed, this method raises another problem in that the memory characteristics of the synchronous memory device are deteriorated.
SUMMARY OF THE INVENTION
With these problems in mind, therefore, the object of the present invention is to provide a clock-synchronous semiconductor memory device high in access speed, by which data of column bits more than the number of registers can be accessed continuously, in spite of the minimum number of registers, and further the column address from which the access starts can be selected freely.
To achieve the above-mentioned object, the present invention provides a semiconductor memory device, comprising: a memory cell array composed of a plurality of memory cells arranged roughly in a matrix pattern including a plurality of columns; data register means provided with two first and second registers each having a-units of one-bit data register; control means for selecting two sets of a-units of the column from a plurality of the columns for each a-cycles in accordance with inputted and read addresses, and for storing the a-units of data of the selected 2a-units of column in either one of the first and second registers alternately on the basis of a sequence of the read addresses; and data output means for scanning and outputting data of the 2a-units of the one-bit data register in sequence.
The data output means outputs data in synchronism with a clock inputted from the outside. The a-units of the column forms one column group in said memory cell array. The control means comprises a plurality of column select lines each for selecting one column group. The columns are connected to the one-bit data registers, respectively through a data transfer line. The data transfer line includes 2a-units of data transfer line.
The control means executes such a first control operation, in response to a head column address for data output, that 2a-units of data on 2a-units of the column are transferred to 2a-units of the data transfer lines, by activating the column select lines for selecting the column address group including a column corresponding to the head column address and further the column select lines for selecting the column group including columns corresponding to the column addresses selected successively in sequence. Further, the control means executes such a second control operation that any given column data are outputted as head data for each a-cycles, by selecting a-units of data from the 2a-units of data onto 2a-units of the data transfer lines, by storing the selected data in a-units of the one-bit data register of the registers, to which data are not stored in the preceding data transfer operation, in output sequence, and by repeating the above-mentioned operation.
In accordance with the read address, the control means selectively turns on two predetermined groups of column gate groups to transfer 2a-unit data to the data line groups. Further, a-unit data (based on the read address) of 2a-unit data are stored in the a-unit registers of the first data register group in sequence of the data read operation under control of the control means. The same operation is applied to the second data register group. The above-mentioned operation is repeated to output the data from the respective columns in read address sequence.
In the semiconductor memory device according to the present invention, column data more than the number of the data registers arranged on the output side can be accessed continuously, irrespective of the number of the data registers directly, and further any access start address can be determined.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is block diagram showing one embodiment of the semiconductor memory device according to the present invention;
FIG. 2 is a timing chart for assistance in explaining the operation of the memory device shown in FIG. 1;
FIG. 3 is a block diagram showing another embodiment of the semiconductor memory device according to the present invention;
FIG. 4 is a block diagram showing a semiconductor memory device disclosed in a prior application by the same inventors;
FIGS. 5 and 6 are block diagrams showing other embodiments of the present invention; and
FIG. 7 is an illustration for assistance in explaining the present invention in more generic form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention will be described hereinbelow with reference to the attached drawings.
FIG. 1 is a block diagram showing one embodiment of the semiconductor memory device according to the present invention. In the drawing, a memory cell array MCA includes a plurality of memory cells arranged in matrix pattern. To the memory cell array MCA, decode signals are applied from a row decoder RD. As shown in FIG. 1, columns b11, b12, b21, b22, b31, b32, b41, b42, . . . , b(n/2)1, b(n/2)2 which constitute the memory cell array 1 have a pair of complementary bit lines, respectively. Data on the bit lines can be read by sensing the bit line data by sense amplifiers. The columns b11, b12, b21, b22, b31, b32, b41, b42, . . . , b(n/2)1, b(n/2)2 are connected to column gates 11, 12, 13, 14, 15, 16, 17, 18, . . . , ln-1, ln, respectively. The column gates 11 to in are turned on or off by column select lines C1 to Cn/2, respectively. Two of the column select lines are selected by a column gate group selection circuit CGS. Two column gates are turned on by the single selected column select line. Data on the columns b11, b12, . . . , b(n/2)1, b(n/2)2 are transmitted to data lines DLN through the column gates 11 to ln. A scrambler control circuit 10 controls scrambler circuits 61 and 62, and further selects two column select lines C1 to Cn/2 through the column gate group selection circuit CGS. To the scrambler control circuit 10, a read address A READ is applied.
The operation of the memory device thus constructed will be explained hereinbelow.
When the column select line C1 is activated, two data on the columns b11 and b12 are outputted to the data lines DLN through the column gates 11 and 12. In the same way, when the column select line C2 is activated, two data on the columns b21 and b22 are outputted to the data lines DLN through the column gates 13 and 14. In the same way, when the column select line Cn/2 is activated, two data on the columns b(n/2)1, b(n/2)2 are outputted to the data lines DLN through the column gates ln-1 and ln.
Here, two of the column select lines C1 to Cn/2 are activated simultaneously by the scrambler control circuit 10. As a result, four of the column gates 11 to in can be selected, so that 4-bit data are outputted from the four columns to the data lines DLN. In this case, the column select lines C1 to Cn/2 are selected in such a way that a plurality of the data are not outputted to the same data lines DLN for prevention of data interference. For instance, the column select lines C1 and C3 are not selected simultaneously.
The 4-bit data transferred to the data line DLN are amplified by the data buffer 4, and then transferred to the read/write data lines RWD. Two bits of each of the 4-bit data transferred to the read/write lines RWD as described above are selected by the scrambler circuits 61 and 62, respectively, and then stored in data areas R1 and R2 of a data register 51 or in data areas R3 and R4 of a data register 52, respectively under control of the scrambler control circuit 10 to the scrambler circuits 61 and 62. The data in the areas R1, R2, R3 and R4 of the data registers 51 and 52 are selected by a data selection section 9, and then outputted to the outside through a data output buffer 8 as data output.
FIG. 2 is a timing chart which shows the above-mentioned operation in sequence with respect to time. In FIG. 2, (A) indicates a basic clock CLK; (B) indicates a column address select signal /CAS; (C) indicates data including data to be stored in the data areas R1/R2, respectively; (D) indicates a timing at which data are stored in the data areas R1/R2, respectively; (E) indicates a timing at which data are stored in the data areas R3/R4, respectively; (F) indicates data including data to be stored in the data areas R3/R4, respectively; (G), (H) and (I) indicate the statuses of output 1, output 2 and output 3 derived as data output, respectively; and (J) indicates the statuses of the column select lines C1 to Cn/2, respectively.
The selection of the column select lines C1 to Cn/2 are executed newly for each cycle "1", "3", "5", "7", . . . of the clock CLK. The data at the newly selected columns b11 to b(n/2)2 develop on the read/write data lines RWD roughly after two cycles as deterministic data. FIGS. 2(C) and (F) show these deterministic data. Each of these data can be determined being transferred 4 bits by 4 bits. Two bits of the four bits are stored in the data registers 51 and 52, respectively. Therefore, in FIG. 2, data are shown for each data register 51 or 52. Here, FIG. 2 (C) shows 4-bit data including 2-bit data to be stored in the data areas R1 and R2 of the data register 51. Further, FIG. 2 (F) shows 4-bit data including 2-bit data to be stored in the data areas R3 and R4 of the data register 52. When these data have been stored in the data registers 51 and 52 at the time point at which having been determined, it is possible to output these data to the outside by accessing the data stored in the data areas R1, R2, R3 and R4 in sequence with the use of the data selection section 9. FIGS. 2(D) and (E) show the timings at which the data are stored in the data registers 51 and 52 under control of the scrambler control circuit 10. In more detail, when a data storing signal is at "H" level, data are held in the data areas R1, R2, R3 and R4 of the data registers 51 and 52. On the other hand, when a data storing signal is at "T" level, data of the 4-bit data on the read/write data lines RWD are stored in the data areas R1, R2, R3 and R4 of the data registers 51 and 52 in accordance with the selection of the scrambler circuits 61 and 62.
The data output 1 can be obtained from an address determined in response to the clock CLK "1" as follows: The column address select lines C1 to Cn/2 including the determined head address and the column address select lines C1 to Cn/2 adjacent thereto in the output sequence direction are selectively activated under control of the scrambler control circuit 10. Consequently, the corresponding column gates 11, 12, 13, . . . , in are selected, so that 4-bit data are outputted to the data lines DLN. These data are sensed by the data buffer 4 to determine the read/write data line RWD, as shown in FIG. 2(C). Data which constitute the first two bits of the 4-bit output 1 are stored in the data areas R1 and R2 through the scrambler circuit 61, at the timing as shown in FIG. 2(D). Thereafter, in response to the clock "3" two cycles after the cycle at which the head address has been determined, even if an address is not determined from the outside, the scrambler control circuit 10 activates the column select lines in the same way as with the case where the third address of the output 1 has been determined from the outside. FIG. 2(F) shows the status in which the data are read to the data lines DLN and further determined by the read/write data lines RWD. The third and fourth bits of the 4-bit output 1 determined as described above are stored in the data areas R3 and R4 of the data register 52 through the scrambler circuit 62, as shown in FIG. 2(E). The similar operation is repeated in sequence for each two cycles of the clock CLK.
On the other hand, the data stored in the data registers 51 and 52 are accessed in the sequence of the data areas R1, R2, R3 and R4 as shown over the clock CLK in FIG. 2(A). After having been transferred to the read/write data lines RWD, the data are stored in the data registers 51 and 52 in accordance with the address sequence expected by the scrambler control circuit 10. Therefore, it is possible to output the data in the expected sequence. 0n the other hand, when the head address of a series of the data is determined again, the data can be outputted as the output 2 or the output 3, as shown in FIGS. 2(H) and (I), respectively. In more detail, when data are required to be outputted continuously beginning from a new address in response to the clock CLK "12", a new head address is determined from the outside in response to the clock CLK 9. Then, new data can be transferred in the same way as described above; the data are determined as shown by A in FIG. 2(C); stored in the data areas R1 and R2; and further outputted continuously following the output 1.
Further, before a series of the data of the output 2 are outputted, a new head address of the output 3 is determined. The data of the output 3 are outputted beginning from the data area R3 of the data register 52. The sequence of the data transfer is the same as with the case of the outputs 1 and 2. The new head address is determined at the row of the clock CLK "11". The 4-bit data including the head address are determined on the read/write data lines RWD, as shown by B in FIG. 2(F). The 2 bits of the 4-bit data are selected by the scrambler circuit 62, and stored in the data areas R3 and R4 of the data register 52 at the timing as shown in FIG. 2(E). In the same way, the 4-bit data are transferred for each two cycles, and further 2 bits of the data are selected. The above-mentioned sequence is repeated to output a series of data continuously.
Further, in the case where a series of 8-bit data are outputted, the scrambler control circuit 10 selects the column select lines C1 to Cn/2 and the scrambler circuits 61 and 62, respectively in sequence as follows: Here, the description will be made on condition that the column select lines C1 to C4 shown in FIG. 1 correspond to the data sequence of a series of 8-bit data.
The mode in which 8-bit data are accessed in series circularly will be first explained. In this case, the number of the head address is eight. Table 1 lists the relationship among the eight serial and cyclic access modes classified according to the eight head address, a pair of select lines C1 to C4 to be selected, 2-bit read/write data lines RWD to be selected from the read/write data lines RWD on which the 4-bit data have been determined, and the data areas R1 to R4 of the data registers 51 and 52, respectively.
TABLE 1______________________________________SER ACCESS SEQ (a) R1 R2 R3 R4 R1 R2 R3 R4______________________________________(1) (A)(c1,c2) (c2,c3) (c3,c4) (c4,c1)1-2-3-4-5-6-7-8 (B) 1 2 3 4 1 2 3 4(2) (A)(c1,c2) (c2,c3) (c3,c4) (c4,c1)2-3-4-5-6-7-8-1 (B) 2 3 4 1 2 3 4 1(3) (A)(c2,c3) (c3,c4) (c4,c1) (c1,c2)3-4-5-6-7-8-1-2 (B) 3 4 1 2 3 4 1 2(4) (A)(c2,c3) (c3,c4) (c4,c1) (c1,c2)4-5-6-7-8-1-2-3 (B) 4 1 2 3 4 1 2 3(5) (A)(c3,c4) (c4,c1) (c1,c2) (c2,c3)5-6-7-8-1-2-3-4 (B) 1 2 3 4 1 2 3 4(6) (A)(c3,c4) (c4,c1) (c1,c2) (c2,c3)6-7-8-1-2-3-4-5 (B) 2 3 4 1 2 3 4 1(7) (A)(c4,c1) (c1,c2) (c2,c3) (c3,c4)7-8-1-2-3-4-5-6 (B) 3 4 1 2 3 4 1 2(8) (A)(c4,c1) (c1,c2) (c2,c3) (c3,c4)8-1-2-3-4-5-6-7 (B) 4 1 2 3 4 1 2 3______________________________________ (a): DATA AREAS OF DATA REGISTERS (A): A PAIR OF COLUMN SELECT LINES SELECTED (B): RWD LINES CONNECTED TO REGISTERS
The mode in which 3 address bits representative of the 8-bit series data are accessed by repeating "0" and "1" in sequence irrespective of the carry bit from the least significant bit will be next explained. In this access sequence, the least significant bit repeats "0" and "1" alternately for each cycle; the second bit repeats "0" and "1" for each two cycles as "00110011"; and the third bit repeats "0" or "1" for each four cycles as "0000111100001111". Table 2 lists the similar relationship among the eight serial and cyclic access modes classified according to the eight head address, a pair of select lines C1 to C4 to be selected, 2-bit read/write data lines RWD to be selected from the read/write data lines RWD on which the 4-bit data have been determined, and the data areas R1 to R4 of the data registers 51 and 52, respectively.
TABLE 2______________________________________SER ACCESS SEQ (a) R1 R2 R3 R4 R1 R2 R3 R4______________________________________(1) (A)(c1,c2) (c2,c3) (c3,c4) (c4,c1)1-2-3-4-5-6-7-8 (B) 1 2 3 4 1 2 3 4(2) (A)(c1,c2) (c2, c3) (c3, c4) (c4,c1)2-1-4-3-6-5-8-7 (B) 2 3 4 3 2 1 4 3(3) (A)(c2,c1) (c1,c4) (c4,c3) (c3,c2)3-4-1-2-7-8-5-6 (B) 3 4 1 2 3 4 1 2(4) (A)(c2,c1) (c1,c4) (c4,c3) (c3,c2)4-3-2-1-8-7-6-5 (B) 4 3 2 1 4 3 2 1(5) (A)(c3,c4) (c4,c1) (c1,c2) (c2,c3)5-6-7-8-1-2-3-4 (B) 1 2 3 4 1 2 3 4(6) (A)(c3,c4) (c4,c1) (c1,c2) (c2,c3)6-5-8-7-2-1-4-3 (B) 2 1 4 3 2 1 4 3(7) (A)(c4,c3) (c3,c2) (c2,c1) (c1,c4)7-8-5-6-3-4-1-2 (B) 3 4 1 2 3 4 1 2(8) (A)(c4,c3) (c3,c2) (c2,c1) (c1,c4)8-7-6-5-4-3-2-1 (B) 4 3 2 1 1 3 2 1______________________________________ (a): DATA AREAS OF DATA REGISTERS (A): A PAIR OF COLUMN SELECT LINES SELECTED (B): RWD LINES CONNECTED TO REGISTERS
In Tables 1 and 2, the selection (A) of the column select lines C1 to Cn/2 and the connection (B) of the selected read/write data lines RWD to the data areas R1, R2, R3 and R4 of the data registers 51 and 52 are both shown in the same column from the functional standpoint. However, the operational timings are different from each other. Further, the data selected and transferred through the column select lines C1 to Cn/2 are added thereafter to the data areas R1, R2, R3 and R4, as depicted by the timing chart shown in FIG. 2.
Further, in the above-mentioned embodiment, the number of columns b11 to b(n/2)2 connected to the data lines DLN simultaneously by the column select lines C1 to Cn/2 is two. In the actual system, however, this number changes according to the time required to determined the data beginning from the columns b11 to b(n/2)2 to the read/write data lines RWD.
FIG. 3 shows another embodiment of the semiconductor memory device according to the present invention, which is configured on the basis of the above-mentioned standpoint. In FIG. 3, two sets of the data stored in the columns b11, b23, b13, b21, b22, b23, . . . are selected simultaneously 3 bits by 3 bits through the column select lines C1, C2, . . . by the column gates 11, 12, 13, . . . . Therefore, the number of the data lines DLN and that of the read/write data lines RWD are six, respectively. Further, the number of bits of the data register 51 becomes 3 bits in correspondence to the data areas R1, R2 and R3, and similarly the number of bits of the data register 52 becomes 3 bits in correspondence to the data areas R4, R5 and R6.
As described above, in the configuration as shown in FIG. 3, two sets of the columns b11, b12 and b13; the columns b31, b32 and b33; the columns b41, 42 and 43 are selected simultaneously by the column gates 11, 12 and 13, and then outputted to the data lines DLN as 6-bit data. The outputted 6-bit data are transferred to the read/write data lines RWD through the data buffer 4, and further transferred to and stored in the data registers 51 and 52 3 bits by 3 bits through the scrambler circuits 61 and 62, respectively. The stored data can be outputted to the outside through the data buffer 8 by selecting the data areas R1, R2, R3, R4, R5 and R6 of the data registers 51 and 52 through the data selection section 9. In this embodiment, the addresses are updated for each 3 cycles.
In general, when the data are transferred from the columns to just before the registers within a (a indicates an integer) cycles, the number of the columns selected by one column select line is a. Therefore, when two column select lines are selected simultaneously, 2 a-bit data can be transferred. Here, although the number of output registers is 2a, the data are selectively stored in the a-unit registers by selecting a-bit data from the 2a-bit data. As described above, it is possible to access a series of data more than the number of the output registers by selecting the two column select lines for each a cycles.
In the above description, FIG. 1 shows the case where the number of registers of a single register group 51 or 52 is two, and FIG. 3 shows the case where the number of the registers thereof is extended to three. However, it is necessary to store data in any of the register groups 51 and 52 simultaneously as a series of continuous data in which data received from any arbitrary column is arranged as a head data. To satisfy the requirement, a plurality of the column select lines are selected simultaneously, as already described, and a string of data which always contain a series of data are transferred. After that, a series of the data are selected from the string of data, scrambled, and then stored in one of the register groups 51 and 52, respectively, as shown in FIGS. 1 and 2. However, there exist other methods. That is, in the case of the example as shown in FIG. 3, data twice the number of registers constituting the register group are selected and then transferred. However, it is unnecessary to determine the number of data to be transfer twice as large as the number of registers.
FIG. 5 shows another embodiment in which each register group is composed of three registers as in FIG. 3. However, the number of columns selected by one column select line is different between the embodiments shown in FIGS. 3 and 5. That is, the number of columns selected by the single column select line is three in the embodiment shown in FIG. 3 but two in the embodiment shown in FIG. 5.
In the case of FIG. 5, when the column select line corresponding to the head column and the column select line corresponding to the succeeding column are selected, data can be stored in each register group simultaneously in such a way that data of any arbitrary column can be arranged as the head data, as well understood with reference to Table 3 below. Table 3 lists the case where 6-bit serial access is made and the data access range is twice (i.e., eight) the number (i.e. four) of data transferred simultaneously.
TABLE 3______________________________________SERIAL ACCESS COLUMNSEQUENCE (FIG. 1) (a) R1 R2 R3 R4 R5 R6______________________________________(1) (A) (c1, c2) (c2, c3)1-2-3-4-5-6 (B) 1 2 3 4 1 2(2) (A) (c1, c2) (c3, c4)2-3-4-5-6-7 (B) 2 3 4 1 2 3(3) (A) (c2, c3) (c3, c4)3-4-5-6-7-8 (B) 3 4 1 2 3 4(4) (A) (c2, c3) (c1, c4)4-5-6-7-8-1 (B) 4 1 2 3 4 1(5) (A) (c3, c4) (c1, c4)5-6-7-8-1-2 (B) 1 2 3 4 1 2(6) (A) (c3, c4) (c1, c2)6-7-8-1-2-3- (B) 2 3 4 1 2 3______________________________________ (a): Data storing registers (A): Selected column select lines (B): scramble-selected data lines
Table 3 indicates that it is possible to realize the data transfer as shown in FIG. 1 by use of only three registers, without arranging six data lines (twice the number (three) of the registers of each register group).
FIG. 6 shows another embodiment in which a single column line selects three columns simultaneously and further each register group is composed of five registers. In this embodiment, when the three column select lines are selected simultaneously at its maximum, it is possible to store a series of column data in each register group in such a way that data of any arbitrary column can be arranged as the head data.
Table 4 shows this embodiment in the same way as in Table 3. In Table 4, the serial access data length is ten and the data access range is twice (i.e., 18) the number of data transferred simultaneously.
TABLE 4__________________________________________________________________________SERIAL ACCESS COLUMNSEQUENCE (FIG. 2) (a) R1 R2 R3 R4 R5 R6 R7 R8 R9 R10__________________________________________________________________________(1) (A) (c1,c2) (c2,c3,c4)1-2-3-4-5-6-7-8-9-10 (B) 1 2 3 6 7 8 9 1(2) (A) (c1,c2) (c3,c4)2-3-4-5-6-7-8-9-10-11 (B) 2 3 4 7 8 9 1 2(3) (A) (c1,c2,c3) (c3,c4)3-4-5-6-7-8-9-10-11-12 (B) 3 4 5 8 9 1 2 3(4) (A) (c2,c3) (c3,c4,c5)4-5-6-7-8-9-10-11-12-13 (B) 4 5 6 9 1 2 3 4(5) (A) (c2,c3) (c4,c5)5-6-7-8-9-10-11-12-13-14 (B) 5 6 7 1 2 3 4 5(6) (A) (c2,c3,c4) (c4,c5)6-7-8-9-10-11-12-13-14-15 (B) 6 7 8 2 3 4 5 6(7) (A) (c3,c4) (c4,c5,c6)7-8-9-10-11-12-13-14-15-16 (B) 7 8 9 3 4 5 6 7(8) (A) (c3,c4) (c5,c6)8-9-10-11-12-13-14-15-16-17 (B) 8 9 1 4 5 6 7 8(9) (A) (c3,c4,c5) (c5,c6)9-10-11-12-13-14-15-16-17-18 (B) 9 1 2 5 6 7 8 9(10) (A) (c4,c5) (c1,c5,c6)10-11-12-13-14-15-16-17-18-1 (B) 1 2 3 6 7 8 9 1(11) (A) (c4,c5) (c1,c6)11-12-13-14-15-16-17-18-1-2 (B) 2 3 4 7 8 9 1 2(12) (A) (c4,c5,c6) (c1,c6)12-13-14-15-16-17-18-1-2-3 (B) 3 4 5 8 9 1 2 3(13) (A) (c5,c6) (c1,c2,c6)13-14-15-16-17-18-1-2-3-4 (B) 4 5 6 9 1 2 3 4(14) (A) (c5,c6) (c1,c2)14-15-16-17-18-1-2-3-4-5 (B) 5 6 7 1 2 3 4 5(15) (A) (c1,c5,c6) (c1,c2)15-16-17-18-1-2-3-4-5-6 (B) 6 7 8 2 3 4 5 6(16) (A) (c1,c6) (c1,c2,c3)16-17-18-1-2-3-4-5-6-7 (B) 7 8 9 3 4 5 6 7(17) (A) (c1,c6) (c2,c3)17-18-1-2-3-4-5-6-7-8 (B) 8 9 1 4 5 6 7 8(18) (A) (c1,c2,c6) (c2,c3)18-1-2-3-4-5-6-7-8-9 (B) 9 1 2 5 6 7 8 9__________________________________________________________________________
In the above-mentioned embodiments, the data transfer has been studied of the case where the serial access range is 6 and 18. This is because the data access range must be determined twice the number of data lines activated simultaneously in order to prevent data from being mixed on the data transfer lines, in the case of Skip and sequential (cyclic) access. In the case other than the skip and sequential read, it is of course unnecessary to consider the data access range as described above. This is because the column address changes monotonously in the serial access and therefore data will not be mixed with each other.
In general, the number of columns selected by a single column select line at the same time is determined on the basis of the manufacturing precision of the integrated circuit. On the other hand, the number of registers of each register group is decided on the basis of a ratio of the time required to transfer data from the column to the register to the cyclic serial access time.
Under the conditions that the above-mentioned two times are given, the method of how to decide the optimum number of the data transfer lines so that a series of data (in which data at any arbitrary address can be arranged as the head data) can be stored in one register group as shown in FIGS. 5 and 6 will be described hereinbelow.
As shown in FIG. 7, the assumption is made that k-units of columns are selected by a single column select line CSL and k-units of data are accessed. Further, each register group is composed of a-units of registers, and a-units of data are assumed to be stored simultaneously.
The a-bit data are transferred from the columns in a-units of serial cycles. During this time interval, data so far stored in the register group are serial-accessed from the register group.
To transfer data to the a-unit registers simultaneously, it is necessary to select (m=[a/k])-units of column select lines C1 to Cm at the same time, where m denotes an integer portion of a/k. Further, the number of column select lines to be further selected for simultaneous data register differs according to the number of data of the non-selected columns among the data to be stored simultaneously. The number of columns of the non-selected column data coincides with the congruence number x obtained by a modulus of a/k:x≡a [mod k].
In order to select the columns in such a way that a-bit data are obtained continuously by arranging data at any arbitrary column as the head data, it is necessary to further select another number of column select lines in excess of the m-units of the column select lines. This will be explained with reference to FIG. 7.
That is, if x=0 or 1, the a -units of columns can be selected simultaneously by selecting (m+1)-units of the column select lines (inclusive of the head column) at the same time. Further, if x=2 to k-1, the a-units of columns can be selected simultaneously by selecting (m+2)-units of the column select lines at the same time. Therefore, if the number of the maximum column select lines to be selected simultaneously is L, it is necessary to arrange (L×k)-units of data transfer line pairs.
In conclusion, the optimal data transfer system and method can be summarized as follows:
1. The number k of columns selected by a single column select line is decided on the basis of the manufacturing precision.
2. The number a of registers of each register group is decided in such a way that the data transfer time from the columns to the registers becomes a x serial cycle period.
3. The number of maximum column select lines selected simultaneously is decided as ##EQU2## 4. The number n of the data transfer line pairs from the columns to the registers is decided as
n=L×k
5. A scramble circuit for selecting a-unit data from n-unit data and storing the selected data to the register group simultaneously is provided.
As describe above, according to the semiconductor memory device of the present invention, in the synchronous system such that the data are transferred from the columns of the memory cell array to the output registers during a basic data transfer time of a cycles of the basic clock, the operation is as follows: data are transferred from the columns of a bits simultaneously by selecting one column select line. In transferring data for each a cycles, 2a bit data are transferred by selecting two column select lines. As described above, a-bit data are stored selectively in the a-unit output registers of the 2a-unit output registers. Accordingly, since a-bit data exist always in the 2a-bit data transferred from any given address, it is possible to store data in the a-unit registers in a predetermined data access sequence for each a cycles. In other words, a new head address can be set for each a cycles and further a series of data can be accessed continuously, irrespective of the number of the data transfer lines and the data registers, thus enabling an optimum synchronous data access.
As described above, in the semiconductor memory device according to the present invention, column data more than the number of the data registers arranged on the output side can be accessed continuously, irrespective of the number of the data registers, and further any access start address can be determined. | A data transfer system, comprising: a plurality of data input/output gates arranged by k-unit group by k-unit group in a predetermined sequence; gate selector circuit each arranged for k-unit group of the gates, for selecting the gates in unit of k-unit group; a plurality of data transfer paths for transferring data via the gates selected by the gate selector circuit; a first register group composed of a-units of data registers for transferring data simultaneously to and from the data transfer paths, the a-unit data registers being serial-accessed in a constant sequence; and a scrambler circuit for designating any required data input/output gates and for further selectively connecting the data transfer paths connected to said designated data input/output gates with the data registers so that the data transfer paths connected to the designated input/output gates can be connected to the serial-accessible registers in a predetermined sequence, when the number of the data transfer paths is (L×k) under the following conditions: ##EQU1## where L denotes a maximum number of the gate selecting means selectable simultaneously. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of fluid dynamics and heat transfer, and more specifically to a system and method for mixing fluid streams within an industrial drying machine.
[0003] 2. Description of the Prior Art
[0004] Industrial machines, such as those common in the textile, nonwovens and paper manufacturing industries, commonly utilize heated air to dry a newly formed product, as well for thermal bonding, curing and other processes that require an air stream with a uniform temperature profile. Typically, air is heated through conventional combustion means and then directed in various fashions towards the web of wet material. The heated air passes through or impinges the web, losing some of its heat in the drying process. The cooled air, referred to as system air, is then divided into portions that are re-circulated through the drying machine and portions that are exhausted into the atmosphere.
[0005] Drying machines in the aforementioned industries are generally of three types: through-air-dryers (TAD), impingement dryers, or floatation dryers. Each of these types of dryers is typically contained within a drying hood, which supplies and directs heated air to the surface of the web. A vacuum or pressure differential pulls the heated air through or onto the surface of the web and exhausts the cooled air into the system at large, at which point a portion of the cooled air will be exhausted into the atmosphere while the remainder is reused for drying applications. The direction of travel of the web is referred to as the machine direction, and the direction perpendicular to the machine direction and coplanar with the web is referred to as the cross-machine direction.
[0006] A typical dryer system 100 is shown in FIG. 1 . As noted, the system 100 includes a dryer 110 that is partially surrounded by a dryer hood 112 , through which air is drawn from the surrounding structures. A web of goods enters the hood 110 on the wet end 114 and proceeds through the dryer 110 , where heated air is drawn through it, to the dry end 116 . The heated air is pushed in through an intake 118 and is drawn out of an exhaust 120 by a main fan 122 which drives partially closed circuit as shown in FIG. 1 . A portion of the system air is exhausted into the atmosphere through duct 124 .
[0007] The remaining system air is directed to an air heater 126 that combines the system air with combustion products from a burner 128 . The burner 128 is driven by a combustion air source 130 , such as a fan, and fuel 132 . The mixed air 134 is a combination of combustion products and system air that will be used to dry the web passing through the dryer hood 112 . Those skilled in the art will recognize that the combination of the system air and the combustion products will not necessarily produce a uniformly profiled stream of heated air. On the contrary, the introduction of a secondary stream of combustion products into the system air may produce non-homogenous profile for the mixed air 134 . As a result, a typical dryer system 100 generally incorporates a static mixer 136 for inducing turbulence and mixing into the mixed air 134 stream so as to maximize thermal uniformity prior to entering the drying hood.
[0008] The foregoing example demonstrates both the strengths and weaknesses of the state of the art heating systems. While the current art is able to make remarkable use of system air through the re-circulation mechanisms, the necessary mixing of that air with combustion products is potentially hazardous to the end product. An essential aspect of textile and paper manufacturing is that the air that is drawn through or impinged upon the product must have a substantially uniform temperature profile along the cross-machine direction. Particularly for the manufacture of lightweight materials, such as tissue paper, any deviation in the temperature profile can irreversibly damage the finished product. The economic effects of non-uniform heating are multiple, including the energy required to replace the lost product, the costs of replacing the wasted raw materials, and the labor necessary to fix, maintain, manage and operate the dryer through a new production cycle. As such, one of the paramount concerns in the paper industry is designing a dryer that reliably maintains a uniform temperature profile in the cross-machine direction.
[0009] As noted above, it is common practice to re-circulate spent system air and reuse it in the drying cycle. Typically, the system air is combined with newly heated air and then the air is mixed as it passes through the machine ductwork towards the web of goods. Although the industry has made several attempts at efficiently re-circulating the air exhausted through the roll, the current state of the art requires a significant distance between the mixing point and the web in order to ensure that the temperature profile of the mixed stream is sufficiently homogenous.
[0010] For example, attempts have been made to introduce a heated fluid stream into a cooler fluid stream by using a baffling structure. Such a mechanism was contemplated in the invention described in international publication WO/0012202 published on Mar. 9, 2000. Although that invention describes a mechanical means for inducing turbulence, and hence mixing, in the combination of two fluid streams, it still does not do so with optimal efficiency of space and energy. In particular, the baffle design does create a large eddy that induces mixing of the fluid streams, but it does not do so in a symmetrical or uniform manner. Thus, the designers must either remix the turbulent air with a second device such as a static mixer; or alternatively, they must maximize the distance between the baffle location and the intake into the drying hood. Each of these two solutions involves non-trivial modifications to the drying systems described above, and both solutions would cost the producer in terms of energy efficiency and space utilization.
[0011] Given the foregoing, it is readily apparent to those skilled in the art that there is a need for a system and method for mixing fluid streams that is compact, energy efficient and produces a reliably uniform temperature profile across the web. Moreover, there is a need in the art for solutions that can be easily integrated into current drying system design without greatly expanding the hardware and space necessary to manufacture textiles. Lastly, there is a need in the art for a drying system that will minimize energy expenditures while deriving the greatest benefits from the raw materials processed therein.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention relates to a novel drying system that incorporates two-stage processes for heating air for drying a traveling web. In its various embodiments, the present invention operates within a system having a drying hood containing a dryer. The drying hood receives heated air through an intake and expels system air through an exhaust, a portion of which is directed into the atmosphere. In one embodiment, the portion of system air that is maintained in the system is divided into two portions and directed into separate parallel loops for two-stage heating that results in greater temperature uniformity and efficiency within the drying system.
[0013] The first portion of the system air is directed into a first conduit, and the second portion of the system air is directed into a second conduit. The first conduit includes an injection chamber that is disposed serially, or incorporated into, the drying hood intake. The second conduit includes a mixing chamber that is coupled to a burner for heating the air within the system.
[0014] The mixing chamber includes an arrangement of passages that effectively and efficiently mix the second portion of the system air with the combustion products from the burner. This mixed air stream is directed towards the injection chamber, where an injector or series of injectors induce further mixing by injecting the mixed air stream into the first portion of the system air. The injection chamber can also be integrated into the drying hood and controlled in such a manner so as to provide homogenous or non-homogenous air temperature across the running web, as determined by the user and the particular drying application.
[0015] By dividing the heating process into two stages, the present invention greatly increases the drying efficiency of a drying system. Notably, although one embodiment of the present invention utilizes a pair of distinct conduits for the heating process, the physical size of the drying system will not be affected. On the contrary, because of the increased mixing and heating efficiency of the present invention, it is possible to construct a drying system that is both smaller in size and more energy efficient that those presently used in the industry. Moreover, as described further below, the two-stage process of the present invention can also be utilized in a single conduit dryer configuration, in which the injection chamber is used for injecting an external source of heated air into the stream of mixed air from the mixing chamber. Numerous sources of external heated air, described below, can be utilized for improving the performance and efficiency of industrial dryers.
[0016] Further details and advantages of the present invention will become readily apparent from the detailed description of the preferred embodiments that refers specifically to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic representation of a through-air-dryer system typical of the prior art.
[0018] FIG. 2A is a schematic representation of a drying system in accordance with one embodiment of the present invention.
[0019] FIG. 2B is a schematic representation of a drying system in accordance with another embodiment of the present invention.
[0020] FIG. 3 is a perspective view of a mixing chamber of the drying system of the present invention.
[0021] FIG. 4 is a cross-sectional view of the mixing chamber shown in FIG. 3 along line 5 - 5 .
[0022] FIG. 5 is a cross-sectional view of the mixing chamber shown in FIG. 3 along line 4 - 4 .
[0023] FIG. 6 is a perspective view of an injection chamber of the through-air-dryer system of the present invention.
[0024] FIG. 7 is a partial cut-away plan view of the injection chamber shown in FIG. 6 in accordance with one embodiment of the present invention.
[0025] FIG. 8 is a partial cut-away side view of the injection chamber shown in FIGS. 6 and 7 in accordance with one embodiment of the present invention.
[0026] FIG. 9 is a partial cut-away side view of the injection chamber shown in FIG. 6 in accordance with another embodiment of the present invention.
[0027] FIG. 10 is a partial cut-away plan view of the injection chamber shown in FIG. 9 .
[0028] FIG. 11 is a perspective view of a partial manifold of the injection chamber in accordance with the present invention
[0029] FIG. 12 is a cross-sectional view of the manifold of the injection chamber in accordance with the present invention.
[0030] FIG. 13 is a schematic diagram of a dryer system having an integrated injection chamber in accordance with one embodiment of the present invention.
[0031] FIG. 14 is a partial cut-away view of a dryer hood having an integrated injection chamber in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The present invention includes both a system and method for mixing fluid streams, particularly those associated with contemporary drying systems. As described below, the present invention solves a number of problems noted in the textiles, paper and non-wovens industries. Most notably, the present invention includes a significant redesign of the drying system that efficiently utilizes system air and mixes it with combustion products in order to produce uniformly heated air for the web of goods. The mixing efficiencies of the present invention allow for a compact dryer design that is more economical in terms of raw materials, energy and space utilization.
[0033] Turning to FIG. 2A , the system 10 for drying a textile web is shown. As shown, the system 10 is represented schematically, thus it should be understood that the novel features of the present invention are equally applicable to all types of industrial mixers, including at least TAD's, floatation dryers and Yankee impingement dryers, as well as any other dryer that uses heated air for drying goods. The system 10 includes a dryer 12 disposed within a drying hood 14 . The dryer 12 is typically one of the aforementioned dryers commonly used for drying goods, although it should be understood that the present invention is operable with any and all kinds of dryers that utilize heated air. A web enters the drying hood 14 at a wet end 16 and exits the drying hood 14 at a dry end 18 . As discussed in detail above, air drawn through an intake 48 passes through the dryer 12 and the drying hood 14 and is expelled through an exhaust 20 , which is in turn coupled to a pair of parallel conduits that embody the system 10 of the present invention.
[0034] The exhaust 20 is coupled to a first air conduit 22 in circuitous communication with the exhaust 20 and the intake 48 and a second air conduit 24 in communication with the first air conduit 22 . The air expelled through the exhaust 20 is referred to as system air, i.e. air that is not introduced from outside the system 10 . The system air (not shown) is divided into a first portion 32 and a second portion 34 , which are directed into the first conduit 22 and the second conduit 24 , respectively.
[0035] A first fan 26 is part of the first air conduit 22 for receiving the first portion 32 of the system air and directing it through an injection chamber 46 . A second fan 28 is part of the second air conduit 24 for receiving the second portion 34 of system air and directing it through to a mixing chamber 36 . An exhaust port 30 is preferably disposed in the second conduit 24 for optionally expelling some of the second portion 34 of the system air into the atmosphere.
[0036] The mixing chamber 36 is adapted for receiving the second portion 34 of the system air and mixing it into combustion products 40 emanating from a burner 38 , which is fed by a source of combustion air 41 and fuel 42 . The combustion products 40 are too hot for direct introduction into the system 10 . For example, the combustion products 40 may typically be between 1100 and 1550 degrees Celsius. Accordingly, the system 10 of the present invention introduces a two stage mixing process in order to efficiently temper the combustion products 40 into a readily usable stream of air heated to a range typically between 400 to 1500 degrees Celsius, i.e. a stream of mixed air 44 .
[0037] The resulting mixed air 44 is directed towards the injection chamber 46 , where it is injected back into the first portion 32 of the system air. After injection of the mixed air 44 into the first portion 32 of the system air, the intake 48 of the system 10 directs the uniformly profiled air into the dryer hood 14 . The specific means for mixing and means for injection are discussed in detail below.
[0038] FIG. 2B is a schematic representation of another embodiment of the present invention, wherein identical reference numerals refer to similar elements as described with reference to FIG. 2A . As in the previous embodiment, the system 10 includes a dryer 12 disposed within a drying hood 14 . The web enters the drying hood 14 at a wet end 16 and exits the drying hood 14 at a dry end 18 . Air drawn through an intake 48 passes through the dryer 12 and the drying hood 14 , from whence it is expelled through an exhaust 20 . Unlike the prior embodiment, however, that shown in FIG. 2B has a single conduit for recycling the system air.
[0039] The exhaust 20 is coupled to a conduit 24 ′, which is in circuitous communication with the exhaust 20 and the intake 48 . The air expelled through the exhaust 20 is still referred to as the system air. The system air (not shown) consists solely of a portion 34 ′, which is directed into the conduit 24 ′, as noted above.
[0040] A fan 26 ′ is part of the conduit 24 ′ for receiving the portion 34 ′ of system air and directing it through to a mixing chamber 36 . An exhaust port 30 is preferably disposed in the conduit 24 ′ for optionally expelling some of the portion 34 ′ of the system air into the atmosphere.
[0041] As in the prior embodiment, the mixing chamber 36 is adapted for receiving the portion 34 ′ of the system air and mixing it into combustion products 40 emanating from a burner 38 , which is fed by a source of combustion air 41 and fuel 42 . As previously noted, the combustion products 40 are too hot for direct introduction into the system 10 . Thus the system 10 of the present invention introduces another two stage mixing process in order to efficiently temper the combustion products 40 into a readily usable stream of air heated to a typical range of 150 to 600 degrees Celsius referred to as the stream of mixed air 44 .
[0042] The resulting mixed air 44 is directed towards the injection chamber 46 , where it receives an injection of heated air 45 from an external source (not shown). For purposes of the present invention, the heated air 45 may include air that is heated by a turbine, a second burner, exhaust from the machinery of the system 10 , as well as certain types of naturally occurring volumes of air, such as those derived from geothermal processes. Thus as defined herein, the term external source should be understood to refer to a source of heated air that is not derived from a burner located within the system 10 . For example, the external source may be typified as waste heat from another process or heat from another, lower cost source. Accordingly, the burner 42 used in the present invention can be smaller and more fuel efficient, thereby reducing the overall space and energy consumption associated with heating the air. As in previous embodiments, after injection of the heated air 45 into the mixed air 44 , the intake 48 of the system 10 directs the uniformly profiled air into the dryer hood 14 .
[0043] FIG. 3 is a perspective view of the mixing chamber 36 of the system 10 of the present invention. The mixing chamber 36 includes a first passage 50 directing combustion product 40 from the burner 38 , a second passage 52 carrying the second portion 34 of the system air, and a third passage 54 directing the mixed air 44 to the injection chamber 46 . Preferably, the first passage 50 and second passage 52 are in fluid communication and oriented in an orthogonal manner, as shown in FIG. 3 .
[0044] FIG. 4 is a cross-sectional view of the mixing chamber 36 shown in FIG. 3 along line 4 - 4 . As shown, the mixing chamber 36 is preferably outfitted with a perforated sleeve 56 that selectively places air from the second portion 34 in fluid contact with the combustion product 40 that is traveling through the first passage 50 . In the cross-sectional view along line 5 - 5 shown in FIG. 5 , the first passage 50 has a circular cross-section. The second passage 52 terminates near the intersection between it and the first passage 50 , and the perforated sleeve 56 is disposed between the respective passages.
[0045] A volume is defined between the perforated sleeve 56 and the interior surface of the second passage 52 , and the second portion 24 of the system air must of course occupy this volume as it passes through the perforated sleeve 56 . In a preferred embodiment, the volume so defined is variable about the perforated sleeve 56 , such that the pressure gradient along the surface of the perforated sleeve 56 will also be variable. For example, a volume along section 60 is greater than a volume along section 62 , which in turn is greater than a volume along section 64 . By varying the volume defining the intersection between the combustion product 40 and the second stream 24 of the system air, the designers can tailor the mixing rate of the two fluid streams as they form the mixed air 44 .
[0046] FIG. 6 is a perspective view of an injection chamber 46 of the drying system of the present invention. The injection chamber 46 includes a third passage 70 for directing the first portion of the system air. The third passage 70 is intersected by at least one injector 72 that directs the mixed air 44 into the first portion of the system air. The means for injection are described in full detail below in conjunction with alternative embodiments of the system 10 .
[0047] FIG. 7 is a partial cut-away plan view of the injection chamber 46 shown in FIG. 6 in accordance with one embodiment of the present invention. FIG. 8 is a partial cut-away side view of the injection chamber 46 . As shown in FIGS. 7 and 8 , an arrow pointing leftwards represents the first portion 22 of system air. Each of the injectors 72 includes a projection 73 , which in the embodiment shown is defined by a first tubular portion 74 and a second tubular portion 75 . The injectors 72 are arranged orthogonal to the flow of the first portion 22 of system air, which is to say that they are also orthogonal to the third passage 70 described above.
[0048] The first tubular portion 74 and second tubular portion 75 cooperate to define an obtuse structure in the third passage 70 so as to create pockets of low pressure 77 in the flow of the first portion 22 of system air. The projections 73 defined by the first tubular portion 74 and second tubular portion 75 are purposefully obtuse in order to maximize the turbulence in the airflow and thereby induce mixing of between the mixed air 44 and the first portion 22 of system air. A plurality of ports 78 (depicted as small arrows) are defined on the second tubular portion 75 for transmitting the mixed air 44 into the pockets of low pressure 77 . The flow of mixed air 44 into the third passage 70 is controlled by at least one throttle valve 76 disposed between each of the first tubular portions 73 and second tubular portions 75 . The throttle valves 76 are controllable by a system operator either mechanically or electronically, depending upon the configuration of the system 10 .
[0049] FIG. 9 is a partial cut-away side view of the injection chamber shown in FIG. 6 in accordance with another embodiment of the present invention. As shown, the injector 80 includes a manifold 82 having a plurality of nozzles 84 disposed thereon. FIG. 10 is a partial cut-away plan view of the injection chamber shown in FIG. 9 better demonstrating the aerodynamic properties of the manifolds 82 . Each manifold 82 defines a leading edge 86 , a central portion 88 that includes the nozzles 84 , and a trailing edge 90 . As used herein, the terms leading and trailing refer to the standard orientation of an object in a fluid stream, i.e. the leading edge 86 is the first edge to contact the fluid, while the trailing edge 90 serves to smooth out any turbulence in the fluid.
[0050] FIG. 11 is a perspective view of a partial manifold 82 of the injection chamber 46 and FIG. 12 is a cross-sectional view of the manifold 82 of the injection chamber 46 in accordance with the present invention. As shown, the nozzles 84 are disposed on the surface of the central portion 88 for directing a fluid in a direction normal to the surface of the central portion 88 . In particular, the nozzles 84 are configured for injecting the mixed air 44 into the first portion 22 of the system air. The aerodynamic profile of the manifolds 82 , as detailed in FIG. 12 , creates small-scale turbulence in the air stream, as opposed to the large pressure drop described above with respect to the obtuse projections 73 . In particular, for each manifold the surface of the leading edge 86 defines an angle θ relative to the central portion 88 and the trailing edge defines an angle φ relative to the central portion 88 . In preferred embodiments, the angle θ is less than twenty degrees, and is most preferably less than fifteen degrees for optimum aerodynamics. The angle φ is preferably less than twelve degrees, and is most preferably less than eight degrees.
[0051] As the manifolds 82 described herein are specifically designed to reduce turbulence in the system 10 , the only turbulence created in a manifold-style injection chamber 46 is by the injection of the mixed air 44 into the first portion 22 of system air through the nozzles 84 . It follows that in order to maximize the mixing activity of the two streams, each manifold 82 must have a number of nozzles 84 disposed thereon, preferably arranged in multiple rows and on both surfaces of the central portion 88 . As the nozzle velocity of each nozzle 84 can be optimized for variable conditions, a system operator can fine-tune the mixing performance of the injection chamber 46 for particular needs.
[0052] One particular benefit of the manifold approach to fluid injection is that the temperature profile of the air entering the intake 48 can be readily controlled using a control loop for varying the injection rate of the manifolds 82 . This increased control over the air profile near to or within the drying hood 14 allows for customized and optimized temperature control, which in turn permits engineers and manufacturers to develop improved goods at lower costs. Control over the manifolds 82 is precise enough that it is possible to dispose the injection chamber 46 close to, or even integrated into, the intake 48 of the drying hood 14 . In particular, electronic control over the manifolds 82 permits a manufacturer to locate the injection chamber 46 at any point in the system 10 that is downstream from the mixing chamber 36 , including of course integrating the injection chamber 46 into the drying hood 14 .
[0053] By way of example, FIG. 13 is a schematic diagram of a dryer system 10 having an integrated injection chamber 11 in accordance with one embodiment of the present invention. While similar reference numerals refer to similar elements, the system configuration shown in FIG. 13 illustrates an injection chamber 46 integrated into the drying hood 14 . A controller 49 is coupled to the drying hood 14 and the injection chamber 46 , and is preferably configured to receive feedback signals from the drying hood 14 in order to monitor and adapt the nozzle velocity of the manifolds 82 of the injection chamber 46 . The manifolds 82 of the injection chamber 46 can be controlled to create particular temperature profiles in the drying hood 14 in both the machine and cross-machine directions. Moreover, the controller 49 can be adapted to provide instantaneous response from the feedback signals, thus providing an effective bias against unwanted variations in the temperature profile of the hood.
[0054] FIG. 14 is a partial cut-away view of a dryer hood 14 having an integrated injection chamber illustrating the precision and capabilities of the aspect of the invention described above. A web 19 of material is shown disposed within the hood 14 . The web 19 defines three zones of differing dryness, a first zone 190 , a second zone 192 and a third zone 194 . The injection chamber 46 and intake 48 are integrated into the drying hood 14 and disposed in close proximity to the web 19 . The controller 49 receives signals indicative of the dryness/temperature or alternative measurement of the web, and in response to those signals directs the manifolds 82 within the injection chamber 46 to respond in an appropriate fashion.
[0055] For example, the manifolds 82 within the injection chamber 46 can be controlled to produce three streams of differing temperature, a first stream 200 , a second stream 202 and a third stream 204 . The nature of the feedback through the controller 49 ensures that the first stream 200 corresponds to the first zone 190 , the second stream 202 to the second zone 192 , and the third stream 204 to the third zone 204 . Accordingly, the integration of the injection chamber 46 not only provides means for homogenizing the air temperature within the drying hood 14 , it also provides means for biasing the air temperature within the drying hood 14 in a manner that is readily controllable. That is, the injection chamber 46 can be biased to inject hot air into an area correlating with a wet portion of the web 19 , and conversely, the injection chamber 46 can be controlled to inject cooler air towards a dryer portion of the web 19 . In short, by integrating the injection chamber 46 into the drying hood 14 , the present invention enables users to optimize the drying of the web 19 in the most efficient manner.
[0056] The benefits of the present invention, in particular those achieved through the control over the manifolds 82 as well as the integration of the injection chamber 46 into the drying hood 14 , result from the two-stage mixing processes described in detail above, which in turn reduces the length of the conduits necessary to direct the first portion 22 of the system air. Moreover, the usage of an external source, such as heated air from an ancillary process or machine, further lessens the costs associated with heating a uniform stream of air. As illustrated above, the present invention will enable engineers and designers to manufacture industrial dryers that utilize this process, which in turn will increase the drying efficiency of any number of commercial operations.
[0057] While the present invention has been described in detail with respect to its preferred embodiments, these should be understood to be exemplary in nature and not limiting as to the scope of the present invention. It is certain that design modifications could be readily devised by those skilled in the art, and that any such modifications would fall within the scope of the present invention as defined herein by the following claims. | The present invention relates to novel dryer systems that incorporate two-stage processes for heating air for drying a traveling web. The present invention is operable within a drying system having a drying hood containing a dryer. The drying hood receives heated air through an intake and expels system air through an exhaust, a portion of which is directed into the atmosphere. The portion of system air that is maintained in the system is divided into two portions and directed into separate parallel conduits for two-stage heating that results in greater temperature uniformity and efficiency within the system. One loop includes a mixing chamber for the initial mixing of system air with the combustion products of a burner. A second loop includes an injection chamber that receives the initially mixed air and injects it into the other portion of the system air, resulting in greater temperature uniformity within the drying hood and increased operating efficiency for the entire system. The present invention further includes a single conduit system that utilizes heated air from an external source for injection into the system air. ALSO METHOD TO EFFICIENTLY USE SUPPLEMENTAL HEAT. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is concerned with folding chairs which are portable, comfortable, strong and convenient to use. More particularly this invention is concerned with a light weight portable chair unit which is supported by a folding frame and which is adapted to both adult and juvenile usage.
2. Description of the Prior Art
This invention relates to a folding chair and to its related support structure. The prior art is replete with examples of folding chair structures. Folding chairs of a wide variety have been manufactured for over one hundred years.
Examples of pertinent prior art patents are U.S. Pat. Nos. 244,216, 2691,410. 3,136,272, 3,124,387. 4,671,566, 3,838,883 and 4,014,591.
U.S. Pat. No. 244,216 is an example of old prior art in the area of folding chairs. This patent shows a folding chair which is supported on four foldable V shaped supports.
U.S. Pat. No. 2,691,410 illustrates foldable chairs which have both triangular and rectangular bases.
U.S. Pat. No. 3,136,272 discloses a plurality of foldable seats which incorporate pivotally mounted V shaped supports.
U.S. Pat. No. 3,124,387 shows a foldable seat having four legs which are interconnected by V shaped supports.
U.S. Pat. No. 4,671,566 is concerned with a foldable chair which has a triangular base. The support components of the chair are two V shaped supports
U.S. Pat. No. 3,838,883 relates to a collapsible chair which has a rectangular base and seat section. The support structure utilized consist of four V shaped supports.
Lastly U.S. Pat. No. 4,014,591 deals with a collapsible chair having a rectangular base and seat section. The support system comprises two pairs of cross braced legs.
A need exist for a comfortable outdoor chair which is suitable for use by sports fans, beach goers, fisherman, hunters and anyone else wishing to sit comfortably out of doors. In order to be practical, an outdoor chair must be capable of being collapsed or folded compactly in order that it can be readily transported and moved from one location to another. Likewise in order to be functional the chair must be light and as such its support structure must be designed in order to efficiently utilize light weight high strength materials. The chair of this invention meets these criteria in that it is comfortable, foldable, strong, lightweight, transportable and easy to use.
As illustrated by the great number of prior patents and commercial seats, efforts have been continuously made in an attempt to produce practical, foldable chairs which are light and strong. None of these prior efforts, however, suggest the present inventive combination of component elements arranged and configured in order to produce a practical foldable chair as is discussed herein below.
The prior art devices do not provide benefits of the present invention which achieves its intended purposes, objectives and advantages over the prior art devices through a new, useful and unobvious combination of component elements, through no increase in the number of functioning parts, at a minimum of cost and through the utilization of only readily available materials and conventional components.
Therefore it is an object of the present invention to provide a foldable seat which is strong and yet lightweight.
It is a further object of this invention to provide a seat which will fold up in such a manner that its main components are in axial relationship with each other.
Lastly it is an object of this invention to provide a stylish seat which is easy to use and yet comfortable for both adult and juvenile usage.
These objects and advantages should be construed as merely illustrative of some of the more prominent features and applications of the present invention. Many other beneficial results can be obtained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and advantages as well as a fuller understanding of the invention may be had by referring to the summary and detailed description of the preferred embodiment of the invention in addition to the scope of the invention as defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
The present invention is defined by the appended claims with the specific preferred embodiment shown in the attached drawings. This invention is concerned with a chair which utilizes two foldable V shaped supports. These V shaped supports form three legs which comprise the main structural element of the chair. The apex of one V shaped support forms one leg. The other two legs are formed by the arms of the other V shaped support.
The width of one V shaped support is slightly narrower than the width of the other V shaped support. This width difference allows one of the V shaped supports to nest inside of the other V shaped support. The two V shaped supports are pivotally connected to each other at the approximate mid points of the arms of each of the V shaped supports.
The arms of each of the V shaped supports are pivotally connected to each other at the apex of the V. This pivotal connection allows the arms of the V shaped supports to be folded inwardly in such a manner that the subject chair can be folded up into a compact package. The base of the chair is a tripod which is formed by the apex of one V shaped support and the two arms of the other V shaped support. Likewise the upper extremity of the chair is a tripod which is formed by the opposite apex and arms of the V shaped supports.
The foldable chair is supported in the open position by two straps, each of which run from the side or apex of one V shaped support to the arms of the other V shaped support. This strapping limits the travel of the apex in relation to the arms. A triangular piece of cloth is further attached to the upper apex and to both upper arms in order to form a seat.
In addition to the strapping, the structure is further supported in the preferred embodiment by a tubular brace which runs between the backside upper extremity of one V shaped support and the backside lower extremity of the opposite V shaped support.
When the V shaped supports are folded into parallel relationship with each other, the support brace in the preferred embodiment folds into parallel relationship with the V shaped supports. Further the upper support strapping and triangular seat fold up in order to produce a compact package which can be placed in a small carrying case. The foldable chair of this invention is manufactured from strapping and tubing, or their equivalents.
By changing the respective dimensions of the components of the chair of this invention it can be adapted to use by either adult or juvenile occupants.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood whereby the present contribution to the art may be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the present invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed herein may be readily utilized as a basis for modifying or designing other apparatus for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent apparatus does not depart from the spirit and scope of the invention as set forth in the appended claims.
DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the nature, objects and advantages of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective illustration of a foldable chair constructed in accordance with the principles of the present invention;
FIG. 2 is a right-hand side elevational view of the foldable chair as shown in FIG. 1;
FIG. 3 is a rear view of the foldable chair as shown in FIG. 1;
FIG. 4 is a rear elevational view of the top V shaped hinge member as is used in the foldable chair of this invention.;
FIG. 5 is an enlarged perspective illustration of the upper front left portion of the foldable chair as shown in the previous figures and illustrating the attachment of support webbing to the V shaped supports;
FIG. 6 is an enlarged perspective illustration of the foldable slat as shown in the previous figures illustrating the attaching means for the support strapping;
FIG. 7 is a rear view of the lower V shaped hinge member;
FIG. 7A is an end view of the lower V shaped hinge member of FIG. 7;
FIG. 8 is a front view of the foldable chair of this invention in a folded stance;
FIG. 9 is a rear view of the foldable chair of this invention in a folded stance;
FIG. 10 is a perspective view of the chair frame as used in this invention with an alternate bracing means and alternate strap attachment;
FIG. 11 is a rear view of the foldable chair of this invention in a folded stance with an alternate brace means;
FIG. 12 is a perspective view of the foldable chair of this invention showing an alternate body support;
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view showing the foldable chair of this invention and its principle structural parts. The main support frame 3 from chair 2 consist of a first V shaped section 4 and a second V shaped section 6. V shaped section 4 is slightly narrower than V shaped section 6. This difference in width allows V shaped section 4 to nest inside of V shaped section 6.
V shaped section 4 is pivotally connected to V shaped section 6 at point 8 via a pivot pin which passes through arms 10 and 12 of V shaped sections 4 and 6. V shaped sections 4 and 6 further incorporate opposing arms 14 and 16. Arms 14 and 16 are pivotally connected to each other in a manner similar to that described relative to arms 10 and 12.
As can be seen from FIG. 2 pivot point 8 is at the approximate midsection of arms 10 and 12. In this figure additional support brace 18 can be further seen. The function of this brace will be described herein below.
While the main structural support is provided by V shaped sections 4 and 6, the main seating support is provided by a body support 20 which has a back section 22 and a seat section 24. Body support 20 is adapted to fit and give support to the human torso. Body support 20 is attached to the frame which is made up by V shaped sections 4 and 6 at three points. These three attachment points comprise the upper extremities 26 and 28 of arm 10 and 14 and apex 30 of V shaped section 6. This attachment is further illustrated in the rear view of FIG. 3.
In accordance with the preferred embodiment, body support 20 is comprised of a flexible cloth like material such as a cotton duck or a polymeric fabric. The attachment of body support 20 at points 26, and 28 is accomplished by rings and straps as will be described herein below
Body support 20 may be a preformed molded shell, not shown, which is adapted to be secured to points 26, 28 and 30 of support frame 3.
When a human body sits in body support 20 a variety of forces are applied to the support frame 3 which is made up of V shaped sections 4 and 6. These forces are in both horizontal and vertical planes.
Arms 12 and 16 of V shaped section 6 are pivotally attached to each other via a U shaped hinge member 33. Likewise arms 10 and 14 of V shaped section 4 are pivotally attached to each other via U shaped hinge member 34. The details of hinge members 33 and 34 will be discussed herein below. Because of the pivotal attachment of pairs of arms 10 and 14 and 12 and 16 when weight is applied to body support 20 downward force causes respective pairs of arms 10 and 14 and 12 and 16 to move inward toward each other. In order to have a functional folding chair this movement of pairs of arms 10 and 14 and 12 and 16 must be restrained. In the preferred embodiment of the foldable chair of this invention this restraint is effected by a brace 18 which is pivotally connected to the upper half of arm 12 at point 32 and to the lower half of arm 14 at point 38.
Because brace 18 is rigid and connected to an opposing arm of each V shaped section, when the support frame 3 is opened as is illustrated in FIG. 3 the pairs of arms 10 and 14 and 12 and 16 automatically spread to the proper seat position. In accordance with the preferred embodiment, the movement of these pairs of arms is so controlled that the front edge of body support 20 is also spread between attachment points 26 and 28.
FIGS. 10 and 11 show an alternate structure wherein the movement of the arms of V shaped support sections 4 and 6 are restrained. Brace 84 is an alternate structure for brace 18, the function of which was described herein above. Referring to FIGS. 10 and 11 it can be seen that chair frame 3 generally comprises two V shaped sections 4 and 6 which nest inside each other. V shaped section 6 incorporates a pair of arms 12 and 16. Brace 84 comprises a main body brace section 85 and a pair of attachment bosses 86 and 88. Main body brace section 85 is pivotally connected to attachment bosses 86 and 88 at pivot points 90 and 92. Boss 86 is slideably mounted on arm 12. Attachment boss 86 is mounted above pivot point 8. Attachment boss 88 is fixed on arm 16 and is mounted above pivot point 9. When the composite chair is folded up, as is shown in FIG. 11, brace 84 pivots on attachment bosses 86 and 88 and attachment boss 86 slides up on arm 12. The movement of attachment boss 86 is illustrated by arrow 87. This upward and downward movement allows arms 12 and 16 to fold inward on each other and thereby allowing the chair to fold up into a tubular package. When arms 12 and 16 expand outward, brace 84 approaches a horizontal position and further restricts the outward and inward movement of arms 12 and 14. When brace 84 is in the position as is illustrated in FIG. 10 the composite structure is locked into a rigid frame which provides excellent support for a body support not shown.
As can be seen in FIG. 3 the distance between points 9 and 26 and 8 and 32 in the preferred embodiment can be approximately equal and these distances should be such as to allow said composite frame to fold flat as is illustrated in FIGS. 8 and 9. Brace 18 controls the folding action of arms 10, 12, 14 and 16 when the composite structure is changed from a folded to an open stance. Further brace 18 prevents pairs of arms 10 and 12 and 14 and 16 from folding inward or outward when weight is applied to body support 20.
It is evident to one skilled in the art that if support frame 3 is to be functional and provide support for body support 20 the movement of the upper extremities of pairs of arms 10 and 14 and 12 and 16 must be restrained. That is, the movement of points 26 and 28 away from point 30 must be restrained. In order to provide this restraint support frame 3 further incorporates a pair of straps 40 and 42 which effectively limit the travel of points 26 and 28 of arms 10 and 14 away from apex 30 of V shaped section 6. Straps 40 and 42 are advantageous in that when they are pulled taunt by the weight of a person sitting in body support 20, they further function as arm rests. The primary function of straps 40 and 42 is to prevent V shaped frames 4 and 6 from folding flat when weight is applied to body support 20, by the placement of a body therein. In the preferred embodiment, straps 40 and 42 are formed from a high strength webbing material such as woven nylon.
The attachment of straps 40 and 42 to U shaped hinge member 32 is illustrated in FIG. 4. It can be seen that U shaped hinge member 32 incorporates two elongated slots 44 and 46. The ends of straps 40 and 42 are formed into a loop and passed through slot 44. A retaining bracket 48 is then passed through the formed loop. Strap 40 is then pulled forward in such a manner that retaining bracket 48 is lodged in recess 50 which surrounds slot 44. A fully seated and secured strap 42 is shown in slot 46 on the left side of hinge bracket 32.
FIG. 5 shows the means whereby straps 40 and 56 are attached to the upper arms of V shaped section 4. A D ring or formed wire shape 52 is secured in an aperture which is integral with arm 10 of V shaped section 4. The end of strap 42 is sewn into a loop 54, through which is passed D ring 52. D ring 52 is further adapted to receive strap 56 which passes between arms 10 and 14 of V shaped section 4.
The leading edge of body support 20 is sewn into a hem 58 through which is passed strap 56. When arms 10 and 14 are biased outward and forward straps 42 and 56 are pulled taunt. When pressure is applied to support 20 strap 56 is pulled taunt.
By use of straps 40, 42, 56 and brace 18 the components of support frame 3 are locked into a strong lightweight frame for body support 20.
FIG. 6 shows how strap 42 may be secured to arm 12. In this embodiment a loop 60 is sewn in strap 42 and a ring 62 passed through this loop. Ring 62 is in turn passed around arm 12 and secured near hinge bracket 32.
FIGS. 4, 7 and 7A illustrate in detail the construction of U shaped hinge members 33 and 34 which are used to connect the arms of the V shaped sections. The construction of U shaped hinge members 33 and 34 is similar in that both are formed from two sections which are pivotally connected to each other. Referring to FIG. 7 it can be seen that U shaped hinge member 34 is constructed from two sections 74 and 76. These sections are connected to each other with a hinge pin 68 which in the illustrated embodiment is a rivet 68.
Referring to FIG. 7A it can be seen that U shaped hinge member 34 is formed from two sections 74 and 76 which in turn have integral arms 70 and 72 which mesh with each other. The clearance between arms 70 and 72 is such that they can pivot around hinge pin 68. U shaped hinge member 34 further has extended support sections 74 and 76 which increase the surface area of U shaped hinge member 34. Since U shaped hinge member 34 engages the ground this additional surface area is advantageous in that it prevents V shaped section 4 from sinking into the ground, when foldable chair 2 supports the weight of a human occupant.
The pivotal construction of upper U shaped hinge member 33 is similar to that described above for U shaped hinge member 34.
Arms 10, 12, 14 and 16 in accordance with the preferred embodiment are formed from a continuous piece of hollow tubing.
FIGS. 8 and 9 show the chair of this invention folded into a compact tubular package. It should be noted from these Figures that brace 18 folds into approximate parallel relationship with arms 10, 12, 14, and 16. Further when folded body support 20 folds into a compact package around the upper extremities of folded support frame 3.
FIG. 12 shows still another embodiment of the portable chair in accordance with this invention wherein an alternate body support may be utilized. In this structure body support 80 has a back section 82 and a seat section 84. Back section 82 is attached to hinge member 33 in a manner as described above in reference to body support 20. In order to provide a wider seating area the lateral edges of seat section 84 are sewn over and around straps 40 and 42. As a result of this construction, seat section 84 has an enhanced seating area and it further has a comfortable U shaped cross section. The sides of this U shaped cross section are advantageous in that they provide comfortable support to the thighs of a human occupant.
It is evident from FIGS. 1-11 and from the above description that the two V shaped sections with the supporting braces and body support form a lightweight, foldable, strong, convenient chair structure.
The present disclosure includes that information contained in the appended claims as well as that in the foregoing description. Although the invention has been described in its preferred form or embodiment with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, fabrication and use including the combination and arrangement of parts, may be resorted to without departing from the spirit and scope of the invention. | The subject invention comprises a foldable portable chair which has a seat section and a support section. In the preferred embodiment the seat section is a triangular flexible web which is attached to the upper portions of the support section. The support section is made up of a first and second V shaped supports. These V shaped supports are each formed from two arms which are pivotally connected to each other. The V shaped supports are nested one in each other. The apexes of the V shaped supports are oriented opposite to each other. Lastly the V shaped supports are also interconnected to each other by support means to limit the travel of the V shaped supports and their respective arms in relation to each other.
The chair of this invention is suitable for both juvenile and adult usage. | 0 |
PROSECUTION HISTORY
This application is a continuation in part of U.S. application Ser. No. 10/709,744 filed on May 26, 2004 now U.S. Pat. No. 6,918,350.
BACKGROUND OF THE INVENTION
The present invention is a system and method for using wave and wind power for the generation of hydrogen and oxygen. In its simplest form the wind is used to rotate a wind turbine, which is attached to an electric generator, and the waves are used to rotate the blades of an impeller driven by the water pressure created by waves. The electricity produced by the generator is then used to power an electrolysis subsystem, which produces hydrogen and oxygen from the water in the electrolysis salt bath.
The novelty in the present system arises from the fact that both the wind turbines and the wave power generators are located on collection vessels at sea, configured for this purpose. The vessels can be disposed out of the sight of land, which avoids the political problems attendant to the location of wind farms in proximity to residential areas. Furthermore, the collection vessels may be moved to the areas having the optimal wind and sea conditions for the generation of these gasses.
In a sense, the present system is a method of extracting and storing energy from the wind and waves for future use. It has been noted, for example, that the use of hydrogen as a fuel for automobiles requires that energy be expended to produce the hydrogen before it is released to propel an automobile. Storing the energy in the form of compressed gasses is an alternative to the traditional storage methods, such as electric batteries.
In the case of wind power generation systems, the present invention utilizes variable speed, high torque wind turbines that maximize power output per capital dollar expended on the system. Further, the land costs of traditional wind farms are eliminated, together with the location limitations and political issues associated with both wave power and wind turbine sites.
This invention includes a storage, transfer and distribution system that utilizes state-of-the art communication and control sub-systems, thereby minimizing operational labor costs.
The sea west or east of the continental United States, contains the best wind quality for wind turbine applications, and is far superior to most of the land sites available. Furthermore, it is well known that wind and wave conditions are related, so that areas of favorable wind speed and constancy also produce waves favorable for use in the current application. Due to the curvature of the earth, sites located 20 to 25 miles from land are not visible and, therefore, political opposition to the use of such sites is greatly reduced.
There are many ocean sites currently employing wind turbine technology to generate electricity. Denmark, for instance, has very aggressive plans to convert most of its energy generation to wind-based systems within the next ten years. In the United States, locations in Nantucket Sound, off Cape Cod, Mass., are being considered as sites for wind farms.
These sites, however, are connected directly to local power grids, as opposed to the storage of power in the forms of the present invention. Furthermore, most of these pior-art systems are on the land or close to land and are, therefore, impacted by land effect conditions which make energy generation much more costly than generation at sea. The sea-based prior wind-based prior art systems are generally anchored directly onto the ocean bottom and, therefore, must be located in areas of shallow ocean depths.
To overcome these restrictions, the present method provides for wind generation systems at sea which are free floating. Thus, with the present approach there are far fewer site limitations, no land costs, and limited potential political opposition.
Wave power technology is also being developed on both coastal locations, such as the Limpit system in Scotland, described in Appendix A, and on board sea-going vessels, such as the Japanese Mighty Whale as described in Appendix B. The land-based wave power systems must be located at the margins of large bodies of water, however, and furthermore the shore requirements are rather stringent, so that only a minority of these shore locations are practical at all, even before considering possible political objections.
Sea-based wave power generation systems are now being tried in various parts of the world. But the problem of storage and transmission of the power generated by these sea-based systems remains, for the most part, unsolved in any practical way. The present invention deals with the energy storage problem by using the power of wind and waves to produce hydrogen and oxygen, which become, in effect, storage media. Hydrogen in particular has been suggested as a replacement energy source for use in motor vehicles, and the present invention may provide a means for producing hydrogen in the quantities required for fueling hydrogen-powered motor vehicles.
The invention described herein addresses the problems of generation of power, storage of power, and transmission of power in a way that overcomes the major political problems associated with both wind and wave-generated power. It also solves the problem of energy storage associated with sea-based power generation.
The following description discloses and claims a system to cost-effectively generate hydrogen and oxygen gas by using wind and waves as alternative energy source. The application further describes how the floating sites at sea are configured and managed to provide the most cost effective method for these technologies.
SUMMARY OF INVENTION
It is the object of this invention to provide a method for the generation and storage of oxygen and hydrogen from the power of the wind and waves.
It is a further object of this invention to minimize the objections of such a generation system arising from political and environmental concerns.
In accordance with a first aspect of the invention, a method for generation of gasses contained in a salt solution includes the steps of disposing one or more collection vessels, each containing a wave power generation device, in waters distant from a proximate shore. Each collection vessel contains an electrical generator coupled to each of the wave power devices, the resulting electric current generating gasses from a salt solution by means of electrolysis.
In accordance with a second aspect of the invention, the vessels are located in predetermined geographic zones having a suitable sea conditions for such wave power generation. The zones are further located outside of established shipping lanes.
In accordance with a third aspect of the invention, communications between the collection vessels within the zone and a command center are provided.
In accordance with a fourth aspect of the invention one or more storage vessels are located within each predetermined zone for periodic transport of said gasses.
In accordance with a fifth aspect of the invention the collection vessels and storage vessels are controlled by remote control.
In accordance with a sixth aspect of the invention each collection vessel has an entrance below a vessel waterline at the bow so that waves approaching the bow enter the channel and rise above the waterline as the waves advance from the bow to the stern.
In accordance with a seventh aspect of the invention each collection vessel has a valve wall affixed in proximity to the stern end of the tapered channel, the valve wall further containing a multiplicity of check valves disposed across said valve wall, each of which permits the water breaking on the valve wall to enter a collection chamber, but prevents the water from the collection chamber from exiting.
In accordance with an eighth aspect of the invention each collection vessels includes a water turbine disposed beneath the collection chamber which rotates as the water from the collection chamber exits to the sea.
In accordance with a ninth aspect of the invention each collection vessel also contains an electric generator which is coupled to the water turbine.
In accordance with a tenth aspect of the invention a sea based central transfer station is used for collecting the gasses.
In accordance with an eleventh aspect of the invention the gasses are pipelined from the sea based central transfer station into a shore storage and purification facility.
In accordance with a twelfth aspect of the invention means are provided for the remote-controlled docking of any two or more of the vessels at sea, in order to transfer the gasses between the vessels.
In accordance with a thirteenth aspect of the invention one or more of the collection vessels disposes a sea anchor in order to reduce the drift of the vessel and to maintain the vessel with its stern facing into the wind.
In accordance with a fourteenth aspect of the invention a multiplicity of cables are disposed for maintaining the sea anchor in an anchoring position, and one or more retraction cables are further disposed for retracting the sea anchor.
In accordance with a fifteenth aspect of the invention each sea anchor is retracted into a storage tube when not used, and is extracted from the storage tube into disposed mode when in use.
In accordance with a sixteenth aspect of the invention, oxygen and hydrogen are produced by this method.
BRIEF DESCRIPTION OF DRAWINGS
These, and further features of the invention, may be better understood with reference to the accompanying specification and drawings depicting the preferred embodiment, in which:
FIG. 1 depicts a wind-based power collection vessel in collection mode, with sea anchor set.
FIG. 2 depicts a top plan view of a wind-based power collection vessel.
FIG. 3 depicts a front elevation view of the wind-based collection vessel.
FIG. 4 depicts a front elevation view of a wind turbine, with only a single blade shown in detail.
FIG. 5 depicts a hydrogen-oxygen-generator.
FIG. 6 depicts a top plan view of a collection vessel in collection mode attached to a storage vessel.
FIG. 7 depicts a collection vessel with sea anchor, cables, and sea anchor storage tube shown.
FIG. 7 a depicts a cross section view of the storage tube, closed, with sea anchor within.
FIG. 7 b depicts a cross section view of the storage tube, open, with the sea anchor beginning to descend.
FIG. 7 c depicts a side elevation view of the sea anchor being retracted.
FIG. 8 a depicts a top plan view of a wind-power collection vessel in collection mode, with wind turbine set up for operation.
FIG. 8 b depicts a top plan view of the wind-power collection vessel in navigation mode, with the wind turbine set up for navigation.
FIG. 9 depicts a side elevation view of the bows of two vessels beginning a docking operation.
FIG. 10 is a chart compares theoretical power, available practical power and approximate power production for turbines having 3 blades with those having 30 blade designs.
FIG. 11 depicts a side elevation view of a wave-based power collection vessel in collection mode, with sea anchor set.
FIG. 12 depicts a top plan view of the wave-based power collection vessel.
FIG. 13 depicts a front elevation view of the wave-based collection vessel, as seen from the stern.
FIG. 14 depicts a cross sectional view of a swing check valve.
FIG. 15 depicts a cross sectional view of a water turbine.
FIG. 16A depicts a valve wall with collection container empty.
FIG. 16B depicts a valve wall with collection container partially filled.
FIG. 16C depicts a valve wall with collection container almost filled.
FIG. 16D depicts a valve wall with collection container filled to the point that the check valve is closed.
DETAILED DESCRIPTION
The present system utilizes a number of collection vessels each of which has on-board wind or wave power devices to convert the energy contained in the wind and waves to an electrical current which is then used to create hydrogen and oxygen from water by means of electrolysis. The collection vessels are of two distinct types: the wind-based collection vessels use the power of the wind to turn a wind turbine, which is coupled to an electric generator; the wave-based collection system uses the energy stored in waves to perform the same function.
The present wind-based collection system utilizes 19 th century technology, using a turbine with many blades on a single turbine rotor. In this way it maximizes the amount of blade surface area exposed to the wind to create increased torque, which, in turn, increases the output of the generator used for electrolysis. Any combination of voltage and current will cause the electrolysis process to work. Therefore, the main area of concern is to create as much torque as possible to drive the system. The revolutions per minute of the rotor are automatically controlled by the present invention in order to maximize power output under both normal and low wind conditions, and to minimize the stresses on the system in high wind conditions.
Like the use of the wind turbine, using the energy stored in water as a source of power is a very old technology. The novel approach in the present invention bears a distinct resemblance to the water wheel, or mill wheel. In both cases the water first must achieve a potential energy due to its elevation above the rotating device used to extract the energy. As the water descends, the potential energy is converted into kinetic energy as the wheel is made to rotate. In the present invention this rotation is then coupled to an electric generator, which generates a current as it rotates.
In the wind-based systems the revolutions per minute of the rotor are controlled in the present invention by gearing, in order to maximize power output regardless of wind speed. In the wave-based system the velocity of the water flowing past the water turbine is regulated, minimizing the stresses on the system under very high wave conditions.
The system has three key operational modes:
1. Power Conversion:
In this mode the wind turbines are generating power from the wind, and the water turbines are generating power from the waves. In both cases the electricity resulting is used to create hydrogen and oxygen by electrolysis of water.
The collection vessels in both systems utilize an oversized Sea Anchor to provide resistance against the wind when the system is collecting and converting wind and wave energy into hydrogen and oxygen. Sea Anchors are not directly connected to the ocean bottom. Rather, they are a hydraulic version of a parachute that resists drift instead of stopping it. Sea Anchors are well known in the prior art, and are standard for use in lifeboats, since they keep the lifeboat pointed into the wind and greatly slow drifting.
Wind and wave-based power collection vessels utilizing sea anchors during operation would slowly drift in the direction of the wind. The rate of drift depends upon the wind speed and sea conditions.
There is a close correspondence between wind speed and sea height. Rear-Admiral, Sir Francis Beaufort, of the Royal Navy, devised the original Beaufort scale on or about 1805, and it has become a standard still used today. A uniform set of equivalents of Beaufort numbers, wind speed, and sea height was accepted in 1926 and revised slightly in 1946. In 1955 the World Meteorological Organization established a correspondence between Beaufort Number, wind speed, and wave height. For instance, at Beaufort No. 3 the winds are between 7–10 kts, scattered whitecaps appear, and the seas are 2–3 ft. in height. At Beaufort 5 the wind velocity is 17–21 kts., some spray appears, and the wave height is 6–8 ft.
It is well understood and accepted that other factors can cause the height of the waves to depart from the “Beaufort” height at any particular wind speed. For instance, after a storm high waves may appear especially near the shore, even in the absence of wind. Also, bottom conditions may cause wave heights to vary widely from the numbers established by Beaufort.
However, on the high seas, under normal conditions, there will be a reasonably close correspondence between the wind speed and the height of the waves, in accordance with the standards published by the World Meteorological Organization.
Thus, conditions which favor generation of power by the wind turbines also favor use of the wave-generation systems. Thus, it is not unreasonable to include collection vessels of both the wind-power and wave-power together in a flotilla of collection vessels.
The hydrogen and oxygen generated by the collection vessels are temporarily stored in the “bottles” of the type commonly used for storage of these gasses. The bottles will later be transferred to storage vessels, distinctly designed vessels held in tow by the collection vessels to provides temporary additional storage for the gasses.
2. Navigation:
The present invention utilizes a predetermined zone of operation for the collection vessels. Despite attempts to keep the collection vessels from drifting, they eventually do move away from their desired collection location, where the wind and waves are optimum for the generation of the gasses. Repositioning of the collection vessels back to desired locations and transfer points for the collected gasses is needed.
Each collection vessel is free floating. An onboard navigation and communication system is required for each collection vessel in order to provide continual feedback to a shore based control center that monitors location and controls navigation of the collection vessel. Global positioning and radar communication is utilized for this purpose.
On-board propulsion and steering capability for each collection vessel is essential. In the present invention a propulsion drive system utilizing an internal combustion drive system fueled by the hydrogen and oxygen collected by the collection vessel is used.
Thus, the only fuel cost associated with repositioning is the diminution of the gasses produced during collection. However, the frequency and time to reposition is managed to minimize the amount of the gasses needed to fuel the propulsion of the vessels when repositioning them throughout the year.
Increasing the speed of repositioning by retracting the sea anchor and turbine blades, and increasing the horsepower of the main propulsion system thereby, will minimize the costs of repositioning.
3. Product Transfer:
The gasses produced by the collection operation must be transported to one or more distribution points, for transport to end-users. This normally requires transport of the containers of gasses collected to distribution points on the land. Transfer operations will utilize both modern communication technologies and robotics.
A docking, connecting a collection vessel to a secondary fuel storage vessel, would be controlled through GPS, remote controls using vision feedback systems and onboard PLC (Programmable Logic Controller) controls. Docking is also provided between the collection vessels and other stationary locations at sea.
The storage vessel, filled with gasses after transfer, would then detach from the collection vessel and then remotely navigate to a stationary fuel transfer facility at sea. This facility should be located near shore, so that the gasses can be pipelined to an onshore storage facility. Meanwhile another, empty secondary storage vessel will quickly replace the previous one, and rendezvous and dock with the collection vessel, thereby minimizing the downtime in the collection process.
Each storage vessel has an onboard propulsion system that will use Hydrogen as a fuel to transport the vessel to a central off-loading station near the shoreline. The vessel's progress is monitored by GPS positioning. Onboard cameras and radar provide information used by the automatic navigation system.
Once gasses are transferred from the storage vessel to the product transfer facility, the now-empty secondary storage vessel would return to stand by near the collection vessel sailing areas until needed to replace another storage vessel.
Referring first to FIG. 1 , the wind-based collection vessel illustrated possesses the features discussed; the vessel also contains a propulsion system that is located near the bow 4 . The propulsion system may be a standard internal combustion engine or modified gas/steam turbine. However, instead of gasoline or diesel power, hydrogen and oxygen fuel the engine.
Because the wind vessel faces the wind 14 , it travels backward 12 while not under sail or power. The vessel is a “double-ender”, with bow 4 and stern 10 having identical shapes. The bow faces wave activity during production operations and the stern and bow may experience waves while the vessel is under way.
FIG. 1 shows a sea anchor 2 disposed in front of the bow. The sea anchor is in the shape of a “parachute”, and has the same function: it slows the speed of the vessel by creating a drag when the vessel moves in the direction of the wind 14 , which is also the direction of drift 12 of the vessel.
A monohull design as displayed in FIG. 3 is expected to be the most stable platform for this kind of application. However, other types of hulls would work. For example, obsolete naval vessels are often auctioned off by the US government and could be converted to support wind systems.
Controlling Turbine Speeds vs. Power Output:
The current output is dependent upon the available voltage supplied by the generator and the resistance to current flow within the entire electrical circuit. As resistance is reduced more current can flow with any given voltage. Both the generator output (current and voltage) will be monitored by PLC controls and an onboard computer. Turbine speed will be adjusted to maximize current and voltage. The greater the power passing through the system, commonly known as system load, the greater the torque that is applied to the wind turbine main drive shaft by the generator dragging against the wind turbine. The turbine blade will convert wind energy to mechanical shaft power, which speeds up shaft rotation. The generator converts the shaft rotation into electrical power causing an opposing back mechanical torque on the same shaft.
As wind speed increases, mechanical shaft speed increases. Back torque is then applied to the shaft by the generator that is under load. The generator load will increase by reducing line resistance at the hydrogen generator (discussed below) and therefore increasing back mechanical torque on the shaft. A balance of maximizing wind/mechanical energy conversion (creating positive mechanical shaft torque) and back mechanical shaft torque is important to prevent possible run away speeds of the wind turbine. The turbine design will be limited to a maximum rotational speed to minimize the possibility of damage in high winds due to the forces involved with over speeding.
In the modern, hi-tech wind turbines an on-board computer will record both the real and apparent wind speed and angle, so that the blades of the turbine can be adjusted to an angle for optimum power. The use of variable pitch blades is well known and understood in the prior art. It is used not only for wind turbines, but also in marine propulsion screws, in airplanes, and in helicopters. The principle in regard to wind turbines is discussed in detail in U.S. Pat. No. 5,503,525, Pitch-regulated vertical access wind turbine, Brown, et al.
The apparent wind, in this case the wind relative to the turbine blades, is measured by means of transducers. The speed of the blades is also measured by different transducers. This technology is well known, and the wind speed and angle calculations are routinely performed in modern yachts, while the measurement of the shaft speed of the rotor is done by prior-art methods universally known and understood.
The turbine contains a number of blades which have adjustable angles of attack, defined as the angle between the front edge of the turbine blade and the direction of the wind flowing across the front edge. The angle of attack is adjusted to obtain maximum efficiency given the speed and direction of the apparent wind.
An added complexity is that the apparent wind is faster at the ends of the blades than in the center, since the blades are travelling faster at the edges than at the center. To compensate for this difference the turbine blades of the present invention have an angle relative to the plane of rotation, which continuously decreases along the length of the blade to some minimum angle at the end of the blades.
Wind Power Devices
To build upon the discussion above, the absolute available wind energy in a given space can never be completely absorbed by a wind machine. A German Physicist Albert Betz developed Betz's Law in 1919 described in his book “Wind-Energy” published in 1926. According to Betz's Law, the maximum energy that can be absorbed from a wind turbine is about 59% of the available energy (if 100% of the available energy was removed, the wind turbine would not turn because there would be no air flow through the turbine blades). At the same time, energy absorption is directly proportional to the amount of blade surface area driving an electrical generator. For a given area, the greater the blade area exposed to the wind, the greater the torque on the generator.
Common industrial wind turbines have 3 blades and do not take advantage of this basic concept. As a result, within the diameter of the turbine rotor, modern day wind turbines only absorb a fraction of the available wind going through that same space. The present 3-bladed approach has been almost universally adopted in prior art wind farms because almost all of their wind turbines are connected directly to the power grid. This requires strict quality standards for voltage and frequency of the generated electricity. Turbine speed, and therefore generator speed has to be maintained at a constant rate to meet these standards. Any fluctuation due to changing wind speeds is compensated for by feathering the turbine blades to spill air, thereby reducing the surface area exposed to the wind, and minimizing the variations caused by gusts. Also, the turbine blades themselves have to travel at relatively high rates of speed in order to meet frequency standards. This high blade speed exacerbates the effect of the wakes of one turbine blade on a nearby blade residing on the same rotor.
A typical standard 3-blade turbine design having a diameter of 20 feet has a blade area of about 18.5 ft 2 based on standard blade designs. In contrast a turbine with 30 blades of similar design with the same diameter has about 304 ft 2 of working blade area.
In accordance with Betz's Law, the amount of practical power output for a 20-foot diameter, 3 bladed design is about 4.381 Kwatt-hours, while a 30 bladed design will theoretically produce 45,234 Kwatt-hours. The chart shown in FIG. 10 compares the annual power produced at the same wind speeds discussed and compares theoretical power, available practical power (Betz's Law) and approximate power production for turbines having 3 blades and those having 30 blade designs.
In this figure a comparison is made between 3 and 30-blade designs in which the surface area per blade is the same. The diagram demonstrates that the 30-blade rotor produces substantially more power than the 3 blade design.
In this diagram, the data is grouped into sets of four bars per set. The first, or left-most bar of each set represents the same data from FIG. 10 , which represent the available energy in the wind in a 20 ft diameter space off the coast of Northeastern United States. The second bar of each set, to the right of the first bar, represents the impact of Betz's Law on the available wind or what can be practically extracted from the wind by a perfect wind turbine. The third bar of each set, to the right of the second bar, represents the wind energy transformed into mechanical energy with a 3-bladed design. Finally, the fourth bar of each set, to the right of the third bar, represents the wind energy transformed into mechanical energy with a 30-bladed design.
As an alternative manner of viewing this figure, the white bars represent the theoretical power available, the tallest black bars the results of Betz's law, the shorter black bars the calculated effect of a 30 blade turbine or turbine utilizing the maximum available rotor surface area and the short white bars represent the calculated effect of a three bladed turbine of the same diameter and same blade size as the 30 blade example.
These diagrams show that 30 blade turbines provide a much greater opportunity for converting most available wind energy to mechanical energy, based on their greater surface area exposed to the wind. Utilizing more surface area to capture the wind sharply increases annual energy conversion.
Blade Construction:
In the present invention the wind turbine contains a number of blades, each in close proximity to the adjacent blades. The design is depicted in FIG. 3 . The collection vessel is viewed head on, with the bow 4 in view. The wind turbine 6 is seen to contain a large number of blades 7 , packed tightly together. Whereas standard turbine blades are long and thin, the blades of the present invention are equally long, but are wider than standard turbine blades. As a result, the force on each turbine blade is less than that of the standard turbine for the same power produced, since each blade takes a proportionally smaller force.
As a result, each of the blades can be made of lighter, thinner material than in the standard wind turbine.
Furthermore the blades of the present invention do not travel as fast as prior art blades; therefore, there is a lower dependency on high efficiency aerodynamics. The present blades do not present a perfectly aerodynamic airfoil design.
The present blades are of a much lighter construction than prior art blades. Support wires, or stays, are used in the blades of the present invention to provide strength and reduce the cost of construction normally associated with manufacturing high tech/high efficiency/high strength composite blades. Traditional strut and covering construction will be used in this invention to allow for lightweight, high-strength and low cost blades.
Such a configuration is shown in FIG. 4 . A single blade 7 is depicted, although in practice the turbine will contain a multiplicity of these, as seen in FIG. 3 . Still referring to FIG. 4 , the blade is affixed at its center to an armature 20 , which rotates and causes the blades to rotate with it. The blade contains a central beam 18 lengthwise through the center of the blade. It is covered by a foil 20 , which is shown only extending between the hub and the strut nearest to the hub, but which, in actuality extends over the entire surface of the blade.
The preferred embodiment uses a 30-blade rotor. In other embodiments different numbers of blades per rotor may be chosen, in order to maximize available total rotor surface area within a given rotor diameter.
Adjusting the angle of attack of the rotor blades is effected by a hydraulic system. Referring next to FIG. 2 , a cross-section view of the armature on the wind turbine is shown. A primary disc 30 is caused to rotate by the wind, the blades 7 rotatingly attached to the primary disk, so that the angle of attack can be altered. A central shaft 38 communicates between the mechanical elements in the armature 20 , and the control module 34 located in proximity to the armature. When this central shaft rotates, the secondary disk 32 , and the main generator 28 are made to rotate at the same rotational speed. Hydraulic cylinders 24 cause the rotating secondary disk to slide to the left as shown in the diagram, thus moving the activation arm, which controls the angle of attack of the blades 7 . Control of this mechanism is done by a computerized control system, taking into account the actual and apparent wind speed and directions, in order both to maximize efficiency of generation of electricity, and to protect the wind turbine blades in high winds.
Wave Power Devices
The Wave Collection Vessel
As previously discussed, the prior art teaches a number of different designs for wave power conversion. In particular, the oscillating water column approach, and the Tapered Channel (TAPCHAN) types, have been found to be practical for sea-based wave power generation systems. Both of these approaches are also applicable in the present systems in alternative embodiments. However, the first preferred embodiment utilizes the valve wall system, described above. The embodiment of the wave collection vessel described following is dependent upon incorporation of the valve wall system of wave power generation.
Like the wind power collection vessel, the wave power collection vessel is kept relatively stationary in the ocean through the deployment of a sea anchor disposed off the bow of the vessel, which keeps the bow facing the wind, and therefore the waves. In the same way that a conventional anchor affixed to the sea bed will keep the bow of a vessel headed into the wind, the sea anchor provides a countervailing force to the backward drift of the vessel. Unlike a sea-bed anchor, however, the sea anchor will not prevent the vessel from drifting entirely, but will substantially slow the rate of drift.
The stern of the collection vessel contains a channel similar to the prior art TAPCHAN system described in Appendix C. Referring now to FIGS. 11 , 12 , and 13 , it is seen that a wave has entered the wave collection channel 109 , the channel amplifying the wave height, and directing it against the valve wall 103 .
FIG. 12 depicts the wave power collection vessel as viewed from above. Referring now to this figure it can be seen that the tapered channel occupies a substantial portion of the stern of the boat, which faces the approaching waves. The side walls 102 of the valve wall are tapered upwards to retain the wave as it breaks on the valve wall, and this tapered aspect may also be seen by referring to FIG. 11 , which shows the collection vessel as viewed from the side. FIG. 13 , which views the vessel from the bow, also shows these side walls.
Still referring to FIG. 13 , as well as FIG. 11 , it may be seen that the bow end of the tapered channel 109 is disposed below the waterline 88 , to allow for trough of a wave to ascend the tapered channel even when the stern of the collection vessel is riding up on the crest of a prior wave. In this manner, the maximum volume of water is collected from each wave.
FIG. 13 also reveals the relative dimensions of the valve wall 103 , the collection chamber 101 , and tapered channel 109 , as well as showing the height of the tapered channel relative to the beam of the collection vessel. Because the center of gravity of the vessel is raised substantially when the collection chamber 101 fills with water, stabilizing pontoons 88 are provided to prevent excessive roll of the vessel.
An array of check valves is disposed across the entire surface of the valve wall. These check valves allow the water to pass from the tapered channel into the collection chamber, but prevent the water from flowing back from the collection chamber through the valve wall. Thus, a portion of each wave will pass through the check valves of the wall and into the collection chamber. The rest of the water will flow over and around the valve wall and collection chamber, or will pass back down the tapered channel into the sea.
Still referring to FIGS. 11 and 13 , the floor of the tapered channel has a shallow slope beginning below the water line so that it may capture most of vertical height of the wave above its trough. As the wave travels into the collection channel, the channel floor slopes up along its length as the channel progressively narrows, so as to convert much of the horizontal energy of the wave to vertical energy, elevating the wave above sea level.
The portion of the channel below the water level of the collection vessel has a width approximately equal to the beam of the collection vessel, as may be seen from FIG. 12 . At the point where the tapered channel terminates in the valve wall the width of the tapered channel, as well as that of the valve wall, is between one-half and two-thirds of the beam of the vessel.
The valve wall also narrows as it extends upward from the inboard end of the tapered channel, since the volume of water contained in each wave diminishes with height. The collection chamber 101 likewise tapers as it rises upwards from the deck of the collection vessel. As a result the volume of water in the channel decreases as the height of the wave increases. This prevents the vessel from becoming unstable as the center of gravity of the vessel rises due to the inflow of water in the tapered channel.
Referring next to FIG. 14 , the detailed operation of the valve wall itself may be understood. The valve wall 103 contains a multitude of check valves, separated by a distance approximately equal to the aperture of each valve. The greater the number of check valves in the wall the greater the volume of water will be captured with each wave which is collected. However, the check valves cannot be spaced too close together without weakening the wall itself, which must withstand the force of successive waves breaking upon it.
The wave power system describe herein may be considered as a modified version of the TAPCHAN system. The improvement provided by the valve wall increases the efficiency of the system, especially under conditions of reduced wave heights, because it is not now necessary that the waves exceed the height of the walls of the collection vessel as they enter via the tapered channel.
Once the water has entered the collection chamber, the present system operates in a manner similar to the prior art TAPCHAN system. The water within the collection vessel exits via a turbine 124 , which is coupled to an electric generator which produces electrical energy. In the present invention, however, unlike the prior art TAPCHAN system, the electrical energy produced by the turbine is then used to produce hydrogen and oxygen by means of electrolysis.
It should be emphasized that although the preferred embodiment of the present invention utilizes the valve wall/tapered channel system for generation of electricity from wave power, as described below, most of the other prior-art systems for wave-power electrical generation may be used in place of the valve-wall approach in other embodiments of this invention.
Operation of the Valve Wall
As waves riding up the tapered channel impinge on the valve wall a certain amount of water will pass through, depending upon the force of the wave and the amount of water in the collection chamber on the other side of the wall. In the preferred embodiment the wall face is disposed at approximately 45 degrees to the earth's gravitational force. The water will pass through the check valves providing that the force on the wave side of the valve wall is greater than that on the opposite, or collection chamber, side. The force on the wave side of each check valve is dependent upon the force of the water as it rides up the collection channel and onto the valve wall, and upon the cross sectional area of the opening in the valve seat of the check valve. On the collection chamber side the countervailing force for a given check valve depends almost entirely on the height of the water column in the chamber above the valve, and the cross sectional area of the opening of the check valve seat. When the force on the wave side is greater than that on the collection chamber side for a particular check valve, water will pass through to the collection chamber side. Otherwise, no water will pass through from the collection chamber side to the wave side.
Although there are many different types of check valves known in the prior art, the present invention utilizes a “swing valve” type which is illustrated in FIG. 14 . Referring to this figure, the valve is made up of a valve seat 112 , and a disc 115 which rotates about hinge 114 , thereby closing valve aperture 113 as the valve closes, and opening the aperture as the valve opens. Fluid Pressure on the left side of the valve wall due to the water 117 within the collection chamber will cause the disc to swing closed, while water pressure on the right side of the valve wall will force open the valve, causing the hinge 114 to swing clockwise, the disc typically reaching maximum position as seen in FIG. 16A . It is important that this open position never exceeds 90 degrees, because pressure on the disc caused by the buoyancy of the water 117 as it rises in the collection chamber must cause the disc to return toward the valve seat 112 , rather than causing the disc to rotate in the opposite direction.
In the present invention a modified version of the swing valve is used, as shown in FIG. 14 . This modified swing valve requires that the disc 115 be buoyant, so that the rising water causes the disc to rise toward the valve wall 103 , as the buoyant force of the water increases as it rises under the disc. The disc must therefore have a density less than that of water to provide such a buoyant force. This can be accomplished by either using a buoyant material in fabricating the disc, making the disc hollow, or attaching a buoyant material 116 to the disc, as in the embodiment shown in FIG. 14 .
Referring now to FIG. 14 , it may be seen that in one preferred embodiment each individual valve has a floatation disc affixed to the back of the valve disc that lifts the valve into a seated, close position as water rises around it. Once in place the back pressure from the water head created by the column of water in the holding tank will keep the valve shut by increasing force on the valve seat as the head height in the holding tank increases.
The action of the check valve may be understood by referring to FIGS. 16A through D, in which the collection chamber is filled progressively by successive waves. Referring first to FIG. 16A , the water in the collection chamber is so low that the pivot valve disc 15 hangs almost straight down, since the only force on the valve is that of gravity.
Referring next to FIG. 16B , the water has begun to rise causing the disc to rise toward the valve seat. The water rises further in FIG. 16C , as the valve continues to close. And finally, in FIG. 16D , the water has risen above the level of the check valve, so that the valve has closed completely.
Although FIGS. 16A through D depict only a single check valve, the valve wall contains an array of such valves in the preferred embodiment, the valves occupying about 50% of the wall area. The proximity of the valves to each other is limited only by the need to maintain the strength of the wall in the face of recurring blows of the waves as they impinge on the wall. Clearly the valve wall's strength is diminished by each wall aperture 113 formed in the wall.
Each check valve will open when the pressure on the wave exceeds the pressure on the holding tank side, or when the water level in the collection chamber side falls below the level of the check valve. The net result is that the collection vessel will continue to fill by the action of the waves against the valve wall, but will empty by the flow of water out of the collection vessel through the water turbine 132 , as shown in FIG. 15 .
Still referring to this figure, the column of water in the collection vessels creates a hydrostatic head pressure at the bottom of the tank forcing the water through the turbine feed port 105 at the bottom of the collection chamber past a turbine impeller, thereby causing it to rotate. The shaft of this turbine 111 is coupled to a hydro-electric generator 124 which generates the electrical power used to generate hydrogen and oxygen by hydrolysis, as described infra.
The higher the level in the holding tank the greater the head pressure and the more power output is generated by the hydro-electric generator, within bounds. However, it is desireable to control the rate of rotation of the turbine within reasonable bounds, to prevent damage to the turbine and generator components. For this reason a control valve is disposed in the discharge channel 130 leading from the turbine and sending the effluent overboard after it is spent. This control valve is regulated by means of a PLC controller that senses the water level in the holding tank, since the speed of the turbine rotation will be a function of the hydrostatic head in the holding tank.
Hydrogen & Oxygen Generation:
The science of electrolysis has been known for over one hundred years. In the present invention the electricity generated by the generator is used as a source of power for electrolysis, which produces hydrogen and oxygen.
When a DC voltage is applied across a cathode and anode immersed in salt solution, positive and negative ions collect on the electrodes. A typical salt used is KOH (Potassium Hydroxide), which provides the ions to create a conductive path. Water will then be split into its elements. Hydrogen will form on the negative electrode and oxygen will form on the positive one. The gasses will continue to form until sufficient quantities cause them to rise through the water and collect as gas bubbles at the water surface.
Referring now to FIG. 5 , the electrolysis system is shown in cross-sectional view. The hydrogen reactor 40 and oxygen reactor 42 are filled with a salt solution of KOH. Each contains a carbon electrode 60 immersed in the solution. A bridge 58 connects the solution from the two reactors, allowing the migration of ions between the electrodes. The hydrogen gas collected at the hydrogen reactor 40 is pumped into the hydrogen cylinder 54 by means of a compressor, separately from the oxygen, which is pumped into the oxygen cylinder 56 by means of a separate compressor. Care needs to be taken to collect the oxygen and hydrogen separately since they will recombine to form water if allowed to do so, with a danger of explosion.
The rate of generation of the gasses is directly proportional to the amount of power applied, which is the product of the voltage across the electrodes and the current passing through the electrodes and through the solution.
The electrolysis system of the present invention is constructed from materials that will minimize the corrosion. The electrodes are constructed from carbon, that will not break down during electrolysis.
Purified water is used as the starting point for the salt solution, and is first stored in the purified water reservoir 62 . It is pumped into the reservoir through a small micron filter 52 intended to remove any organic impurities. Providing a 1 to 2 micron filter in this manner will minimize the number and size of organic chemicals in the system. For the purposes of generating commercial hydrogen and oxygen, an impurity level less than 0.5% would produce oxygen and hydrogen of sufficient purity for industrial purposes. If needed, however, additional industry standard purification processes can be used as needed to further refine the gasses at a shore based facility.
In an alternative embodiment sea water is used as the starting point for the generation of the KOH salt solution. The obvious advantage of using sea water needs no further amplification. However, it is necessary to first remove all of the significant chemicals from the sea water using purification techniques already in existence before adding the KOH required in the current method. The decision as to whether purify sea water on board, as opposed to transporting water purified on shore, is one based on considerations such as economies of scale. Alternatively, the decision is based on whether it is more energy efficient to purify water on shore, and to transport it to the collection vessels by the storage vessels shuttling back and forth from shore, or, conversely to purify sea water on board the collection vessel.
The presence of organic material in the solution would mix with the salt solution, and could cause additional gasses to be emitted together with the Hydrogen and Oxygen. Nitrogen gas, for instance, is one of the contaminants that result from organic chemicals in the water.
After filtering the purified water, KOH is added. The solution is then in condition for the electrolysis process to begin.
Electrical power is supplied to the solution by the generator 28 , which, in the preferred embodiment, is a single-phase synchronous generator. A back-up battery 50 is provided for starting the generator after periodic idle periods due to a lack of wind. The battery is charged during times of energy production by the generator. AC power is converted into DC by a full bridge rectifier 48 , which is connected to the carbon electrodes 60 immersed in the KOH solution as discussed above.
Gasses are pumped away at approximately the rate that they are produced. Since there are two hydrogen atoms for each oxygen atom in water, twice as much hydrogen will be produced as oxygen. Sensors in the system will sense gas and solution levels in the system and control valves and pumps to maintain levels as required.
Transfer and Distribution:
Referring now to FIG. 6 , there are two vessels involved with retrieving, compressing and storing product gasses. The collection vessel 8 has a small storage capability in which the hydrogen and oxygen cylinders are stored, sufficient to power the propulsion system of the collection vessel as required for maneuvering. The storage vessel 64 , is affixed to the collection vessel by towlines 66 .
Once the onboard storage containers in the collection vessel are filled to capacity, a sensor will detect the pressure and trigger an onboard booster pump on the storage vessel to start pumping. The line connecting the two vessels has a dual purpose. Besides securing the two vessels together, they support gas transfer from the collection vessel to the storage vessel, and further support transfer of purified water lines between the vessels, to allow refreshing of the solution in the electrolysis chambers.
The booster pump will pump down the smaller containers on the collection vessel until they fall below a lower pressure value, at which point the pump will shut off. When the pressure begins to build back up due to new gas production on the collection vessel, and exceeds a high pressure value the pumping will start up again.
Once pressure levels in the storage vessel reach a maximum storage control value, a sensor will trigger a radio message to a shore-based control center to send a second storage vessel to the site of the now-full storage vessel. When it reaches the site a final message will be sent to the control center to stop transferring the gasses and to then detach the storage vessel from the collection vessel. The second storage vessel is then remotely navigated to the collection vessel where the two are docked. The collection and storage cycles are then re-initiated.
The newly arriving storage vessel, which is self-propelled, will supply purified water to the collection vessel, which is then used to refresh the salt solution used for electrolysis.
In order to facilitate the transfers of gasses at sea as just described, the vessels will have remote docking capability, similar to air-to-air refueling systems currently being practiced by the armed forces.
The system of the current invention would utilize a similar technology. Referring now to FIG. 9 , a collection vessel 8 and a storage vessel 64 are approaching each other. The female end 66 of the transfer line is floating in the water, connected by hydrogen, oxygen and water feed lines to a securing cable 68 , while the male end 70 , connected to the storage vessel is lying in proximity. The male & female ends are rigid so they cannot rotate laterally but they can pivot vertically, so that they will effectively ride atop the waves. Flotation buoys 72 keep the transfer line afloat. Through the use of inexpensive sensors and computer controls the docking maneuver is automated so that a minimum of human intervention is involved.
In a further embodiment the docking maneuver is totally automated, once the vessels are maneuvered to a predetermined distance from each other.
In one of the preferred embodiments a central discharge station is used as an intermediate storage location. It is located on the water, but where the depth of the water is sufficiently small so that a pipeline can be conveniently laid, to relay the stored gasses to a shore storage station.
Docking to the central discharge station would even be performed in a similar manner to the docking between vessels at sea. Automated docking is the preferred method, but manual override is available as a back up option should the autonomous docking system experience problems.
The entire system is under the control of a shore-based central control center where all vessel movement and off-loading is controlled. All vessels will have the same navigational capability, which is monitored and remotely controlled from this location. This central control center is the only location requiring human, hands-on operation. All other activity in the system, with the exception of maintenance, is at the central control center through the use of remote controls and communications. As a result the potential safety risks of handling vessels at sea loaded with hydrogen is minimized.
Vessel Drift
The collection vessels and storage vessels, while not under power for navigating to a new zone or changing storage vessels, will drift in a controlled manner from the force of the wind. FIG. 8 a shows a collection vessel in collection mode, with the sea anchor 2 deployed. The rate of drift will depend upon the speed of the wind, as well as any local tides. A sea anchor 2 also keeps the turbine facing the wind in order to maximize turbine efficiency. As previously stated the sea anchor further minimizes drift.
Repositioning of vessels drifting outside their predetermined zones is accomplished with the aid of GPS systems on-board the collection vessels that continuously monitor the vessel position, and relay this information back to the control center. If any of the vessels require repositioning their onboard propulsion systems are started in order to navigate to the new position.
In the wind propulsion systems, prior to retrieving the sea anchor the engines are firing up, the turbine blades are feathered and then retracted. The collection vessel is then maneuvered forward to relieve tension on the sea anchor and its lines so that it can then be retrieved. Once the sea anchor and turbine blades are secured, navigation to a new location can occur. Once the new position is achieved, the sea anchor is redeployed to continue converting wind energy to mechanical energy.
In the case of the wave power systems, repositioning is slightly different. As the wave vessels reposition, each propulsion system backs up the vessel to relieve pressure on the sea anchor. The sea anchor is then retracted and the vessel is propelled forward, with the wave channel trailing, to navigate to a new position.
Handling of the wave power collection vessels in heavy seas requires special treatment. The sea anchor is first retracted, the bow swung into the oncoming sea by the onboard propulsion system, and a smaller sea anchor is deployed from the bow to hold the vessel in a relative position with the bow facing the sea. This maneuver is similar to the way that life boats are managed in high seas.
Once the storm subsides and the seas calm, and assuming the vessel is still well within its operating zone, the smaller sea anchor is retracted, the swung back into the on coming sea, and the main sea anchor redeployed to continue the wave energy conversion operation.
If the vessel is outside of its operating zone after the storm, the on-board propulsion system repositions the vessel to a more desirable location within the zone, and then the main sea anchor is be redeployed at the stern.
Referring now to FIG. 8 a , it may be seen that when deployed the sea anchor 2 is forced taught by the force 80 of the water filling the anchor like a parachute while the collection vessel is pushed by the wind 82 . The higher the wind the more the anchor will resist the force of the wind on the vessel. Furthermore, the sea anchor aligns the bow of the vessel directly into the wind.
The collection vessel continues to drift in this way until the vessel has drifted outside of the zone boundaries, and therefore needs repositioning. Before getting under way, the sea anchor must be retrieved otherwise the vessel may move into the sea anchor, fouling the vessel, and damaging or destroying the sea anchor.
Referring now to FIG. 8 b the collection vehicle has been reconfigured so that it may safely navigate to a new position. The blades 7 have been retracted into a position facing the bow of the collection vehicle and the sea anchor 2 has been stored in the sea anchor storage compartment 76 .
Referring next to FIG. 7 a retraction of the sea anchor is accomplished by means of a retraction cable 84 connected to the center of the sea anchor 2 . The retraction cable is limp as shown in FIG. 7 a when the sea anchor is deployed and under tension when retracting the sea anchor.
To retract, the vessel would move forward slightly using its onboard propulsion system and begin to draw the retraction cable into the storage tube 76 , which is secured on the vessel, by means of an onboard retraction winch 92 which are powered by the rechargeable batteries. As the retraction cable 84 becomes taught, drawing the center of the sea anchor toward the vessel, and the sea anchor disposal cables 86 become slack. The sea anchor collapses as the “parachute” shape is destroyed, and its drag on the collection vessel is drastically reduced, allowing the sea anchor to be winched in.
The winch 92 which draws in the retraction cable 86 is located on the back-end 90 of the storage tube and draws the retraction cable through the storage tube 76 , located along the length of the vessel hull. A cross-section of the storage tube is shown in FIG. 7 a , with the sea anchor 2 stored within.
When the new desired position is achieved, the collection vessel pulls into the wind and the sea anchor is re-deployed. The storage tube is hinged along one side, as shown in the cross-sectional view of FIG. 7 b , so that the tube opens along its entire length, allowing the sea anchor to fall into the water below when the tube opens. Backing the vessel further assists the deployment of the sea anchor.
Once deployment is complete, the turbine blades are rotated into position and the on-board engines are shut down.
Wind Turbine Retraction:
The ability of the wind turbine blades to retract for the purposes of vessel transport and vessel protection during high windstorms is a truly unique feature for wind turbine designs.
In standard wind turbines the blades are subject to high shear forces, requiring thick bases and heavy composite construction to withstand high torques at the base of the turbine blades where they meet the armatures. In the present design, in contrast, the blades are subject to forces which act largely in compression so that torques at the armature are minimized.
Because of the diminution of forces in the present design a much lighter-weight construction is possible. Referring again to FIG. 8 a , wire stays 96 , or guy wires, support the turbine blades, which can be of lighter construction as a result of the support of the stays, which are secured at one or more points along the length of the blades at one end, with the other end secured to the center of the armature extension. The extension protrudes from the center of the armature nose 21 and is approximately equal in length to two-thirds the length of a blade. Each blade is supported in this manner resulting in multiple cables converging at the armature nose extension end.
When the collection vessel is under power the turbine blades must be first stowed, as shown in FIG. 8 b . As seen in this figure, the stays have been retracted in the armature nose extension, thereby keeping the blades from opening. The blade bases are hinged where they meet the armature, and the blades themselves must be rotated to a completely feathered position prior to retracting. With a high number of turbine blades in close proximity, as shown in FIG. 3 , feathering is essential before retraction so that the blades do not physically interfere with each other when retracted.
While the invention has been described with reference to specific embodiments, it will be apparent that improvements and modifications may be made within the purview of the invention without departing from the scope of the invention defined in the appended claims. | A method for generation of gasses contained in a salt solution in accomplished by disposing automated, floating wave power collection vessels in waters distant from shore, the vessels navigating within one or more predetermined geographic zones, having suitable wave conditions for such operation. The wave power devices generating electricity and the gasses are extracted from the salt solution by electrolysis. Automated storage vessels are used as shuttles to deliver the gasses to shore facilities. | 5 |
This is a Divisional of application Ser. No. 08/443,985 filed on May 18, 1995, now U.S. Pat. No. 5,615,801 which is a continuation-in-part of U.S. patent application Ser. No. 08/178,721 filed Jan. 10, 1994 (now U.S. Pat. No. 5,494,193), which was a divisional of U.S. patent application Ser. No. 07/843,757 (now U.S. Pat. No. 5,305,923), which was a continuation of U.S. patent application Ser. No. 07/752,406 filed Aug. 30, 1991 (now abandoned) and having the same title, which was in turn a continuation-in-part of U.S. patent application Ser. No. 07/634,857 filed Dec. 27, 1990 (now abandoned) and having the same title, which was in turn a continuation-in-part of U.S. patent application Ser. No. 07/534,601 filed Jun. 6, 1990 with the same title (now abandoned), and is also a continuation-in-part to U.S. patent application entitled "Progressive Cavity Pump" filed Jun. 14, 1991, Ser. No. 07/715,433 (now abandoned).
BACKGROUND OF THE INVENTION
This invention relates to postmix juice dispensing and in particular to a disposable and recyclable juice concentrate package for insertion into a postmix juice dispenser.
Postmix juice dispensers are known as are disposable and recyclable juice concentrate containers for use therein, which include a juice container, an integral pump (operated by a motor in the dispenser), and a dispense nozzle. Previously the concentrate pump was a part of the dispenser itself however, to overcome the servicing problem of cleaning the pump, it became the practice to provide the pump (or at least the portion of the pump that contacts the juice--such as the tube of a peristaltic pump) and the dispensing nozzle as part of the disposable concentrate package. The operator then simply needs to remove the package and replace it with a new or different one and proceed to dispense drinks. No cleaning is needed.
One known pump for such a package uses a flexible bellows reciprocating pump which pumps separate independent slugs of concentrate to the mixing chamber.
It is an object of this invention to improve mixing by pumping a continuous stream of concentrate to the mixing chamber.
SUMMARY OF THE INVENTION
A new and improved disposable juice concentrate package includes a package housing and an integral mixing nozzle. The package housing includes a container housing and a pump housing. The pump is a progressive cavity (or moineau) pump that provides a continuous stream of concentrate to the mixing nozzle (in contrast to separate, spaced-apart, shots of concentrate provided by other available types of pumps). This continuous stream is spread into a thin film against which the water is directed, provide for excellent mixing. The package also includes a low level indicator to let the operator know that it is almost time to replace packages, and a product identification (I.D.) label that a dispenser can automatically read and set the correct ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood from the detailed description below when read in connection with the accompanying drawings wherein like reference numerals refer to like elements and wherein:
FIG. 1 is a front, top, left side perspective view of the concentrate package of this invention, with the mixing nozzle turned up for shipping;
FIG. 2 is a front elevational view of the package of FIG. 1, but with the mixing nozzle rotated down for insertion into a dispenser;
FIG. 3 is a partly cross-sectional, right side elevation view of the package of FIG. 1;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2 through the lower portion of the package, including the pump and mixing nozzle;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 3 and showing the float;
FIG. 6 is a cross-sectional view along line 6--6 of FIG. 7 showing the stiffening rib;
FIG. 7 is a cross-sectional view along line 7--7 of FIG. 3 showing the fill cap and air vent valve thereof;
FIG. 8 is an exploded perspective view of the mixing nozzle;
FIG. 8A is a top view of the mixing element 80;
FIG. 8B is a cross-sectional side view of the mixing element 80, taken along line 8B--8B of FIG. 8A;
FIG. 9 is a partial perspective view showing the flag; and
FIG. 10 is an enlarged cross-sectional view through the housings connection, taken along line 10--10 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIGS. 1-10 show a concentrate package 10 including a package housing 12 and a mixing nozzle 13. The package housing 12 includes an upper juice concentrate container housing 14 and a lower pump housing 16.
The container housing 14 includes an upper wall 18 having a fill opening 20, and a sidewall 22 having a lower peripheral connecting edge 24 surrounding a container housing bottom opening 26.
The pump housing 16 encloses a pumping chamber 28 and has an upper peripheral attaching edge 30 that mates in a liquid-tight sealing connection with said connecting edge 24.
A fill plug 32 is fitted into said fill opening in a liquid-tight sealing fit. The fill plug can be snap-fit alone or preferably can also be induction welded, spin welded or sonically welded, as at 33, in place. The fill plug includes a one-way air vent valve 34 that prevents egress of liquid but allows air to enter the package as concentrate is pumped out causing reduced air pressure therein. This prevents the package from collapsing. The valve 34 includes a plurality of holes 36, a flexible diaphragm 38 and an annular valve seat 40.
Referring to FIG. 10, the attaching edge 30 includes a peripheral groove 42, a locking bead 44 and a plurality of sealing beads 46. The connecting edge 24 includes a peripheral tongue 48 that matingly fits in said groove 42 with a liquid-tight seal. A bead 43 of sealant is preferably located in the groove 42 to assist in making a liquid-tight seal.
A progressive cavity pump 50 (or moineau pump) is located in the pump chamber 28 in the pump housing 16. The pump 50 includes a rotor 54 and a stator 56. The stator includes a flexible bellows 58 at its distal end to allow the stator to move radially. A stop 60 abuts the proximal end of the stator to prevent axial movement thereof. The rotor 54 includes a drive shaft 62 extending exteriorily of the pump housing for connection to a drive motor through a liquid-tight seal 64. The pump housing includes a concentrate outlet opening 65.
The mixing nozzle 13 includes a nozzle housing 66 rotatably connected to the pump housing 16 and enclosing a mixing chamber 68, a concentrate passageway 70 leading from a concentrate inlet opening 72 to a concentrate inlet port 73 into said mixing chamber, a water inlet opening 74, a water passageway leading from said water inlet opening 74 into said mixing chamber, and a beverage discharge spout 78. The mixing chamber 68 includes a mixing element 80 which is also a shut-off valve. The mixing aspect of element 80 operates as follows: the incoming concentrate from the pump is forced to spread out around the conical surface 82 and enter the mixing chamber through the narrow annular slot 84 where it is hit and sheared by water which is directed against the concave bottom of the element 80 and then spreads out toward the slot 84 where it violently hits and mixes with the concentrate. Preferably, a flange 86 extends radially into the chamber 68 below the slot to further agitate and mix the water and concentrate. This violent action fully mixes the two components and no unmixed solids (such as occur in orange juice with pulp) are found in the bottom of a dispensed cup of beverage. The element 80 is preferably made of foamed polyethylene to increase its buoyancy. The flanges 81 are preferably at an angle so that the water hitting the concave underside of the element 80 causes it to rotate. This dynamic movement of the element 80 further assists the dynamic mixing.
The valve aspect of the mixing element 80 is that it floats in the single strength juice in the mixing chamber when the dispenser is off, and seals against a valve seat 88 to prevent any concentrate from flowing into the mixing chamber. When a drink is to be dispensed, the element 80 is pushed down by the flow of concentrate from the pump, thus opening the valve.
The container housing is rectangular in horizontal cross-section with two long side walls and two short side walls. The container housing tends to bulge outwardly in the middle due to the weight of the juice concentrate and the thinness of the housing walls. It is preferred to include a stiffening rib 90 inside the housing 14 to prevent such bulging. The rib 90 is a separate member that is slid into a pair of grooves 92 and 94 that are preferably molded in place on the inside side walls of the long walls of the housing 14. The rib 90 can be welded in place or preferably held by a locking bead on the rib. One or more such ribs can be used, as desired. The upper portion of the rib 90, below the fill opening 20, does not extend all the way across the package, so as to avoid interfering with a fill tube; the rib 90 does extend all the way across the package toward the lower portion of the package.
An important aspect of the package of this invention is the inclusion of a low level indicator 95, so that the operator will know when the package is low and so the dispenser will know when it is empty, and for preventing further dispensing when it is empty. These features are accomplished by means of a movable float 96. The preferred float 96 is hingedly connected at one end thereof to the housing 12 and the other end is free to move (float) between an upper position, when the liquid level is at or above the float, and a lower position as the liquid level falls below the upper position. The float 96 includes an elongated arm 98, a hinge pin 100, a wing 102 for floating on the liquid surface, and a flag 104 that descends into a narrow pocket 106 as the float falls to its lowermost position. The flag is preferably formed with white pigment to increase its opacity to infrared radiation and is preferably about 3/8" thick. The float is preferably air-foamed polyethylene to increase its buoyancy. The dispenser will have an infrared transmitter and receiver on opposite sides of said trough to detect said flag. The flag is preferably attached to the hinge posts 108 on the top wall of the pump housing 16 prior to the housings 14 and 16 being connected together.
The package 10 preferably includes a product identification label 110 on the left side of the pump housing as shown in FIG. 1. It preferably includes a shiny surface with a series of one, two or three black lines.
The mixing nozzle 13 preferably can rotate about its connection to the package housing 12 so that the nozzle 13 can be rotated up during shipping and handling, to take up less room and prevent damage thereto, and can be rotated down just prior to insertion into a dispenser.
The package 10 preferably includes tamper evidence means such as a shrink wrap around the package. The housings are preferably injected molded of polyethylene.
While the preferred embodiment of this invention has been described above in detail, it is to be understood that variations and modifications can be made therein without departing from the spirit and scope of the present invention. For example, other shapes and sizes and numbers and locations of stiffening ribs can be used. Also other shapes and sizes and locations of the float can be used. It is preferred that the mixing nozzle be rotatable but this is not essential. The mixing element is preferably also the shut-off valve, but a separate valve can be used, so the mixing element need not necessarily be movable. Any type of flow meter can be used, although it is preferred to use a paddle wheel flow meter as described in U.S. Pat. No. 5,381,926. Other types of air vent valves can be used in the fill cap. The package is all recyclable; the rotor and housings are high density polyethylene, the diaphragm 38 is low density polyethylene and the stator is preferably a soft thermoplastic elastomer such as sold under the trade name Santoprene. | A disposable and recyclable juice concentrate package for a postmix juice dispenser includes a package housing connected to an integral mixing nozzle. The package housing includes a concentrate container housing sealed to a pump housing. A progressive cavity pump is located in the pump housing for feeding a continuous stream of concentrate to the nozzle for intimately and violently agitating and mixing the water and concentrate and dispensing the beverage. The package also includes a low level indicator and a product identification label. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for driving controlling displacement of a plurality of yarn feeders arranged in a flat knitting machine.
Reflecting widely diversified fashions of garments in recent years, those modern knits including sweaters knitted by operating flat knitting machines contain a variety of color yarns and various kinds of yarns.
Any of those conventional flat knitting machines available for knitting color yarns of various kinds are furnished with a plurality of carriages which are secured to needle beds in order to adjust movement of knitting needles into and out of a knitting zone. In addition, a plurality of yarn feeders are slidably installed in the front and on the back of a plurality of yarn-guide rails which are secured above and in the longitudinal direction of those needle beds. In this case, it is necessary for respective yarn feeding apertures at the bottom tips of those yarn feeders to properly feed yarns at predetermined positions close to the tips of knitting needles when those knitting needles on the needle bed project themselves at the knitting position.
However, when setting all the yarn feeding apertures of those yarn feeders at predetermined positions close to the tips of knitting needles while knitting needles project themselves at the knitting position, those yarn feeding apertures collide with each other on the way of shifting positions of those yarn feeders which presents a critical problem to solve.
Now, therefore, in order to solve this problem, the applicant of the present invention previously proposed prior art related to a knitting yarn feeding system as disclosed in the Japanese Laid-Open Patent Publication No. 50-13657 of 1975. The disclosed prior art features the structure described below.
A plurality of carriages for adjusting positions of knitting needles into and out of a knitting zone are installed on a plurality of yarn guide rails disposed above and in the longitudinal direction of needle beds. An operating pin is also provided, which is capable of controllably moving itself in the vertical direction from those carriages to the yarn feeders.
A coupling recess available for engagement with the operating pin is provided on the top surface of each yarn feeder. Concretely, when the operating pin which is engaged with the coupling .recess moves in association with yarn feeders, the operating pin forcibly opens a link in resistance against attractive energizing force of a spring in order to lower yarn feeding apertures on the bottom tip of respective yarn feeders down to a predetermined position close to the tips of the knitting needles. On the other hand, when the operating pin engaged with the coupling recess is not accompanied with yarn feeders, the operating pin attracts the link by an attractive energizing force of a spring to lift the yarn feeding apertures at the bottom tips of respective yarn feeders, thus preventing yarn feeding apertures of other remaining yarn feeders from interferring with each other.
Nevertheless, since the preceding prior art disclosed in the above-cited Japanese Laid-Open Patent Publication No. 50-13657 of 1975 is structured to shift yarn feeders by forcibly opening a link composed of two pairs of levers and pins in resistance against tensile force of a spring on the way of shifting an engaged rod available for shifting a yarn guide unit, when the spring exerts such tensile force stronger than a sliding resistance generated by yarn feeders, those yarn feeders are transferred in such a state in which the link is not fully spread, in other words, in such a state in which yarn feeding apertures are not fully down.
Furthermore, since the tensile force of the spring is exerted in the direction of proceeding yarn feeders, even when the engaged rod available for shifting a yarn guide unit halts at the predetermined position, due to effect of a tensile force generated by the spring, yarn feeders are obliged to travel themselves furthermore, thus making it difficult for the flat knitting machine to correctly control the shifting movement and stopping operation of the yarn feeders.
OBJECT AND SUMMARY OF THE INVENTION
Therefore, the invention has been achieved to fully solve those technical problems described above. The object of the invention is to provide a novel apparatus which is capable of precisely arranging all the yarn feeding apertures of yarn feeders by way of fully lowering them down to the predetermined position, and at the same time, precisely controlling the shifting movement and stopping operation of the yarn feeders.
To achieve the above object, the apparatus for driving yarn feeders built in the flat knitting machine related to the invention features the structure described below.
Basically, the flat knitting machine available for embodying the invention incorporates a plurality of carriages which respectively adjust the movement of knitting needles mounted on respective needle beds, a pair of yarn guide rails which are respectively secured above and in the longitudinal direction of respective needle beds, and a plurality of yarn feeders which respectively feed yarn to knitting needles in association with those yarn guide rails while the carriages operate themselves.
In order to embody the invention, the flat knitting machine is furnished with the following; a plurality of yarn feeders which are respectively disposed in the front and on the back of a yarn guide rail; a means for selecting specific yarn feeders to have them operate in association with each other; and a means for lowering yarn feeding apertures of respective yarn feeders to be very close to the tips of the knitting needles; wherein these two means are respectively installed between those carriages and yarn feeders. More particularly, the above-identified yarn feeder selecting and carrying means has a carrying pin capable of moving itself in the forward and backward directions from specific carriages respectively facing a yarn feeder and a coupling recess for allowing the carrying pin to be engaged with a predetermined domain of the yarn feeder facing the carriages. On the other hand, the above-identified lowering means energizes a feeder rod in the upward direction by means of a spring, and then, when causing the carrying pin to move itself in company with a selected yarn feeder, the lowering means simultaneously lowers the tip of the feeder rod in resistance against an upwardly energized force from the spring.
Next, functional operation of the apparatus embodied by the invention is described below.
First, a plurality of carriages are activated to operate themselves on the top surface of corresponding needle beds. Next, when adjusting the movement of knitting needles in the movement directions, the above-identified lowering means starts to operate itself in association with the above-identified yarn feeder selecting and carrying means. As a result of the activated operation of the yarn feeder selecting and carrying means, selected yarn feeders respectively adjust the movement of knitting needles in the proper directions by way of being accompanied with the carriages. Simultaneously, the lowering means lowers yarn feeding apertures down to a predetermined position very close to the tips of knitting needles, and then securely feeds the yarn to knitting needles mounted on respective needle beds.
Next, as soon as those carriages arrive at the predetermined position to stop the movement of yarn feeders, the yarn feeder selecting and carrying means and the lowering means are respectively freed from their operating condition. As a result, carriages are also released from the state of being accompanied by those yarn feeders before these carriages are brought to a full stop.
Simultaneous with the release of the lowering means from an operating condition, yarn feeding apertures of respective yarn feeders ascend themselves. In consequence, even when those yarn feeding apertures of other remaining yarn feeders individually pass by themselves, unwanted interference between those yarn feeding apertures at the bottom ends of respective yarn feeders can securely be prevented from occuring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a lateral view of carriages built in the flat knitting machine related to the invention;
FIG. 2 is a schematic front view of the apparatus for driving yarn feeders embodied by the invention;
FIG. 3 is a schematic lateral view of the apparatus for driving yarn feeders embodied by the invention; and
FIG. 4 is a schematic lateral view explanatory of operative condition of the apparatus for driving yarn feeders embodied by the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings, detail of the apparatus for driving yarn feeders built in a flat knitting machine is described below.
FIG. 1 illustrates a lateral view of the flat knitting machine designated by the reference numeral 1 in the accompanying drawings.
Basically, the flat knitting machine 1 incorporates a pair of needle beds 3 and 3 on the top surface of a body bed 2 by way of a reverse-V shaped formation as viewed from a lateral side. Each needle bed 3 incorporates a plurality of knitting needles 4 to permit all the knitting needles 4 to move themselves in the forward and backward directions as required. A pair of carriages 5 and 5 are mounted on the top surface of those needle beds 3 and 3, these carriages 5 and 5 are slidably movable by a drive unit (not shown) in order to shift the position of the knitting needles back and forth. These carriages 5 and 5 are linked with each other by means of a gate-shaped connecting frame 7 formed by way of spanning yarn guide rails 6 which are disposed in the longitudinal direction of a pair of needle beds 3 and above the tip ends of those needle beds 3, thus enabling those carriages 5 to jointly and simultaneously operate themselves.
As shown in FIGS. 1 and 2, sections off the yarn guide rails 6 are formed in approximately a H-shape. Each yarn feeder 8 is slidably set to the front and back surfaces of each yarn guide rail 6. Each yarn feeder 8 is selected by a drive unit 9 secured in the center of the gate-shaped connecting frame 7 before being driven by the drive unit 9.
As shown in FIGS. 2 and 3, the drive unit 9 available for driving a plurality of yarn feeders 8 is installed on the bottom surface of a base plate 10 secured to the gate-shaped connecting frame 7. Characteristically, the drive unit 9 comprises a carrying means 11 and a lowering means 13 available for lowering each yarn feeding aperture 12 at the bottom tip of each yarn feeder 8, down to a predetermined position close to the tips of the knitting needles 4 being opposite from those yarn feeders 8 on the yarn guide rails 6.
Structurally, the above-identified yarn feeder carrying means 11 comprises a coupling recess 14 which is provided in the upper end and the center portion of each yarn feeder 8, a bistable solenoid 15 which is activated into operation by an operating signal from a control unit (not shown), and an output force transmission rod 18 which transmits the moving force of an output shaft 16 of the bistable solenoid 15 to a carrying pin 17. On the other hand, the above-identified lowering means 13 features the structure described below.
A feeder rod 8a is secured by means of a feeder case 20 onto the center domain of the recess 14 formed in the center domain of the top end of each yarn feeder 8. The feeder rod 8a is secured to the feeder case 20 in such a state in which the intermediate height position is upwardly energized by a push-up spring 19. Each yarn feeding aperture 12 is formed at the bottom end of the feeder rod 8a. An end of a connecting plate 31 is connected to the intermediate height position of the carrying pin 17, whereas the other end of this connecting plate 31 is connected to the top end of a cam plate 22 (which is to be described later on) which presses the feeder rod 8a downward. By virtue of the arrangement of those components described above, the cam plate 22 swings itself back and forth by way of pivoting on a swing-movement supporting pin 21 in relation to the vertical movement of the carrying pin 17. As shown in FIG. 3, the bottom-end domain of the cam plate 22 is substantially of a " twin-hill" cam shape which accommodates a pair of cams 23 available for pressing down a slide roller 24 at the tip end of the feeder rod 8a at such intervals substantially being equal to the width of the coupling recess 14.
Next, operation of the drive unit 9 available for driving yarn feeders 8 is described below.
First, drive signal output from a control unit (not shown) activates operation of a carriage drive unit to move the carriages 5 on the upper surface of needle beds 3. As a result, these carriages 5 are permitted to properly adjust forward and backward movement of those knitting needles 4 mounted on respective needle beds 3.
While these carriages 5 still keep on operating, a bistable solenoid 15 is activated by a control signal available for pattern knitting in such a region where no knit is composed. Then, as shown in FIG. 3, output shaft 16 of the bistable solenoid 15 enters into a set position in such a state in which the output shaft 16 projects itself in the downward direction. Simultaneously, the carrying pin 17 of the above-identified yarn feeder carrying means 11 ascends itself via the above-identified moving force transmission rod 18 in resistance against the tensile force of a push-down spring 30, operative above carrying pin 17. When the carrying pin 17 ascends higher, the cam plate 22 of the above-identified lowering means 13 is already pushed upward by way of pivoting on a swing-movement supporting pin 21.
When the designated carriages 5 arrive at the position of the predetermined yarn feeders 8 which respectively feed yarns to knitting needles 4, the control unit (not shown) detects this effect and then outputs a control signal to feed power to the bistable solenoid 15. This in turn puts the output shaft 16 of the bistable solenoid 15 into a "reset" position simultaneous with the retraction of the output shaft 16 in the upward direction. As a result, the lifted carrying pin 17 is pressed downward by tensile force generated by the push-down spring 30. Simultaneously, in association with a downward movement of the carrying pin 17, the cam plate 22 of the lowering means 13 swings itself in a vertical state by way of pivoting on the swing-movement supporting pin 21 via the connecting plate 31.
The descended carrying pin 17 then thrusts in the coupling recess 14 of the feeder case 20 and then the predetermined carriages 5 jointly keep on running themselves while this condition is present. Of a plurality of cams 23 of the cam plate 22, a cam 23 on the upstream side in the running direction of those carriages 5 pushes down a slide roller 24 on the top end of the feeder rod 8a until reaches the feeder rod a position close to the tips of the knitting needles 4.
Next, referring to FIG. 4, as soon as the lateral domain of the carrying pin 17 coupled with the coupling recess 14 of the feeding case 20 comes into contact with the lateral domain of the coupling recess 14, those predetermined yarn feeders 8 are drawn to the carriages 5, and then, desired knit (not shown) is eventually knitted up by those knitting yarn supplied to knitting needles 4 via the yarn feeding apertures 12.
Whenever those carriages 5 jointly stop the movement of those yarn feeders 8 or when those carriages 5 arrive at the predetermined position to activate movement of other yarn feeders 8, the control unit (not shown) detects this effect and then outputs a control signal to feed power to the bistable solenoid 15. Then, the descended carrying pin 17 is forcibly lifted in resistance against a tensile force generated by the push-down spring 30. Now that the carrying pin 17 ascends itself, the cam plate 22 of the lowering means 13 swings itself upward by way of pivoting on the swing-movement supporting pin 21.
As soon as the lifted carrying pin 17 is disengaged from the lateral domain of the coupling recess 14, movement of the corresponding yarn feeder 8 is discontinued. Simultaneously, by effect of swing movement of the cam plate 22 in the upward direction, the push-up spring 19 then pushes up the lowered feeder rod 8a until reaching a predetermined position at which the bottom-end yarn-feeding apertures 12 are perfectly free from incurring unwanted interference with each other.
Next, when the predetermined carriages 5 arrive at the predetermined position to activate operation of other remaining yarn feeders 8, the control unit (not shown) detects this effect and then outputs a control signal to shut off power from the bistable solenoid 15. As a result, the ascended carrying pin 17 is depressed by effect of a tensile force generated by the push-down spring 30, and simultaneously, the cam plate 22 of the lowering means 13 swings itself in the vertical direction by way of pivoting on the swing-movement supporting pin 21.
Next, the descended carrying pin 17 thrusts in the coupling recess 14 of the feeder case 20, and then, while this condition is present, when the carriages 5 respectively proceed themselves furthermore, the slide roller 24 on the top of the feeder rod 8a is pushed downward by the upstream-side cam 23 of the cam 22 in the running direction of the carriages 5. As a result, the bottom-end yarn feeding aperture 12 is pushed downward until reaching a predetermined position close to the tips of the knitting needles 4.
Thenceforth, using those knitting yarns supplied from the yarn feeding apertures 12 of respective yarn feeders 8 in accordance with the sequential steps thus far described, desired knits are eventually formed.
The reference numeral 32 shown in FIG. 3 designates a stopper which is secured to the yarn guide rail 6 at an outer position of a knit width. The top end of the yarn feeder 8 thrusts in the coupling recess 14, where the tip domain of the top end of each yarn feeder 8 is provided with an incline in order to prevent the carrying pin 17 and the coupling recess 14 from incurring unwanted damage otherwise caused by additional run of those carriages 5 when the stopper 31 stops the movement of respective yarn feeders 8.
The above embodiment of the invention merely refers to provision of a pair of yarn guide rails 6 as shown in FIGS. 1 through 4. However, it is of course possible for the embodiment of the invention to provide a single yarn guide rail or a minimum of three of them as well. Furthermore, it goes without saying that a plurality of yarn feeders can also be provided for each yarn guide rail.
Furthermore, the above embodiment merely provides a conventionally called "double-piece bed" flat knitting machine which disposes a tip portion of needle beds in a reverse-V shaped formation as shown in FIG. 1 for example. However, it should be understood that the scope of the invention is also applicable to a conventionally called "quadruple-piece bed" flat knitting machine which is furnished with a pair of the "double-piece bed" flat knitting machines in the upper and lower positions. Concretely, when embodying the invention relative to the "quadruple-piece bed" flat knitting machine, in order to provide a surpassing functional feature like the knitted hall garments (which are substantially tubular knits) for the objective knitting machine, normally, it is essential for the knitting machine to secure physical space in the knitting region close to the teeth portion of carriages in order to dispose a movable sinker capable of controlling cam plate or such space for accommodating a stitch presser drive unit needed for pressing meshes of a knit and such space needed for permitting rotation of the stitch presser. In consequence, a vacant area of a knit region close to the teeth portion of a carriage is narrowed, and yet, since it is much more difficult for any conventional quadruple-piece bed knitting machine to smoothly operate yarn feeders in limited space than the case of operating the double-piece bed type flat knitting machine, the arrangement of the teeth region of needle beds in a reverse-V shaped formation embodied by the invention is extremely useful to solve technical problems. | There are disclosed improvements in flat knitting machines incorporating a plurality of carriages which respectively adjust the forward and backward movement of knitting needles mounted on respective needle beds, a pair of yarn guide rails which are respectively secured above and in the longitudinal direction of respective needle beds, and a plurality of yarn feeders which respectively feed yarns to knitting needles in association with those yarn guide rails while the carriages run themselves. The improvements comprise novel apparatus for arranging the yarn feeding apertures of the yarn feeders by lowering same to a predetermined position while controlling the shifting movement and stopping operation of the yarn feeders. | 3 |
STATEMENT OF GOVERNMENT INTEREST
This invention was made with United States Government support under SBIR Grant No. DE-FG02-03ER-83679. The United States Government has certain rights in this invention.
RELATED APPLICATION
This patent application is related to that entitled “MICRON SIZE POWDERS HAVING NANO SIZE REINFORCEMENT,” Ser. No. 11/531,771, filed Sep. 14, 2006, and which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to nano powders/particulates and micron powders/particulates and mixtures thereof.
2. Description of the Related Art
Nano powders/particulates (<100 nm size) produced by various synthesis methods such as gas condensation, sol gel, flame synthesis and other methods typically are in the agglomerate form. These agglomerates are very difficult to handle for using them in powder metallurgy processing operations such as filling into dies and compacting into uniform net shape.
Attempts to break up such nano powder agglomerates using conventional blending processes, ultrasonic mixing or simple milling proved not highly successful.
In the technology of powder metallurgy, different types of powders are blended together, sometimes with the inclusion of lubricants. Different types of blending devices are used, one type being the well-known V-blender.
A problem has been observed in attempting to mix together specific sizes of powders, such as nano-sized powders with micron-sized powders. When one mixes two such powders in the conventional manner and then attempts to compact and sinter the mixture, it is found that the nano powders tend to clump together and form separated islands within the matrix of the micron-powders. A highly homogeneous mixture is not attained.
FIG. 1 is a photo-micrograph of such a mixture. The bright areas indicate the metallic phase. The dark areas indicate the ceramic material. The reference dimension is 200 micro-meters or 200 microns.
The lack of homogeneity causes the physical and chemical properties to be non-uniform throughout the bulk of the mixture of powders. This non-uniformity carries over to the sintered product, which will also exhibit variance in properties throughout. The variance is not desired in many situations.
Sometimes milling is used to produce fine powders, by pulverizing coarser particles into a finer size. Milling can also be used to achieve mechanical alloying of two different powders.
In the ball milling process generally, one or more powders are placed into a milling jar, together with balls (or suitable grinding media) of hard material. The milling jar is rotated, to cause the contents to tumble. During the tumbling, the hard balls fracture the powders into finer sizes. If the milling is done at appropriate speeds for long duration, such as more than 10 hours, freshly formed surfaces of different materials react and mechanical alloying takes place.
What is needed is a system and process that overcomes one or more of the problems of the prior art.
SUMMARY OF THE INVENTION
The Inventors have developed a process that deagglomerates nano or fine powders to enable their homogenous distribution in other powder materials for powder metallurgy processes and net shape forming using short ball milling times at low speeds, which reduces, or eliminates, the non homogeneity in distribution of the nano powder.
An object of the invention is to provide an improved process for blending nano powders with micron-powders.
A further object of the invention is to provide a process for blending fine size (e.g., less than 10 microns) and nano (100 nanometers or less) powders or particulates with micron powders or particulates, which produces a highly uniform distribution of both powders throughout the mixture.
In one form of the invention, a hard nano powder of 0 to 50 weight % is combined with a soft micron powder. The mixture is situated in a mill, such as a ball mill or jet mill, and milled for a short time, such as four hours or less. The ball milling rotational speed is less than 109 rpm in a 5.5 inch diameter jar. This process produces a mixture in which the nano powder is uniformly dispersed.
In one aspect, one embodiment comprises a method, comprising: placing first particles into a low energy ball mill (milling to deagglomerate), the first particles ranging in size from S1 to S2, and all first particles being smaller than 100 nano meters; placing second particles into the ball mill, the second particles ranging in size from (10×S1) to (2000×S2); and operating the ball mill at room temperature for mixing the two powders. Desirably, the ball mill provides minimal amount of shearing action, while permitting the softer matrix powder to be coated with the fine-size or nano powders.
In another aspect, one embodiment comprises a method, comprising: mixing first particles ranging in size from S1 to S2, and all first particles being smaller than 100 nano meters; placing second particles with second particles ranging in size from (10×S1) to (2000×S2) to permit the softer matrix powder to be coated with the fine-size or nano powders.
In another aspect, one embodiment comprises a method, comprising: combining a nano-sized powder of one material with a micron-sized powder of another material; and ball-milling the particles to produce a mixture in which the number of nano-sized particles in any volume is substantially proportional to the surface area of micron-sized particles in the volume.
In still another aspect, one embodiment comprises a method, comprising: preparing a mixture which includes a relatively hard powder of average particle size X, and a relatively soft powder, of average particle size greater than 10X; and subjecting the mixture to ball milling in a dry condition for no more than four hours. The short milling times enable dispersion of finer powders in micron-size powders without mechanical alloying.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photo-micrograph of a metallic micron powder mixed with a ceramic nano powder, mixed using conventional agitation;
FIG. 2 shows scanning electron micrograph of a hybrid powder particle (prepared via gentle ball milling process) described in the Background of the Invention consisting of a metallic micron powder particle coated with nano ceramic powder particles;
FIG. 3 shows the photomicrograph of such powder blends after sintering and the uniformity of microstructure of sintered material is noteworthy and is a desirable feature in many applications;
FIGS. 4 and 5 are test plots of energy dispersive x-ray undertaken on the particles discussed herein in FIG. 2 ; and
FIG. 6 illustrates, in simplified form, circles, which represent acyclic particles, for purposes of measuring particle concentration.
DETAILED DESCRIPTION OF THE INVENTION
The invention combines a charge of nano-sized powder with a charge of micron-sized powder in a ball mill. Preferably, the diameter of the micron-sized powder is about 10-2000 times that of the nano-sized powder. In one example, a 20 to 30 nano meter titanium carbide powder is combined with a 20 micron titanium metal powder. The titanium metal powder is relatively soft compared to the carbide. This combination was ball-milled using ¼-inch and 3/16 inch alumina balls, at 109 rpm speed, in a dry condition for two hours. The ball mill used was a model no. 784AVM, manufactured by U.S. Stoneware located in East Palestine, Ohio.
The hybrid powder produced by the ball milling process was found to possess good flow characteristics, which is desirable for powder filling and compaction, as used in sintering operations.
In addition, after compacting and sintering, the individual components, that is, the titanium metal and the titanium carbide, were found to be much more uniformly distributed throughout the bulk of the material, compared with compaction and sintering done using an ordinary mixer, such as a V-blender, which produces a result of the type shown in FIG. 1 .
One definition of the term uniform is any distribution of particles that minimizes or eliminates agglomerations in the sintered part, for example, for any cell, N is always within five percent of the average. Thus, in this example, if N is always more than 950 and less than 1050, then the smaller particles are considered to be uniformly distributed.
Another definition is that N is within five percent of the average for more than 90 percent of the cells.
Similar definitions can be applied to uniformity in distribution of the larger particles.
The ball milling accomplishes at least two objectives. One, it de-agglomerates the nano powder. Two, it coats the nano powder onto the micron particles. In particular, it is believed that the ball milling embeds the nano particles into the larger, softer, micron particles, thereby mechanically locking the smaller particles into the larger particles to some extent.
For a given amount of micron-sized powder, a certain amount of nano powder is required to provide a single layer of coating. If a larger amount of nano powder is used, then the coating will become multi-layered. On one embodiment, a range from 0 percent to 50 percent by weight of nano powder is used. As a specific example, if 100 grams of micron powder are used, then the range of nano powder used will run from one gram to 50 grams.
In this range, all nano powder becomes bonded to the larger micron particles. That is, in one form of the invention, large islands of non-coating nano powder are not present.
However, it is recognized that a primary purpose of one form of the invention is to provide enhanced chemical and physical properties of a sintered product produced from the powder mixture of the invention. Experimentation may show that certain of these properties may be enhanced, while some islands of nano powder are present. Thus, in some forms of the invention, strict attainment of the uniformity defined herein may not be required.
Moreover, in the illustration being described, this invention can also provide enhanced properties in non-sintered products. For example, one such example is where finer resins are mixed with micron powders to form bonded type of product that does not require any sintering.
Additional Considerations
Two types of energy dispersive X-ray analyses were undertaken. One analysis was of the interior of the large particle shown in FIG. 2 . The other analysis was of the surface of the large particle shown in FIG. 2 . Resulting plots are shown in FIGS. 4 and 5 .
The two analyses indicated that a carbon peak was present in the spectrum of surface-coated particles, but absent from the spectrum of the particle interior. This absence leads to the inference that carbon is present in the coating, which is consistent with the creation of a titanium carbide coating through the processes described herein.
In one form of the invention, the nano powder used as a coating is one-tenth, or less, the size of the coated particle. As a specific example, particles in the 30 nm to 50 nm range will successfully coat particles in the 20 micron to 40 micron range.
In another form of the invention, the nano powder used as a coating is between 0.0005 and 0.1 of the size of the coated particle.
The ball milling preferably is done for 5 minutes to four hours, at room temperature, and without solvents. Under these conditions, no significant mechanical alloying or chemical reaction occurs between the two types of powders.
The short milling times and low milling speeds enable gentle deagglomeration and dispersion of nano powders in micron-size powders to take place with out any solid state diffusion or mechanical alloying.
As stated above, the nano particles used as the coating are harder than the particles which are coated. In one embodiment, the nano particles are at least 2 times harder, using the same hardness scale.
If the nano particles and the micron particles are of the same, or similar, hardness, a third type of particle can be used as an intermediate layer. As one example, the third particle can be (1) of the same size as the nano particles, (2) in the same quantity as the nano particles, and/or (3) softer than the nano particle, but harder than first particle which is of micron-size.
The edges of the harder nano particles can embed into the third particle, and the edges of the third particle can embed into the micron particle. Thus, the third particle forms a type of coating around the micron-size particle, and the nano particles adhere to the coating.
The third particle can also be harder than the other two.
The ball milling described above was done dry, without liquids. Alternately, the ball milling can be done wet, using solvents.
Specific examples of micron-sized powders usable in the invention are the following: copper, aluminum, magnesium, iron, various steels, cobalt, nickel, zinc, zirconium, niobium, molybdenum, palladium, silver, tungsten, hafnium, tantalum, rhenium, platinum, neodymium, samarium, gadolinium, and terbium.
Nano-sized and fine powders for coating these micron-sized powders include alloys of the preceding, other metals, other alloys, ceramics, and resins.
Some distinctions between the present invention and prior art processes should be noted.
In the prior art, ball milling of powders was used to fracture the powders into smaller particle sizes. Sufficiently rigorous, or lengthy, ball milling can produce powders in the nano meter size range. However, such a ball milling process will produce a wide distribution of particle sizes, of a single material type. Further, such ball milling begins with particles much larger than the nano-size particles produced.
This is different from one form of the invention, wherein two different materials are milled, and the initial charge of each material consists of particles of a specified size range, such as 20 micron titanium metal and 20-30 nano meter titanium carbide.
Further, under the invention, the smaller particles are harder than the larger particles, allowing the smaller particles to become mechanically keyed, or bonded, into the larger particles. That bonding will not occur in milling particles of a single type, at least for the reason that the particles are of similar hardness.
The particles in question are generally irregular in shape. Particle size for such particles generally refers to the largest cross-sectional dimension of the particle. Other dimensions can be used, but this particular dimension (largest cross-sectional dimension) is convenient to measure using simple microscopy.
The particles can also be regular shaped such as spherical, cylindrical and variations and combinations of the above.
One definition of ball mill is a hopper containing balls which are harder than materials processed in the hopper, and wherein the hopper is rocked or tumbled, to impact the balls against the materials.
One feature of the invention is that the concentration of nano particles in any volume is proportional to the surface area of the micron particles in that volume. This provides another definition of uniformity of distribution.
For example, if a given volume contains a single large micron-size particle and if nano particles coat the large particle in a single layer, then the number of nano particles depends on the surface area of the large particle.
Similarly, if the nano particles coat the micron particle in two or more layers, then the number nano particles depends on the surface area of the micron particle.
If two different micron particles are present and are coated with nano particles, then the number of nano particles again depends on the total surface area of the micron particles.
Therefore, the concentration of the nano particles, in terms of number of particles in a selected volume, will be generally proportional to the surface area of the micron particles within that volume.
This is a different type of distribution of nano particles, compared with that described in the Background of the Invention, and shown in FIG. 1 . In that case, the nano particles agglomerated together, and were found in islands containing few, and possibly no, micron particles. The nano particle concentration was not proportional to the surface area of the micron particles.
A nano-sized powder is defined as one having particle size between 1 and 100 nano meters. A micron-sized powder is defined as one having particle size between 1 and 200 microns.
In the illustration being described, two particulate materials with correct size distributions and ductility's/hardness gently ball milled for short periods, for example, 5 minutes to four hours at low speeds so that harder powder particles (which are also smaller in size) embed onto the surface of ductile larger powder particle matrix. The ball milling times are sufficiently small (only 5-240 minutes) so that no mechanical alloying or chemical reactions take place between the constituents. In the case of mixtures with nano powders, such short gentle milling deagglomerates the nano powders and coats onto micron size powder particle surfaces.
The ball milling conditions for a given ball mill size and grinding media, the milling time and speeds are set to create surface coatings on the matrix powders. Such ball milling of powders can be accomplished in dry form or with the suitable solvents. In this process no substantial chemical reactions or mechanical alloying occurred. For example, a mixture of 300 gms of 20 micron titanium powders of irregular shape with 20-30 nm titanium carbide powders were ball milled in an alumina jar using ¼ inch and 3/16 inch alumina balls at 109 rpm speed. The mixture was ball milled in dry condition for 2 hours.
In addition, in the case of mixture with nano powders, the ball milling deagglomerated the nano powders and then coated the nano powder particles evenly onto the matrix powders. The uniformity and thickness of the coating varies depending on amount of coating particles in the blend, the relative sizes of the matrix and coating particles, milling speeds and time. The coating thickness can be varied based on the amount of coated material in the blend. For example, 0 to 50 weight % of ceramic coatings onto metal matrix powders are demonstrated by this method. In the case of high weight % of hard particle concentrations, the metal particles will have thicker, multiple layers of ceramic coatings. Typically, the coating powder particle size needs to be smaller at least by a factor of 10. For example, nano particles (˜30-50 nm) coat very efficiently onto micron size (20-40 microns) matrix powders. FIG. 2 shows the Scanning Electron Micrograph (SEM) of a hybrid coated powder particle at high magnification. The fuzzy surface on the top is nano titanium carbide and inner core powder particle is titanium particle. Energy dispersive x-ray (EDX) of the hybrid powder particle revealed the composition of the top layer to be TiC and composition of the core particle to be titanium. FIG. 4 shows EDX peaks identifying larger titanium particle. Notice that a carbon peak is absent in the spectrum. FIG. 5 shows the identification of smaller coated powder particles as TiC.
Relative hardness of the matrix and coated powders has to be sufficiently different for harder particle to embed onto the surface of the softer particle. For example, nickel matrix powders of 20 micron size are coated with Si 3 N 4 powders of 20 nanometer size, and titanium powders of 20-80 microns are coated with 20-80 nanometer powders of titanium carbide (TiC), titanium nitride (TiN), titanium boride (TiB), titanium carbonitride (TiCN) and alumina (Al 2 0 3 ).
When the matrix and reinforcement have similar hardness, a third material can be used as an intermediate surface to enable coating of the reinforcement to the matrix material.
As mentioned earlier, milling can be done either dry or wet with solvents in air or special environment.
Such powder blends containing hybrid powders of matrix particle with evenly coated hard particles on the surface have good flowability and can be compacted and sintered to obtain desirable properties.
This process is applicable to various powder blends such as metal powders (Cu, Al, Mg, Fe, steel, Co, Ni, Zn, Zr, Nb, Mo, Pd, Ag, W, Hf, Ta, Re, Pt, Nd, Sm, Gd, Tb) and alloy powders of these for blending with resins, or ceramics or with other metals and alloys. For example, the blends of fine/nano ceramic particles onto metal powders such as aluminum, titanium, iron, copper, nickel, tungsten, molybdenum, steel, and their powder alloys.
Under one form of the invention, the ball milling process is insufficient, either in terms of time or vigor of agitation, to further pulverize the component particles. That is, neither the micron nor the nano powders are further fractured into smaller particles to any significant extent.
Numerous substitutions and modifications can be undertaken without departing from the true spirit and scope of the invention. What is desired to be secured by Letters Patent is the invention as defined in the following claims. | A method of uniformly dispersing a nano powder throughout a micron powder. Ordinary mixing or agitation does not succeed in attaining uniform dispersal: the nano powder agglomerates into microscopic masses. In one form of the invention, a charge of a micron powder, with fifty weight percent of charge of nanopowder is loaded into a ball mill. The mixture is ball milled for less than two hours, at room temperature in a dry condition, and produces a highly uniform distribution of the nano powder throughout the micron powder. | 2 |
This application is a division of application Ser. No. 09/318,096, filed May 25, 1999, now U.S. Pat. No. 6,388,194, issued May 14, 2002; which in turn is a division of application Ser. No. 08/312,650, filed Sep. 27, 1994, now U.S. Pat. No. 5,922,996, issued Jul. 13, 1999, the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cables and conductors and, in particular, to insulation therefore.
2. Brief Description of the Prior Art
In alternating current or direct current electrical power transmission, electrical conduction processes in condensed matter, under certain conditions, consist of the transport of heat, electric charge, mass, and magnetism or some combination of the four in some possible response to an imposed temperature gradient, electric field, density gradient, or magnetic field. Electrical conductivities vary greatly between various materials, and conductivities may vary by an amount of 20 decades or more between metals and most commercially used insulating materials. In electrical cables a thermodynamic equilibrium is established between the particular materials used as the electrical insulation and the electrical conductors.
Influences on the conduction processes in insulation are known as traps, polarizability or treeing. Such influences contribute to what is known as electrical breakdown, either thermal or electronic. External cold temperature plays a part in insulation degradation (i.e., cracking) by what is known as cold bend or static temperature. An insulation or dielectric material can under certain conditions experience dielectric breakdown or may spark over when the insulation or dielectric strength drops either because of deterioration, impurities, moisture or physical abuse or damage by the user or abnormal electrical conditions. The existence of foreign materials in the insulation and also what is known as electrically stressed insulation, may under certain conditions result in dielectric break down resulting in heating and unwanted shorts. Some dielectric heating may also result from molecular friction from alternating current which may result in a dielectric loss and dielectric strength drops. Presently today's commercial insulation on an electrical cable assembly or wire hides electrical damage and does not have the capabilities to indicate and/or locate varied inner cable faults and/or malfunctions and/or damage and/or hazard. My invention show it and more.
Therefore, it is an object of the present invention to provide an electrical cable assembly that will indicate, through an attention getting means, preferably visually through sight or by smell or taste or touch, the presence of a fault and/or malfunction and/or damage and/or hazard in the electrical cable assembly. A further object of the present invention relates to a repair jacket and tape to be used in combination with an electrical cable assembly where in the repair jacket or tape also has the capability to indicate the presence of electrical repaired cable faults, and/or malfunction, and/or damage, and/or hazard by an attention getting means.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a new jacket, sheath or insulation covering for electrical cables or a new electrical cable assembly with at least one attention getting stimulation means, which will be know as a reactee, having a noticeable awareness means, by giving off at least one response by a reacting material that may be at least one visual or color change that is temporary or permanent or in combination and/or testable and/or odoriferous and/or physically changeable that may extend or travel through some dimension of the cable that will:
detect an electrical overload condition of itself;
detect and/or locate the spot of internal electric sparks and arcs and/or a pre-shortening condition, and/or an intermittent malfunction;
detect and/or locate the spot where the beginning of an internal dielectric break down process is starting and/or taking place;
detect and/or locate the spot where internal dielectric break down is occurring and/or was occurring;
give information as to whether a particular circuit is on or off under the proper environmental and engineered conditions;
give an indication of an arc or spark and or dielectric break down and the conduction process occurring internally;
detect and/or locate its own internal electrical malfunction quickly without devices or electrical and electronic instruments, making itself capable of indicating its own condition or conditional level without reference to a normal function, and may automatically reset itself with no calibration needed;
allow inspectors to see dangerous cable and wires that should be taken out of service;
reduce the risk of fires, electrical shock and electrocution and thus make for a safer electrical distribution system;
warns of harsh environment temperature, example: cold bend, “WARNING—DO NOT BEND,” so cable insulation does not crack when cable assembly is bent;
give a visual warning of the existence of critical temperature ranges or thermal ratings for electrical insulation as is set forth by the National Electric Code or a governing agency or a manufacturer's specifications:
to deter a child or pet from playing with (i.e, especially putting in the mouth);
provide any of the above mentioned functions so that a partially color blind persons can see critical points or critical temperatures and detect and/or locate electrical problems;
provide any of the above mentioned functions so a totally blind person can tell a critical point or critical temperature and detect and/or locate electrical problems;
provide any of the above mentioned functions so that the hearing impaired person can identify a critical point or critical temperature and detect and/or locate electrical problems;
provide any of the above mentioned functions if desired a better higher surface electrical resistance of ohmic values by spacing strategically the visually reacting formulation so a surface area of higher resistance surrounds the surface area of a lower resistance visually reacting formulation or by adding at least one additive;
provide any of the above mentioned functions with a displayable form of moving colors, or a color moving effect, and/or a readable language or alphanumerics.
This new electrical cable assembly, repair jacket and tape, alone or in combination, consist of an electrically insulating means which can be described as containing or coupled to a reacting material. The reacting material, a reactee, reacts while maintaining its insulating properties to various cable conditions. The reacting material can be coupled to an electrically extending electrovisual wire, cord or cable. A reactor is an internal and/or outer abnormal condition occurring within or on an electrical cable assembly and having noticeable results to the outside of the electrical cable assembly through the reacting material, the reactee. The preferred action of the electrically insulating means is an outer visually reacting reactee reacting to an internal reactor.
The term “reactive” or “reacting” as used herein will be understood to mean a change which will gain the attention on one via the sense of sight or touch. Examples include color changes or lettering or words which suddenly appear and become visible or physical deformations like swelling, blistering, shrinking and/or melting. Other sensory-like changes will include non-palatability when a material or composition is chewed or bitten into, (i.e., hot pepper extract, citric acid, etc.) or audio resulting from special materials that produce sounds when undergoing physical deformation, and/or smell, from releasing material composition (i.e., methyl nonylketone, oil base odor releasing gels, a sulfur base composition that may contain chlorides, etc.).
The term “electrical cable” as used herein will be understood to mean or comprise an electrical wire, cable or cord, electrically insulated wire conductor, an electrical cable assembly or anything used in the form of an extending or rope-like insulating and conducting medium for the transmission, distribution, conduction or retainment of electrical energy. The electrical cable may have at least one delivery system, for example, an insulated conducting path, which is used as a facilitator for the transmission, distribution, conduction or retainment of electrical energy. The electrical cable assemblies disclosed in this patent application may facilitate electrical energy of the alternating current, direct current, analog, or digital type. The electrical cable assemblies discussed in the patent application may also use the inventive features in this patent application separately or in some combination. The term “visually reactive material” or “visually reacting material” as used herein may be, but is not limited to, a liquid crystal material because of (i.e., electrorheological fluid, magnetorheological fluid, thermochromic polymer gels). Preferred liquid crystals derive from the thermotropic group, particularly: cholesteric and/or chiral nematic subgroups. They may have designer formulations so that they function via color change within a predetermined range. The term “visually reactive material” or “visually reacting material” may also include electrical or magnetic field sensitive compounds that can also display a color change due to variations in electrical or magnetic field sensitive compounds that can also display a color change due to variations in electrical or magnetic fields. Additionally, some chemical compounds exist in materials that produce deformations in themselves and the surfaces to which they are coupled when subjected to pressure variations (i.e., pressure variations stemming from variations in heat within an electrical cable assembly).
The term “visually reacting material” as used herein may be-a thermochromic liquid crystal material which may be selected from but not limited to one or more of the following: Methoxybenzylidenebutylaniline or terephthal-bis-p-butylanaline. Some preferred liquid crystal materials are commercially available from the company “Hallcrest” under trade names BN-g90 C5w, BCN-g100 C, BCN-g-30 C5w, BN-R88 F10w, BN-G98 F10W or BN-R98 F10W. “Visually reacting materials” of the type that visually indicate variations in electrical or magnetic fields may be-commercially available from the company “E. M. Science Co.” under the trade name of Licrilite.
The term “visually reacting material” will also include thermochromic ink and/or die and/or paint compositions and/or a thermochromic polymer and/or a liquid crystal polymer. It is found that some visually reacting materials may be advantageously used in amounts from 0.05 to 5 grams per square foot. Attention getting materials or visual reactance may be in powered form.
The term “visually reacting material” will also include any other material that emits light or has a fluorescence property or changes in transparent, or in color in response to, changes in temperature or electrical activity. These materials may also exist in the form of slurries, inks, dyes, paint combinations or can be impressed/impregnated in any flexible or inflexible substance so that the material can be coupled in some manner to an electrical cable assembly, repair jacket and/or tape.
Some visually reacting materials may require a specific background or dropback of a certain color in order to properly contract the visually reacting material when it undergoes a color change. This background can be used to enhance, aid or manipulate the visual effect of the visually reacting material. The color of the background can be made from inks, paints, dyes or even the natural color of the cable or its insulation or the color stemming from their ordinary manufacturing processes.
Protective coverings, which may range from transparent to opaque, may be utilized to protect some types of visual reacting materials or reactees. The protective coverings may also have an electromagnetic frequency selectivity ability. They may also have some of the proprieties of filtering, absorbing or reflecting lightwaves so as to transform the reactions of the reactor or reactee in order to aid the reacting material's reactance to it. Protective coverings may also be designed for harsh environments or weatherproofing. This new electrical cable assembly, repair jacket and tape, alone or in combination, may also consist of this protective cover which can be described as containing or coupled to a reacting material, to be known as a reactee reacting to a reactor, while maintaining its protective properties.
The term “protective” will be understood to mean protection for visually reactive material from environmental harm. Some examples are the damaging effects of chemicals, solvents, oils, moisture, water, radiation, sun rays, insects and animals or weather conditions. Further, the electrical insulation of an electrical cable assembly, repair jacket or tape may contain insect, animal and/or child-protective or repulsive qualities (i.e., an unpalatable insulation composition, i.e. methyl nonylketone, hot pepper extract, citric acid, etc.).
Even a-protective cover may have visually reacting results or physical deformations by way of polymer liquid crystals or thermochromic impregnated rubber compound coatings or heat-shrinking polyester coatings that blister, bubble or peel on a cable subjected to a malfunction which causes a variation in the cable's temperature or electrical/magnetic field. The protective cover may also be heat retaining or heat reflective or heat conducting depending on desired results that my be-wanted from such protective coverings.
The term “transparent,” as used herein as a property of a protective covering will be understood to mean clear, color-tinted or semitransparent or as understood in the art. The transparent protective covering may have openings used as vents and/or transparent protective coverings may be made of a porous material (i.e., osmotic polymer or a semi-permeable membrane).
Another feature of the present invention is that the electric cable assembly may contain a bad tasting composition to prevent the cable from being chewed by rodents or other animals, which may act as a pet or child-proofing. In another extreme it may be designed to attract insects and rodents in order to trap or exterminate them.
The term “couple” will be understood to mean containing, or united with, any manufacturing process that makes (i.e., screening, layer, impregnate, film, paint, die, etc.) in order to join together various materials, structures, or layers of an electrical cable assembly, that has means for indicating all functions therein, in particularly the means.
The next three terms “damage”, “fault”, and “hazard” are mentioned together here not only because of their differences but because of their relative relationships with one another. The three terms “damage”, “fault”, and “hazard” as used herein will be understood to mean the following as described in the next three paragraphs.
The term “damage” as used herein will be understood to mean: any physical injury or harm suffered by an electrical cable assembly. This may include any abnormal material condition occurring, or that has occurred, or that may occur in, and/or on an electrical cable assembly, either to an insulation thereof (i.e., traps, polorizability, treeing, dielectric breakdown, thermo breakdown, etc.) and/or a conductor within the electric cable assembly (i.e., an open conductor, an intermittent conduction by conductor, an irregularity etc.).
The term “fault” as used herein will be understood to mean: any electrical conduction process, and/or electrical condition that is abnormal for an electrical cable assembly (i.e., shorts, ground, phase to phase, return to hot, overload, under voltage load resistance short, etc.).
The term “hazard” as used herein will be understood to mean: a risk of danger, because of an increment of deterioration to be and/or done, either by damage and/or fault to an electrical cable assembly. Thus a hazardous electrical cable assembly may have at least one damage resulting in at least one fault, and/or at least one fault resulting in at least one damage to an electrical cable assembly. Both damage and fault may, under certain conditions, give variation in temperature, and/or agenetic, and/or electrical fields. When the two results, fault nd damage feed one another, a serious situation develops that can get very dangerous, fires or electrocution and the likes will result especially when fuses or breakers do not work properly for whatever reason. Thus making my electrical insulated cable having means or manifestation abilities for indicating malfunction therein, an excellent warning means, detecting trouble, potential trouble, and/or location of, in and/or on an electrical cable assembly, by this new electrical cable assembly itself.
Therefore, I have invented a hazard and/or fault self-indicating electrical cable assembly, repair jacket and tape which may be used in conjunction with one another or alone. The electrical cable assembly may include electrical insulation surrounding electrical wires, wherein the insulation is covered by a layer of or impregnated with a reacting and/or visually reacting material. The layer of reacting material and/or the layer of visually reacting material or impregnated insulation may then be covered by a transparent protective cover and/or may be a protective cover with a means to path the release of responses of reactable materials, and protective cover may be reactive. In another embodiment, the electrical cable assembly and repair jacket may also have visually reacting material embedded in a groove that runs axially to the electrical cable assembly. Furthermore, the reacting and/or visually reacting material may be arranged on the outside of the electrical insulation in spaced repeating sets of locations and/or markings where a set is comprised of multiple locations and/or makings of reacting and/or visually reacting material. Each mark and/or location within a set would be capable of measuring a different magnitude of a hazard an/or fault and/or producing a different response to same magnitude of hazard and/or fault. Alternatively, each spaced repeating sets of markings can be spaced repeating sets of bands that encircle the cable assembly and give the appearance of motion. These locations and/or marks or bands may also be embedded into the transparent protective layer rather than layered atop the insulation. Reacting and/or visually reacting material may also be applied to the outer surface of the insulation in the form of descriptive words or alphanumerics so that these would communicate a hazard and/or fault to a user or observer in a special predetermined manner.
An embodiment of the hazard and/or fault self-indicating electrical cable repair jacket comprises a shell formed as a rectangular or tubular sleeve member where the shell is composed of an electrical insulation covered by a reacting and/or visually reacting material. The jacket may have a longitudinal split on one side to facilitate adapting it over and around an electrical cable, possibly for cable repair purposes, or electrical trouble shooting. Reacting and/or visually reacting material may be either layered on the outside or impregnated into the insulation and may be covered by a transparent protective cover like that of the cable assembly. In another embodiment, the electrical cable jacket may be a tubular sleeve-like member where the inner diameter of the jacket is larger than the outer diameter of an electrical cable so that a small gap is formed, possibly for fire-preventative purposes whereby the jacket acts as a flame conduit.
An embodiment of the fault-indicating electrical tape comprises a substrate with an adhesive backing-on one side and on the opposed side a reacting and/or visually reacting material which may be covered by a transparent protective cover like that of the cable assembly. Alternatively, the electrical tape may include electrical insulation on the opposed side whereby visually reacting material may be embedded into this insulation. This tape will be flexible, and may be stretchable.
BRIEF DESCRIPTION OF THE DRAWINGS
The electrical cable of the present invention is further described with reference to the attached drawings in which:
FIGS. 1 a-c is a cross-sectional views of an electrical cable which is a preferred embodiment of the present invention;
FIG. 2 is a cross-sectional view of an electrical cable embodying an alternate form of the present invention and including a detectable irregularity and/or an impurity;
FIG. 3 is a cross-sectional view of an electrical cable embodying still another form of the present invention and in which several detectable malfunctions are also illustrated;
FIG. 4 is a schematic illustration of various aspects of the operation of the cable shown in FIG. 3;
FIG. 5 is a top perspective view of a cable jacket embodying still another form of the present invention;
FIG. 6 is a bottom perspective view of the cable jacket shown in FIG. 5;
FIG. 7 is a cross-sectional view through line VII—VII in FIG. 5;
FIG. 8 is a cut-away perspective view of an electrical cable showing still another embodiment of the present invention;
FIG. 9 is a cross-sectional view through line IX—IX in FIG. 8.;
FIG. 10 is a cross-sectional view through line X—X of FIG. 8 of a repair boot embodying the present invention which may be used, for an example, on the cable shown in FIG. 8, or outer electric cable assemblies;
FIG. 11 is a cross-sectional perspective view of a roll of repair tape which may be used, for example, in or on an electric cable assembly;
FIG. 12 is a cross-sectional view through line XII—XII of FIG. 8 of an electrical conduit which may be used, for an example, to house, guide flame path, or give extra mechanical abrasive protection to original cable shown in FIG. 8, or inner electric cable assemblies;
FIG. 13 is a broken of perspective view of an electrical extension cord;
FIG. 14 is a broken of perspective view of an electrical power cord;
FIG. 15 is a cross-sectional perspective view of an electrical wire or cable;
FIG. 16 is a cross-sectional perspective view of an electrical wire or cable;
FIG. 17 is a cross-sectional perspective view of an electrical wire or cable.
DETAILED DESCRIPTION
Referring to FIG. 1, this electrical cable assembly may include any features of FIGS. 1 through 17 including 17 . In FIG. 1 this electrical cable assembly has a conductor 10 surrounded by an insulation 12 . Now taken the steps of progression of which improves and makes a new cable assembly out of the old one, it would be to preferably have a background or colored dropback, exposed by the outer surrounding surface of insulation 12 which preferably would be a dark background, and if not, an artificial dropback may be needed to be added which would then cover at least a portion of this outerly insulation of 12 . Insulation 12 is then surrounded by a layer of visually reacting material 14 . The visually reacting material 14 , may be a thermochromic material, a luminescence material, a liquid crystal material a odor-releasing material, or a taste-releasing material either used separately or in some combination. The thermochromic materials of it may include thermochromic ink, die, paint, etc. The liquid crystals at 14 may include liquid crystals polymers, or thermochromic liquid crystals, or thermochromic polymers. That layer of visually reacting material or reactee having its special purpose is covered by a transparent protective cover 16 . The transparent protective covering 16 may also be made of a cellophane, a clear polymer, a clear polyester, an osmotic polymer, a semipermeable membrane and the transparent protective cover may even have thermochromic properties. The osmotic polymers or semipermeable membrane covers of 16 are means in which to release the responses from reacting material of 14 and 17 . Any break in the conductor would cause the visually reacting material to glow or can become fluorescent or change colors in the vicinity of that break thereby indicating the location of the break and the facilitation of its repair, the reactor being or being started by electrical energy internally. Referring to FIGS. 1 a - 1 b also, the number 16 may be a physical deformation material, and the number 14 may be a fragrance or odor releasing material. In this alternate type of assembly both 16 and 14 are reactees having their own special purpose, reacting to an internal and/or external reactor. Referring to FIGS. 1 a - 1 b also, the number 16 may be an easy deformable material protective covering, and the number 14 may be a bad or very repulsive tasting material, in this alternate type of assembly only 14 would be a reactee having its own special purpose, reacting to an outer reactor. Referring to FIGS. 1 a - 1 b , also, the number 16 may be a physical shrinking material and/or number 12 may be a physical swelling material while number 14 may be a pressure sensitive material producing a visual change or fluorescence when 16 and/or 12 is activated.
Referring to FIGS. 1 a - 1 b also, the number 16 may be an opaque deformable material protective covering, and the number 14 may be a luminescence phosphorescence and/or fluorescence material that would be covering number 12 the insulation of an electrical cable assembly. Also, the protective transparent cover 16 is a means to release visual responses of visually reactive material 14 , and the protective transparent cover may be thermochromic.
Also referring to FIG. 1 an alternate cable assembly may consist of number 13 being a odoriferous releasing material or 13 may be a tasteable material or 13 may be a combination of both odor releasing and bad tasting materials with a protective cover 17 that has openings or vents at 9 in which 9 makes a means to path the release of said material responses. The openings or vents may be on an angle 8 , making a closeable flap 7 , so the material of 13 does not get on anything when cable is being handled. The protective cover 17 may have pores represented by number 8 and 9 , the protective cover 17 may also be a transparent protective covering. Also the said materials at numbers 13 and/or 14 may be classified as reactable or reacting materials having an attention getting and/or awareness means, which makes an excellent electric cable assembly for handicap people that may be blind or hearing impaired. The materials of numbers 13 and/or 14 may be used also as a pet or child proofing electric cable assembly, as well as a handicap cable, because they will be notified by an announcement from this kind of electrical cable assembly that something is wrong, or something is being done wrong. The vapors or gas of an odoriferous (odor and/or fragrance) material number 13 may be activatable by the internal heat from a malfunction occurring within the electrical cable assembly and may travel through pores 8 and/or 9 or alternate porous semipermeable membrane or osmotic polymer covering number 16 , also number 17 may open and close pores and/or vents 9 and/or 8 by thermo expansion and contraction the thermo energy coming from internally of cable assembly.
Also referring to FIG. 1, it should be mentioned that the visually reacting or an attention getting material of 14 completely surrounds the conductor 10 , so even if conductor 10 or insulation 12 was not circular there would still be a viewing range of at least 360 geometric degrees as in FIG. 15 at number 146 of the reacting materials in FIG. 1 number 14 .
Referring to FIG. 2, this electrical cable assembly may include any features of FIGS. 1 through 17 including 17 . In FIG. 2 the electrical cable assembly includes two lengths of electrical conductors 18 and 20 and in both conductor 18 and 20 here is an irregularity 22 and in the insulation 24 there is a impurity 21 , detectable under certain conditions by the cable's electrical insulation 24 which is impregnated with a visually reacting material, and may have an optional protective transparent covering 26 . In this type of alternate cable assembly the reactee is in the cable's insulation.
Referring to FIG. 3, this electrical cable assembly may include any features of FIGS. 1 through 17 including 17 . In FIG. 3 the electrical cable assembly includes conductors 28 , 30 and 32 along with insulation 36 . Layers of visually reacting and/or reactive material which react at different temperature ranges or some physical component of electrical energy either directly or indirectly and upon their activation appear in different colors at same critical condition are shown at 38 , 40 an 42 . The entire cable is covered by an optional transparent protective cover 44 . Another assembly method is to consecutively have embedded in this protective cover 44 —starting at 45 A or either embedded into cable insulation 36 starting at 37 ; or layered in consecutive sections at 39 between an optional protective transparent cover 44 , and an optional outer dropback of outer cable insulation 36 ; layered sections or pockets of the first type of visually reacting or reactive material at 45 A, 45 B and 45 C. The second type of visually reacting or reactive material is housed in or layered at pockets at 46 A, 46 B and 46 C. The third type of visually reacting or reactive material are at the layers or pockets at 47 A, 47 B and 47 C. Some malfunctions in the cable as would cause visual or physical reaction in the visually reacting or reactive material are shown, for example, in the conductor 28 at numeral 29 dielectric breakdown is in the insulation 36 , at numeral 48 shorting is in the insulation 36 , at numeral 50 is in the conductor 32 making a load condition. Also referring to FIG. 3 a luminescence material, fluorescence and/or phosphorescence may coat an electrical cable assembly at 38 , then it may be coated with a clear substrate or covering at number 40 , so as to coat substrate or covering 40 with a thermochromic material at 42 which is dark or opaque at normal electrical and/or insulating conditions and then has transparency to abnormal electrical and/or insulating conditions which is protected with a protective cover 44 .
Referring to FIG. 4, principles of which may be used in any FIGS. of 1 through 17 including 17 . In FIG. 4 there is shown a diagram in which various colors are visible at same temperature in the cable shown in FIG. 3 . At the point shown at numeral 52 colors are blue, yellow and red at 50 degrees C. At the point shown at 54 colors are red to yellow to blue at 40 degrees C. to 50 degrees C. At numeral 56 colors are red to yellow to blue at 45 degrees C. to 55 degrees C. At point 58 colors are red to yellow to blue at 50 degrees C. to 60 degrees C. Point 60 coincides with 54 , point 62 coincides with 56 and point 64 coincides with 58 . This chart indicates that if the critical temperature of an electrical cable assembly is, for example, 50 degrees C. then a color can be seen by a partially color blind person at numeral 52 . At 50 degrees C. three colors would be visible at once, they are in one spot, or each color may neighbor each other at same general location of an electrical cable assembly. Each different color at numeral 52 comes from each different reacting range of numeral 54 , 56 , and 58 . A partially color blind person may only see one, or possible two of these colors, but they would see at least one.
Referring to FIGS. 5 through 7, there is shown a jacket that may have any features of FIGS. 1 through 17 including 17 . In FIGS. 5 through 7 the jacket is to be used to retrofit an existing electrical cable assembly with the features of this invention. The cover has a split 66 , pockets or locations of thermal liquid crystal or visual reactive material 68 and 70 , and clear protective heat reflective cover 72 . There is an electric insulating and heat conducting jacket 74 , and the space 76 between this jacket cover 74 , and the clear protective cover 72 , may have a heat absorbing sealing material or be vulcanized together sealing the space 76 . The entire or part of this structure may also have mechanical memory, clipping onto or off of a cable, being reusable.
Referring to FIGS. 8 and 9, another electrical cable assembly that may include any features of FIGS. 1 through 17 including 17 . In FIGS. 8 and 9 another electric cable assembly with a variety of inner cable assemblies having same purpose is shown. FIGS. 8 and 9 have a cable jacket 78 and at least one abrasive resistance groove and/or refillable groove 80 containing the visually reacting and/or attention getting and/or protective material 83 which is overlaid by an optional transparent layer of protective coating 82 which may also be abrasive resistant at 81 by being inside of groove or indentation 80 , and still covering the visually reacting material 83 making a viewing lens also. This electrical cable assembly also includes at least one cable getting gatherer or string cable strengthener or cable filler or cable separator indicated by number 84 which may be comprised of thermochromic: paper, textile fabric or rubber. Also included may be an inner cable assembly of thermochromic impregnated insulation 86 at X and/or liquid crystal 88 at Y over which there is a, not necessarily, clear protective coating 90 because of being in an insulating housing 79 or having an outer jacket 78 . Alternately at Z 86 may be a conventional insulation with a simple coating of liquid crystals 88 . A clear protective covering 90 , also includes an optional braided metal shielding 92 which may alternatively be a cloth cover having at least one thermochromic thread interwoven, also there is a stranded electric wire cable or power conductor lead 94 at X, Y and Z. This electric cable assembly of FIG. 9 also has a pilot conductor lead 96 , either having a liquid crystal covering 99 A, and optional clear cover 99 B, surrounding a conventional insulation 98 , that could be alternately a thermochromically impregnated insulation 98 , thus eliminating 99 a and still optional transparent protective cover 99 b . A ground wire is at numeral 100 . All of the internal parts for this cable assembly's construction may exist in it's own insulation housing 79 . All internal insulation parts for this cable construction or cable assembly are best made of a permanently changing visually reacting material unless its' insulating housing 79 and its' outer jacket 78 are clear and can be seen through, then temporary changing visually reacting material could be used. Alternately, the insulating housing 79 could be thermochromic having a clear jacket 78 without 82 and 80 . Another alternative would be to have the insulating housing 79 layered with or already having an optional dropback and then layered with liquid crystals as at number 78 without 80 , if the outer jacket 82 is clear and can be seen through. All inner electric cables comprising the electrical cable assemblies of FIGS. 8 and 9 and even other Figures in this patent may be color coded as known in the art, for the distinguishment of separate phases or internal individual circuits, markings of coded colors may alternately be used. Also referring to FIGS. 8 and 9 number 78 may be an odor releasing material that could be combined with a bitter tasting material. Also, referring to FIG. 8, conductor 94 is surrounded by a heat shrinkable material 86 , thus making another alternate electric cable assembly activatable upon predetermined conditions. Or to be used in other said electrical cable structures at this patent application, an example is to have number 82 have heat shrinkable qualities to a predetermined hazard.
Referring to FIG. 10, there is shown a section view of a repair kit or boot that may include any features of FIGS. 1 through 17 including 17 . In FIG. 8 said repair kit or boot 105 is on the cable assemblies of FIG. 8 through lines X that are in need of a waterproof electrical repair in which includes thermochromic material 102 impregnated into principal elastic electric insulation 104 and an optional elastic protective transparent cover 106 . Alternately, 102 may be visually reacting and/or reacting material layered on a form fitting elastic principal electrical insulation 104 with a form fitting elastic protective transparent cover 106 . This repair boot may also have at least one abrasive resistant groove or indention as in FIGS. 8 and 9 at numbers 80 , 81 and 83 .
In FIG. 11 there is shown tape that may include any features of FIGS. 1 through 17 including 17 . In FIG. 11 there is shown tape for modifying or repairing an existing electrical cable assembly with or without the features of the present invention in which the tape is at numeral 108 which has adhesive backing 110 which may be a self-vulcanization or vulcanizing material at 110 which makes a sticking contact means and in which a layered or impregnated visual reacting and/or reacting material 112 which is in or on the transparent protective cover 114 . Also referring to FIG. 11, 114 may be a thermally rated thermochromic impregnated electric insulation strip or tape having an adhesive backing 110 , comprising the tape at numeral 108 . In both references this tape may function with the features at this present invention. Also referring to FIG. 11, a heat shrinkable tape 108 with an adhesive side 110 and markings or means to indicate an amount of shrinkage or overload or hazard at 112 .
Referring to FIG. 12, a section view of electric conduit that may have any other features of FIGS. 1 through 17 including 17 . In FIG. 12 a section view of electric conduit 115 of FIG. 8 through lines XII, it 115 includes main insulation having flexible flame path shown in FIG. 8 at number 119 , also it 115 can be made of, fire or chemical proof electric insulation that can be a metal rigid structure 116 , a visually reacting material and/or reacting 118 that can be layered on/or impregnated into 116 and an optional transparent protective cover 120 . This electric conduit may also have at least one abrasive resistant groove or indention as in FIGS. 8 and 9 at numbers 80 , 81 and 83 .
Referring to FIG. 13, the cord section of the extension cord that may include any features of FIGS. 1 through 17 including 17 . In FIG. 13 the cord section is at numeral 112 , and there is a male plug 124 , and at least one female receptacle 126 , both 124 and 126 are electrical connective devices. There is a trip of visually reacting material 128 . Alternatively the visually reacting material may be at intermittent markings as at 130 , and have an optional transparent protective cover 129 , the visually reacting material may completely cover plug 124 which is a male end 124 , and the female receptacle 126 which is a female end 126 with same optional transparent protective cover 129 . Alternately the entire extension cord can have all its' insulating parts thermochromically impregnated.
Referring to FIG. 14, there is shown a power cord that may include any features of FIGS. 1 through 17 including 17 . In FIG. 14 the power cord which has been modified, for example, by use of the tape shown in FIG. 11 in which the cord is shown generally at 131 , having an electrical connective devices 132 , which is a male end 132 which is a male plug 132 , and conductive leads 136 , and in which the tape 138 is arranged in a spiral wrapped around pattern wrapping around cable 131 . The entire power cord could be made of a thermochromic impregnated insulation, which would include the male end 132 , restraining lamp 139 , and flexible semi-stiff cable strain relief ribs of 137 . Also referring to FIG. 14, a heat shrinkable tape 138 for any electrical cable assembly not of this patent application.
Referring to FIG. 15, there is an electrical cable assembly that may include any features of FIGS. 1 through 17 including 17 . In FIG. 15 there is a conductive element 142 , surrounded by insulation 144 , and an exploded view of a layer of visually reacting material 146 which is covered by a transparent protective cover 148 . Visually reacting materials which are sensitive to different temperatures or some physical component of electrical energy whether directly or indirectly, are separated by separations as at 150 , so that different sections of different types of visually reacting material will indicate increases or decreased in temperature, or increments of electrical faults, or overload conditions by movement of the visually activated section of the cable. Preferably adjacent sections blending or over-lapping into one another will contain materials which are visually reacting in adjacent temperature ranges, or increments of electrical faults, or over load conditions so that said changes in temperature and so forth will be most likely to give a clear appearance of movement. It will also be seen that the separations between the various visually reacting materials may be arranged transversely as in section 152 , these separations may be arranged to give the appearance of bands in/or on the cable jacket and to create the appearance of longitudinal movement. Examples of possible temperature ranges at which materials in these bands would be activated are also shown in section 152 . Coatings or layers of different types of visually reacting material or thermochromic ink may also be included in the form of lettering as in section 154 where possible temperature ranges for activation are also shown. Separations may also be arranged longitudinally as is shown in section 156 , where possible temperatures changes for activation are also shown to create the appearance of a colored strip having rotational movement around cable or give the illusion of the cable rolling. Finally as is shown in section 158 a background of coating applied with lettering coating may also be established by concentric layers as was shown in FIG. 3 to indicate increments of temperatures or electrical faults, in section 154 . Possible ranges for activation of the visually reacting materials in those ranges is also shown at 158 . Cable assembly may be designed to have separate features separately, or in some combination. Temperature ranges that are in FIG. 15 are there for example only.
Referring to FIG. 16, there is an electrical cable assembly that may include any features of FIGS. 1 through 17 including 17 . In FIG. 16 there is a conductive medium 160 , surrounded by insulation 162 , and visually reacting material 164 that may be impregnated into the insulation 162 which is covered by a transparent protective cover 166 . On the transparent protective over 116 , there is lettering with holographic ink as at 168 which may be a coating thickness layer of visually reacting material which indicates the presence of an electrical malfunction. Over his lettering there is a transparent protective covering of holographic film 170 . Also referring to FIG. 16 a conductor 160 surrounded by a principle insulation 162 with a luminescence, or non-changing color and/or descriptive terminology added at 164 and 168 with a thermochromic material that changes from same dark color or opaque at normal electrical conditions, to having transparency during abnormal electrical conditions at 166 , which is protected with an optional protective covering at 170 .
Referring to FIG. 17, FIG. 17 is an electric cabling assembly that may include any features of FIGS. 1 through 17 including 17 . In FIG. 17 there is a conductive medium at 172 , surrounded by insulation 174 , and visually reacting materials in the form of understandable language 176 which may be visual information or descriptive terminology 176 , which is covered by a transparent protective cover 178 . On the insulation 174 some of the visually reacting material reacts temporary as at 182 , some of the visual reacting material may react permanently as at 188 and 190 , because the visually reacting material is the same color as the insulation 174 , and if the insulation 174 were a different color, then a drop back would be needed surrounding insulation 174 so as to camouflage, the understandable language 176 this makes a camouflage means, that would be printed on the drop back. The understandable language 176 is not seen, until activation occurs at a predetermined electrical and/or thermal condition, for example the phrase at 184 may appear before 186 . The phrases of 188 and 190 could be last to appear if harmful electric condition were not corrected. Likewise, in FIG. 17 the insulation 174 may be impregnated and or covered with a visual reactive material, then an understandable language 176 printed on with normal ink, being both the same color, again phrases would be camouflaged until a predetermined electrical and/or thermal condition was to occur for activation of 176 phrases this also makes a camouflage means. In both processes an optional transparent protective cover could be tinted to aid the visual results. In both processes it may be desirable to employ the use of a visual and/or heat retardant or inhibitor, to be an ingredient in any of the visual reacting material 176 and/or the insulation 174 , in order to predetermine the timing or occurrence of the visual activation process, and/or rate of visual activation duration. The mass at a cable assembly would also be another factor. In both processes some of the understandable language 176 , may be designed to disappear. An example is the word normal, which may contrast the background at 174 during normal conditions and then camouflage itself into the background or dropback of 174 either temporary and/or permanently at predetermined conditions, in predetermined fashions. In both processes and other Figures of this patent, an artificial background may be needed to cover the outside of insulation 174 to aid visual result, if the insulation is not of a suitable natural color.
Referring to FIGS. 1, 2 , 3 , 9 , 13 , 14 , 15 , 16 , 17 some General rules for building reacting insulated electrical cables. If an attention getting material having some response triggered at some predetermined hazard, has a high enough insulating value, the right durability factors, flexibility, and meets all proper electrical or insulating standards. It may be used solely as insulating means coupled directly to a conductor, and should handle without reacting to processes of normal electrical conduction by the conductor. In cases where an attention getting material does not always meet the standards required for an electrical cable assembly, it will then have to be a structure comprisement, or a consistent of a known insulation that does, and will still meet the required standards after that manipulation. Depending on the environmental influences to attention getting material would warrant or not, the use of a protective cover, that would have a means to release the responses of the attention getting material.
Although the invention has been described in a certain amount of detail, it will be understood that this disclosure has been made only as an example and that the scope of the invention is defined by the following claims. | Disclosed is an electrical cable assembly in simplest form including at least one conductor, at least one insulator, and at least one attention getting material and/or a visual reacting material such as a thermochromic material or liquid crystal formulation, which will, visually and/or physically react to certain critical temperature ranges. May give off a response to variations in temperature an/or magnetic and/or electrical fields which are indicative of a hazard and/or fault, or to the direct and/or indirect results of electrical energy behavior, to provide an indication of an electrical overload condition, and/or a malfunction, and/or the incremental stages of hazard experienced by, and being experienced by, and to be experienced by, the electrical cable assembly itself, which undergoes on its own, at least one noticeable manifestation, to get your attention. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a divisional of U.S. patent application Ser. No. 13/588,788, filed Aug. 17, 2012, issued Jun. 18, 2013 as U.S. Pat. No. 8,465,335, which is a divisional of U.S. patent application Ser. No. 12/484,201, filed Jun. 13, 2009, issued as U.S. Pat. No. 8,246,408 on Aug. 21, 2012, which claims the benefit of U.S. provisional patent applications 61/061,338; 61/061,347; 61/061,353; 61/061,358; 61/061,365; and 61/061,369, all filed Jun. 13, 2008, which are incorporated by reference along with all other references cited in this application.
BACKGROUND OF THE INVENTION
[0002] This patent generally relates to displays and particularly to large display systems comprising groups of light emitting elements. The invention discloses improvements in the calibration of the light emitting elements.
[0003] Large display systems for entertainment, architectural, and advertising purposes have commonly been constructed of numbers of light emitting elements, such as LEDs or incandescent lamps mounted onto flat tiles. The light emitting elements can be selectively turned on and off to create patterns, graphics and video displays for both informational and aesthetic purposes. It is well known to construct these displays as tiles or large panels which are assembled in position, such as on a stage, for a specific entertainment show or event, or as an architectural or advertising display, such on the tops and sides of buildings.
[0004] Many of these systems require large numbers of light emitting elements or pixels acting independently and thus require robust high speed data distribution systems, often driven by computer derived data or video signals.
[0005] A requirement of such displays is that the light emitting elements for all pixels on the display be matched within a reasonable tolerance for color and luminance intensity. For example, in a large display comprising many thousands of pixels, each of which may include at least a red, green, and blue LED, an object should appear the same color and brightness wherever it is on the display. Light emitting elements, such as LEDs and their associated drive circuitry, are not manufactured to a close enough tolerance to allow their use uncalibrated in such displays. Although the manufacturers of LEDs sort their production into bins by nominal intensity and color, the tolerance of these bins are not good enough for this demanding application. It is therefore advantageous to adjust or calibrate the output of every LED individually so that an even and cohesive display is produced. Conventional display calibration techniques utilizing colorimeters and luminance meters can be prohibitively expensive and time consuming when applied to a large display having very large numbers of pixels. Such procedures typically use stored CIE chromaticity coordinates and luminance information to calculate the transformation matrices for color calibration. However, such techniques do not allow the display to be operated at different color standards without recalibration, nor do they allow for the differences in photopic (day-time) and scotopic (night-time) vision.
[0006] The invention seeks to solve these problems and discloses improvements in the measurement, characterization, and calibration systems for a display comprising groups of light emitting elements so as to provide improved accuracy and flexibility of such calibration across any color space.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention provides for a method of calibrating a large display having a plurality of display panels, each display panel having a plurality of light emitting elements. The method includes: measuring the luminance and chromaticity of each of the plurality of light emitting elements to obtain measured luminance and chromaticity data for each of the plurality of light emitting elements, the luminance data independent of the chromaticity data; and storing the measured luminance and chromaticity data with the corresponding display panel. The method further comprises performing a calibration procedure over the entire large display with the stored luminance and chromaticity data for the corresponding light emitting elements. The method also comprises: remeasuring only the luminance of at least one of the plurality of light emitting element in-situ; and performing a recalibration procedure over the entire large display in-situ responsive to the remeasured luminance data.
[0008] The disclosed invention also provides for a large digital display which comprises: a plurality of display panels; each display panel having a plurality of light emitting elements and a memory storing luminance and chromaticity data for each of the light emitting elements, the luminance data independent of the chromaticity data; and a central controller connected to each of the display panels, the central controller performing a calibration procedure over the entire large display with the luminance and chromaticity data for each of the light emitting elements.
[0009] Other objects, features, and advantages of the present invention will become apparent upon consideration of the following detailed description and the accompanying drawings, in which like reference designations represent like features throughout the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an illustration of an embodiment of the present patent showing an LED spectral measurement system.
[0011] FIG. 2 is a further illustration of an embodiment of the present patent showing an LED spectral measurement system.
[0012] FIG. 3 is an illustration of typical normalized power spectral density (NPSD) functions of red, green, and blue LEDs.
[0013] FIG. 4 is an illustration of the CIE X, Y, and Z color matching functions.
[0014] FIG. 5 is an illustration of the photopic and scotopic luminosity functions.
[0015] FIG. 6 is a representation of a display and its constituent display panels, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] To calibrate prior art display systems comprising groups of light emitting elements, such as light emitting diodes (LEDs), prior practice has been to store values of the Commission Internationale de L'Eclairage (CIE) chromaticity coordinates (x, y) for photopic vision and luminance for each pixel to calculate transformation matrices for color calibration. However, using the CIE chromaticity coordinates ties the display to a specific color space and standard, thereby precluding any operation with alternate color spaces or in the scotopic vision color space. In other words, the prior art systems use stored values which already include correction factors or coefficients which limited the calibration of the light emitting elements to certain color spaces and standards.
[0017] In contrast, the system disclosed herein stores luminance and chromaticity data for each of the light emitting elements with the display panels to which the elements belong. From the stored normalized power spectral density function (NPSD) for each light emitting element, calibration matrices are dynamically derived for the color space required. Advantageously, this methodology allows the disclosed system to compensate for the differences in photopic (day-time) and scotopic (night-time) vision, as well as the implementation of other color spaces. The disclosed system allows for separate luminance measurement and calibration of a display in the field. The luminance, or brightness, of the light emitting elements used in such displays varies with age and use, while the chromaticity remains comparatively constant. Thus, it is important to be able to adjust the luminance calibration separately from the chromaticity as the display gets older. The disclosed system stores data for luminance and chromaticity separately so that an in-field luminance only calibration system may be used to maintain screen uniformity over the lifetime of the product. Because luminance calibration is easier to perform than chromaticity calibration, this significantly reduces the complexity of in-situ calibration without compromising the accuracy of such calibrations.
[0018] Measuring Chromaticity
[0019] Accurately measuring the chromaticity of a light emitting element requires a full spectral measurement of the element and is typically performed under controlled conditions. Because only color information is required at this stage, and not luminance, only the NPSD is measured, which may then be adjusted for luminance at a later time. This substantially simplifies the measurement procedure.
[0020] FIG. 1 an illustration of an embodiment of the present patent showing a light emitting element spectral measurement system. In this description, the light emitting elements 101 of a display panel 100 are LEDs. Each of the LEDs 101 of the display panel 100 may be measured using diffraction grating spectrometers 103 , such as the USB4000 manufactured by Ocean Optics, Inc. of Dunedin, Fla. If necessary, the light from each of the LEDs 101 may be passed through a diffusing element 104 to homogenize the light output from each pixel. The spectrometers 103 accept input from a fiber optic channel, which attaches to an optical element to aid measurements, such as a collimating lens, or cosine-correcting lens. A number of measuring heads of the spectrometers 103 may be mounted on a moving head. The heads are positioned above each LED, allowing measurement of each of the LEDs spectral characteristics. Following successful measurement, the head may be moved to the next bank of LEDs until all LEDs are measured. Note that as NPSD is being measured, very accurate control of the distance of the measurement optical elements from the LEDs is not critical. However, controlling the signal-to-noise ratio (SNR) and ensuring that the spectrometer does not limit may be important.
[0021] The speed of this measurement process may be determined by:
[0022] 1. the number of measurements that can be taken simultaneously;
[0023] 2. the speed of measurement;
[0024] 3. the time it takes to move the head;
[0025] 4. the number of LEDs to be calibrated at one time; and
[0026] 5. the time it takes to upload the coefficients into the tile.
[0027] These parameters may be optimized to achieve a satisfactory cycle time. Further improvement in measurement time may also be achieved by adding additional spectrometers.
[0028] FIG. 2 is a further illustration of an embodiment of the present patent showing an LED spectral measurement system utilizing multiple spectrometers. Optical receptors 105 , each of which utilizes an optical element such as a collimating lens or cosine corrected lens, are located above each of the LEDs 101 of the display panel 100 . A number of these receptors (four are illustrated here, although the patent is not so limited) connect together via a fiber optic splice 106 that sums the light from each connected receptor 105 and transmits the result to a spectrometer 107 . As illustrated, five spectrometers would allow measurement of 20 LEDs. Illuminating only one LED per splice unit (denoted A, B, C, and D in FIG. 2 ) at a time, allows five simultaneous readings to be taken. Four readings, one for each of the A, B, C, and D LEDs, will measure the entire array.
[0029] Care needs to be taken that the surrounding environment does not significantly contribute to the measurement, and that neighboring LEDs do not interfere with each other. Interference of neighboring LEDs may be controlled, for example, through careful lens selection or through the use of optical baffles. The fiber diameter and measurement distance each may need to be chosen to minimize the exposure time required to measure each LED while preventing saturation of the spectrometer and maintaining an acceptable signal-to-noise ratio. Preferably, the LEDs are set to 100 percent on during this measurement, i.e. no pulsing associated with PWM signals. Because the linear CCD detector within the spectrometer is progressively scanned, an LED fed with a pulsed signal may result in a missing reading, which will be manifested as a hole in the spectrum. If pulsing an LED is required, then the missing data may be compensated for by software through detection of any faults and interpolation and by multiple scans.
[0030] FIG. 3 is an illustration of the typical NPSD function of red, green, and blue LEDs that are commonly utilized in video displays. As can be seen in FIG. 3 , the red and blue power spectral density (PSD) functions are narrow and do not overlap. Thus, the red and blue LEDs may be measured simultaneously, thereby reducing the number of measurements required by 33 percent. As the green PSD function overlaps the blue and red, it may be preferable to measure it separately. However, to further reduce the measurement time, all three colors may be measured simultaneously by interpolating the spectra where the green LED spectrum overlaps the red and blue LED spectra.
[0031] While PSD functions accurately represent the power (radiance) components of the light being emitted, they do not provide a simple way for mathematically quantifying a color or the way a human perceives a color. The science of the relationship between PSD and perceived color is referred to as colorimetry. In 1931, the CIE developed a standard set of three color-matching functions for describing color as perceived by a Standard Observer, and this system has been internationally adopted as a standard method of color definition for luminous and source displays (i.e. not influenced by an alternative PSD such as reflective display).
[0032] The CIE system consists of a luminance component ( y ) and two additional color or chromaticity components ( x and z ). The three components are based upon a series of experiments, and the result is that a color can be expressed in three tristimulus values. FIG. 4 shows the standard color matching functions.
[0033] From the PSD of a given color, the CIE X, Y and Z tristimulus values may be determined by correlating the PSD with each of the corresponding color matching functions as shown below.
[0000]
X
Y
Z
=
x
_
y
_
z
_
T
·
PSD
[0034] where: x , y and z are 1×n matrices representing the color functions (n is typically 3) and PSD is a n×1 matrix representing the PSD of the color.
[0035] Note that X, Y and Z take into account brightness or luminance. In terms of perception of color independent of brightness, the CIE proposed a method of normalizing the XYZ tristimulus values to obtain two chromaticity values or coordinates with x and y determined as follows:
[0000]
x
=
X
X
+
Y
+
Z
y
=
Y
X
+
Y
+
Z
[0036] These coordinates form the basis of the standard CIE 1931 color diagram and are used in prior display systems for calibration. The CIE values include correction factors or coefficients.
[0037] For more sophisticated color processing, it is preferable to store the NPSD data in the product and determine the appropriate CIE tristimulus values within the fixture or controller. This technique allows using other color matching functions such as the CIE 1964 10 degree observer functions (proposed to be more accurate in low ambient light conditions), CIE 1960, CIE 1976 functions or any other color spaces known in the art.
[0038] If only CIE x, y, and z are required, then only x and y need to be stored, because z (required to form the complete matrix) can be easily determined from the relationship z=1.0−x−y. Note that as we are ultimately only interested in determining x and y, normalized PSD functions can be measured so the repeatability of luminance measurement in this process is not of concern.
[0039] For some LEDs, the PSD may be highly dependent upon drive current, for example, with Nichia Green LEDs. The PSD may also be slightly influenced, but this influence is largely overshadowed by the high dependence of luminance on junction temperature, and thus ambient temperature and drive current. This must be taken into account when determining the operating current of the LEDs, as changing this later on in the life of the product will require complete recalibration of both chromaticity and color.
[0040] Measuring Luminance
[0041] Luminance is a photometric unit, as opposed to a radiometric one, based on the statistical response of the human eye that provides a measure of perceived brightness. Luminance has a unit of candela per square meter. The candela is an SI unit and is the measurement unit for luminous intensity, which is defined as the power emitted by a light source in a particular direction spectrally weighted by a luminosity function that is modeled on the spectral response of the human eye. The CIE 1931 specification includes a series of standard observer luminosity functions for photopic (the response during daylight hours centered around 555 nanometers) and scotopic vision (the response during night hours centered around 505 nanometers). These luminosity functions are illustrated in FIG. 5 . Note the similarity between the photopic curve in FIG. 5 and the CIE tristimulus function for luminance (Y).
[0042] Substantial care should be taken when measuring absolute luminance, particularly regarding calibration of the measurement unit and ambient light conditions. It is much easier to determine relative luminance, particularly if the ambient conditions can be controlled.
[0043] Within a batch of LEDs, it is possible for a 1:1.4 ratio between the most and least bright LEDs. This means that the least bright LED could be 71 percent of the luminance of the brightest LED. Thus, accurate determination of luminance is critical to maintaining uniformity.
[0044] Additionally, the luminance of an LED degrades with temperature and time, so while the PSD or color of the LED might not change much over the LED's life, the brightness does, and this degradation is the primary source of uniformity degradation in LED displays. Uniformity degradation may appear as if the color is changing, particularly with white, where all LEDs are illuminated. However, this degradation is almost entirely due to the varying luminance levels for each primary changing independently, changing the color mix. Typically, Green and Blue degrade substantially more than Red.
[0045] The disclosed calibration system uses a two stage process for measuring luminance; first a CCD based imaging system is used to determine the relative luminance between each LED for each color, and then a standard luminance meter is used to determine the average absolute luminance for the panel. The two measurements may then be combined to obtain absolute luminance readings for each color, for each pixel. Though a CCD based system can be calibrated, the system may drift over time and the calibrated reference point is needed to correct this drift.
[0046] Control of the ambient temperature and ambient lighting conditions are critical for ensuring repeatability for luminance measurement. Additionally, the thermal time constant of the display must be determined experimentally. The thermal time constant is the time required for a display panel to reach steady state luminance readings for red, green, and blue when operating at the chosen calibration temperature. The display panels need to be stored for a sufficient period of time at the calibration temperature, and then each display panel must be run for an identical period of time before measurements are taken.
[0047] The calibration system has ambient temperature measurement capability and will only calibrate when the environment is within specification. A suitable calibration temperature may be, for example, 20 degrees C.±1 degree C.
[0048] Parameters that require strict control when measuring luminance may include but not be limited to:
[0049] 1. Ambient temperature
[0050] 2. Warm up time
[0051] 3. Measurement distance (for both the CCD and luminance meter)
[0052] 4. Lens parameters such as aperture, focal length
[0053] 5. Exposure/measurement time
[0054] 6. Relative humidity
[0055] 7. Ambient light conditions
[0056] 8. Light reflections (can be controlled through the use of optical baffles.)
[0057] 9. Regular calibration for all equipment
[0058] 10. Regular verification of the system through the use of standard modules with known calibration
[0059] The more controlled the environment and the process, the more accurate and repeatable the calibration will be. Appropriate checks and balances need to be incorporated into the calibration process to ensure that these ambient conditions are not only within specification, but also logged for future diagnostic purposes.
[0060] But even with the cautionary notes above, the measurement of, and proper calibration for, the luminance of the LEDs of the display panels is relatively easy and can be done in-situ, i.e., at the installed display. On the other hand, properly measuring the chromaticity of the LEDs in-situ is very difficult given the difficulty in measurement under controlled conditions.
[0061] Storage on Display Panels
[0062] Once all measurements have been taken for the LEDs of a display panel, the luminance and chromaticity data are stored on the display panel. FIG. 6 form an overall display 200 formed by a plurality of display panels 100 arrayed in tiles of rows and columns. In this representation only nine display panels 100 are shown and are separated to better illustrate their organization. Graphic or video information for each of the light emitting elements 101 of each display panel 100 to display is passed from a central video processor unit controller 205 over a data bus 223 which interconnects the display panels 100 and connects them to the controller 205 . The controller 205 can receive display information as represented by an external source 219 . To process the information for display by each display panel 100 and its constituent light emitting elements 101 , the central controller 205 has a graphics processor unit (GPU), a central processing unit (CPU), network interface card (NIC) and memory storage 209 , and the high-speed data bus 223 carries the display information to the display panels 100 . Although a NIC is depicted, the video processor may be connected by any output means to the display panels, including, for example, video transport (e.g., DVI, HDMI, VGA, or other).
[0063] Each display panel 100 also has a memory unit 109 which holds the measured luminance and chromaticity data described for each light emitting element so that the element remains properly calibrated. Memory units 109 for only two display panels 100 are shown for drawing simplicity. Preferably the memory units 109 are based on nonvolatile memory, such as EEPROM integrated circuits, so that the stored data is not lost when power is cut to the display panels. The video processor unit controller 205 also performs the calibration and recalibration procedures described below. A second bus 221 , shown by a dotted line, interconnects the display panels 100 and connects them with the controller 205 . As shown by the double-headed arrow, the panels 100 can pass their luminance and chromaticity data to the controller 205 for processing and once processed, the controller 205 can send the data back to the control panels 100 for storage. It should be understood that accompanying the luminance and chromaticity data there is information to identify the display panel and constituent light emitting element to which the data refers. With this arrangement the central controller 205 can perform the calibration and recalibration procedures so that the individual light emitting elements are matched over the entire display. This contrasts with less desirable calibration (and recalibration) procedures by which the elements are matched over a display panel.
[0064] More details on a display system are described in U.S. patent application Ser. Nos. 12/415,627, filed Mar. 31, 2009, 12/484,200, filed Jun. 13, 2009, and U.S. provisional patent applications 61/072,597, filed Mar. 31, 2008, and 61/170,887, filed Apr. 20, 2009, which are incorporated by reference.
[0065] Calibration and Recalibration: Determination of the TRA Matrix for Each Pixel
[0066] The measured chromaticity and luminance data of each light emitting element is used to calculate the calibration values for the element. Some prior art products simply calculate a transformation matrix (TRA) based upon the color and luminance measurements and a predetermined destination color space (such as PAL or NTSC). However, to recalibrate luminance in the future, both parameters may need to be stored separately, because when combined into a TRA, luminance and chromaticity cannot be independently extracted.
[0067] Notwithstanding the above, it may be advantageous to additionally store the CIE x, y chromaticity coordinates as well as luminous intensity for each LED in the memory unit 109 for each display panel 100 , as shown in FIG. 6 . As discussed above, because x+y+z=1.0, it is only necessary to store x and y. Thus, an example matrix stored in the EEPROM follows:
[0000]
x
R
x
G
x
B
y
R
y
G
y
B
I
R
I
G
I
B
[0068] The method described below for determining the transformation matrix is based almost entirely on SMPTE Recommended Practice 177-1993 entitled “Derivation of Basic Color Television Equations.” In order to assist with understanding, the appropriate section of that document is referenced in square brackets.
[0069] Form source (target matrix) (P). In the SMPTE Recommended Practice “source” refers to the source color space, but in this case this is the target color space. In order to duplicate the same color space as the source (e.g. PAL), the PAL color space would be the target color space. However, to exploit the extended color gamut it may be necessary to adjust these coordinates. Adjustments will provide a display with more vibrant, but less accurate colors. For decorative applications of video display products, it is generally preferable to exploit maximum color gamut.
[0070] The required color space may be selected in a control system, and this information is sent to the display to calculate the TRA. Including this selection may allow the user to determine if they prefer accuracy or vibrancy.
[0071] The source color space is defined as:
[0072] Red (x SR , y SR ) e.g. (0.64, 0.3) for PAL Red
[0073] Green (x SG , y SG ) e.g. (0.3, 0.6) for PAL Green
[0074] Blue (x SB , y SB ) e.g. (0.15, 0.06) for PAL Blue
[0075] Additionally, the source white point (x W , y W ), needs to be defined. A common white point is D65 which is the standard for television transmission (0.3127, 0.329).
[0000]
P
S
=
x
SR
x
SG
x
SB
y
SR
y
SG
y
SB
I
SR
I
SG
I
SB
and
W
=
x
w
/
y
w
1.0
z
w
/
y
w
[0076] Note here that each coordinate for the W matrix is normalized with respect to y W (luminance) so that white luminance as a value of 1.0 (i.e. R=G=B=1 for white).
[0077] Compute the coefficient matrix. These coefficients effectively determine the relative gain required from each of the primaries such that R=G=B=1 produces white.
[0000]
C
SR
C
SG
C
SB
=
P
S
-
1
·
W
[0078] Form the diagonal matrix C S as follows:
[0000]
C
S
=
C
SR
0
0
0
C
SG
0
0
0
C
SB
[0079] Compute the final source normalized primary matrix NPM S as the product of Ps and Cs:
[0000]
N
P
M
S
=
X
SR
X
SG
X
SB
Y
SR
Y
SG
Y
SB
Z
SR
Z
SG
Z
SB
=
P
S
·
C
S
[0080] This finally relates the linear RGB values from the video signal to CIE X, Y, Z tristimulus as:
[0000]
X
Y
Z
=
X
SR
X
SG
X
SB
Y
SR
Y
SG
Y
SB
Z
SR
Z
SG
Z
SB
·
R
S
G
S
B
S
[0081] Note that for the NPM S , Y SR +Y SG +Y SB =1.0, so the ratios of Y SR , Y SG and Y SB represent the ratios of red, green, and blue that are required to get the designated white point. For example, for PAL, these ratios are: Red 21 percent, Green 72 percent and Blue 7 percent.
[0082] Form destination (LED display) primary matrix (P). The same process is repeated to determine the destination normalized primary matrix (NPM), which may be based upon the chromaticity coordinates obtained in the calibration process.
[0000]
C
DR
C
DG
C
DB
=
P
D
-
1
·
W
P
D
=
x
R
x
G
x
B
y
R
y
G
y
B
(
1
-
x
R
-
y
R
)
(
1
-
x
G
-
y
G
)
(
1
-
x
B
-
y
B
)
and
W
=
x
w
/
y
w
1.0
z
w
/
y
w
C
D
=
C
DR
0
0
0
C
DG
0
0
0
C
DB
N
P
M
D
=
X
DR
X
DG
X
DB
Y
DR
Y
DG
Y
DB
Z
DR
Z
DG
Z
DB
=
P
D
·
C
D
[0083] This allows the determination of tristimulus values for a destination RGB color:
[0000]
X
Y
Z
=
N
P
M
D
·
R
D
G
D
B
D
=
X
DR
X
DG
X
DB
Y
DR
Y
DG
Y
DB
Z
DR
Z
DG
Z
DB
·
R
D
G
D
B
D
[0084] Thus, it is possible to determine the RGB values required to reproduce a given set of tristimulus values:
[0000]
R
D
G
D
B
D
=
N
P
M
D
-
1
·
X
Y
Z
=
X
DR
X
DG
X
DB
Y
DR
Y
DG
Y
DB
Z
DR
Z
DG
Z
DB
-
1
·
X
Y
Z
[0085] Consequently, it is possible to determine the RGB values required for the target color space to reproduce the color of the source RGB color space, and, in turn, determine the transformation matrix.
[0000]
R
D
G
D
B
D
=
N
P
M
D
-
1
·
X
Y
Z
=
N
P
M
D
-
1
·
N
P
M
S
·
R
S
G
S
B
S
=
TRA
·
R
S
G
S
B
S
[0086] Thus:
[0000] TRA=NPM D −1 ·NPM S
[0087] Note that if any term in the TRA is negative, then the target on source color space cannot be rendered completely by the display. To maximize accuracy, negative coefficients need to be allowed for and coefficients of less than zero are rounded to zero.
[0088] Gain adjust the TRA. The process above works on normalized luminance, so the scale factors on gains must also be applied to each color to get the target luminance. The process also assumes that red, green, and blue are adjusted so when set to 100 percent, they combine to form the white point, at the target luminance.
[0089] Assume, for example, a target luminance is L W is 5000 candela per square meter. This luminance may be multiplied by the square area for each pixel to determine a target luminous intensity pen pixel for white (Iw). The luminous intensity for each LED measured at the time of calibration, I R , I G , and I B is stored in the memory 109 of the corresponding display panel.
[0090] The second row of the NPM D (Y DR , Y DG and Y DB ) determines the ratio of the red, green, and blue LEDs that are required to meet the set white point. For example, for red, I W ×Y DR determines the luminous intensity required of the red LED to meet the red requirement of the white set point, for the given I W .
[0091] Thus, the gain adjustments required for each LED, where a gain of 1 gives the required luminous intensity to meet the white point at the specified brightness are:
[0000]
k
R
=
I
W
·
Y
DR
I
R
k
G
=
I
W
·
Y
DG
I
G
k
B
=
I
W
·
Y
DB
I
B
[0092] Note that if any of the gains are greaten than 1.0, then that color cannot be displayed at the requested luminance level.
[0093] To determine the PWM values for each of the LEDs in an efficient manner, these gains may be included the TRA.
[0000]
TRA
′
=
k
R
·
TRA
11
k
R
·
TRA
12
k
R
·
TRA
13
k
R
·
TRA
21
k
R
·
TRA
22
k
R
·
TRA
23
k
R
·
TRA
31
k
R
·
TRA
32
k
R
·
TRA
33
[0094] Thus, the PWM values required for the LEDs (range 0.0 to 1.0) are:
[0000]
PWM
RED
PWM
GREEN
PWM
BLUE
=
TRA
′
·
R
S
G
S
B
S
[0095] Note that all these calculations occur in linear space, therefore any gamma correction must be performed following the color space conversion.
[0096] Verification of Calibration
[0097] Once TRAs have been calculated for each LED, a test may be required to verify the calibration. Measuring the relative luminance at an LED level may be difficult because the PWM is active, and due to the progressive scanning of the CCD, errors may occur. Higher grade, ultra-fast, scientific CCDs can compensate for this effect, as can increasing the exposure time, although due to the high brightness compensation may also be difficult. To truly test accuracy, a high-speed, scientific CCD with x, y and z color filters is required, including, for example, CCDs available from Radiant Imaging, Inc. of Redmond, Wash. on MunaTest. Alternatively, a standard spectroradiometer such as a CS-1000 on SpectraScan may be used to determine panel compliance.
[0098] Embodiments disclosed herein may provide for one on more of the following advantages. First, the calibration system disclosed herein may allow for calibration of displays to arbitrary color spaces. The calibration system disclosed herein may also allow for the adjustment of a display to both photopic vision (day) and scotopic vision (night). Furthermore, the calibration system disclosed herein may allow for enhanced screen uniformity across a display as the elements within a display wear. Finally, the calibration system disclosed herein may reduce the complexity of in-field calibrations of displays. The display can be recalibrated by remeasuring the luminance of the light emitting elements only in-situ.
[0099] This description of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications. This description will enable others skilled in the art to best utilize and practice the invention in various embodiments and with various modifications as are suited to a particular use. The scope of the invention is defined by the following claims. | Large digital displays for entertainment, architectural and advertising displays have interconnected display panels with pluralities of light emitting elements. To solve calibration problems, each of the display panels stores measured luminance and chromaticity data for each of the light emitting elements of the panel. The luminance data is independent of the chromaticity data. A central controller can then perform calibration procedures so that the light emitting elements are matched across the entire display. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to stimulating production of wells producing natural resources such as crude oil, gas, and/or water; in particular the invention relates to a method and apparatus for stimulating a geologic formation using a downhole tool to apply low-frequency mechanical waves.
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office file or records, but otherwise reserves all copyrights associated with this document.
BACKGROUND OF THE INVENTION
[0003] A major challenge with production of natural resources such as oil, gas and water from wells is that the productivity gradually decreases over time. While a decrease is expected to naturally accompanies the depletion of the reserves in the reservoir, often well before any significant depletion of the reserves, production diminishes as a result of factors that affect the geologic formation in the zone immediately surrounding the well and in the well's configuration itself. For example, Crude Oil production can decrease as a result of the reduction in permeability of the rock formation surrounding the well, a decrease of the fluidity of oil or the deposit of solids in the perforations leading to the collection zone of the well.
[0004] In production wells, perforations aid the fluid from the formation seeping through cracks or fissures in the formation to flow toward a collection compartment in the well. Hence, the pore size of the perforations connecting the well to the formation determines the flow rate of the fluid from the formation toward the well. Along with the flow of oil, gas or water, very small solid particles from the formation, called “fines,” flow and often settle around and within the well, thus, reducing the pore size.
[0005] Solids such as clays, colloids, salts, paraffin etc. accumulate in perforation zones of the well. These solids reduce the absolute permeability, or interconnection between pores. Mineral particles may be deposited, inorganic scales may precipitate, paraffins, asphalt or bitumen may settle, clay may become hydrated, and solids from mud and brine from injections may invade the perforations. The latter problems lead to a flow restriction in the zone surrounding the perforations.
[0006] As a result of the reduction of productivity, of oil wells for example, the exploitation may become prohibitively expensive forcing abandonment of the wells.
[0007] Production wells of oil and gas, for instance, are periodically stimulated by applying three general types of treatment: mechanical, chemical, and other conventional techniques which include intensive rinsing, fracturing and acid treatment.
[0008] Chemical acid treatment consists of injecting in the production zone mixtures of acids, such as hydrochloric acid and hydrofluoric acid (HCI and HF). Acid is used for dissolving reactive components (e.g., carbonates, clay minerals, and in a smaller quantity, silicates) in the rock, thus increasing permeability. Additives, such as reaction retarding agents and solvents, are frequently added to the mixtures to improve acid performance in the acidizing operation.
[0009] While acid treatment is a common treatment to stimulate oil and gas wells, this treatment has multiple drawbacks. Among the drawbacks of acid treatment are: 1) the cost of acids and the cost of disposing of production wastes are high; 2) acids are often incompatible with crude oil, and may produce viscous oily residues inside the well; precipitates formed once the acid is consumed can often be more obnoxious than dissolved minerals; and 3) the penetration depth of active or live acid is generally low (less than 5 inches or 12.7 cm).
[0010] Hydraulic fracturing is a mechanical treatment usually used for stimulating oil and gas wells. In this process, high hydraulic pressures are used to produce vertical fractures in the formation. Fractures can be filled with polymer plugs, or treated with acid (in rocks, carbonates, and soft rocks), to form permeability channels inside the wellbore region; these channels allow oil and gas to flow. However, the cost of hydraulic fracturing is extremely high (as much as 5 to 10 times higher than acid treatment costs). In some cases, fracture may extend inside areas where water is present, thus increasing the quantity of water produced (a significant drawback for oil extraction). Hydraulic fracture treatments extend several hundred meters from the well, and are used more frequently when rocks are of low permeability. The possibility of forming successful polymer plugs in all fractures is usually limited, and problems such as plugging of fractures and grinding of the plug may severely deteriorate productivity of hydraulic fractures.
[0011] Another method for improving oil production in wells involves injecting steam or water. One of the most common problems in depleted oil wells is precipitation of paraffin and asphaltenes or bitumen inside and around the well. Steam or water has been injected in these wells to melt and dissolve paraffin into the oil or petroleum, and then all the mixture flows to the surface. Frequently, organic solvents are used (such as xylene) to remove asphaltenes or bitumen whose melting point is high, and which are insoluble in alkanes. Steam and solvents are very costly (solvents more so than steam), particularly when marginal wells are treated, producing less than 10 oil barrels per day. The main limitation for use of steam and solvents is the absence of mechanical mixing, which is required for dissolving or maintaining paraffin, asphaltenes or bitumen in suspension.
[0012] Empirical evidence have shown that seismic type waves may have an important effect on oil reservoirs. For example, following seismic waves, either from earthquakes or artificial induction, there is a rise in the fluid levels (water or oil), yielding an increase in oil production. A report on these phenomena is published by I. A. Beresnev and P. A. Johnson (GEOPHYSICS, VOL. 59, NO. 6, JUNE 1994; P. 1000-1017), which is included in its entirety herewith by reference.
[0013] Several methods using sound waves to stimulate oil wells have been described. Challacombe (U.S. Pat. No. 3,721,297) describes a tool for cleaning wells using pressure pulses: a series of explosive and gas generator modules are interconnected in a chain, in such a manner that ignition of one of the explosives triggers the next one and a progression or sequence of explosions is produced. These explosions generate shock waves that clean the well. There are obvious disadvantages of this method, such as potential damages that can be caused to high-pressure oil and gas wells. Use of this method is not feasible because for additional dangers including fire and lack of control during treatment period.
[0014] Sawyer (U.S. Pat. No. 3,648,769) describes a hydraulically controlled diaphragm that produces “sinusoidal vibrations in the low acoustic range”. Generated waves are of low intensity, and are not directed or focused to face the formation (rock). As a consequence, the major part of energy is propagated along the perforations.
[0015] Ultrasound techniques have been developed to increase production of crude oil from wells. However, there is a great amount of effects associated with exposing solids and fluids to an ultrasound field of certain frequencies and energy. In the case of fluids in particular, cavitation bubbles can be generated. These are bubbles of gas dissolved in liquid, or bubbles of the gaseous state of the same liquid (change of phase). Other associated phenomena are liquid degassing and cleaning of solid surfaces.
[0016] Maki Jr. et al. (U.S. Pat. No. 5,595,243) propose an acoustic device in which a piezoceramic transducer is set as radiator. The device presents difficulties in its manufacturing and use, because an asynchronous operation is required of a high number of piezoceramic radiators.
[0017] Vladimir Abramov et al., in “Device for Transferring Ultrasonic Energy to a Liquid or Pasty Medium” (U.S. Pat. No. 5,994,818) and in “Device for Transmitting Ultrasonic Energy to a Liquid or Pasty Medium” (U.S. Pat. No. 6,429,575), propose an apparatus consisting of an alternating current generator operating within the range of 1 to 100 kHz to transmit ultrasonic energy, and a piezoceramic or magnetostrictive transducer emitting ultrasound waves, which are transformed by a tubular resonator or wave guide system (or sonotrode) in transverse oscillations that contact the irradiated liquid or pasty medium. However, these patents are conceived to be used in containers of very large dimensions, at least as compared with the size and geometry of perforations present in wells. This shows limitations from a dimensional point of view, and also for transmission mode if it is desired to enhance production capacities of oil wells.
[0018] Julie C. Slaughter et al., in “Ultrasound Radiator of Dowhole Type and Method for Using It” (In U.S. Pat. No. 6,230,788), propose a device that uses ultrasonic transducers manufactured of Terfenol-D alloy and placed at the well bottom, and fed by an ultrasonic generator located at the surface. Location of transducers, axially to the device, allows the emission along a transverse direction. This invention proposes a viscosity reduction of hydrocarbons contained in the well through emulsification, when reacting with an alkaline solution injected to the well. This device considers a forced shallow circulation of fluid as a refrigeration system, to warrant continuity of irradiation.
[0019] Dennos C. Wegener et al., in “Heavy Oil Viscosity Reduction and Production,” (U.S. Pat. No. 6,279,653), describe a method and a device for producing heavy oil (API specific gravity less than 20) applying ultrasound generated by a transducer made of Terfenol alloy, attached to a conventional extraction pump, and powered by a generator installed at the surface. In this invention the presence of an alkaline solution is also considered, similar to an aqueous sodium hydroxide (NaOH) solution, to generate an emulsion with crude oil of lower density and viscosity, thereby facilitating recovery of the crude by impulsion with a pump. Here, a transducer is installed in an axial position to produce longitudinal ultrasound emissions. The transducer is connected to an adjacent rod that operates as a wave guide or sonotrode.
[0020] Robert J. Meyer et al., in “Method for improving Oil Recovery Using an Ultrasonic Technique” (U.S. Pat. No. 6,405,796), propose a method to recover oil using an ultrasound technique. The proposed method consists of disintegrating agglomerates by means of an ultrasonic irradiation technique, and the operation is proposed within a certain frequency range, for the purpose of handling fluids and solids in different conditions. Main oil recovery mechanism is based in the relative momentum of these components within the device.
[0021] The latter mentioned prior art generates ultrasonic waves via a transducer that is externally supplied by an electric generator connected to the transducer through a transmission cable. The transmission cable is generally longer than 2 km, which has the disadvantage of signal transmission loss. Since high-frequency electric current transmission to such depths is reduced to 10% of its initial value, the generated signal must have a high intensity (or energy), enough for an adequate operation of the transducers within the well. Furthermore, since the transducers need to operate at a high-power regime, water or air cooling system is required, which in turn poses great difficulties when placed inside the well. The latter implies that ultrasound intensity must not exceed 0.5-0.6 W/cm2. This level is insufficient for the desired purposes, because threshold of acoustic effects in oil and rocks is from 0.8 to 1 W/cm2.
[0022] Andrey a. Pechkov, in “Method for Acoustic Stimulation of Wellbore Bottom Zone for Production Formation” (RU Patent No. 2 026 969), disclose methods and devices for stimulating production of fluids within a producing well. These devices incorporate, as an innovating element, an electric generator attached to the transducer, and both of them integrated in the well bottom. These transducers operate in a non-continuous mode, and can operate without needing an external cooling system. The impossibility of operating in a continuous mode to prevent overheating is one of the main drawbacks of this implementation since the availability of the device is reduced. Moreover, because the generator is located in the wellbottom, and especially because of the use of high power, the failure rate of the equipment is likely to be high, thus raising the cost of maintenance.
[0023] Oleg Abramov et al., in “Acoustic Method for Recovery of Wells, and Apparatus for its Implementation” (U.S. Pat. No. 7,063,144), disclosure an electro-acoustic method for stimulation of production within an oil well. The method consists of stimulating, by powerful ultrasound waves, the well extraction zone, causing an increase of mass transfer through its walls. This ultrasonic field produces large tension and pressure waves in the formation, thus facilitating the passage of liquids through well recovery orifices. It also prevents accumulation of “fines” on these holes, thereby increasing the life of the well and its extraction capacity.
[0024] Kostyuchenko in “Method and apparatus for generating seismic waves” (U.S. Pat. No. 6,776,256) generates seismic waves in an oil reservoir for well stimulation by chemical detonation. A packer is lowered into the well, where a fuel and air mixture is injected, and then detonated, generating seismic waves that reach the well walls. Some problems may appear considering possible unwanted explosions and difficulties regarding the transportation of a fuel and air mixture deep into the well.
[0025] Kostrov in “Method and apparatus for seismic stimulation of fluid bearing formations” (U.S. Pat. No. 6,899,175) describe another device for seismic waves generation. Shock waves are generated when compressed liquid is discharged to the well casing, forming seismic waves in the well borehole. This device has a limited range of applications as it may be only used in injection wells.
[0026] Ellingsen in “Sound source for stimulation of oil reservoirs” (US patent application publication 2009/0008082) a seismic wave generator is presented. Pressurized gas from a compressor located on the surface is transported into the wellbore where it operates a sound source that emits the seismic waves. The main limitation of this device is that it cannot operate over 1 kHz.
[0027] Murray in “Electric pressure actuating tool and method” (U.S. Pat. No. 7,367,405) describes using a tool to stimulate a down-hole using mechanical waves. This tool comprises a housing having a chamber filled with liquid, where an electrical discharge is produced. The discharge vaporizes the liquid creating a shock wave that pushes a piston, thus generating a pressure wave in the surrounding fluid. However, the presence of moving parts in the down hole may present difficulties, for instance, to provide required maintenance.
[0028] In “The application of high-power sound waves for wellbore cleaning”, Champion et al., analyze techniques related to high power sound waves used in well stimulation, and indicate that a variety of techniques exists for the generation of sound waves, with one of the most common laboratory methods comprising the use of either piezoelectric or magnetostrictive type transducers. The piezoelectric devices employ a crystal that oscillates in response to an applied oscillating voltage, while the magnetostrictive devices employ an alloy that changes shape in the presence of a magnetic field and, creates a powerful force. In both cases, this study indicates that, the oscillatory movement generated is used to drive an acoustic transmitter element. The average power level of these devices is in the region of 0.5 watts/cm2, and the potential to increase this significantly is limited because of the presence of gas bubbles released by the periodic pressure oscillations within the fluid. Instead of this method based on transducers Champion et al. proposes the generation of high power sound waves by initiating a high voltage electrical discharge in a liquid medium—the electrolyte. This concept of sound wave generation has been practiced previously in the development and application of marine and downhole seismic “sparker” sources.
[0029] A high-energy electrical discharge, which may be of the order or several hundred joules, is triggered at a spark gap submerged in an electrolyte. Typical electrical-breakdown times in water can be engineered to occur in the nanosecond time scale. A high current flows from the anode to cathode, which causes the electrolyte adjacent to the spark gap to vaporize and form a rapidly expanding plasma gas bubble. After the discharge stops, the bubble continues to expand until its diameter increases beyond the limit sustainable by surface tension, at which point it will rapidly collapse (cavitation mechanism), producing the shock wave that propagates through the fluid and is used for wellbore cleaning. Previous work in the field has demonstrated that the creation of this transient acoustic shock wave, in the form of a pressure step function, has the potential to generate high power ultrasound with an intensity of greater than 50 watt/cm 2 .
[0030] Sidney Fisher and Charles Fisher in “Recovery of hydrocarbons from partially exhausted oil wells by mechanical wave heating” (U.S. Pat. No. 4,049,053) describe heating underground viscous hydrocarbon deposits, such as the viscous residues in conventional oil wells, by mechanical wave energy to fluidize the hydrocarbons thereby to facilitate extraction thereof. The latter invention comprises a system for generating mechanical waves located on the ground surface transmitting the waves to the bottom of the well.
[0031] Therefore, what is needed is a method and system for improving well productivity that do not present, or at least that minimize, the above-mentioned drawbacks of each respective prior art.
SUMMARY OF THE INVENTION
[0032] The invention is a method and apparatus for stimulating wells of natural resources such as oil gas and water. The invention provides an apparatus enabled with one or more elastic wave generators and a power supplier.
[0033] An apparatus embodying the invention comprises a device capable of generating low-frequency acoustic waves. Such a device may produce low-frequency elastic waves by means of an electrical discharge in a liquid confined in a radiating chamber. Furthermore, the apparatus does not require to be removed between treatment and may be left in the well while production is ongoing in order to collect valuable information.
[0034] An apparatus embodying the invention provides short duration pulse discharges in a controlled environment inside a radiating chamber in order to generate seismic type waves. The energy storage device may be located in the well and may be driven by means of a power source located at the surface. When the required energy levels are reached the energy is pulse-discharged from the energy storage device into the radiating chamber, resulting in shock waves that are transmitted to the chamber surface and into the geologic formation.
[0035] By combining one or several acoustic modules, the system embodying the invention may be adapted to treat a large number of different types of wells, depending on a set of parameters that characterize each particular well and/or geologic formation. The components are modular and may be combined for any particular use. The apparatus comprises at least one low frequency and high power electro-acoustic module. Low attenuation of low frequency mechanical waves allows the waves to travel large distances. This configuration is intended for long-range applications in reservoirs. The latter device configuration allows for reservoir acoustic treatment at extremely deep depths (5000 to 15000 meters), and also at shallow depths. The low frequency regime may be operated in-phase mode as the energy pulse discharge can be done in phase with the radiating chamber deformation. In addition, the low-frequency module may be involved in applications that utilize seismic wave reflections to map underground geologic structures.
[0036] One or more embodiments of the invention deliver an acoustic device for oil, gas, and/or water wells, which does not require injection of chemicals for their stimulation. One of the advantages of the invention is that the system delivers an acoustic device for downhole that has no environmental treatment costs associated with returning the liquids to the well after their treatment.
[0037] An acoustical device is provided for the perforation zone (downhole) that can operate inside a tube without needing the withdrawal or elimination of said tube. In accordance with the invention, the device is able to operate within the tubing, at the end of the tubing using a coupling adapter to attach the device to the end of the tubing, and/or one or more stimulation devices may be mounted in a series with the tubing. In the latter case, a stimulation device may be interposed with the tubing i.e. the device is attached to the end of tubing and another tubing segment is attached to the second end of the stimulation device. The process may be repeated to install several stimulation devices.
DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows a schematic representation of a typical well for extracting oil and/or gas, aiming at presenting the context in which an embodiment of the invention is utilized.
[0039] FIG. 2 is a block diagram representing components (or modules) of a tool for stimulating wells in accordance with an embodiment of the invention.
[0040] FIG. 3 schematically depicts parts of a low-frequency mechanical wave generator and a power supplier to drive the low-frequency mechanical waves generator in accordance with an embodiment of the invention.
[0041] FIG. 4A schematically represents an electronic circuit for providing a high voltage electric discharge in accordance with an embodiments of the invention.
[0042] FIG. 4B and FIG. 4C are plots of the output voltage of electronic circuits as a function of time in accordance with embodiments of the invention.
[0043] FIG. 5 is a block diagram representing components for stimulating wells in accordance with an embodiment of the invention.
[0044] FIG. 6 is a flowchart diagram representing steps involved in applying a mechanical wave discharge delivered to a geological formation in accordance with one embodiment of the invention.
[0045] FIG. 7 is a schematic representation of a production oil field having a plurality of wells, where one or more wells are equipped with a system embodying the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] The invention provides a method and apparatus for stimulating oil, gas or water wells using a high-power electric discharge within a device embodying the invention in order to generate low-frequency mechanical waves. Furthermore, a device embodying the invention may be configured with one or more sensors to enable the system to collect a plurality of real-time information data that is processed and analyzed for further optimization of well stimulation.
[0047] In the following description, numerous specific details are set forth to provide a more thorough description of the invention. It will be apparent, however, to one skilled in the pertinent art, that the invention may be practiced without these specific details. In other instances, well known features have not been described in detail so as not to obscure the invention. The claims following this description are what define the metes and bounds of the invention.
[0048] FIG. 1 shows a schematic representation of a typical well for extracting oil and/or gas, aiming at presenting the context in which an embodiment of the invention is utilized. Well 120 , for extracting fluids from a geological formation, is basically a hole lined with a cement layer 125 and a casing 128 that houses and supports a production tube string 130 coaxially installed in its interior. Perforations (e.g., 140 ) in the well lining, provide a path or trajectory that allow fluids produced in the reservoir 110 to flow from the reservoir 110 toward the collection area of the well 105 .
[0049] Typically, there are numerous perforations (e.g., 140 ) that extend radially from the lined or coated well. Perforations are uniformly separated in the lining, and pass to the outside of the lining through the formation. In an ideal case, perforations are only located within the formation, and their number depends on the formation thickness. It is rather common to have nine (9), and up to twelve (12) perforations per depth meter of formation. Other perforations extend longitudinally, and yet other perforations may extend radially from a 0°-azimuth, while additional perforations, located every 90° may define four sets of perforations around azimuth. Formation fluids pass through these perforations and come into the lined (or coated) well.
[0050] Preferably, the oil well is plugged by a sealing mechanism, such as a shutter element (e.g., 132 ), and/or with a bridge-type plug, located below the level of perforations (e.g., 134 ). The shutter element 132 may be connected to a production tube, and defines a compartment 105 . The production fluid, coming from the formation or reservoir, enters the compartment and fills the compartment until it reaches a fluid level. Accumulated oil, for example, flows from the formation and can be accompanied by variable quantities of natural gas. Hence, the lined compartment 105 may contain oil, some water, natural gas, and solid residues, with normally, sand sewing at the bottom of the compartment.
[0051] A tool 100 for stimulating the well in accordance with embodiments of the invention, may be lowered into the well to reach any level of the formation that is selected to be subjected to mechanical wave treatment. The tool may be connected to the ground surface through an attachment means 150 , attached to the extremity of the tube 130 using an adapter coupling, and/or interposed with the tubing. In the latter case, one or more stimulation devices may be mounted in a daisy chain manner, where one or more stimulation devices are mounted in series with segments of the tubing. Thus, a tool 100 may be lowered momentarily into a well for well treatment or by attaching the tool to the end of the tube 130 , the tool may be operated even as the production continues from the well. The attachment means comprise a set of cables for providing the strength for holding the weight of tool 100 . The attachment means may also comprise power cables for transmitting electrical energy to the tool, and communication cables such as copper wires and/or fiber optics for providing a means of transmitting data between control computers on the ground and the tool.
[0052] FIG. 2 is a block diagram representing components (or modules) of a tool for stimulating wells in accordance with an embodiment of the invention. A tool 100 comprises one or more acoustic wave generators. The acoustic wave generator 220 may be powered by a power supplier that may be hosted ( 210 as shown in FIG. 2 ) within the tool or may be located outside of the tool, such for example, on the ground surface. Tool 100 optionally comprises a sensing system 240 . These modules may be mounted in a chain in any number, combination and sequence.
[0053] The invention provides a manager with the flexibility to adapt the tool to specific needs for stimulating a well. A tool 100 may combine any number of modules. The type, number and configuration of the modules depend on the goal a well manager may desire to achieve through the stimulation of the well. For example, a tool 100 allows a well manager, after studying the composition of the formation, the flow rate of the liquid, pressure, temperature and any other parameter of the well, to configure tool 100 for a target purpose. The target purpose may be to induce vibration in the rock at a greater distance (e.g., several meters from the well), in which case the manager may choose to use one or more low-frequency wave generators.
[0054] Power supplier 210 may be located with tool 100 , outside of the tool 100 (e.g., as an attachment), on the ground surface or any other location that may be selected for optimal operation.
[0055] Power supplier 210 is comprised of an electric system capable of receiving power (e.g., direct-current power and or alternative current, AC) from the ground surface through a power transfer cable. The power supplier module is capable of transforming the power in accordance with requirement of the other components, such as the low-frequency mechanical wave generator 220 , and delivering power to other component such as a set of sensors and data collection and transmission modules. In transforming power, power supplier 210 may convert direct current (DC) to alternative current or vice versa (AC); generate AC currents at one or several frequencies; generate pulsed currents or any type of electric power regime that may be necessary for the proper functioning of any of the component of tool 100 . To the latter end, power supplier 210 comprises one or more electronic circuits to provide the correct electric current to components 220 in the tool. For example, tool 100 may comprise an electronic circuit for storing energy in a capacitor and delivering a high-voltage pulse when the energy stored in the capacitor reaches a predetermined threshold. The latter is useful, for example, for driving a low-frequency wave generator that utilizes a high-voltage current to generate an electric arc within a radiating chamber, thus, generating elastic waves.
[0056] In implementations of the invention where the power supplier is located on the ground surface, high power electric pulse signals are sent through geophysical cables to the downhole tool.
[0057] Power supplier 210 may also comprise electronic circuits enabling it to receive information and execute commands from a computer and/or another electronic circuit. For example, power supplier 210 may receive an instruction from a ground computer to start, stop or resume the operation of any component. It may receive instructions to deliver more or less power to any of the components or change the frequency of operation of one or more wave generators.
[0058] Embodiments of the invention comprise one or more low-frequency wave generators 220 . Low-frequency sound waves are characterized by their ability to transfer energy over long distances (e.g., hundreds of meters). Embodiments of the invention may utilize any available device capable of generating elastic waves of low frequency (e.g., 1 to 100 Hz).
[0059] Embodiments of the invention utilize, in particular, a low-frequency wave generator that is based on the principal of creating an electric arc, which may be configured to emit powerful sound waves. A detailed description of a low-frequency mechanical wave generator in accordance with the invention is given further below in the disclosure.
[0060] The low frequency stimulation of the formation allows fluids whose move has slowed down to increase their movement towards the well. Fluid found in a formation is a colloidal system, as a solid phase is found in the fluid. This gives rise to a non-Newtonian fluid, which behaves as a solid or may have extremely high viscosity in certain conditions. Formation fluid affects the near-wellbore region by blocking the flow through the pores, and decreasing the permeability of the zone. This process is known as formation damage.
[0061] A tool embodying the invention (e.g., 100 ) may comprise a sensing system 240 . A sensing system comprises one or more sensors designed to capture physical parameters such as temperature, pressure, gas content and any other physical manifestation relevant to oil recovery and well management. Sensors are chosen for the task based on their industrial design to withstand the stress of the elements in the operating environment. For example, sensors must be designed to withstand the corrosive environment under which operations are conducted.
[0062] A sensing system 240 in accordance with implementations of the invention, may comprise a set of transducers for converting physical information into digital information for transmission to a remote computer.
[0063] FIG. 3 schematically depicts parts of a low-frequency mechanical wave generator and a power supplier to drive the low-frequency mechanical waves generator in accordance with an embodiment of the invention. The low-frequency mechanical wave generator of FIG. 3 comprises a radiation chamber 360 where high energy short duration pulse discharges are performed in a controlled environment inside the chamber.
[0064] The low-frequency mechanical wave generator 300 may be constructed using an outside casing 320 , two or more lids (e.g., 340 and 345 ), a first and a second electrodes 310 and 312 , respectively, a rubber interior coating 330 , insulating sleeves 315 (e.g., Teflon sleeves) and rubber flanges (e.g., 350 ). The chamber 360 within which the electrodes protrude may be filled with a fluid. In some application the fluid in chamber 360 may be more or less electrically conducting depending on the desired application.
[0065] The low frequency mechanical wave generator 300 comprises a wave deflector 332 . The wave deflector 332 may be any surface, such a parabolic-shaped surface, capable of deflecting and/or reflecting the acoustic wave. In embodiments of the invention, one or more deflectors are utilized to change the direction of part or the entire wave. For example, from an initial wave that may have a spherical shape, the reflection off of a parabolic surface may direct as much of the acoustic power in the wave perpendicularly to longitudinal axis of tool 300 as possible to maximize the amount of energy propagated inside the formation.
[0066] Casing 320 may be constructed using a corrosion-resistant metal or any other material that provides necessary strength, resistance to corrosion and other physical properties such as electric and heat conductance, density or any other property that would be relevant for any given application. It is noteworthy that the casing's material's physical properties are relevant because the shape and size of the casing may determine relevant vibration properties of the tool. For example, low-frequency mechanical waves generator may be designed to have a given desired resonance frequency.
[0067] The low-frequency mechanical waves generator 300 comprises an energy storage device that is charged by means of a power source. When the required energy levels for breaking the electric breakdown voltage of the non-conductive fluid inside the radiation chamber 360 are reached, all the energy is pulse-discharged from the energy storage device into the fluid. The latter results in an explosion inside chamber 360 , creating shock waves.
[0068] In embodiments of the invention, the interior of chamber 360 may be carved to provide one or more surfaces that reflect pressure waves in such a manner that the waves can be focused and/or propagated in a specific direction. For example, shape feature 332 may be a parabolically-shaped surface the reflection on which would transform a spherical pressure wave emanating from the inter-electrode space into a radial pressure wave that propagates perpendicularly to the axis of tool 300 .
[0069] Low-frequency mechanical waves are generated due to the excitation regime of the pulse discharges of the energy storage system. A system embodying the invention comprises a radiating chamber the length of which may be half the wave length (λ/2, where “A” symbolizes the wave length) or an integer multiple of the wavelength of the electro-acoustic vibration. The wavelength depends on the speed of pressure wave in the material chosen for the construction of the chamber. For example, using stainless steal which has an approximate conductivity of sound waves of 5000-6000 m/s, the chamber would possess a wavelength of between 2.5 m and 12.5 cm for a resonance frequency of 1 kHz to 20 kHz.
[0070] In embodiments of the invention, in order to increase transmission of the electro-acoustic power, chamber 360 may be filled with a conductive fluid (e.g., calcium chloride dissolved in water). Electrodes may also be positioned at a specific distance to break the electrical breakdown voltage of the liquid. An electric discharge regimen may be established for the low frequency radiation (e.g. for low frequency oil/gas or water reservoir stimulation 0.1 Hz to 1000 Hz is recommended, which results in wavelengths of between 1 meter and 3000 meters). Said regimen is achieved by means of charging and discharging the energy storage device (e.g., using a high voltage low impedance capacitor).
[0071] An embodiment of the invention provides a corrosion-resistant heatsink chamber capable of being used as an acoustic resonance chamber. The disposition of the chamber in relation to other wave generators attributes to the device its resonance characteristics. The corrosion-resistant heatsink chamber also prevents the system from overheating by means of a heat-sink liquid which fills the device, allowing the system to work in gas reservoirs or oil wells with high concentration of gas. When working in heavy oil wells, the capacity to efficiently transfer the heat generated by the wave radiators to the environment also improves the capacity of the system to reduce the viscosity of the crude, thus facilitating crude oil extraction.
[0072] In a device embodying the invention comprising a low-frequency electro-acoustic radiating module, the chamber may be made of corrosion-resistant rubber 330 (e.g. rubber wrapped in Teflon) the length of which may be half the wavelength (λ/2), or an integer multiple of the wavelength (λ).
[0073] An embodiment according to FIG. 3 , where the material inside the corrosion-resistant radiating chamber is a non conductive material (e.g. air). The energy needed in the energy storage device must reach the necessary levels for achieving the electric breakdown voltage in the gap between the electrodes. When such levels are reached, a pulse discharge of the energy stored in the energy storage device will be performed in the gap between the electrodes creating the shock wave of the elastic wave.
[0074] In embodiments of the invention the device comprises an adapter (not shown) that connects the low-frequency wave generator to the well's casing. In the latter embodiment low frequency is radiated to the reservoir through the natural resonance frequency of the well's casing. For instance, the natural resonance frequency of steel casing of a 2.5 km well is 1 Hz, considering a sound speed of 5000 m/s in steel from which said casing is typically made. As an added benefit, a device embodying the invention may be used in abandoned wells (within a reservoir) that may be dedicated to stimulating the reservoir with high-power low-frequencies, without concern for damage to the cement walls of those wells.
[0075] Embodiments of the invention provide a power supplier 370 for powering the mechanical waves generating device 300 . Power supplier comprises a comparator 372 and at least one power storage unit 274 . Comparator 372 is capable of receiving user input from a user interface 380 . For example, a user may use the user interface 380 to set a threshold for triggering power transmission into the electrodes 310 and 312 . Power supplier 370 comprises one or more power storage means 374 . The power storage means are any electric device, such as a capacitor, capable of storing an electric charge. The latter is preferably a high capacity electric charge storage that is once charged can be discharged as a high-voltage pulse into the electrodes, thus causing an arc discharge i.e. explosion. Power supplier 370 may be powered by a power source 390 . The power source comprises one or more electric devices for transmitting, transforming and converting electric power.
[0076] FIG. 4A schematically represents an electronic circuit for providing a high voltage electric discharge in accordance with an embodiment of the invention. An electronic circuit in accordance with the invention comprises means (e.g. 416 ) for receiving electric power from a power source. When implemented in a downhole tool (e.g., 100 above), power may be provided to the electronic circuit through a power cable. The means for receiving electric power may comprise one or more device for adapting and converting power. For example, the circuit may comprise one or more voltage and/or electric current transformers, regulators, AC/DC converters or any other electric device for involved in implementing the invention for a specific application.
[0077] An electronic circuit in accordance with the invention comprises a switching devices (e.g., 415 ) which triggers a high energy pulse discharge of the power stored in a storage device (e.g., 418 ) through the electrodes inside the radiating chamber. The switching device is enabled with means to receive power input and threshold means 410 to receive a power threshold value. The switching device (e.g., 415 ) may compare the voltage accumulated in the power storage device, such as a capacitor 418 , with a user-defined discharge threshold (e.g., received on input 410 ). The capacitor may be in a charging mode while the voltage is below the predetermined level i.e. the discharge threshold. When the discharge threshold is reached, the switch commutates by means of an automatic switching device and the discharge process begins. Once a lower threshold is reached the switch commutates again and the charging process may restart. For example, an operational amplifier set up as a comparator and a relay may be used to construct the switching device. Thus, a device embodying the invention may be set to continuously deliver acoustic waves to a well without requiring manual operation by a user.
[0078] In embodiments of the invention a switching device comprises a timer (e.g., an electronic programmable timer). In the latter case, the switching device may utilize the signals from the timer to determine the periodicity for triggering pulse discharges.
[0079] FIG. 4B and FIG. 4C are plots of the output voltage of electronic circuits as a function of time in accordance with embodiments of the invention. In the instance illustrated in FIG. 4B , the energy storage device is supplied with a fixed current power source, whereas FIG. 4C shows a plot of the voltage as a function of time when the energy storage device is supplied with a voltage power source. The voltage of the power storage (e.g., the capacitor) rises 432 while the voltage is below a predetermined threshold. Once the voltage reaches a threshold voltage, the power is discharged 434 through the electrodes in the discharge chamber.
[0080] The voltage charging ratio over time is the value of the current over the capacitance of the capacitor.
[0000]
m
=
i
C
[0081] Where i is the current and C is the capacitor's capacitance. The necessary charging time for achieving a desired voltage V 0 with a constant current source is
[0000]
t
=
V
0
C
i
[0082] Plots 420 and 430 show voltage as a function time where the discharge frequency of the energy storage device is controlled by means of a voltage power source in accordance with an embodiment of the invention. In the latter configuration, the voltage charging time depends on the constant RC, where C is the capacitor's capacitance and R is the resistance of the cable from the generator to the capacitor. And the necessary time to charge the capacitor to a certain voltage using a constant voltage source is given by
[0000]
t
=
-
RC
·
ln
(
1
-
x
100
)
;
0
≤
x
≤
100
[0083] Where x represents the relation (percentage) between the charging voltage and discharge threshold voltage.
[0084] An electronic circuit in accordance with embodiments of the invention may be configure to provide one or more profiles and timings for the successive charging phases (e.g., 422 and 432 ) and discharges (e.g., 424 and 434 ), the succession of which determine an inter-pulse discharge time interval. Therefore, by adjusting the threshold and the capacity of capacitor, the power and/or the frequency of the discharges may be controlled.
[0085] FIG. 5 is a block diagram representing components for stimulating wells in accordance with an embodiment of the invention. The most important factor in recovering a natural resource, such as oil, gas or water, is the geologic formation 510 in which the natural resource resides. The content in minerals, texture compaction are among the physical factors that characterize the geologic formation. When stimulating a well, one has to also take into account the characteristics of the resource itself. For example, oil may greatly differ in its chemical composition and gas content from one well to another within the same reservoir, even as the geologic formation remains similar. The latter is taken into account when selecting the methods by which a well should be stimulated.
[0086] Embodiments of the invention provide a tool (e.g., 100 ) that may comprise one or more components for applying several different stimulation regimens using mechanical waves, applying one of more treatments such as high-pressure water blasting, and collecting information from the well in order to assess the result of the stimulation and re-adjust the treatment parameters.
[0087] As described above, the system comprises a tool of a downhole type (e.g., 100 ). The tool comprises a plurality of devices comprising one or more low-frequency acoustic wave generators (e.g., 530 ), one or more power generators 540 , and one or more sensing devices 538 . In addition, a system embodying the invention comprises a data processing and control system 550 . The data processing and control system is comprised of a one or more computers. A computer (e.g., of the personal computer type or server) may be any computing device equipped with a processor, memory, data storage system, capable of executing software instructions. The computer for implementing the invention may be enabled with electronic interfaces for communication with other computers and other devices such as analog and digital networking switches, telephones lines, wireless communication, and any other device capable of receiving, processing and/or transmitting data.
[0088] The data processing and control system 550 provides a user interface that allows a user to interact with data processing and control. During operation, the acoustic treatment of a well results in changes that affect the geologic formation 510 . The latter changes may be reflected in one or more physical parameters such as temperature, pressure, acidity of the water, flow rate of natural resource, gas content or any other parameter that may be measured with a sensor placed in the sensing system. Other types of information are not directly reflected in the measured parameters, but through data processing a user may be enabled with the expertise to interpret the result of the data processing and make decision for further treatments accordingly. For example, after collecting the data over a period of time, the manager may learn from the result of the processed data that a given trend is taking place, upon which, the user may make a decision to increase or decrease the power and/or the frequency of the discharge pulses.
[0089] The data processing and control system may provide the energy necessary to supply the energy supplier 540 . A power cable (e.g., 570 ) is typically lowered into the well along with the downhole tool. The control system may deliver the power, for example, in a raw form such as direct-current power or as modulated electrical power that directly controls the downhole device. In the case where the power is delivered to the power supplier, the control system may simply communicate commands to the power supplier. Communication is established through communication means 586 which may be wires, fiber optic cables or other means selected to implement the invention. The commands from the control system to the power supplier may include instructions that determine the driving power the power supplier delivers to any of the devices such as the acoustic wave generators or the sensing system. For example, the data processing and control system allows a manager to preset the periodicity at which a low-frequency acoustic wave generator should operate.
[0090] The power supplier 540 comprises a plurality of electronic circuits each of which may be designed to drive an individual component. For example, power supplier 540 may generate high-voltage pulses that drive (e.g., 572 ) the low-frequency acoustic wave generators; power supplier 540 may generate the power necessary to drive other devices (e.g., heating system) for carrying out one or more treatments to stimulate the well.
[0091] The data processing and control system may connect with the sensing system in order to collect data through communication means 580 . The sensing system enables embodiments of the invention to collect data in real-time. Since the downhole tool may be permanently installed in the wells (as described above), using embodiments of the invention allows for treating a well while simultaneously collecting data and following the progress of the treatment.
[0092] FIG. 6 is a flowchart diagram representing steps involved in applying a mechanical wave discharge delivered to a geological formation in accordance with one embodiment of the invention. At step 610 , a system embodying the invention may receive a set threshold used to trigger the pulse discharge into the electrodes. A user may use the user interface provided by the invention to input a threshold and/or alternatively a default threshold may be built in the electronic circuits that drive the wave-generating device. The threshold may be set to determine the voltage at which the discharge is triggered, which may also determine the periodicity at which the discharge is triggered.
[0093] At step 620 , a system implementing the invention accumulates power in the electric charge-storing device (e.g., one or more high capacity capacitors). At step 620 , the system connects electric power from a power source to the electric charge-storing device. At step 630 , a system implementing the invention constantly compares the level of charge with the set threshold. The system may determine, based on the reached threshold and user input for discharge, whether to deliver the power to the electrodes. If a determination is made to deliver the electric power to the electrodes, at step 640 , the electronic circuits of the power supplier deliver a high-power pulse discharge to the electrodes, thus causing an explosion triggering the mechanical waves that spread through the geological formation.
[0094] FIG. 7 is a schematic representation of a production oil field having a plurality of wells, where one or more wells are equipped with a system embodying the invention. A typical oil field (e.g., 710 ) hosts a plurality of wells (e.g., W 1 , W 2 , W 3 , W 4 , W 5 , W 6 and W 7 ). A device embodying the invention may be installed in one or more wells (e.g., 720 and 730 ) to deliver low-frequency stimulation to the reservoir. The oil field map 710 shows isopach lines (e.g., 715 ) that represent regions of equal thickness of a geological layer, which may be the layer that contains the natural resource of interest or any other layer above or below the layer of interest. A reservoir manager may utilize the topographical data to select one or more wells for installing a low-frequency well stimulation device embodying the invention. In the example schematically depicted in FIG. 7 , wells 720 and 730 are equipped with a device for stimulation a well using low-frequency acoustic waves. As stated above, low-frequency waves tend to travel over long distances. The range of propagation 725 from stimulation device in well 720 may overlap with the range of propagation 735 from stimulation device in a different well (e.g., 730 ).
[0095] In addition to the selection of which particular well (or wells) may be used to stimulate production in a reservoir, the selection of the regime of low-frequency acoustic waves application may be important. For example, even though low-frequency acoustic wave application may increase productivity of a given well, intermittently applying the mechanical waves may prove more beneficial for production than a continuous application. The invention allows for modifying the periodicity by which the mechanical waves are applied in order to find a range time patterns of stimulation that optimize production.
[0096] Thus a method, device and system for generating low-frequency mechanical waves that are propagated within and in the vicinity of a production well in a natural resource-producing geological formation in order to enhance the flow of the natural resource from the geological formation toward the well for collection. | The invention provides an apparatus and method for stimulating a borehole of a well. The invention provides an apparatus that generates low-frequency seismic type elastic waves that propagate to the geologic formation and in order to enhance the movement of fluids in the geologic formation toward a well. The apparatus may operate automatically driven by a power source that may be located on the ground surface. The regime of operation may be determined by user input. Operation of the apparatus may carried out while production of a natural resource is ongoing. | 4 |
[0001] This application is a continuation in part of U.S. patent application Ser. No. 11/001,935, entitled Bilevel Bicycle Storage System, filed on Dec. 2, 2004, and which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains to storage systems for bicycles. More specifically, the present invention pertains to a multiple-level storing system for bicycles.
[0004] 2. Description of the Prior Art
[0005] Bicycles are becoming more prevalent in many places. However, it is often difficult to find a safe or appropriate place to park the bike once you have arrived at your destination. Many different bike racks and similar devices have been developed to solve these issues, but these solutions are incomplete at best.
[0006] For example, arrays of a large number of exposed racks or rails have been implemented for many years. However, the bikes parked in these arrays are exposed to the elements and can contact each other, causing damage to the bikes. Other systems provide an individual storage box for each bike. However, these boxes are often leased to a particular user, and no one else can access them. Further, there are often not nearly enough boxes available usually because they take up too much space. Existing designs are bulky and are tall enough to accommodate only one bike. There is no provision for safely stacking bicycles in these enclosures.
[0007] Thus, it is desired that a multiple-level bicycle parking system be created, to provide more efficient use of space for parking bicycles. Further, a mechanism to raise and lower the bicycles to the multiple upper storage levels is desired, such a system requiring zero or minimal effort by the user. Further, it is desired that such bicycle parking spaces be open to all consumers, who will pay for the parking spaces based upon the amount of time they park there. Such a system should accept cash or noncash payments.
SUMMARY OF THE INVENTION
[0008] The device is a modular, three-level parking system for bicycles. The parking spaces include mechanisms that enable the user to easily insert and remove bicycles into the upper parking levels. To accommodate the second level of bicycles, the device includes a movable upper receiver which is pivotally attached to a support frame. The pivoting upper guide bar enables simple loading or unloading of bicycles. It is drawn toward the customer from its horizontal, upper storing position and then angled downward so that the proximal end of the upper receiver is lowered toward the floor. The bicycle can then be easily secured onto or removed from the upper receiver. When it is extended and angled downward, the upper receiver is at least partially supported by a pneumatic spring or other comparable mechanism. A less complex lower receiver accommodates a bike in the lower parking space. The lower receiver is less complex because no lifting or lowering mechanism is required. The upper receiver is shifted or slid over the support frame so that the upper receiver protrudes into the customer's area of movement only during the loading and unloading procedure.
[0009] A third bicycle storage level is arranged above the second level. The third level uses a cable-lift system that attaches to a bicycle and pulls it up above the second level. The cable-lift mechanism is incorporated into a support beam that is itself suspended from a track. The track permits the slid into a position directly above the first and second levels to maximize the efficient use of space. This arrangement enables three layers of bicycles to be stored one on top of another in a space-saving manner. A mechanism similar to the third level can be used to create fourth and subsequent levels depending upon the needs to the users and the space parameters within a building or structure.
[0010] The stored bicycles are protected in three different ways: firstly against theft, secondly against accidental or intentional damages, and thirdly against weather conditions. A separate structure or a storage system within an existing building is usually provided for the storage system. The storage system—similar to automobile parking garages under surveillance—is run by a minimal number of personnel. Thus a parking fee is charged for storing a bicycle in such a storing system. The three above-mentioned types of protection are attained by the structure that houses the storing system and the personnel. Of course, buildings must be present in which such a storing system can be constructed, or open areas have to be available where a building for housing such a storing system can be constructed.
[0011] The enclosure may be locked to provide reliable protection against theft. The system uses standard, automatic locks to facilitate operating the system with a minimum number of personnel. Suitable lock-pay systems are already known in regard to lockers. The use of a door with such a lock enables the use of readily-available standard components, which can be significantly more economical than using special lock or bolt components. Locking doors eliminate the need to lock the bicycle to the upper receiver.
[0012] It is not necessary to construct a building or dedicated structure to house the storing system, because the storing system provides box-type enclosures for each storing space. The disclosed storing system can thus be erected at any location with sufficient free space. Thus the number of locations in which such a storing system could be erected is increased when compared to systems or locations requiring a separate, dedicated building to house a storing system.
[0013] Because a separate building to house the storing system is not necessary, the time required from planning to set-up of the storing system is significantly shorter. This system can be set up very quickly. For the previously-mentioned reasons and others, comprehensive protection of a bicycle is provided. The design is economically favorable and operation of the system provides a competitive advantage over previous systems.
[0014] In operating the second level, in one embodiment the vertical raising and lowering movement of the upper receiver is carried out on a pivot point. The pivot point is the tension pulley axle that the front guide roller is mounted on. In the preferred embodiment, the pivot point operates as close to the front opening of the enclosure as possible in order to ensure that the upper receiver extends outside of the enclosure and does not collide with the lower enclosure and the lower storing space. In case the storing system is open and exposed, without enclosures, the pivot point of the upper receiver can, in contrast, be well inside and away from the front of the lower receiver, because the highest point of a bicycle stored underneath is the saddle. Thus the pivot point of the upper receiver can, for example, be directly above the saddle of the lower bicycle. In this example, the pivoted upper receiver, which is tilted downwards in its loading and unloading position, will not interfere with the rear wheel or rack of the bicycle stored below. Compared to this alternative construction, the pivot point of the enclosed upper receiver is, according to the invention, shifted to the front edge of the enclosure so that the lowered upper receiver clears the closed door of the lower enclosure.
[0015] The movement of the pivot point and the upper receiver is provided for by an upper mounting frame, on which the upper receiver is moved. The movable upper receiver, on which the bicycle is secured and which has its pivoting point on the mounting frame, can be moved to the front edge of the enclosure adjacent to the mounting frame and lowered for loading and unloading.
[0016] Alternatively, the upper receiver can be fixed to the mounting frame at the pivot bearing. Here, the mounting frame is horizontally extendible. In order to move the pivot point of the upper receiver, the upper receiver is moved together with the mounting frame. This enables the upper receiver to be moved toward the front of the enclosure together with the mounting frame until the pivot point is near the front edge of the enclosure.
[0017] A bicycle can be secured into the upper receiver by a wheel bail, or similar mechanism, so that it cannot be moved. The wheel bail is movable so that it reliably rests against one of the wheels of the bicycle due to its own elasticity or its movable, spring-loaded mechanism. In this manner the wheel bail controls the bicycle even when the bicycle is moved on the upper receiver. A wheel lock is provided on the upper receiver in order to limit movement. The wheel lock holds the other wheel of the bicycle in place.
[0018] The wheel bail's elasticity and spring mechanism ensures that bicycles of various sizes with various dimensions between axles or different wheel sizes can be secured reliably. The elasticity of the wheel bail provides tolerance compensation and ensures that the wheel bail always rests against the wheel of the secured bicycle in the correct manner
[0019] The wheel bail is provided at the distal end of the upper receiver and away from the customer so that it is not in the way when loading or unloading the bicycle and so that the bicycle can be mounted without demounting the system. The wheel lock can be constructed as a comparably small protrusion from the upper receiver. The bicycle to be secured can easily run over or be lifted over the wheel lock when loading or unloading the bicycle.
[0020] This is especially advantageous when the upper receiver is supported or counterbalanced by a spring. This spring support ensures that the spring is taut when the lowered upper receiver is in the loading and unloading position. Release of tension from the spring assists the customer on lifting the upper receiver to the horizontal storing position. In this manner the customer does not have to lift the complete weight of the bicycle and upper receiver when the upper receiver and the bicycle are lifted from the downwards-tilting loading and unloading position and to the horizontal storing position.
[0021] Support for the upper receiver can also be provided by a motor, especially an electric motor. The electric motor can operate the upper receiver by means of a gear mechanism, cable or chain so that the upper receiver is lifted into or lowered from its horizontal position. The use of a motor can ensure that the support almost or completely compensates for the weight of the upper receiver, with or without a bicycle, so that the customer does not need to exert himself to lift or lower the bicycle and upper receiver.
[0022] The space required for storage spaces with separate enclosures is larger than the space required by the optimum “packing density” of unprotected and unseparated bicycles stored next to each other. According to the invention, it is thus provided that the storing system with separate enclosures for each bicycle is to be combined with some open storage spaces without enclosures and to which the upper and lower receivers are arranged closer to each other than is the case where frames are employed. Thus, a larger number of bicycles can be stored in the same storing system, especially when the closely situated receivers are arranged in staggered heights to minimize or eliminate collisions between those bicycles. These storage systems without enclosures can, for example, be operated using appropriate automatic locking devices to secure each storing space until payment is received. Alternatively, payment may be completely inapplicable when municipal facilities offer free parking spaces in order to bring order to bicycle storage in designated areas.
[0023] One object of the invention is to provide secure, reliable protection for bicycles in a storing system run as economically as possible.
[0024] Another object of the invention is to teach a multiple-level storage system for bicycles.
[0025] Another object of the invention is to teach a multiple-level storage system for bicycles that includes a mechanism for loading and unloading a bicycle.
[0026] Another object of the invention is to teach a multiple-level storage system for bicycles that is modular.
[0027] Another object of the invention is to teach a multiple-level storage system for bicycles that provides protection against the weather.
[0028] Another object of the invention is to teach a multiple-level storage system for bicycles that provides protection against theft.
[0029] Another object of the invention is to teach a multiple-level storage system for bicycles that provides protection against accidental or intentional damages.
[0030] Another object of the invention is to teach a multiple-level storage system for bicycles where a bicycle storing space may be rented on a regular or irregular basis.
[0031] Another object of the invention is to teach a multiple-level storage system for bicycles that securely locks a bicycle until the owner claims it.
[0032] Another object of the invention is to teach a multiple-level storage system for bicycles that securely locks a bicycle until rent payment is received for the storage space.
[0033] Another object of the invention is to teach a multiple-level storage system for bicycles that is automated.
[0034] Another object of the invention is to teach a multiple-level storage system for bicycles that monitors its lock, payment and security systems.
[0035] Another object of the invention is to teach a multiple-level storage system for bicycles that requires a minimum number of personnel to operate.
[0036] Finally, it is an object of the present invention to accomplish the foregoing objectives in a simple and cost effective manner.
[0000] In the following section the invention is described in an exemplary manner according to extremely simplified, schematic drawings which are not drawn to scale.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] shows a side view of a Bilevel Bicycle Storage System in the loading and unloading position, according to the invention;
[0038] shows a top view of the upper receiver mechanism of the Bilevel Bicycle Storage System, according to the invention;
[0039] shows a side view of the wheel bail of the Bilevel Bicycle Storage System, according to the invention;
[0040] FIG. 4 shows a distal end view of the upper receiver and mounting frame for the Bilevel Bicycle Storage System, according to the present invention;
[0041] FIG. 5 shows a detailed distal end view of the upper receiver, mounting frame and pivot mechanism for the Bilevel Bicycle Storage System, according to the present invention;
[0042] show various examples of the Bilevel Bicycle Storage System in use, according to the present invention;
[0043] shows a detailed view of a clamp arm for the Bilevel Bicycle Storage System, according to the present invention;
[0044] hows a detailed view of the proximal end of the upper receiver for the Bilevel Bicycle Storage System, according to the present invention; and
[0045] a detailed view of an alternative embodiment of the proximal end of the upper receiver for the Bilevel Bicycle Storage System, according to the present invention.
[0046] FIG. 13 shows a side view of a three-level bicycle parking system, according to the present invention.
[0047] FIG. 14 shows a front view of the three-level bicycle parking system, according to the present invention.
[0048] FIG. 15 is an elevated perspective view of the lift mechanism for the upper level of the three-level bicycle parking system, according to the present invention.
[0049] FIG. 16 is a side view of the lift mechanism for the upper level of the three-level bicycle parking system, according to the present invention.
[0050] FIG. 17 is a side view of an alternative embodiment of the second level of the three-level bicycle parking system, according to the present invention.
[0051] FIG. 18 is a front end view of the mounting frame for the second level of the three-level bicycle parking system, according to the present invention.
[0052] FIG. 19 is a side view of the mounting frame for the second level of the three-level bicycle parking system, according to the present invention.
[0053] FIG. 20 is a view through the assembled mounting frame and upper receiver for the second level of the three-level bicycle parking system, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] FIG. 1 shows a side view of the Bilevel Bicycle Storage System, herein referred to as the Doubleparker. The Doubleparker has enough space to store two bicycles, one above the other. A lower receiver 10 is fixed to the floor within an enclosure 12 enclosure 12 . The enclosure 12 has an upper door 14 and a lower door 16 attached with hinges to the front of the enclosure 12 , see FIG. 8 . The enclosure 12 has generally level upper floor panel 18 (see FIGS. 9 and 10 ) which separates the storing spaces from each other and also prevents water and soil from the upper storing space from dripping down onto the bicycle stored below. In another embodiment, the pair of storing spaces do not have a joint enclosure 12 , but each storing space is contained within its own enclosure, which can be stacked and secured on top of each other.
[0055] An upper receiver 20 , which is shown it loading and unloading position in FIG. 1 , is provided for in the upper level of the Doubleparker. For loading and unloading a bicycle the upper receiver 20 is pulled out of the enclosure 12 and tilted downward so that the proximal end 22 of the upper receiver 20 is directed to the floor. A foot 24 is arranged below the proximal end to prevent damage to the upper receiver 20 or the floor when the upper receiver 20 is lowered.
[0056] In FIG. 1 a bicycle is shown secured into the upper receiver 20 . In this position the upper receiver 20 is easily lifted with a handle 26 . The upper receiver 20 is raised into a generally horizontal position to insert the upper receiver 20 into the enclosure 12 . In this manner the enclosure 12 can be secured and two bicycles stored, loaded and unloaded on top of each other in the enclosure 12 .
[0057] FIG. 2 shows a top view of the upper receiver 20 . Components within the upper receiver. 20 are also visible through the upper receiver. A mounting frame 28 is provided to connect to the upper receiver 20 , whereby the mounting frame 28 is fixed to a vertical support 30 which is attached to the floor. In another embodiment, the upper floor 18 between the two storing spaces can serve as a support for the mounting frame 28 instead of the vertical support 30 . In this case the upper floor 18 would be fixed to the enclosure 12 .
[0058] A tension pulley axle 32 is positioned horizontally on the proximal end of the mounting frame 28 , upon which a front guide roller 34 and a tension pulley 36 are mounted. The proximal end of the mounting frame 28 is the end closest to the front of the enclosure 12 and the doors 14 , 16 . A rear guide roller 38 is mounted on a rear guide roller axle 40 which in turn is horizontally attached near the midpoint of the mounting frame 28 . The upper receiver 20 travels forward and back on the rear guide roller 40 and front guide roller 34 . The guide rollers 34 , 40 engage a pair of guide rails 42 inside the top and bottom walls of the upper receiver 20 . In FIG. 2 one guide rail 42 is represented by the dashed line parallel to the longitudinal axis of the upper receiver 20 .
[0059] The tension pulley 36 is mounted on the tension pulley axle 32 next to the front guide roller 34 . A retraction cable 44 is wound around the tension pulley 36 and the free end of the retraction cable 44 is attached inside the upper receiver 20 at the proximal end 22 . A tension pulley spring (not shown) is attached to the tension pulley 36 and the tension pulley axle 32 and acts to wind the retraction cable 44 onto the tension pulley 36 . The tension pulley spring may be integrated into the tension pulley 36 so that they are a single unit, or they may be separate pieces.
[0060] When the upper receiver 20 is pulled out of the enclosure 12 , then the retraction cable 44 is pulled taut against the tension pulley spring. Thus, sufficient tension is available to assist the user in inserting the upper receiver 20 into the enclosure 12 .
[0061] In other embodiments, the tension pulley 36 and spring are mounted to the enclosure 12 or other suitable support inside the enclosure 12 . Alternatively, the tension pulley 36 and spring may be mounted to the upper receiver 20 with the pulley 36 located near the midpoint of the cable 44 . The two free ends of the retraction cable 44 are fixed to the proximal end 22 of the upper receiver 20 and an immovable position that is beyond the distal end of the upper receiver 20 when the upper receiver is fully retracted.
[0062] A pivot link 46 , shown as a flat bar, is arranged between the mounting frame 28 and the upper receiver 20 . One end of the pivot link 46 is connected to the mounting frame 28 by a pivot shaft 48 . The guide roller axle 40 is attached to the other end of the pivot link 46 . The rear guide roller 38 is mounted to the guide roller axle 40 . The upper receiver 20 moves parallel to its longitudinal axis and along the pivot link 46 by the rear guide roller 38 . The pivot link 46 serves to guide the upper receiver 20 longitudinally and secures it against excessive lateral motion.
[0063] The pivot link 46 also aids in lifting the upper receiver 20 . A tag line 50 runs from a tag anchor 52 on the mounting frame 28 to a levelling spring 54 attached to the enclosure 12 or another fixed location near the distal end of the mounting frame 28 . In between the levelling spring 54 and the tag anchor 52 , the tag line 50 is routed around a deflection pulley 56 , mounted to the pivot link 46 opposite the pivot shaft 48 , and an idler pulley 58 mounted to the mounting frame 28 . When the upper receiver 20 is pulled out of the enclosure 12 and the proximal end 22 is lowered, the pivot link 46 pivots clockwise around the pivot shaft 48 . The displacement of the pivot link 46 pulls the tag line 50 tight against the levelling spring 54 . In this manner, a restoring force is created, which helps lift the upper receiver 20 to horizontal, whether unloaded or loaded with a bicycle.
[0064] The amount of support to the upper receiver 20 is easily adjusted by varying the strength or preload of the tension pulley spring and the levelling spring 54 . This can be accomplished by the manufacturer or user. Multiple springs may be used in either or both positions if needed to provide an appropriate tension.
[0065] Bicycles are usually loaded and secured into the receivers 2 , 4 in the travelling direction so that the front wheels of both bicycles in FIG. 1 are both arranged to the left, farthest into the enclosure 12 . A wheel bail 60 is pivotally attached to the upper receiver 20 to hold the front wheel of the bicycle straight. The wheel bail 60 is biased by a bail spring 62 as shown in FIGS. 1 and 3 and thus rests against the front wheel of the bicycle secured in the upper receiver 20 . The spring-mounted and flexible nature of the wheel bail 60 enables it to adjust to and partially encompass the bicycle wheel. In FIG. 2 , the wheel is shown in cross-section. The wheel bail 60 can be constructed out of a plate stock or out of a wire material, whereby it can exhibit material-based elasticity. The wheel bail 60 can thus be pivoted about its root against in order to adapt to various diameters of bicycle wheels or to adapt to various overall bicycle lengths.
[0066] FIG. 3 shows the interaction of the wheel bail 60 with a bicycle wheel. FIG. 3 shows the wheel bail 60 in two different positions. It can take on these two positions and an infinite number of intermediate positions in adjusting itself to the dimensions of various bicycles. The bicycle can be pushed as far as a bail limiter (not shown) when storing a bicycle in the upper receiver 20 , as shown in the position to the right of the wheel bail 60 in FIG. 3 . The bicycle is automatically returned to the proximal end 22 of the upper receiver 20 due to the spring tension on the wheel bail 60 until the rear wheel of the bicycle rests against the wheel lock 64 , explained below. This equilibrium position of the wheel bail 60 is represented by the position to the left in FIG. 3 .
[0067] The upper receiver 20 has a channel built into its upper surface. The channel has a u-shaped or v-shaped cross-section to guide the wheels of the bicycle along the upper receiver 20 . Two side flanks 66 are attached near the proximal end 5 of the upper receiver 20 , see FIG. 1 . These flanks 66 can be made from bar stock to form an open support framework or out of metal as complete sheets to form a wall. The flanks 66 enable the extremely reliable positioning and retention of the rear wheel in the upper receiver 20 . The wheel bail 60 ensures that the rear wheel is located in the area of the flanks 66 . As described earlier, the wheel bail 60 presses the bicycle toward the proximal end 5 of the upper receiver 20 and the flanks 66 .
[0068] In the area of the proximal end 5 of the upper receiver 20 a wheel lock 64 is shown. The wheel lock 64 captures the bicycle wheel at the proximal end 22 of the upper receiver 20 . As shown the wheel lock 64 is in the form of a cross-beam, which stretches across the channel atop the upper receiver 20 and against the spokes of the bicycle wheel. The low level of the wheel lock 64 above the upper receiver 20 aids in securing the bicycle in the upper receiver 20 , and also ensures that the bicycle is close to the proximal end 5 of the upper receiver 20
[0069] An additional security feature is effected by slots or apertures through the flanks 66 , through which a U-lock or a chain lock can be threaded. This provides protection against theft and safely fixes the bicycle in the upper receiver 20 . The necessary slots or apertures are readily evident, especially when flanks 66 are made of curved round bar stock.
[0070] FIG. 6 shows a cross-section of the upper receiver 20 and pivoting mechanism lying flat in the storing position. The rear guide roller 38 is mounted on the guide roller axle 40 , which extends from the pivot link 46 to the inside of the upper receiver 20 . The groove-shaped U or V section of the upper receiver 20 is easily seen. The pivot link 46 is rotatably attached to the mounting frame 28 by the pivot shaft 48 . The deflection pulley 56 can be seen behind the pivot shaft 48 in FIG. 6 . The deflection pulley 56 is located behind the pivot shaft 48 in FIG. 6 .
[0071] In FIG. 4 it is shown that the box profile of the upper receiver 20 can be open to the side opposite from the mounting frame 28 . FIG. 4 shows that the bail spring 62 has a direct effect on the wheel bail 60 . In one embodiment the bail spring 62 is offset from the root or pivot point of the wheel bail 60 , closer to the proximal end 5 of the upper receiver 20 , so that the wheel bail 60 is forced into a position resting against the bicycle. In another embodiment, the bail spring 62 is generally concentric with the root or pivot point of the wheel bail 60 .
[0072] The lower part of the upper receiver 20 , which has a generally box-shaped profile, has upper and lower guide rails 42 which project inwards as presented in FIG. 6 . These guide rails 42 form a track for the rear guide roller 38 and the front guide roller 34 , which each have a circumferential groove for receiving the guide rails 42 to guide the upper receiver parallel to the mounting frame 28 . When the upper receiver 20 is moved between its loading and unloading position and its storing position, it travels on the guide rollers 34 , 38 and the guide rails 42 . If the upper receiver 20 has a generally closed profile, elongated slots in the side of the upper receiver 20 will provide for the movement between the upper receiver 20 and the guide rollers 34 , 38 . The tension pulley axle 32 and the guide roller axle 40 extend through these elongated slots.
[0073] In FIG. 6 , the pivot link 46 is shown in a horizontal position, parallel to the upper receiver 20 . In this position, the pivot link 46 lies against the lower, horizontal section of a support bracket 68 , so that the weight of the upper receiver 20 , on which a bicycle could possibly be loaded, is supported not only by the tension pulley axle 32 , the pivot shaft 48 and guide roller axles 34 , 38 , but also extensively by the support bracket 68 on the mounting frame 28 .
[0074] FIG. 7 shows a line system of Doubleparkers, whereby the enclosures 12 have doors both above 14 and below 16 , which are lockable using locks 72 . This bicycle storing system can be operated by means of a terminal 74 set up among the enclosures 12 .
[0075] The shown storing system or similar storing systems can be run fully automatically with few personnel. In such a system, the period of usage of each individual storing space is automatically registered, i.e. the elapsed time since the storing space was locked. The terminal or main controls attached to the terminal have a storage memory, which stores the time when every single storing space was locked, or if any storing spaces are not locked.
[0076] When a user wants to open a specific locked storing space, he must register at the terminal 74 first, identify the storing space and prove his right of access to the storing space. These three steps can be carried out by numerous actions, or just one single transaction, i.e. by using a key or access card or something similar, which the user can have checked at an appropriate reader or sensor at the terminal 74 . The fee for use is dependent on the period of use for the identified storing space and can be displayed to the user at the terminal.
[0077] Payment of a fee for use can be made directly at the terminal or at one of the connected pay stations by using coins, bills or tokens or by cashless payments using debit or credit cards, or by providing account data and an ID-code. A data transfer from the terminal to a bank or other organization can be carried out depending on the required method of payment. This may be accomplished through a wired or wireless system. After payment is accepted, the appropriate storing space is automatically unlocked so that the user can open the door or the locking device of this storing space and remove his bicycle from the storing space.
[0078] A cabled or wireless data transfer from the terminal 74 to the main controls is provided via a telephone line or wireless communication system. The main controls can be a great distance away from a storing system—even hundreds of miles away. In this manner it is possible to run numerous storing systems from a collective main control system with few personnel. Technical information can be evaluated in the main control system, i.e. all errors or defects registered by sensors, so that service personnel can be sent to the storing system to repair and eliminate the defect or error. Sensory-detected information can also be stored and evaluated for business management reasons, i.e. it can be determined if any storing space is empty or if a bicycle is secured in the storing system, so that the utilization of the storing system can be evaluated for business management reasons. Invoices can also be drawn up in the main control system and sent to users, when, for example, long-term customers who do not need to pay directly at the terminal 74 , but are billed at regular intervals, i.e. monthly.
[0079] FIG. 8 shows a closer view of a single Doubleparker, where both doors 14 , 16 are closed. FIG. 9 shows a Doubleparker during the loading or unloading of the upper storing space. The wheel bail 60 and further details of the upper receiver 20 are not presented in this figure. A lean-against bracket 88 and clamps 78 are shown as an alternative to the wheel bail 60 and flanks 66 . The lean-against bracket 88 is made of round pipe or tubing. In the preferred embodiment, the bracket 88 includes a protective cover made of a soft material, like PVC, in order to prevent damage to the bicycle frame. The bracket 88 aids in the security of the bicycle during loading, unloading and in the parking position. The leaning bracket 88 extends the entire length of the upper receiver 20 so that standard commercially-purchased chains or U-locks can be used to attach the bicycle to the bracket 88 in a number of user-defined positions. The lean-against bracket 88 is designed in such a way that the bicycle can be pushed into the upper or lower receiver until it is stable.
[0080] FIG. 10 shows a Doubleparker with two open doors, whereby both bicycles are shown in their storing position. The floor 18 is visible immediately below the upper receiver 20 . The enclosure 12 may be clad or covered with a wide variety of suitable materials based upon decorative or functional requirements. In another embodiment, the lower storing space can be constructed so that the door 16 is curved or bent inward above its center, and with a matching profile on the enclosure 12 , so that the top of the door 16 goes beneath the interior of the upper storing space. In this embodiment the pivot point near the proximal end of the mounting frame 28 is at the front edge of the enclosure 12 . Any inward curve or bend in the front of the lower storing space would thus enable the upper receiver 20 to slant downward just above the bend, without interfering with the door 16 of the lower storing space.
[0081] In another embodiment, the upper receiver 20 is slidingly mounted to a guide bar 76 . The guide bar 76 is slidingly mounted in turn to the mounting frame 28 . The upper receiver 20 can be moved along the guide bar 76 so that the upper receiver 20 and the bicycle can be telescoped into the guide bar 76 and the guide bar 76 telescoped into the mounting frame 28 . A much shorter overall length of the mounting frame 28 and the upper receiver 20 may be employed by telescoping them together. Minimal space is required for storing a bicycle in such a system.
[0082] The telescoping feature of the upper receiver 20 within the guide bar 76 allows for the upper receiver 20 to lower earlier as it is pulled out of the enclosure 12 . It is not necessary to pull out the entire upper receiver 20 from the enclosure 12 and then lower the upper receiver 20 to the loading and unloading position only when the pivot point is near the leading edge of the enclosure. The telescoping feature of the guide bar 76 and the upper receiver 20 provides for easier handling of the upper receiver 20 and an early lowering of the upper receiver 20 so that easier handling is enabled for the customer when loading and unloading.
[0083] FIGS. 11 and 12 show a two-part bicycle retention clamp 78 that attaches to the receivers 10 , 20 . The clamp 78 uses the weight of the bicycle to secure the bicycle automatically, so that it cannot roll backward. The clamp 78 can be made of round stock, FIG. 13 , or plate and sheet stock, FIGS. 11 and 12 . Clamp 78 movement occurs as the bicycle enters the elongated hole 80 in the receiver 10 , 20 due to its own weight. A pair of clamp arms 82 pivot about a pair of hinge points 84 outside the receiver 10 , 20 on a pair of clamp mounts 94 . A pair of actuator arms 70 overlap inside the elongated hole 80 so that the bicycle wheel acts upon the clamp arms 82 uniformly. A pair of clamp pads 86 bear against the bicycle wheel in response to the weight of the bicycle upon the actuator arms 70 . The clamp 78 opens to release the wheel when the bicycle wheel is lifted out of the elongated hole 80 in the receiver 10 , 20 . Retention roller 90 may be employed to prevent shifting.
[0084] The clamp 78 can be used in all rail-like facilities in which the bicycle is pushed on or into the system. On the lower level, where a determination of the bicycle in the receiver is perhaps not necessary due to handling or security considerations, this locking device may still be provided for additional safety to hold the bicycles reliably. The clamp 78 may be incorporated into a security system to protect against theft. The clamp 78 can be devised as a mechanical self-locking device, so that the clamp automatically goes from open to locked when a bicycle is pushed into the storing system. A simple mechanical lock may be used with the lock apertures 92 on each clamp arm 82 .
[0085] The clamp 78 can be controlled using appropriate sensors as well. As soon as the bicycle is in the “parking position” the bicycle is automatically locked. Additional sensors monitor the parking time and user identification by means of software, hardware and clock timers. The clamp 78 can be opened again by means of payment or other arrangement.
[0086] FIG. 13 shows a side view of a three-level bicycle parking system, here in referred to as the TripleParker 100 . Three bikes A,B,C are shown mounted on the TripleParker system 100 . The bike C at the lowest level is easily rolled onto the lower rack 112 via a process that is described above. Bicycle B, in the middle level, is supported on an extendable rack 114 that also deflects downward for easy loading and unloading of bike B. Bicycle A is suspended above bikes B and C by a pair of cables 115 that are attached to a shuttle 116 .
[0087] The shuttle 116 travels along a track mechanism 118 that is attached to the ceiling or another support. Shuttle 116 ′ is the same shuttle as shuttle 116 , but is shown at the opposite end of track 118 and ready to load or unload bicycle A′. Bicycle A′ is also the same as bicycle A.
[0088] A control box 120 , 120 ′ is shown suspended from shuttle 116 , 116 ′ to control the position of the shuttle 116 , 116 ′ along track 118 . The control box 120 , 120 ′ also controls the cables 115 , 115 ′ that lift and lower the bicycle A, A′. The control system may be set up to permit the cables 115 to be lowered only when the shuttle 116 is in the position shown by shuttle 116 ′.
[0089] FIG. 14 shows a front view of the TripleParker 100 . Notice that the bicycles C and B, in the first level 112 and the second level 114 , may be staggered in elevation to eliminate the possibility of handlebars becoming entangled. The mounting positions 112 , 114 are assembled to incorporate this elevation stagger through minor manufacturing variances.
[0090] FIG. 15 is an elevated perspective view of the lift mechanism for the upper level of the TripleParker system 100 . The track 118 is mounted within a housing 122 to shield the track mechanism 118 and to provide a simplified means to mount the track overhead. In the embodiment shown, the control box 120 is replaced with a control handle 124 and loop 126 . The control handle 124 is manipulated by pulling or twisting to direct the shuttle 16 along the track 118 . Motion of the shuttle 116 can be powered via an electric motor or similar means. The loop 126 is attached to an enclosed gear-reduction mechanism to raise and lower the cable 115 and any attached bicycle A.
[0091] FIG. 16 is a side view of the lift mechanism for the upper level of the TripleParker system 100 . The housing 122 in this embodiment enclosed the shuttle 116 , but the cables 115 are seen extending downward from the concealed shuttle 116 . In this view the track 118 and housing 122 are slightly shortened for illustration purposes. A cable spacer 128 is attached to the cables 115 and keeps them properly separated and weighted to assure proper functioning, even without the weight of a bicycle A, and also prevents tangling of the cables 115 . A handlebar hook 130 and a seat hook 132 are attached to the cables 115 and make it very easy to quickly attach a bicycle A.
[0092] FIG. 17 is a side view of an alternative embodiment of the second level of the TripleParker 100 . This is mechanism is distinct in several ways from that described in FIG. 1 above. This embodiment still uses the vertical support 30 and the mounting frame 28 as seen in FIG. 1 , but the upper receiver 20 is mounted to the mounting frame 28 using an entirely different mechanism. This mounting mechanism, shown in FIG. 18 , enables the upper receiver 20 to be extended along and parallel to the mounting frame 28 for a predetermined distance at which point the proximal end 22 of the upper receiver 28 is deflected downward toward the floor. This enables easy loading and unloading of bicycles.
[0093] FIG. 18 is a front end view of the mounting frame 128 . The mounting frame 28 includes a U-shaped channel 134 , a pair of deflection rails 136 , a pair of fulcrum rollers 138 and a support roller 140 . The upper receiver 20 , shown in cross-section in this view, includes an inverted-U channel that is parallel to the U-channel of the mounting frame 28 so as to conceal the fulcrum rollers 138 and support roller 140 . The upper receiver 20 rides directly on the support roller 140 inside the top of the inverted-U. The upper receiver 20 also includes two pairs of parallel rails 141 which are also parallel to the length of the upper receiver 20 , which envelope the fulcrum rollers 138 , thereby providing three points of support for the movable upper receiver 20 assembly.
[0094] FIG. 19 is a side view of the mounting frame 128 . The deflection rails 136 are parallel to the length of the upper receiver 28 except near the fulcrum rollers 138 , where the deflection rails 136 curve smoothly upward. The upper receiver 20 is in the retracted position, which is evident because the upper receiver 20 is level and parallel to the mounting frame 28 , and the deflection roller 142 , which is attached to one end of the upper receiver 20 is at the distal end of the deflection rails 136 .
[0095] FIG. 20 is a view through the assembled mounting frame 28 with the upper receiver 20 attached. In this view the upper receiver 20 is extended and deflected downward. The upper receiver 20 is easily extended and rolls on the deflection roller 142 , the fulcrum rollers 138 and the support roller 140 . As the upper receiver 20 is extended to a predetermined position, the deflection roller 142 encounters the upwardly curved portion of the deflection rails 136 , which forces the distal end of the upper receiver 20 upward. The support roller 140 is mounted to a deflection lever 146 which is attached to the mounting frame 28 via a fulcrum bolt 144 . The deflection lever 146 rotates to accommodate the upward deflection of the distal end of the upper receiver 20 , thus, the support roller 140 is deflected downward along with the proximal end of the upper receiver 20 . This is exemplified in FIG. 17 as upper receiver 20 ′.
[0096] Some resistance should be provided to prevent the upper receiver 20 from falling in an uncontrolled manner towards its extended and deflected position. For this purpose a gas spring (not shown) is mounted between spring mounts 147 and 148 . Spring mount 147 is anchored to a fixed position inside the mounting frame 28 . Spring mount 148 is attached to the deflection lever 146 opposite from the support roller 140 . As the upper receiver 20 is deflected downward, the deflection lever 146 is rotated so that the spring mount 148 is moved away from spring mount 147 . The gas spring acts to resist this movement and provides a restorative force to the deflection lever 146 , and thereby the upper receiver 20 . The gas spring thus damps the motion of the upper receiver 20 and aids in returning the upper receiver 20 to its level and retracted position. | A multiple-level bicycle storing system includes a framework having a vertical support and a horizontal mounting frame. The framework defines a lower storing space with a lower receiver, a middle storing space with an upper receiver attached to the mounting frame with a pivot mechanism, and an upper storing space. The upper storing space includes an upper track having a horizontal rail, a shuttle movably engaging the rail, an electric shuttle motor attached to the rail and the shuttle and a power source, a cable winch incorporated into the shuttle, an electric winch motor attached to the cable winch and the power source, a control box attached between the winch motor, the shuttle motor and the power source, and a bicycle support attached to the cable winch. The pivot mechanism includes a pluraility of rollers, rails, a lever and a gas spring to enable extension of the upper receiver. | 4 |
BACKGROUND OF THE INVENTION
The present invention pertains to the field of burners, particularly industrial burners of the type used in various high-temperature process applications. It is well established that, in burner systems used in industrial furnaces where two reactants are combusted, (i.e., where a hydrocarbon fuel is combusted with an oxidant) various nitrogen oxide compounds are generated (known collectively as NOx) which has been identified as an environmental pollutant. The reduction of NOx production has become the policy in recent years of various state and federal regulatory agencies. Typical mandates require NOx levels of about 30 ppmv for ambient temperature air. Thus, methods of NOx reduction are of great value.
The factors contributing to NOx production are understood, qualitatively if not quantitatively. In general, it is believed that NOx production is a path-dependent phenomenon resulting from uneven mixing of the fuel and oxidant, which results in sharp temperature gradients, localized peak flame temperatures and elevated oxygen concentrations in the hottest parts of the flame. Various techniques are typically used to reduce these factors. However, such schemes offer various tradeoffs in installed cost and operating efficiency.
A frequently used technique for reducing NOx emissions is external flue gas recirculation (FGR) in which inert combustion products are mixed with the oxidant and/or fuel streams upstream of the burner. This adds a thermal ballast to the system and reduces flame temperatures, thus inhibiting NOx formation. However, FGR systems require additional installation due to larger fans and motors and increased pipe requirements. FGR systems require more energy to operate and are less efficient in the yield of useful heat. Also, FGR components tend to have a short useful life, requiring increased maintenance and/or replacement expenses. During operation, FGR systems tend to be unstable and difficult to control, resulting in increased production expenses due to down time of the system. These difficulties are aggravated as lower NOx levels are attempted, and such systems may become economically unfeasible if further NOx reductions are mandated by the regulatory agencies.
Other burner system designs have been contemplated for complying with NOx production mandates that avoid the problems associated with external FGR. Such systems include air or fuel staged burners in which mixing of fuel and air takes place in multiple stages, allowing heat loss and dilution of reactants with products of combustion between the physically defined stages, thus reducing peak temperatures. However, staged burners are physically large and have complex oxidant and/or fuel passages, increasing installed costs and maintenance requirements.
Another method involves dilute reactant injection in which a furnace is heated to auto-ignition temperature, and fuel and oxidant are injected into the furnace in such a way that each entrain combustion products prior to mixing and combustion. While these systems provide very low NOx levels, additional penetrations to the furnace walls are required compared to conventional burners. This adds to the cost of a new furnace, and makes retrofitting an existing furnace difficult and expensive.
BRIEF DESCRIPTION OF THE INVENTION
In view of the difficulties and drawbacks associated with previous systems, there is therefore a need for a low NOx burner that is simplified in construction.
There is also a need for a low NOx burner with improved efficiency.
There is also a need for a low NOx burner that can be installed to existing furnace penetrations.
There is also a need for a low NOx modification which can be easily installed as an insert to existing burners.
There is also a need for a low NOx burner that permits easy and inexpensive retrofitting to existing furnaces.
These needs and others are satisfied by the low NOx burner and method of the present invention, including the steps of supplying a first reactant stream and introducing a second reactant stream into the first reactant stream at a first point so as to produce co-flowing streams. This resulting fuel/oxidant stream is discharged into a furnace environment having inert combustion products substantially equilibrated to furnace temperature, so as to entrain the combustion products and mix them together with the co-flowing stream. The temperature of the co-flowing stream is increased by the entrained products until it ignites in a combustion region displaced from the first point. Thus ignition cannot occur until the reactant stream has been diluted by inert products of combustion, reducing both oxygen concentration and peak flame temperature, so as to suppress NOx production.
As will be appreciated, the invention is capable of other and different embodiments, and its several details are capable of modification in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the invention will now be described by way of example only, with reference to the accompanying figures when the members bear like reference numerals and wherein:
FIG. 1 is a side sectional view showing the present integral low NOx injection burner.
FIGS. 2A, 2 B and 2 C are diagrammatic views depicting various operational and performance aspects of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the apparatus 10 of the present invention for firing two reactants, e.g. hydrocarbon fuel and oxidants, is shown in FIG. 1 . An oxidant inlet 12 provides an oxidant that can be air, either ambient or preheated by recuperative or regenerative means. The oxidant may also be oxygen-enriched air, pure oxygen, or vitiated with inert gas such as recirculated furnace products. The oxidant is supplied to an oxidant plenum 14 contained within a front housing 34 . The oxidant plenum 14 reduces the momentum of the incoming air stream to allow proper distribution of the air across the stabilizer 16 . The stabilizer 16 has apertures, (e.g. holes, slots, annulus, etc., or any combination) to ensure an even distribution of oxidant, and in some instances acts as a bluff body to maintain a stable flame when furnace temperature is below the reactant auto-ignition point. The pattern of apertures can be designed to produce any desired heat release pattern for any required application. A choke ring 18 and a baffle 20 may each be optionally used, alone or in combination, to produce the desired modifications in air flow such as is known in the art. The oxidant is flowed through a port 22 , and then discharged past the plane of a furnace wall 24 and then into furnace 26 .
A back housing 36 preferably includes a primary fuel inlet 40 , which supplies fuel, preferably hydrocarbon gas, to a primary fuel plenum 42 . The primary fuel plenum 42 supplies primary fuel to one or more primary fuel passages 44 , and in turn to a low NOx fuel injector 46 , and out through a low NOx fuel injection port 48 . The injection port 48 may be located at a first point inside a burner tile 30 , flush with the furnace wall 24 or within the furnace volume 26 . In any case, the injection port 48 delays ignition of the fuel and oxidant until they have been vitiated by the inert combustion products in the furnace, as will be set forth below in the discussion of the present method. The number, placement and orientation of injector ports 48 can vary, depending on burner type and the characteristics of the desired application. The injector 46 can be offset from the burner axis 50 (as illustrated) and also may optionally have ports inserted axially, radially or at a desired angle between radial and axial, so as to match fuel velocity to a specific oxidant velocity, in magnitude and direction, to produce a particular combustion characteristic. For many applications, a single injector 46 located on the burner axis with a single axial port 48 will achieve the required NOx emissions. Such a design is not mechanically complex, resulting in savings in manufacturing, and great ease and low cost to install.
In the illustrated embodiment, an optional secondary fuel inlet 60 supplies secondary fuel to a secondary fuel plenum 62 . The secondary plenum 62 is connected to a secondary passage 64 , which delivers fuel to secondary gas ports 66 , located at a second point downstream of oxidant plenum 14 but upstream of the low NOx injector ports 48 . In this embodiment, the secondary passage, is concentric with the primary passage 44 , permitting an annular flow passage for secondary fuel. The secondary passage 64 terminates at the stabilizer 16 , which promotes mixing of the secondary fuel and oxidant. Optional premix ports 68 may be used to preliminarily mix fuel and oxidant. The stabilizer 16 may be supported by secondary passage 64 , or it may be attached to the front housing.
The present burner 10 may include a burner tile 30 to optionally provide an area of stabilization for the flame envelope during the heat up stage. The tile 30 is made of a material capable of withstanding the heat of combustion (e.g. refractory or metal). The tile 30 defines the port 22 for directing oxidant into the furnace. The tile 30 is mounted to a burner mounting plate 32 , typically metal, for permitting attachment of the burner internals. In the illustrated embodiment, the mounting plate 32 is bolted to a front housing 34 , which houses the oxidant plenum 14 . The back housing 36 is bolted to the back of the front housing 34 for housing other burner internals, as indicated above.
Fuel may be supplied to the secondary fuel elements during furnace heat up for raising furnace temperature, or for maintaining a desired furnace temperature below the auto-ignition point. During operation when furnace temperature is below the level of reactant auto-ignition, an appropriate fraction of the total fuel is supplied respectively through each of the primary and secondary fuel elements. The secondary fuel provides a stable flame for raising furnace temperature, and also may be used to provide a desired flame shape or heat transfer profile suitable for a specific application.
During furnace heat up, the fraction of fuel supplied through the primary injector 46 will be sufficient to cool it, while the fraction of fuel supplied to the secondary ports 66 will be enough to maintain a stable flame in the burner tile. Depending on the process application, reactant composition and emissions requirements, the fraction of secondary fuel may be reduced or eliminated when furnace temperature reaches the reaction auto-ignition point. For applications where the secondary fuel option is not used, alternative methods (such as auxiliary burners) must be used to raise the temperature inside the furnace to the auto-ignition level.
The apparatus may also include a pilot 70 for lighting the burner 10 , and an observation port 72 for visually observing the flame, and a flame supervisory port (not shown) for electronically monitoring the flame state and generating a respective signal to a control system.
In the method according to the preferred embodiment of the present invention, as shown qualitatively in FIGS. 2A, 2 B and 2 C, an oxidant stream A is flowed out of the port 22 at a particular velocity V 1 . A fuel stream F is injected into the oxidant stream out of the low NOx fuel injector 46 at a velocity V 2 . The co-flowed fuel and oxidant streams are discharged into the furnace 26 which is filled with chemically inert combustion products P that are equilibrated to the operating temperature of the furnace (in the embodiment of FIGS. 2A, 2 B and 2 C, at least the auto-ignition temperature, about 1400° F.). The fuel and oxidant streams are discharged into the hot furnace environment. Thus, as shown especially in FIG. 2A, the large momentum and temperature differentials between the combustion products P and the co-flowing fuel and air streams result in high entrainment 80 and rapid mixing of the combustion products into the combined stream.
In the illustrated embodiment, as can particularly be seen in FIGS. 2B and 2C, the low NOx fuel injection port 48 is positioned a distance X 1 from the plane of the surface of the interior furnace wall, the oxidant port 22 being flush with said wall. The fuel injection port 48 is designed so as to result in an exit fuel velocity V 2 appropriately matched to the velocity V 1 of the oxidant stream exiting the oxidant port 22 . The term “matched” as used herein refers to a defined relationship between V 1 and V 2 in the unconfined furnace volume that results in a minimum of mixing between the co-flowing fuel and oxidant streams, in contrast to the accelerated mixing typical in prior burners where expanding jets of reacting fuel and oxidant turbulently mix in the confined space of the burner tile. By matching the velocities, the rate of mixing of fuel and oxidant is greatly slowed as compared to previous burners, and mixing is delayed, allowing time for entrainment of the combustion products P to occur.
Thus, a combustible mixture is first produced at a distance X 2 from the burner wall 24 , where auto-ignition occurs as a “lifted flame” 82 . Since by this time a significant quantity of inert combustion products have been mixed into the fuel and oxidant streams, oxygen concentrations are diluted, and the rate of the chemical reaction is slowed. Thus, thermal gradients and peak flame temperatures within the combustion zone are reduced, thereby suppressing NOx formation to extremely low levels. These low NOx levels are achieved even when the fuel is injected into the oxidant stream at a point where it has not yet been diluted by the inert products of combustion in the furnace, as is described below.
In an embodiment where the fuel is natural gas, and the oxidant is air, and where fuel and air are substantially at ambient temperature, and where a uniform heat release rate along the burner axis is desirable, the preferred range for the air velocity (V 1 ) is 80 to 160 fps in the axial forward direction, and the matching fuel velocity (V 2 ) is 60 to 100% of the air velocity (V 2 /V 1 between 0.6 and 1.0) in the same direction.
In an embodiment using preheated air as oxidant, but otherwise similar to the ambient air embodiment described above, the preferred range of air velocities is 200 to 400 fps, and the matching fuel velocity is 50 to 75% of V 1 (V 2 /V 1 between 0.5 and 0.75) to maintain minimal mixing between air and fuel and excellent mixing of the combined stream with the inert products, resulting in extremely low NOx.
The applicability of the invention is not limited to the velocity ranges described above. Generally, higher air velocities will not be as economical in operating cost, while lower velocities will result in higher NOx emissions than the preferred velocities described above. For retrofit application with ambient air velocities less than 60 fps, V 2 should be 2.0 to 3.0 times V 1 for optimal NOx emissions.
FIGS. 2B and 2C show particularly the mixing profiles resulting from the present method. X 1 , X 2 , and X 3 represent displacement in the direction of the burner axis, with the furnace wall (and oxidant port exit) as origin. X 1 represents the displacement of the low NOx injector fuel port from the furnace wall. Generally, X 1 may be slightly negative (displaced into the oxidant port), zero (coincident with the oxidant port exit), or positive (displaced into the furnace), without changing the mechanism described, and thus without departing from the invention. In FIGS. 2A, 2 B, and 2 C, X 1 is positive; that is, the injector nozzle is displaced into the furnace from the oxidant port exit. Within the oxidant port 46 , and immediately beyond the furnace wall 24 , up to point X 1 , the oxidant A, the fuel F, and combustion products P are completely unmixed. The air stream diverges in the pattern of a turbulent jet from the exit of the oxidant port. The momentum and temperature difference between the air stream A exiting the oxidant port 22 and the combustion products P causes rapid entrainment of products P into the air stream to occur along the boundaries of the stream so as to define a region A,P as illustrated in FIG. 2B, where a high level of mixing occurs between the oxidant and combustion products. As the distance from the oxidant port 22 increases, the products P penetrate farther into the core of the flowing air stream.
Another region A,F is defined where fuel and oxidant mixing occurs. Within the boundary of the stream formed by the air exiting the oxidant port 22 , the fuel exits the low NOx injector fuel port 46 , and creates a fuel flow stream within the flowing air stream, beginning at the exit of the fuel injector at X 1 . The fuel exit velocity V 2 is matched to the oxidant exit velocity V 1 so as to minimize the momentum gradient between the co-flowing air and fuel streams, in contrast to the large momentum differential between the flowing streams and the furnace products P noted above. The result is that the products P are mixed into the co-flowing streams A and F more rapidly than the air and fuel streams are mixed together.
Chemical and thermal requirements must be satisfied in order to initiate and sustain a combustion reaction. Mixing of the oxidant and fuel is necessary to satisfy the chemical requirements. In the present invention, mixing is delayed as shown above to allow time for entrainment of furnace products to dilute the combustible mixture. In prior burners, the thermal requirements were satisfied by using mechanical structures to create turbulent eddies within the confined space of a burner tile to recirculate some of the just combusted products back into the just-arriving fuel and oxidant. In the present invention, the predominant mechanism for satisfying the thermal requirements for sustaining combustion is entrainment of furnace products already equilibrated to furnace temperature into the co-flowing streams of fuel and oxidant. Referring to FIG. 2B, it can thus be seen that within the areas labeled “A”, “F”, and “A,P”, the chemical requirements for combustion are not satisfied. In the areas labeled “A”, “F”, and “A,F”, the thermal requirements are not satisfied. Thus, combustion cannot occur in these regions.
X 2 is the point where the converging cone formed by entrainment of products into the air “A,P” meets the diverging fuel-air cone “A,F” resulting from the slowly mixing air and fuel; this new region is shown as “A,F,P”. This region is a flame base where partial combustion can begin to occur. At X 3 , sufficient entrained products P have penetrated to the center of the stream, and mixing of fuel and air has progressed so that the fuel, air and entrained products provide the chemical and thermal requirements to continuously sustain a dilute low NOx combustion reaction. In an embodiment that uses pre-heated air, the thermal requirements may be partially or completely satisfied by air itself. In such a case, measures can be taken to delay establishment of the chemical requirements. One such measure is displacement of the fuel nozzle exit (X 1 ) downstream from the oxidant nozzle. Another such measure is to displace the fuel nozzle so that it is off-axis, or to orient it so that the direction of the fuel velocity is inclined with respect to the axis of the oxidant port.
The embodiment of FIG. 1 shows the injector axis 50 displaced from the central axis of the oxidant port 22 . When the two axes are collinear (as in FIGS. 2A, 2 B, and 2 C), the radial distance between the fuel exiting the port 48 and the combustion products P is greatest. However, it may be desirable for certain applications to use an off-axis injector 46 so as to place the fuel F closer to the combustion products P, which are the source of dilution. In such an alternate embodiment, the diverging fuel cone shown in FIG. 2B would be displaced toward the oxidant port 22 perimeter, thus displacing the regions A,F; A,P; and A,F,P. This can also be effected by using more than one injector 46 .
An example of a system to provide excellent combustion characteristics and extremely low NOx emissions for many applications requiring ambient air as oxidant and natural gas as fuel would use a single fuel injector per oxidant port, with the fuel injector located concentric to the air port. The air discharge would be sized for a velocity of 150 fps (V 1 ), and the fuel discharge would be sized for 125 to 150 fps fuel velocity (V 2 ). The fuel nozzle exit would be displaced downstream of the air nozzle exit by 0 to 0.5 times the oxidant port diameter.
For a typical application using air preheated from 400 to 900 F., the air discharge would be sized for a velocity of 350 fps, and the fuel discharge would be sized for 225 to 250 fps.
The velocities described above will provide combustion characteristics suitable for many applications, will result in extremely low NOx emissions, and are within practical capabilities of existing equipment (combustion air blowers, fuel piping, etc.) installed in many applications to supply. However, the invention is not limited to the velocities and configurations described. The invention is capable of reducing NOx by 50% or more compared to prior burners sized for the same supply conditions of air and fuel in retrofit applications where the oxidant velocity at the maximum firing rate can range from 40 to 500 fps, and where the oxidant velocity can include or not include a rotational component (swirl), by matching the fuel velocities as described.
In the present invention, the flame is “non-anchored” in contrast with previous systems which use specific flow structures that create eddies and currents within the reactant streams for mixing the fuel and oxidant with each other and with the combustion products. No mechanical structures are provided at present for ensuring the fluidic stability of the flame. However, the flame has considerable thermal stability, and a consistent flame with high temperature uniformity results from the present method and apparatus. The flame is supervisable by detection of furnace temperature above the auto-ignition point, or by detection of UV radiation by equipment used for the same purpose in conventional burners. By eliminating the complex flow structures of previous systems, the present invention is mechanically simple in construction and thus inexpensive to manufacture.
The present invention is easy to retrofit to existing burners. In some instances, retrofitting can be as simple as attaching a package including a back housing 36 with attached injector 46 and related structures to an existing front housing 34 . This can result in savings as much as 60-70% over comparable competing retrofits. Such savings would be welcome by users with many burners who are required to retrofit to comply with regulatory mandates. Since the present burner can be installed to existing furnaces without making additional penetrations or other modifications to the furnace enclosure, the present invention can be installed quickly with a minimum of lost production time, resulting in further savings.
As described hereinabove, the present invention provides a system with improved performance and efficiency over previous devices. However, it will be appreciated that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | A low NOx burner and related method are disclosed including the steps of supplying a first reactant stream and introducing a second reactant stream into the first reactant stream at a first point so as to produce co-flowing streams. This resulting fuel/oxidant stream is discharged into a furnace environment having inert combustion products substantially equilibrated to furnace temperature, so as to entrain the combustion products and mix them together with the co-flowing stream. The temperature of the co-flowing stream is increased by the entrained products until it ignites in a combustion region displaced from the first point. Thus ignition cannot occur until the reactant stream has been diluted by inert products of combustion, reducing both oxygen concentration and peak flame temperature, so as to suppress NOx production. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to the field of treating wastewater, and more specifically, a system for separating and retaining fats, oils, greases (FOGs) and miscible organics from wastewater, thereby allowing safe and economical treatment of both the wastewater and the separated organic material.
BACKGROUND OF THE INVENTION
[0002] Fats, oils, and greases (FOGs) and miscible organics (hereinafter collectively referred to as “organic wastes”) that are present in the waste water from businesses, institutions, and industries such as restaurants, hospitals, and food processing plants congeal in the conveyance pipes that lead to the municipal or other water treatment plants whose function is to purify the water to the degree that it can be safely reused or released to the environment. This causes backups and sewage overflows in the conveyance systems that are environmentally hazardous and costly to clean up. Furthermore, FOGs (Organic wastes) have a high oxidation demand, which can interrupt normal biological processing in the wastewater treatment plant.
[0003] As a consequence of the problems created by the presence of FOGs (Organic wastes) and miscible organics, many municipalities and states in the United States of America and other countries around the world are requiring restaurants, institutions, food processing plants, and other generators of organic waste streams to install grease traps to collect the organic fraction prior to entry into the wastewater conveyance systems.
[0004] These trapped organic wastes have a high moisture content (92-98% water) and high oxygen demand. Current practice is to store these wastes in tanks and routinely pump them out of the storage tanks and transport them by tanker truck to remote locations. At these locations they are treated in special wastewater treatment facilities or mechanically dewatered with the organic fraction either incinerated or treated by composting or land application. The current practice of sporting the organic laden wastewater great distances is costly and inefficient and has the further disadvantages of adding to congestion on the roads and unfavorable environmental impact as a result of truck emissions.
[0005] There is a need to provide a system for separating fats, oils, greases, and miscible organics from wastewater.
[0006] There is another need to provide a system for separating fats, oils, greases, and miscible organics from the wastewater produced in a facility, which can be installed on site at the point at which the wastewater exits the facility.
[0007] There is an additional need to provide an efficient, relatively inexpensive, environmentally friendly process for treatment of waste water that contains fats, oils, greases, and miscible organics.
[0008] Further purposes and advantages of this invention will appear as the description proceeds.
SUMMARY OF THE INVENTION
[0009] The various embodiments of the present invention pertain to the separation of the organic wastes and miscible organics from wastewater exiting a facility such as food related businesses, institutions, and industries, either with or without grease traps, in order to produce an fluid which can be discharged into a municipal wastewater treatment plant or meet the standards for on site disposal either above or below ground.
[0010] The concept of the present invention is to provide a substantially watertight container filled with absorption/filtering media to absorb or otherwise remove FOG from wastewater from a restaurant or other enterprise. Wastewater is introduced into the top of the container, and the organic waste is selectively absorbed by the absorption/filtering media, thereby separating it from the water. The filtered water without the organic waste drains to the bottom of the container and from there into the municipal sewerage system or other disposal holding system.
[0011] Periodically, a truck comes to the site and mixes or agitates the absorption/filtering media to break up the surface crust and provides new surface area to allow for more absorptive capacity in the material. Periodic inspections of the quality of the wastewater are carried out either manually or automatically. When it is determined that the absorption/filtering media is saturated and no longer effective, then the material is replaced and the material containing the absorbed organic wastes is then either hauled off to a central compost facility, a land application site, a landfill, an incinerator, or potentially composted on site (in the container by attaching a blower to maintain aerobic conditions).
[0012] The subsequent descriptions will be directed towards the treatment of wastewater with high levels of organic wastes and miscible organics from food related establishments. It should be understood that the invention could also be used to treat wastewater of high organic strength from other types of facilities as well e.g. facilities for manufacturing home care products or paint. The system as described can be utilized as either a continuous or batch process as will be described hereinbelow.
[0013] One aspect of the present invention of the organic waste separating apparatus includes a sealable container, a hinged or removable or otherwise movable cover, and a network of wastewater input ports and fluid outlet ports disposed in or integral to the sealable container and removable cover.
[0014] The sealable container can include a chamber, a top opening, and an outlet port. The chamber includes a top portion, a bottom portion, and two opposing inwardly inclined chamber bottom surfaces. The chamber is of sufficient volume to hold absorption media plus a certain amount of unfiltered wastewater (freeboard).
[0015] In one embodiment of the present invention a pipe is disposed below the chamber. The pipe includes a plurality of holes disposed along a top surface to allow fluid from the chamber to enter into the pipe.
[0016] The hinged or removable cover seals the top opening of the sealable container. In one embodiment of the removable cover of the present invention, the removable cover includes a bottom surface, at least one inlet port, and a plurality of organic waste distribution plenums disposed along the bottom surface of the removable cover in fluid communication with at least one inlet port to deposit the organic waste within the chamber.
[0017] The chamber also can include an inclined fluid channel, for example a false bottom, disposed in proximity of the bottom portion of the chamber. The inclined fluid channel is in fluid communication with the outlet port and the chamber permitting the transfer of fluid from the chamber to an external disposal source connected to the outlet port, whereby waste products contained within the organic waste are substantially absorbed by the absorption/filtration media and the residual fluid can be safely disposed of according to environmental procedures.
[0018] Other embodiments of the present invention illustrated herein disclose alternative inclined fluid channels and options that included an absorption/filtration media mixer/agitator and blower.
[0019] All the above and other characteristics and advantages of the invention will be further understood through the following illustrative and non-limitative description of preferred embodiments thereof, with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which:
[0021] FIG. 1 is a perspective view showing one embodiment of an organic waste separating apparatus of the present invention;
[0022] FIG. 2 is a cross-sectional view of the present invention taken along line A-A in FIG. 1 ;
[0023] FIG. 3 is a cross-sectional view of the present invention taken along line B-B in FIG. 1 ;
[0024] FIG. 4 schematically shows a portable mixer adaptable to the organic waste separating apparatus of the present invention illustrated in FIG. 1 ;
[0025] FIG. 5 is a perspective view showing a blower adapted to the organic waste separating apparatus of the present invention illustrated in FIG. 1 ;
[0026] FIG. 6 is a top view of a fluid removal pipe of the present invention illustrated in FIG. 1 ; and
[0027] FIG. 7 is a bottom view of a distribution pipe of the present invention illustrated in FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] Referring now to FIGS. 1, 2 and 3 illustrating views of an organic waste separating apparatus 1 of the present invention FIG. 1 is a perspective view showing the organic waste separating apparatus 1 of the present invention of the system of the invention. Organic waste separating apparatus 1 includes a sealable container 2 having a top opening 2 A that is preferably water tight and made of high density plastic or corrosion resistant metal. Container 2 has a removable cover 4 attached to it by hinges 6 to substantially seal or close top opening 2 A to keep vectors from the organic matrix and wastes, and to keep odors enclosed in the system. Cover 4 is preferably closed at all times except when the absorption/filtering media 22 is being added, mixed/agitated, or removed.
[0029] Organic waste separating apparatus 1 can be fitted with a plurality of extensions 8 along its exterior bottom surface 2 B, such as legs and/or roller devices (for example, wheels or casters), to raise it off the ground and/or allow it to be rolled from place to place.
[0030] Affixed to the inside surface of container cover 4 are one or more plastic or corrosion resistant metal distribution pipes 10 to form a network of fluid channels. One end 10 A of the distribution pipe 10 includes an inlet port 15 for connection to the wastewater outlet of, for example, a fast food restaurant, via a flexible hose or pipe (not shown). Preferably, a valve and/or other suitable connector 12 is disposed at end 10 A for closure inlet port 15 . Distribution pipe 10 includes a plurality of organic waste distribution ports (such as holes 10 B, FIG. 7 ) spaced, preferably evenly spaced, along bottom surface 11 to distribution of the wastewater over the surface of the absorption/filtering media. Thereby, placing plurality of organic waste distribution ports in fluid communication with inlet port 15 . The organic waste distribution ports 10 B must be large enough to allow the wastewater to flow smoothly. The distribution pipe 10 is fitted with a cleanout port 18 (see FIG. 2 ) at the end of the pipe opposite end of connector 12 to remove any large object which could clog the distribution pipe 10 .
[0031] For large systems, multiple pipes 10 or fluid channels may be utilized to even out the spread of the wastewater on the surface of the absorption/filtration media 22 .
[0032] The interior or chamber 13 of the organic waste separating apparatus 1 can be seen in FIGS. 2 and 3 . FIG. 2 is a cross-sectional taken along line A-A of FIG. 1 and FIG. 3 is a cross-sectional view taken along line B-B if FIG. 1 . The chamber 13 includes a top portion 13 A and a bottom portion 13 B. The volume of interior or chamber 13 is of sufficient volume for absorption/filtration media 22 to fill most of the interior or chamber 13 of container 2 . The interior or chamber 13 of container 2 is not filled to the top with absorption/filtration media 22 to allow a freeboard zone 13 C where the wastewater (or organic waste) can sit if it is applied at a rate greater than the conductivity through the absorption/filtration media 22 .
[0033] The absorption/filtration media 22 is organic in nature, such as woodchips, bark, yard waste, or other wood derived products, which are slightly hydrophobic but will absorb organic waste. Waste products contained within the wastewater are substantially absorbed by the absorption/filtration media 22 as the wastewater percolates through the absorption/filtration media 22 . The residual fluid, such as water, is separated for safe disposal according to environmental standards. The absorption/filtration media 22 can be, for example, comprised of chips of varying size in order to increase the surface area in contact with the wastewater while allowing a good infiltration rate and conductivity through the matrix.
[0034] At the bottom portion 13 B of container 2 can be a false bottom 20 made of either high density plastic or corrosion resistant metal. One example of the false bottom 20 is an inclined fluid channel 20 C defined by two downwardly opposing inclined chamber bottom surfaces 20 A, 20 B. As illustrated in FIG. 2 , false bottom 20 , for example, can be inclined or slanted downward toward the lower end 14 A of fluid removal pipe 14 . As illustrated in FIG. 3 , false bottom 20 , for example, can be inclined or slanted in two opposing directions to allow the fluid to go to the center and rapidly drain from the container 2 . The illusion is not to limit the false bottom 20 to any particular angle of inclination or slant, or number of bottom surface segments. Another example of an acceptable false bottom 20 may only include one bottom surface forming a fluid channel 20 C with a side 2 D of the container 2 .
[0035] There are many alternative embodiments of the false bottom 20 configuration for separating the water from the absorption/filtration media 22 . One embodiment includes the false bottom 20 being preferably hermetically sealed to the walls 2 D of the container 2 and to the sides of an fluid removal pipe 14 . A fluid removal pipe 14 can be disposed below the interface of bottom surfaces 20 A, 20 B. Fluid removal pipe 14 includes a plurality of holes 14 H ( FIG. 6 ) along its top surface 14 E which will allow fluid, but not the absorption/filtration media 22 , to drain from the container 2 .
[0036] At the lower end 14 A of fluid removal pipe 14 , after it passes through the wall of container 2 , is located an fluid outlet port 14 F. Optional, a sampling port 16 followed by a valve and/or other type of connector 17 may also be located at the lower end 14 A. Connector 17 is connected to a hose or pipe, which conducts the fluid to the wastewater conveyance system, i.e. the manhole and sewer pipes leading to the public or private wastewater treatment plant, or to a surface or below ground treatment system. The upper end 14 B of the fluid removal pipe 14 is fitted with a clean out port 18 .
[0037] Another embodiment of the false bottom configuration of the present invention includes the false bottom 20 being a single surface hermetically sealed to the walls 2 D of container 2 and a plurality of holes in the false bottom 20 . The fluid removal pipe being located in the volume between the false bottom and the actual bottom 2 E of container 2 into which the fluid will drain.
[0038] Another embodiment of the false bottom configuration of the present invention can be a single bottom surface or a pair of opposing bottom surfaces that form a fluid channel downwardly inclined toward said at least one fluid outlet port directly connected to connector 17 , thereby eliminating fluid removal pipe 14 .
[0039] At the sampling port 16 the fluid will be tested for one or more of the following parameters: pH, conductivity, biochemical oxygen demand (BOD), organics content, or other similar parameter depending on the characterstics of the wastewater. Numerous types of testing devices can be used, e.g. dyes, pH meters, spectrophotometers, or conductivity meters. The fluid is tested according to a fixed schedule e.g. every evening, on a random spot check basis, automatically and nearly continuously if suitable automation and control systems are provided or every time the media is mixed.
[0040] Alternative embodiments of the present invention may include a sensor 24 near the top portion 13 A of container 2 , which will signal a warning (such as an audible signal, data signal, or visual signal) if the water level rises to high.
[0041] Periodically, a separate truck equipped with a portable mixer 26 , such as one schematically shown in FIG. 4 , will visit a site having the organic waste separating apparatus 1 . When the truck arrives, removable cover 4 of container 2 will be raised and mixer 26 will be dropped through top opening 2 A of container 2 and onto the top of the media 22 . Mixer 26 comprises a plurality of tines 30 attached to a central shaft 28 . Shaft 28 is attached to a motor (not shown). The motor causes shaft 28 to rotate and tines 30 to break up the surface crust and mix or agitate the absorption/filtration media 22 , thereby reducing the potential for surface clogging and increasing the absorptive capacity of the media. The frequency of the mixing will be a function of wastewater loading and characteristics.
[0042] Now turning to FIG. 5 , an alternative embodiment of the present invention may include a blower 34 in fluid communication with the chamber 13 of container 2 to maintain aerobic conditions within the container 2 . When the results of the test performed on the fluid at the sampling port 16 indicates that the absorption/filtration media 2 is saturated to the point that it is no longer effectively removing the organic waste from the wastewater, then the distribution pipe 10 , for example, is disconnected from the wastewater outlet of the facility and the absorption/filtration media 2 saturated with the organic waste is composted within the container 2 .
[0043] Typically at each mixing, the fluid will be tested to determine if the absorption/filtration media 2 is saturated to the point that it is no longer effectively removing the organic waste from the wastewater. If absorption/filtration media 2 is saturated, then a number of scenarios are possible including, but not limited, to the following:
[0044] (1) The truck that comes to mix the media can carry a replacement container filled with fresh absorption/filtration media that is placed on the ground near the original container. The input and outlet lines are disconnected from the original container and reconnected to the replacement container. The container containing the absorption/filtration media saturated with organic waste is loaded on the truck and transported to a tip station where the absorption/filtration media is removed from the container. The container is cleaned out and reloaded with fresh media and readied to be brought to a new site. At the tip station, the absorption/filtration media saturated with organic waste is either offloaded into a storage tank or directly into the collection box for separation of excess water. The water is then easily treated by a wastewater treatment plant or by surface disposal. The absorption/filtration media and saturated organic waste is then either composted, for example by windrow compositing; be land applied; or added to a landfill or bioreactor. In a very much less preferred embodiment, the media and absorbed organic waste can be incinerated.
[0045] (2) The absorption/filtration media can be replaced with fresh absorption/filtration media on site. In this scenario, the truck that comes to mix the absorption/filtration media carries an empty tank and a supply of fresh absorption/filtration media. The absorption/filtration media saturated with organic waste is tipped out of the container into the tank on the truck, the container is refilled with fresh media, and the saturated absorption/filtration media is disposed of as in the first scenario.
[0046] (3) There can be two or more containers of the present invention placed at each site. After the absorption/filtration media has been mixed one or more times and the measurements indicate that the absorption/filtration media in the first container has become saturated, the input and outlet lines are disconnected from the first container and connected to a second container that contains fresh absorption/filtration media. The first container is then turned into a bioreactor for composting the absorption/filtration media in the container with the aid of a blower and periodic mixing or agitation to maintain aerobic conditions. Upon completion of the composting process, typically in about ten days, the compost is removed from the container and can be used either locally or sold. The empty container is refilled with fresh absorption/filtration media and is ready to be used to treat the wastewater when the absorption/filtration media in the second container becomes saturated.
[0047] (4) In the case of small facilities, it might not be economically viable to have an organic waste separating apparatus of the present invention placed permanently on site. Typically, the wastewater containing organic waste could be temporarily stored in a storage tank on site. Currently, a tanker truck would come to the site to empty the storage tank and take the wastewater to an offsite water treatment facility for treatment. Alternatively, an organic waste separating apparatus of the present invention can be mounted on a truck that periodically visits the site. The stored wastewater is introduced into the distribution pipe on the top of the organic waste separating apparatus on the truck and fluid exits through the fluid removal pipe into the municipal sewerage system or is otherwise disposed of on site. This procedure reduces transportation costs since only the absorption/filtration media saturated with the organic waste is transported to the treatment site and not large amounts of fluid.
[0048] Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims and the Doctrine of Equivalents. | An apparatus for separating fats, oils, and greases (FOGs) and miscible organics that are present in the wastewater from businesses, institutions, and industries such as restaurants, hospitals, and food processing plants. The apparatus can be installed in situ or can be mobile. The apparatus provides for wastewater to flow through a network of fluid channels, for example a distribution pipe, on to an absorption/filtration media within a substantially watertight container. The wastewater percolates through the absorption/filtration media leaving FOGs behind inside the container, which have been absorbed by the organic absorption/filtration media. Fluid, free of the organic waste, flows through a fluid removal pipe at the bottom of the container, thereby exiting the container. The organic absorption/filtration media saturated with organic waste can then be treated in an environmentally sensitive manner by composting, land application, incineration or land filling at a remote site or composted on site. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 178,804, filed Mar. 29, 1988, now U.S. Pat. No, 4,810,521, which, in turn, is a continuation of application Ser. No. 885,623, filed July 15, 1986, abandoned.
BACKGROUND OF THE INVENTION
In the automotive industry, rubber-coated metal parts are in widespread use. Such parts may be found in shock absorber bushings, engine mounts, or other applications where it is necessary or desirable to bond a natural or synthetic rubber to a metal substrate, often a tubular piece of metal.
By reason of the poor bonding which is obtained with straight rubber-to-metal bonds, adhesives are used which are first applied to the metal part, and thereafter forms a bond to the rubber part. Such adhesives may become cured in the same vulcanizing step in which the rubber is vulcanized and are known as post vulcanizing or PV bonding. However, pre-vulcanizing bonding materials may also be employed.
One method of applying such coating material to the parts in question has been that of conventional spray coating, while rotating the part, to form a coating of the bonding material on the outer surface. The spray coated part may the be heated to drive off the solvent. This process is inefficient in that only about 30 percent of the total adhesive sprayed is deposited on the part, and the remaining 70 percent is lost or can be recovered only with great difficulty. Dip coating also is found to have drawbacks and is inefficient in that the entire part is coated, with the coating running into the center openings or the like where it is not desired. Further dip coating may cause excessive buildup of material on the edges of the parts when the part is withdrawn from the solution, and some excess material can contribute to bond failure between the rubber and the metal at a later time.
In the patent of Robertson et al., U.S. Pat. No. 4,296,708 issued Oct. 27, 1981 and assigned to the same assignee as this invention, there is described and claimed a roll coating apparatus which has been employed to coat hollow metal sleeves or other metal parts. However, while the apparatus as disclosed and claimed in the Robertson et al patent has been successfully operated, the apparatus does not lends itself to high volume production rates, and further, the coating apparatus employed required extensive cleanup at the end of each production run and required monitoring to prevent undesired buildup of the coating material. There accordingly exists a need for a more efficient method and apparatus of applying rubber-to-metal bonding materials to rubber parts, such as hollow metal sleeves and the like.
SUMMARY OF THE INVENTION
This invention relates to the coating of metal, such as tubular metal parts, with adhesive bonding materials to provide for the bonding of natural and synthetic rubbers thereto, or for the priming of such metal parts with an adhesive primer for a subsequent application of a bonding material, and includes the employment of electrostatic disc coating apparatus in such coating processes.
Electrostatic disc atomization of paint and other materials has been employed by pumping the paint to an atomizer disc which spins to cause the paint to spread out to the atomizing edge. The paint is then atomized under the influence of an electrostatic field, where it receives a charge, such as a negative charge, and is repelled away from the atomizer. The atomized mist is then attracted toward the grounded workpiece. Disc-type atomization has not been successfully used, to applicant's knowledge, for the application of such undercoat adhesives for the bonding of natural or synthetic rubbers to metal, primarily by reason of the fact that such adhesives, when used with the recommended solvents, and mixed to the desired viscosity, do not lend themselves to electrostatic application. Generally, the solvents or diluents are too fast, and the material reaches the grounded metal parts in a dried or semi-dried state, and good coating is not achieved. Also, some of the adhesives are non-polar or have low polarity and are not carried well by the electrostatic charge.
It has been discovered that rubber-to-metal bonding agents may be successfully electrostatically applied by a disc applicator where certain slower solvents are substituted for the recommended diluents or solvents, to ensure that a wet film is applied to the substrate, and where the solvent has been modified to raise the polarity of the adhesive.
The principal bonding materials employed in this invention in the adhesive bonding of elastomers to metal comprise a 200-series family of rubber-to-metal adhesive and adhesive primers made by Lord Chemical Products (formerly Hughson Chemical Company) of Erie, Pa. under the "Chemlok" trademark. These include Chemlok 205 as a primer, Chemlok 220, 220E and 233 as high strength bonding agents over the 205 primer, and Chemlock 250, 252, 253 and 257 as single coat adhesives without primer. Additionally, Thixon OSN-2, P-6-1, P-10 and 508 may be applied to preprimed metal and are available from the Dayton Chemicals Division, Whittaker Corporation, West Alexandria, Ohio. The noted "Chemlok" and "Thixon" materials are low solids adhesives. The noted "Chemlok" adhesives have solids contents ranging by weight within the range of about 19-26 wt. % and the noted "Thixon" products have solids contents ranging from about 14-26 wt. %. "Low solids" means having less than about 40 percent by weight solids content.
Such adhesives as described above are normally diluted with toluene, xylene, MEK or methyl isobutyl ketone. Such compounds as identified and as conventionally employed for the priming and coating of metal articles for rubber bonding, such as was used in the above-identified patent of Robertson et al., have not been successfully spray coated from disc-type electrostatic coaters. The present invention employs the use of such basic coatings materials and a diluent or solvent consisting primarily of cyclohexanone and petroleum solvents, with a small amount of methyl ethyl ketone added, in a ratio of approximately 1 part of adhesive to 1 part of such solvent. Such slower solvents have been found to be compatible with electrostatic application and ensure that a wet film is applied to the substrate. They permit such adhesive materials to be successfully electrostatically atomized from a disc atomizer and applied to stacks of metal parts such as tubes and sleeves, carried on grounding rods by a conveyor. Preferably, the materials are applied in two passes, on a continuous conveyor, using a pair of disc-type electrostatic applicators and a double pass oven between the applicators.
It is accordingly an important object of this invention to provide a method of coating metal parts with an adhesive coating, utilizing electrostatic atomization.
Another object is the provision of a process of applying adhesive coating to parts employing relatively slow solvents or diluents to maintain the atomized adhesive in a wet condition during its transportation from an atomizing disc to a grounded support or workpiece.
Another object of the invention is the provision of a process of electrostatically coating metal objects, such as metal sleeves, with rubber-to-metal elastomer in an electrostatic disc-type coater.
A further object of the invention is that of a method or process for the coating of cylindrical metal elements with an rubber-to-metal adhesive including the steps of electrostatically coating a base material, which material has been diluted with a retarding or slow solvent, curing the coated material, followed by the electrostatic coating of a second material, which material has also been retarded as the first material, followed by curing of the second material. More particularly, it is an object of the invention to heat such materials to decrease their viscosity and enhance their coatability in a disc-type electrostatic coater.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a somewhat diagrammatic and broken away view of a portion of the process of this invention, showing the conveying for conveying stacks of tubular elements for the application of adhesive in a disc-type electrostatic coater;
FIG. 2 is a flow diagram showing the manner in which the parts are carried to two electrostatic coaters on a continuous conveyor through a double pass oven; and
FIG. 3 is a perspective view of a part which has been coated with adhesive according to the process of this invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring first to FIG. 1, a conveyor 10, which is grounded, is shown as supporting a plurality of depending wire rods 12 therefrom, on which have been stacked in end-to-end abutting relation a plurality of workpieces 15 in the form of tubular metal sleeves. FIG. 3 shows a perspective view of one of such sleeves, which may form the inside bushing of the eye of a shock absorber and have bonded to its outer surface a quantity of natural or synthetic rubber. The sleeves 15 are held in such stacked relation on the depending rods by a bottom keeper key or pin 17.
The conveyor 10 is shown as passing about an applicator disc 20 of an electrostatic disc-type applicator 22. The disc 20 is mounted for rotation by a motor 23 on a rod or shaft 24. A supply of diluted adhesive (not shown) is delivered through a pipe 25 to the disc 20 for application to the surface of the disc.
In accordance with known technology, such as shown in the U.S. Pat. No. of Miller, 3,649,408 of Mar. 14, 1972, a direct current supply (not shown) is attached to apply a suitable potential to the disc 20, such as a negative potential of between 72,000 and 78,000 volts. The disc 22 is reciprocated on an insulating shaft 24, such as by a piston motor 30 and is slowly moved up and down with relation to the rods, in the housing 32 for the purpose of evenly distributing the elastomer material which is being atomized off of the circumference of the disc. As an example, the disc 20 may be fifteen inches in diameter and be driven at a rate of 1,800 rpm.
Preferably, a pair of disc-type electrostatic applicators 22 are employed, such as the applicators 22a and 22b as diagramatically illustrated in FIG. 2. The conveyor 10 is a continuous or closed loop conveyor leading past a loading station 35, at which point the rods 12 and assembled workpieces 15 are loaded onto the conveyor for passage through a first disc-type applicator 22. The applicator 22a may apply a priming adhesive coat such as the material previously identified above as Chemlok 205. The electrostatic field results in the coating being uniformly applied to the outer surface of the grounded workpieces, such as the coating represented by the reference numeral 36 in FIG. 3, with very little if any coating forming on the interior. The support rods 12 may be rotated as they are carried by the conveyor 10 so that all sides of the sleeves are exposed for coating.
The thus coated sleeves 15 on the rods 12 are delivered in a first pass through one side of a double pass oven 40 for initial curing. The oven 40 is preferably operating at a temperature of approximately 150° F., and the coating, in accordance with this invention, is cured in approximately three minutes. The now somewhat heated workpieces are delivered to the second disc-type electrostatic coater 22b, where the second or final adhesive coating is applied. After the application of such coating, by reason of the passage of the depending rods 12 and stacked workpieces thereon about the disc 20, the conveyor 10 exits and follows a second pass through the oven 40 for curing of the second coat. The second coat is enhanced in its curing by reason of the preheating which had been applied to the pieces following the first application of coating material. Upon leaving the oven 40, the pieces are returned to the station 35 for removal.
A particular improvement in the process of the present invention resides in the employment of an especially formualted diluent or solvent in place of the recommended solvents for each of rubber-to-metal adhesives applied by the applicators 22a and 22b. It has been found that a solvent which contains, as its principal constituents, cyclohexanone and petroleum solvents, is particularly effective in maintaining the desired wetness of the atomized adhesive while still permitting the desired dilution and viscosity. For example, one part of adhesive is mixed with about one to 1.25 parts of solvent. The solvent is added to obtain an average viscosity of between 22 and 26 seconds in a No. 2 Zahn cup, at room temperature.
The solvent may be formulated as follows:
4 parts cyclohexanone
2 parts SC150 (a heavy aromatic naphthalene petroleum based solvent consisting primarily of C10 hydrocarbon and 9% naphthalene by mass)
2 parts SC100 (a light aromatic naptha petroleum based solvent consisting primarily of C9 aromatic hydrocarbon and containing 5% xylene by mass, of Exxon Corporation)
1 part methyl ethyl ketone (MEK)
The solvent as identified above raises the polarity of the adhesive, thus optimizing the efficiency of atomization with the optimum polarity being between 0.3 and 0.5 megohms achieved by the addition of the cyclohexanone and MEK. About one part of solvent is mixed with one part of adhesive, in lieu of the diluents or solvents conventionally employed, to provide a sufficiently low viscosity and slow drying rate.
The general rule in formulating the solvent mix identified above it not to add any more SC150 petroleum based solvent than is necessary. If an excess of SC150 is used, the evaporation rate can be slowed down to the point where the subsequent drying of the coating may prove to be more difficult, and unevaporated solvent in the coating could present problems with the subsequent elastomer molding operation. While the favorable slow evaporation rate of the SC150 component is particularly useful in enabling the delivery of a wet adhesive to the parts, it is a general rule not to add any more of this component than necessary to assure such wet delivery and wet coating qualities. It is also within the scope of this invention, if required, to preheat the adhesive mix prior to application of the disc, and thus the diluted adhesive may be preheated such as to 110°-130° F. by a heater and a recirculating pump, for each of the solvent supplies associated with the applicators 22a and 22b. Heating may be useful in some instances to adjust the viscosity.
While the process herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise process, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | A method for applying rubber-to-metal adhesives to metal parts, such as tubular metal sleeves, employs electrostatic disc-type coaters includes the employment slow solvents which maintain the adhesive in a wet or liquid condition from its atomization at the disc to its deposition on the parts. The adhesives are diluted with a solvent which contains cyclohexanone and petroleum solvents. | 1 |
FIELD OF THE INVENTION
The invention relates to an instrument for use in orthopedic surgery, and more particularly, to an instrument used as a cutting guide for prosthetic joint revision surgery.
BACKGROUND OF THE INVENTION
Replacement of joints, such as knees and hips, with prostheses in human beings has become quite common. As replacements have become more common, the need to replace the artificial joints, known as revision surgery, has also become more common. Reasons for replacement include wear of the artificial joint, installation of a newer, stronger prosthesis or to address or readdress other issues relating to a patient's bone structure.
Removal of a previous prosthesis can cause destruction of a significant amount of bone tissue in the area where the prosthesis was attached. This renders it difficult to mount to the bone instruments that guide cutting tools used to resect the bone as required for installation of a new prosthesis. One approach for mounting instruments requires placement of an intramedullary alignment rod into the bone being resected. Then, instrumentation, such as drilling guides, cutting guides and the like, may be located on the intramedullary alignment rod.
U.S. Pat. No. 5,387,216 provides an example of intramedullary rod based instruments for total knee revision, wherein a notch guide is located on the rod by means of a handle. A dovetail joint connects the handle to the notch guide. However, instruments configured for use with dovetail joints can be heavy, difficult to position correctly and could impede access to the surface of the bone being resected. Furthermore, the instrument does not include structures for securely binding the notch guide to the rod to prevent movement of the instrument during surgery.
In another example, U.S. Pat. No. 5,053,037 discloses femoral instrumentation that is located on the femur by means of an elongated drill/reamer. A removable collet is used to locate a drilling guide with respect to the drill/reamer. The removable collet resides in an elongated slot in the drilling guide and is registered on posts which may be provided with spring loaded locking means, such as a spring loaded ball. Instruments located by collets that are held in place by spring balls can suffer from many of the problems described with regard to instruments that are held in place by dovetail joints. Further, spring balls may have a limited life.
Instruments such as those described above have helped to improve the accuracy of bone resection, and in particular, resection of the distal portion of a femur for the introduction of a prosthesis. However, devices capable of providing a more secure connection of an instrument to an intramedullary rod are needed to move to the next level of accuracy.
SUMMARY OF THE INVENTION
The present invention provides a medical instrument including a block, such as a cutting guide, and a bushing securable to the cutting guide. A locking device associated with the cutting guide securely binds the bushing to the cutting guide.
In an exemplary embodiment, a medical instrument for orthopedic surgery includes a block having a first face, a second face, a passage through the block from the first face to the second face, a first recess formed in the first face, and a second recess formed in the first face that is separated from the first recess. A locking device is secured to the first surface of the block, wherein a portion of the locking device is selectably positionable over a portion of the first recess. A bushing defining a bore, is receivable within the first recess to align the bore with at least a portion of the passage through the block. The bushing can include a first flange receivable within the first recess of the block, an intermediate portion defining the bore, and a second flange receivable within the second recess.
The bore through the bushing can be offset to one side of the bushing and the bore can also be offset from the longitudinal axis of the bushing. Furthermore, the bore through the bushing can be angled. A protuberance can be provided on one of the flanges of the bushing for insertion into a complimentary secondary recess defined in the recess that is dimensioned to receive the flange.
The block can include a bias element, such as a spring washer, that urges a face of the locking device, including a notch, toward the first face of the block. A notch engagement element, such as a sphere that is partially disposed within the block and which is rotatable with respect to the block, enters the notch when a selected portion of the locking device is positioned over a portion of the first recess and a portion of the bushing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a view of a cutting guide and bushing in accordance with the present invention;
FIG. 2 is a perspective view of the cutting guide shown in FIG. 1 without a bushing;
FIG. 3 is a view of the cutting guide and bushing shown in FIG. 1;
FIGS. 4-6 illustrate additional features and embodiments of the bushing shown in FIG. 1; and
FIG. 7 is a partial sectional view of the cutting guide of FIG. 1 taken along line 7--7.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a medical instrument is illustrated that includes a block or cutting guide 10 having a first face 12 and a second face (not shown) opposite the first face. The cutting guide 10 defines a passage 14 through the cutting guide from the first face to the second face. A bushing 16 is shown mated to the cutting guide 10 so as to transect or cross at least a portion of the passage 14. The bushing defines a bore 18 that is aligned with at least a portion of the passage 14. Although the bushing can be variously configured, in FIG. 1 the bushing is shown as an elongate body that includes a first flange 20, a second flange 22, and an intermediate portion 24 between the first and second flanges. First and second locking devices 26 and 28, respectively, are secured to the first face 12 of the cutting guide 10 and are selectively positionable, as described in greater detail below, to trap a portion of the bushing 16 within the cutting guide 10.
Referring now to FIG. 2, the cutting guide 10 is shown without a bushing 16 in order to reveal features of the cutting guide obscured by the bushing in FIG. 1. In the illustrated embodiment, the cutting guide 10 includes a first recess 30 separated from a second recess 32 in opposition across the passage 14. Fewer or additional recesses can be provided as desired to correspond with the configuration of a selected bushing 16.
In an exemplary cutting guide 10, each recess abuts and opens into the passage 14. Each recess further includes a surface 34 which is substantially parallel to the first face 12, and a side wall 36. The exemplary recesses 30 and 32 are substantially rectangular in shape with rounded corners and are substantially identical. While the rectangular shape may be advantageous, any recess configuration which comports with the objects of the invention may be used. Such configurations could include, for example, an annular recess with a circumferential side wall.
The recesses 30 and 32 can be provided with secondary recesses 38 and 40, respectively. As shown the secondary recesses 38 and 40 are substantially cylindrical and are generally located in a central portion of a wall portion that defines the distal end of the recesses 30 and 32.
In the exemplary embodiment shown in FIG. 2, the first locking device 26 is associated with the first recess 30 and the second locking device 28 is associated with the second recess 32 in such a way as to allow at least portions of each locking device to be selectively positionable over at least a portion of each respective recess in the cutting guide 10. Each of the exemplary locking devices 26, 28 includes a cover portion 42 rotatable about a screw 44 that is partially embedded within the cutting block 10. A handle portion 46 can be provided for leverage to rotate the cover portion 42.
Each locking device 26, 28 can be configured and positioned so that no portion of the locking device covers its respective recess 30, 32, thereby defining an unlocked position. Conversely, each locking device 26, 28 can be also be configured and positioned to cause some portion of the locking device to cover its respective recess 30, 32, thereby defining a locked position.
The operation of the exemplary selectively positionable locking devices 26 and 28 is further explained by reference to FIGS. 2, 3 and 1 in succession. In FIG. 2, the cutting guide 10 is shown without a bushing. The locking devices 26 and 28 are in the unlocked position. Now referring to FIG. 3, the bushing 16 has been mated to the cutting guide 10, but the locking devices 26 and 28 remain in the unlocked position as described above. Finally, referring to FIG. 1, the bushing 16 is shown mated to the cutting guide 10, and the locking devices 26 and 28 have been selectively moved to the locked position. Thus, the bushing 16 is tightly bound and substantially immovable with respect to the cutting guide 10.
Referring again to FIG. 2, the cutting guide 10 may also include one or more guide surfaces such as chamfer guides 48, notch guide surfaces 50, and a transverse cut guide surface 52. The depicted guide surfaces may be used by a surgeon to direct a saw or an osteotome to remove portions of bone as required. The cutting guide 10 may also be provided with a one or more holes 54 to allow for the insertion of pins (not shown), or more particularly, Steinman pins, during surgery to secure the cutting guide to a bone.
Additional features of the bushings are now described with respect to FIGS. 4-6, wherein the intermediate portion 24 of the bushing 16 is substantially cylindrical and thicker than the first flange 20 and the second flange 22. Regardless of whether the intermediate portion 24 of the bushing is thicker than the flanges 18, 22, and regardless of its shape, the intermediate portion, and more particularly the bore 18 can be offset longitudinally from a longitudinal center point 56 of the bushing as illustrated in FIGS. 4-6. Additionally, the bore defined by the intermediate portion can be offset laterally from a longitudinal axis 58 of the bushing as shown in FIG. 6.
The bushing 16 can define a plane that is substantially parallel with first face 12 of the cutting guide 10 when the bushing is received within the cutting guide, and the bore 18 defined by the intermediate portion 24 can include a longitudinal axis 60 that intersects the plane defined by the bushing at an angle less than 90 degrees to provide an angled bore. FIGS. 4 and 5 depict different views of the same exemplary bushing 16 to illustrate an angled bore 18, wherein one end of the bore is visible in FIG. 4 and a second end of the bore is visible in FIG. 5. Angulation of the bore 18 can be defined with respect to the angular deviation of the longitudinal axis of the bore 60 with respect to a plane defined by the bushing. In selected embodiments, the bore is angled 5° to 7° from the vertical.
Yet another feature of the invention is illustrated in FIG. 4, wherein a protuberance 62 extends from a surface 64 of one of the flanges. The protuberance 62 is receivable within the secondary recesses 38, 40 of either the first or the second recess 30, 32, respectively, depending on the orientation of the bushing 16 as it is mated with the cutting guide 10.
Additional features of an exemplary locking device are shown in FIG. 7, wherein the medical instrument further includes a bias element 66 such as a spring or curved washer that urges a face 68 of the locking device toward the first face 12 of the cutting guide. A notch 70 is defined in the face 68 of the locking device that is urged toward the first face 12 of the cutting guide. Extending from the first face 12 of the cutting guide is a notch engagement element 72 that enters the notch 70 when a selected portion of the locking device is positioned over a portion of the first recess and a portion of the bushing as shown and described above. In the illustrated embodiment, the notch engagement element 72 is a sphere that is partially disposed within the cutting guide and which is rotatable with respect to the cutting guide. Entry of a portion of the sphere 72 into the notch 70 can provide aural and/or tactile assurance that the locking device has reached the locked position. Depending upon the bias force provided by the bias element 66, the engaged sphere 72 and notch 70 can inhibit the locking device from becoming unintentionally unlocked.
The instrument described above may be used for knee revision femoral augmentation as follows. A bushing is selected and inserted into the cutting guide with the appropriate orientation, right or left, for the right or left femur. The bushing guide is next positively locked into place by rotating the locking devices into the locked position. The bore is mated with an intramedullary alignment rod and advanced to the distal surface of the femur. Steinman pins may be introduced through the cutting guide and into the femur as needed to prevent rotational movement of the guide about the intramedullary alignment rod and to hold the guide member in place for cuts that may be made after the intramedullary alignment rod is removed. Bilateral notch cuts and chamfers may then be made by directing an oscillating saw using guide surfaces provided in the cutting guide. The locking devices can be unlocked to remove the bushing and the intramedullary alignment rod from the femur without disturbing the position of the guide member. With the intramedullary alignment rod removed, transverse cuts may be made using a 1/2 inch blade or an osteotome. The proximal anterior chamfer may be fashioned in a like manner. It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. | An instrument for orthopedic surgery comprising a block or cutting guide having a recess, and at least one locking device located on the cutting guide. The locking device is selectively movable between a first position in which a portion of the locking device covers a portion of the recess and a second position in which the recess is unobstructed. A bushing having a portion adapted to removably and replaceably mate with the recess on the cutting guide is also disclosed. The instrument is particularly useful for distal femoral augmentation in knee revision surgery. | 0 |
This application is a divisional of application Ser. No. 08/946,101, filed on Oct. 7, 1997, which is a divisional of allowed application Ser. No. 08/624,105, filed on Mar. 29, 1996, U.S. Pat. No. 5,739,401 the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to N-(α-alkylbenzylidene)-α-phenylalkylamine, its use, a process for producing the same and a process for producing intermediates therefor.
RELATED PRIOR ART
Optically active α-phenylalkylamines are useful compounds which are intermediates for agricultural chemicals and pharmaceuticals, such as phenylalkylcarbamate type pesticides and aralkylamine type calcium antagonists (for example, see JP-A 63-238054, JP-A 2-76846, JP-A 2-11550). As a process for producing optically active 1-(2',4'-dichlorophenyl)ethylamine, there has been known a process by optically resolving its racemate using N-formylphenylalanine as a resolving agent (JP-A 2-306942). As a process for production of optically active 1-(3-methoxyphenyl)ethylamine, there has been known a process by optically resolving its racemate using malic acid or the like as a resolving agent (JP-A 58-41847).
It has been desired that the undesirable antipode which is left after separation of useful optically active compound is effectively used, for example, that the undesirable compound is converted to its racemate by racemization to reuse the compound.
As a process for producing racemate of α-arylalkylamines by racemization of optically active compounds thereof, there have been known a process for producing racemate of α-phenylethylamines by a treatment with sodium naphthalene (JP-A 50-49235), a process for producing racemate of α-naphthylethylamines by a treatment with sodium hydride (JP-A54-5967), a process for producing racemate of α-phenylethylamine by a treatment with sodium carried on alumina (JP-A 50-50328) and the like.
However, when the above known processes were applied, for example, to optically active α-halogen-substituted phenylalkylaminess, there arises a problem that racemization reaction does not proceed at all. In addition, when applied to optically active α-alkoxy-substituted phenylalkylamines, there arises a problem that racemization reaction does not proceed at all depending upon the kind of the amines and that a large amount of catalyst is required and sufficient yield can not be obtained even in the case of the amines where racemization reaction proceeds.
On the other hand, as a process for producing racemate of α-halogen-substituted phenylalkylamines by racemization of optically active α-halogen-substituted phenylalkylamines, there has also been known a process for producing racemate of 1-(4-chlorophenyl)ethylamine by a treatment with alkali metal alkoxide in dimethyl sulfoxide. However, when this process was applied, for example, to other optically active α-halogen- or α-alkoxy-substituted phenylalkylamines, there arises a problem that racemization reaction does not proceed at all depending upon the kind of the amines and that a large amount of catalyst is required and the sufficient yield can not be obtained even in the case of the amines where the reaction proceeds.
OBJECTS OF THE INVENTION
A main object of the present invention is to provide a useful N-(α-alkyibenzylidene)-α-phenylalkylamine and a process for producing the same.
Another object of the present invention is to provide a process for producing useful intermediates therefor.
These objects as well as other objects and advantages of the present invention will become apparent from the following description.
SUMMARY OF THE INVENTION
Under these circumstances, the present inventors studied processes for producing α-phenylalkylamines by racemization of optically active compounds. As a result of intensive studies, they discovered that compounds obtainable by condensing optically active α-phenylalkylamines with phenyl alkyl ketones are easily racemized by a treatment with alkali metal alkoxides in a specific solvent and that the racemates thereof can be easily converted to α-phenylalkylamines. By the discoveries and further studies, the present invention had been accomplished.
That is, the present invention relates to an N-(α-alkylbenzylidene)-α-phenylalkylamine represented by formula (1): ##STR2## wherein the R 1 substituents may be the same or different and represent a lower alkyl group, the R 2 substituents may be the same or different and represent a hydrogen atom, a halogen atom, a lower alkyl group or a lower alkoxy group, and X substituents may be the same or different and represent a halogen atom or a lower alkoxy group, as well as its use, a process for producing the amines and a process for producing intermediates therefor.
DETAILED DESCRIPTION
The present invention will be described in detail.
As used herein, "an optically active isomer of a compound" means the R isomer in pure form or substantially free from the S isomer, S isomer in pure form or substantially free from the R isomer, or a mixture of the R isomer and the S isomer which contains an excess of either the R isomer or the S isomer, except for optically active mandelic acid below.
An optically active isomer of an N-(α-alkylbenzylidene)-α-phenylalkylamine (1) in the present invention can be prepared by condensing an optically active α-phenylalkylamine represented by formula (2): ##STR3## wherein R 1 , R 2 and X are as defined above, with a phenyl alkyl ketone represented by formula (3): ##STR4## wherein R 1 , R 2 and X are as defined above. Preferably, in formula (1), the R 1 substituents are the same, the R 2 substituents are the same and the X substituents are the same. Preferably, the R 2 and X substituents are attached to the phenyl moiety at the same position.
The phenyl alkyl ketone of formula (2) are commercially available or may be produced by known processes or by analogy with known processes.
R 1 in formula (1) and (2) is typically a lower alkyl groups having 1 to 5 carbon atoms, preferably 1 to 4 carbon atoms. Typically, R 1 is a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, sec-butyl group, pentyl group, and the like. Methyl is preferred.
Examples of R 2 are hydrogen atom; halogen atoms such as fluoro atom, chloro atom and bromo atom; lower alkyl groups having 1 to 4 carbon atoms, such as methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, sec-butyl group and the like, and lower alkoxy groups having 1 to 3 carbon atoms, such as methoxy group, ethoxy group, n-propoxy group, isopropoxy group and the like.
Examples of X are the same halogen atoms and lower alkoxy groups as those described in R 2 .
Specific examples of optically active isomers of α-phenylalkylamine (2) are optically active isomers of 1-(2'-chlorophenyl)ethylamine, 1-(3'-chlorophenyl)ethylamine, 1-(4'-chlorophenyl)ethylamine, 1-(2',3'-dichlorophenyl)ethylamine, 1-(2',4'-dichlorophenyl)ethylamine, 1-(2',5'-dichlorophenyl)ethylamine, 1-(2',6'-dichlorophenyl)ethylamine ,1-(3',4'-dichlorophenyl)ethylamine, 1-(3',5'-dichlorophenyl)ethylamine, 1-(4'-bromophenyl)ethylamine, 1-(2',4'-dibromophenyl)ethylamine, 1-(3'-bromophenyl)ethylamine, 1-(3',4'-dibromophenyl)ethylamine, 1-(2'-methoxyphenyl)ethylamine, 1-(3'-methoxyphenyl)ethylamine, 1-(4'-methoxyphenyl)ethylamine, 1-(2',3'-dimethoxyphenyl)ethylamine, 1-(2',4'-dimethoxyphenyl)ethylamine, 1-(3',4'-dimethoxyphenyl)ethylamine, 1-(3',5'-dimethoxyphenyl)ethylamine, 1-(2'-methyl-4'-chlorophenyl)ethylamine, 1-(3'-methyl-4'-chlorophenyl)ethylamine, 1-(2'-bromo-4'-ethylphenyl)ethylamine, 1-(3'-chloro-4'-ethylphenyl)ethylamine, 1-(2'-methoxy-4'-bromophenyl)ethylamine, 1-(3'-methoxy-4'-chlorophenyl)ethylamine, 1-(2'-bromo-4'-ethoxyphenyl)ethylamine, 1-(3'-chloro-4'-ethoxyphenyl)ethylamine, 1-(2',4'-dichlorophenyl)isobutylamine, 1-(3',4'-dichlorophenyl)isobutylamine, 1-(3'-methoxyphenyl)isobutylamine, 1-(3',4'-dimethoxyphenyl)isobutylamine, 1-(3',4'-dichlorophenyl)propylamine, 1-(2'-fluorophenyl)ethylamine, 1-(3'-fluorophenyl)ethylamine and 1-(3'-methoxyphenyl)propylamine.
Examples of R 1 in phenyl alkyl ketone (3), formula (4), formula (5) and formula (6) are the same as the examples given for R 1 in α-phenylalkylamine (2). Methyl is preferable.
Examples of R 2 in phenyl alkyl ketone (3), formula (4), formula (5) and formula (6) are the same as the examples given for R 2 in α-phenylalkylamine (2).
Examples of X in formula (3), formula (4), formula (5) and formula (6) are the same as the examples given for X in α-phenylalkylamine (2).
Specific examples of phenyl alkyl ketone (3) are 2'-chloroacetophenone, 3'-chloroacetophenone, 4'-chloroacetophenone, 2',3'-dichloroacetophenone, 2',4'-dichloroacetophenone, 2',5'-dichloroacetophenone, 2',6'-dichloroacetophenone, 3',4'-dichloroacetophenone, 3',5'-dichloroacetophenone, 3'-bromoacetophenone, 4'-bromoacetophenone, 2',4'-dibromoacetophenone, 3',4'-dibromoacetophenone, 2'-methyl-4'-chloroacetophenone, 3'-methyl-4'-chloroacetophenone, 2'-bromo-4'-ethylacetophenone, 3'-methoxy-4'-ethylacetophenone, 2'-methoxy-4'-bromoacetophenone, 3'-methoxy-4'-chloroacetophenone, 2,-bromo-4'-ethoxyacetophenone, 3'-chloro-4'-ethoxyacetophenone, 2'-methoxy-4'-bromoacetophenone, 2',4'-dichlorophenyl isopropyl ketone, 3',4'-dichlorophenyl isopropyl ketone, 3'-methoxyphenyl isopropyl ketone, 3',4'-dimethoxyphenyl isopropyl ketone, 3',4'-dichlorophenyl ethyl ketone, 2'-chlorophenyl ethyl ketone, 3'-chlorophenyl ethyl ketone, 4'-chlorophenyl ethyl ketone, 2'-chlorophenyl i-propyl ketone, 3'-chlorophenyl i-propyl ketone, 4'-chlorophenyl i-propyl ketone, 2-chlorophenyl n-propyl ketone, 3'-chlorophenyl pentyl ketone, 2'-methoxyacetophenone, 3'-methoxyacetophenone, 2',3'-dimethoxyacetophenone, 2',4'-dimethoxyacetophenone, 3',4'-dimethoxyacetophenone, 3',5'-dimethoxyacetophenone, 2'-fluoroacetophenone, 3'-fluoroacetophenone, 4'-fluoroacetophenone, 3'-chloro-4 '-fluoroacetophenone and 3-methoxyphenyl ethyl ketone. Usually, phenyl alkyl ketone (3) have the same kind and position of substituents R 1 , R 2 and X as do the α-phenylalkylamine (2).
Optically active isomer of N-(α-alkylbenzylidene)-α-phenylalkylamine (1) can be obtained by condensing optically active isomer of α-phenylalkylamine (2) with phenyl alkyl ketone (3) according to the known process, for example, disclosed in J. Org. Chem., (1984), 49, 2624-2626. In the condensation reaction, phenyl alkyl ketone (3) is usually used at an amount of 0.5 to 2 mole, preferably 0.95 to 1.05 mole, per one mole of optically active isomer of α-phenylalkylamine (2).
The condensation reaction is usually carried out in the presence of a catalyst and a solvent. Alternatively, the reaction may be carried out without a solvent. When a solvent is used, solvents may be used as long as they do not ED affect adversely on the reaction. Examples of the solvent are aromatic hydrocarbons, such as toluene, benzene, xylene, chlorobenzene and the like; ethers such as dioxane, methyl t-butyl ether and the like; aliphatic hydrocarbons such as hexane, heptane and the like; and halogenated hydrocarbons such as dichloroethane, chloroform and the like. The reaction is preferably carried out while water produced by the condensation is removed from the reaction system.
The amount of the solvent to be used is usually 0 to 20 parts by weight, preferably 3 to 10 parts by weight, per one part by weight of optically active isomer of α-phenylalkylamine (2).
Examples of the catalyst are Lewis acids such as zinc chloride, zinc bromide, zinc fluoride, titanium tetrachloride, boron trifluoride, boron tribromide, phosphorus trichloride, magnesium bromide, iron chloride, aluminium chloride, tin tetrachloride, titanium alkoxide, copper (II) triflate and the like; sulfonic acids such as benzenesulfonic acid, p-toluenesulfonic acid, sulfonic ion-exchange resin and the like; and heteropolyacids such as 12-tungsto(IV)phosphoric acid, 12-tungsto(IV)silicic acid and the like.
Among them, zinc chloride, titanium alkoxide, titanium tetrachloride, boron trifluoride and p-toluenesulfonic acid are preferably used. More preferably, zinc chloride and titanium alkoxide are used.
The amount of the catalyst to be used is usually 0.001 to 0.1 mole, preferably 0.005 to 0.05 mole per one mole of optically active isomer of α-phenylalkylamine (2).
Reaction temperature is usually from about 70 to 180° C. The reaction is preferably carried out while water produced by the condensation is removed from the reaction system.
A reaction time is usually about 1 to 20 hours.
The resulting optically active isomer of N-(α-alkylbenzylidene)- α-phenylalkylamine (1) may be used as it is in the next step after the catalyst is removed from the reaction mixture. Alternatively, fractions having low boiling point may be removed, for example, by distillation or the like. Alternatively, the optically active isomer of compound (1) may be further purified by distillation, recrystallization, various chromatographies or the like after separation.
Thus, optically active isomer of N-(α-alkylbenzylidene)-α-phenylalkylamine (1) are obtained. Examples thereof are optically active isomers of N-(α-methyl-2'-chlorobenzylidene)-α-(2'-chlorophenyl)ethylamine, N-(α-methyl-3'-chlorobenzylidene)-α-(3'-chlorophenyl)ethylamine, N-(α-methyl-4'-chlorobenzylidene)-α-(4'-chlorophenyl)ethylamine, N-(α-ethyl-2'-chlorobenzylidene)-α-(2'-chlorophenyl)propy lamine, N-(α-ethyl-3'-chlorobenzylidene)-α-(3'-chlorophenyl)propylamine, N-(α-ethyl-4'-chlorobenzylidene)-α-(4'-chlorophenyl)propylamine, N-(α-n-propyl-2'-chlorobenzylidene)-α-(2'-chlorophenyl)-n-butylamine, N-(α-n-propyl-3'-chlorobenzylidene)-α-(3 -chlorophenyl)-n-butylamune, N-(α-n-propyl-4'-chlorobenzylidene)-α-(4'-chlorophenyl)-n-butylamine, N- (α-methyl-2',3'-dichlorobenzylidene)-α-(2',3'-dichlorophenyl)ethylamine, N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)ethylamine, N-(α-methyl-2',5'-dichlorobenzylidene)-α-(2,5'-dichlorophenyl)ethylamine, N-(α-methyl-2',6'-dichlorobenzylidene)-α-(2',6'-dichlorophenyl)ethylamine, N-(α-methyl-3',4'-dichlorobenzylidene)-α-(3',4'-dichlorophenyl)ethylamine, N-(α-methyl-3',5'-dichlorobenzylidene)-α-(3',5'-dichlorophenyl)ethylamine, N-(α-methyl-2',5'-dichlorobenzylidene)-α-(2',5'-dichlorophenyl)ethylamine, N-(α-ethyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlarophenyl)propylamine, N-(α-ethyl-3',4'-dichlorobenzylidene)-α-(3',4'-di chlorophenyl)propylamine, N-(α-ethyl-2',5'-dichlorobenzylidene)-α-(2',5'-dichlorophenyl)propylamine, N-(α-methyl-4'-bromobenzylidene)-α-(4'-bromophenyl)ethylamine, N-(α-ethyl-2'-bromobenzylidene)-α-(2'-bromophenyl)propylamine, N-(α-ethyl-3'-bromobenzylidene)-α-(3'-bromophenyl) propylamine, N-(α-ethyl-4'-bromobenzylidene)-α-(4'-bromopheny 1)propylamine, N-(α-methyl-2',4'-dibromobenzylidene)-α-(2',4'-dibromophenyl)ethylamine, N-(α-ethyl-2',4'-dibromobenzylidene)-α-(2',4'-dibromophenyl)propylamine, N-(α-methyl-2'-chloro-4'-methylbenzylidene)-α-(2'-chloro-4'-methylphenyl)ethylamine, N-(α-ethyl-3'-chloro-4'-methylbenzylidene)-α-(3'-chloro-4'-methylphenyl)propylamine, N-(α-methyl-2'-chloro-4'-methoxybenzylidene)-α-(2'-chloro-4'-methoxyphenyl)ethylamine, N-(α-ethyl-3'-chloro-4'-methoxybenzylidene)-α-(3'-chloro-4'-methoxyphenyl)propylamine N-(α-isopropyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)isobutylamine, N-(α-isopropyl-3',4'-dichlorobenzylidene)-α-(3',4'-dichlorophenyl)isobutylamine, N-(α-ethyl-3'-methoxybenzylidene)-α-(3'-methoxyphenyl)propylamine, N-(α-ethyl-3',4'-dimethoxybenzylidene)-α-(3',4'-dimethoxyphenyl)propylamine, N-(α-methyl-2'-methoxybenzylidene)-α-(2'-methoxyphenyl)ethylamine, N- (α-methyl-3'-methoxybenzylidene)-α-(3'-methoxyphenyl)ethylamine, N-(α-methyl-2',3'-dimethoxybenzylidene)-α-(2',3'-dimethoxyphenyl)ethylamine, N-(α-methyl-2',4'-dimethoxybenzylidene)-α-(2',440 -dimethoxyphenyl)ethylamine, N-(α-methyl-3',4'-dimethoxybenzylidene)-α-(3',4'-dimethoxyphenyl)ethylamine, N-(α-methyl-3',5'-dimethoxybenzylidene)-α-(3',5'-dimethoxyphenyl)ethylamine, N-(α-methyl-2'-fluorobenzylidene)-α-(2'-fluorophenyl)ethylamine and N-(α-methyl-3'-fluorobenzylidene)-α-(3'-fluorophenyl)ethylamine.
The optically-active isomer of N-(α-alkylbenzylidene)-α-phenylalkylamine (1) can be racemized by treatment with an alkali metal alkoxide in the presence of dimethyl sulfoxide.
N-(α-alkylbenzylidene)-α-phenylalkylamine (1) wherein R 2 and/or X is lower alkoxy group such as methoxy group are particularly effective in the racemization compared with conventional processes.
Examples of appropriate alkali metal alkoxide are salts of tertiary alkoxides with alkali metals such as potassium t-butoxide, sodium t-butoxide, potassium t-amyloxide, sodium t-amyloxide and the like.
The amount of the alkali metal alkoxide to be used is usually 0.01 to 2 mole, preferably 0.03 to 0.2 mole, per one mole of N-(α-alkylbenzylidene)-α-phenylalkylamine (1).
The amount of dimethyl sulfoxide to be used is usually 0.1 to 10 mole, preferably 0.5 to 5 mole, per one mole of N-(α-alkylbenzylidene)-α-phenylalkylamine (1). Dimethyl sulfoxide may be, of course, used as a solvent at a large amount.
Racemization reaction is usually carried out in the presence of a solvent.
The solvents may be used as long as they do not affect adversely on the reaction. Examples of the solvent are aromatic hydrocarbons such as toluene, benzene, xylene, chlorobenzene and the like; ethers such as diethyl ether, methyl t-butyl ether, dioxane and the like; aliphatic hydrocarbons such as hexane, heptane and the like; and dimethyl sulfoxide.
The amount of the solvent varies depending upon the kind of the solvent used and is usually 0.3 to 100 parts by weight, preferably 0.5 to 10 parts by weight, per one part by weight of N-(α-alkylbenzylidene)-α-phenylalkylamine (1).
Reaction temperature and reaction time vary depending upon the kind and the amount of alkali metal alkoxide and the like. Reaction temperature is usually from 0° C. to boiling point of the solvent used, preferably from 0 to 100° C., more preferably from 10 to 80° C., particularly preferably from 10 to 50° C. Reaction time is usually about 1 to 48 hours.
The progression of the reaction can be monitored by polarimetry, i.e. by collecting a portion of the reaction mixture and measuring the angle by which it rotates polarised light. Alternatively, it is possible to analyse the composition of the reaction mixture by high performance liquid chromatography using an chiral column after hydrolysis.
The resulting racemate of N-(α-alkylbenzylidene)-α-phenylalkylamine (1) may be usually used as it is in the next step after dimethyl sulfoxide, alkali metal alkoxide or decomposition products thereof are removed from the reaction mixture by washing with an aqueous solution containing an inorganic salt such as sodium chloride. Alternatively, the compound (1) may be separated by distilling off fractions having low boiling point or the like. Alternatively, the compound (1) may be further purified by distillation, recrystallization, various chromatographies or the like after separation.
Racemate of N-(α-alkylbenzylidene)-α-phenylalkylamine (1) can be converted to racemate of α-phenylalkylamine (2) and phenyl alkyl ketone (3) by hydrolysis.
The hydrolysis is carried out, for example, in the presence of an acid such as dilute aqueous hydrochloric acid or dilute aqueous sulfuric acid optionally in the presence of a solvent.
The amount of the acid to be used is usually 1 to 10 equivalents, preferably 1.05 to 1.5 equivalents of the racemate of N-(α-alkylbenzylidene)-(x-phenylalkylamine (1).
The amount of Water including the one in the acid is usually from 1 to 1000 mole, preferably 20 to 100 mole, per one mole of racemate of N-(α-alkylbenzylidene)-α-phenylalkylamine (1).
When a solvent is used, the amount thereof is usually 0.1 to 5 parts by weight per one part by weight of racemate of N-(ac-alkylbenzylidene)-α-phenylalkylamine (1) .
The solvents may be used as long as they do not affect adversely on the reaction. Examples of the solvent are alcohol such as methanol, ethanol and the like; aliphatic hydrocarbons such as hexane, heptane and the like; halogenated hydrocarbons such as dichloroethane, chloroform and the like; esters such as ethyl acetate and the like; ethers such as dioxane, diethyl ether and the like; and aromatic hydrocarbons such as toluene, benzene, xylene, chlorobenzene and the like.
Reaction temperature and reaction time vary depending upon the kind and amount of the solvent used. The temperature is usually from 0° C. to boiling point of the solvent, preferably from about 30 to 70° C. The reaction time is usually 10 minutes to 5 hours.
Water-soluble acid salt of racemate of α-phenylalkylamine (2), and phenyl alkyl ketone (3) are formed by the hydrolysis. When the reaction is carried out without a solvent, racemate of α-phenylaklylamines (2) can be taken out by adding a water-insoluble solvent to the reaction mixture to extract and separate phenyl alkyl ketone (3) into oil layer, making the aqueous layer alkaline with an aqueous alkali solution such as an aqueous sodium hydroxide solution, extracting the alkaline aqueous layer with a water-insoluble solvent, and concentrating the resulting organic layer under reduced pressure.
When hydrolysis is carried out using an aqueous solvent such as alcohols or the like, after the alcohol is distilled off, the above treatment may be carried out. When a water-insoluble solvent is used, the same treatment as that described above may be carried out except that layers of the reaction mixture are separated as it is to extract and separate phenyl alkyl ketone (3) into the organic layer.
Alternatively, racemate of α-phenylalkylamine (2) may be taken out by steam-distilling the reaction mixture to remove phenyl alkyl ketone (3), adjusting aqueous layer to alkaline with an aqueous alkali solution such as aqueous sodium hydroxide solution, extracting with a water-insoluble solvent, and concentrating the resulting organic layer under reduced pressure.
Alternatively, the reaction mixture is adjusted to alkaline using an aqueous alkali solution such as aqueous sodium hydroxide solution, followed by extraction with a water-insoluble solvent to obtain a mixture of phenyl alkyl ketone (3) and racemate of α-phenylalkylamine (2), which may be subjected to conventional separation method such as column chromatography or the like to separate both compounds.
The separated and recovered phenyl alkyl ketone (3) can be recycled as raw materials.
Racemate of α-phenylalkylamine (2) can be optically resolved according to a method, for example, by J. Chem. Soc., (B) 1971, 2418, Bull. Chem. Soc. Jpn., 66, 3414 (1993), or J. Am. Chem. Soc., 105, 1584 (1983), to obtain optically active isomer of α-phenylalkylamine (2).
The optical resolution of 1-(3,4-dichlorophenyl)ethylamine, 1-(2,4-dichlorophenyl)ethylamine, 1-(2,3-dichlorophenyl)ethylamine, 1-(2-fluorophenyl)ethylamine, 1-(2-chlorophenyl)ethylamine, 1-(3,4-dimethoxyphenyl)ethylamine and the like (hereinafter, referred to as substituted amines (2)) using optically active mandelic acid is explained below.
As optically active mandelic acid, either S- or R-mandelic acid is used depending upon which isomer of optically active substituted amines (2) is required.
The amount of the optically active mandelic acid used is usually about 0.1 to 1.2 moles, preferably about 0.3 to 1 mole per one mole of the racemate of the substituted amines (2).
This reaction is usually carried out in an organic solvent. Examples of the solvent used are alcohols such as methanol, ethanol, n-propanol and the like; ketone such as acetone, methyl isobutyl ketone and the like; esters such as ethyl acetate and the like; ethers such as methyl t-butyl ether, dioxane, diethyl ether and the like; aromatic hydrocarbons such as toluene, xylene, chlorobenzene and the like; nitriles such as acetonitrile and the like; and a mixture of two or more of these. The solvent may contain water.
The amount of the solvent to be used varies depending upon the kind of solvent and that of substituted amines (2) and is usually 2 to 100 parts by weight, preferably 2 to 10 parts by weight, per one part by weight of racemate of the substituted amines (2).
Upon the optical resolution, after racemate of the substituted amines (2) and optically active mandelic acid are reacted in the above solvent to form diastereomer salts or pre-prepared diastereomer salts are dissolved in the above solvent, one of diastereomers is precipitated while settling or stirring the solution, and if necessary, cooling or condensing. The temperature is usually from -20° C. to boiling point of the solvent.
Thereafter, the precipitated salts are separated. If necessary, the resulting salt may be recrystallized. Then, the salt is decomposed using an alkali and the resulting oil or crystals is/are separated or extracted with an organic solvent to obtain the optically active substituted amines (2).
The remaining aqueous layer from which the oil or crystals has/have been separated or extracted may be made acidic with an acid, followed by extraction with an organic solvent to recover optically active mandelic acid.
On the other hand, the similar procedures to those described above may be applied to the mother liquor after one of diastereomers have been separated, to recover optically active isomer of substituted amines (2) having different absolute configuration and optically active mandelic acid.
Examples of alkali used for decomposing diastereomer salts are hydroxides, carbonates and bicarbonates of alkali metal such as sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate and the like. The amount of the alkali is usually 1 to 5 moles per one mole of the salt.
Examples of the solvent used for extracting optical isomers of the substituted amines (2) produced by salt decomposition are esters such as ethyl acetate and the like; ethers such as methyl t-butyl ether, tetrahydrofuran, diethyl ether and the like; and aromatic hydrocarbons such as toluene, xylener chlorobenzene and the like. The amount of the solvent is usually 0.1 to 5 parts by weight per one part by weight of the salt.
Examples of the acid used for recovering optically active mandelic acid are mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid and the like. The acid is used so that pH of the aqueous layer becomes 0.5 to 2. In this case, a salt such as sodium chloride or the like may be added thereto. The amount of the salt such as sodium chloride is usually about 0.1 to 0.2 part by weight per one part by weight of the aqueous layer.
Examples of the solvent used for extracting optically active mandelic acid are ethers such as methyl t-butyl ether and the like, esters such as ethyl acetate and the like, and alcohols which form separate layer to water, such as n-butanol and the like. The amount of the solvent is about 0.1 to 10 parts by weight per one part by weight of the aqueous layer.
α-Phenylalkylamine (2) can be prepared by a method heating a mixture of phenyl alkyl ketone (3), ammonium formate and formic acid according to J. Am. Chem. Soc., 58, 1808 (1936) or J. Am. Chem. Soc., 60, 919 (1938), or a method by heating a mixture of phenyl alkyl ketone (3) and formamide to obtain phenylalkylformamide represented by formula (4): ##STR5## wherein R 1 and R 2 are as defined above, and hydrolyzing the phenylalkylformamide (4). Alternatively, a α-phenylalkylamine (2) may be prepared by reacting phenyl alkyl ketone (3) with ammonia and hydrogen in the presence of Raney-nickel catalyst deactivated by a sulfur compound at a pressure of 120 atmospheric pressures as described in JP-A 2-73042.
However, since the yield of phenylalkylformamide (4) is low in the method described in J. Am. Chem. Soc., 58, 1808 (1936) or J. Am. Chem. Soc., 60, 919 (1938), the yield of α-phenylalkylamine (2) is consequently insufficient. In addition, in the method of JP-A 2-73042, there is not only a facility problem caused under a high pressure condition during the method, but also a problem that by-products such as alcohol, resulting from direct reduction of the phenyl alkyl ketone (3), are produced. Therefore, an improved method has been desired.
Thus, the present inventors discovered that an α-phenylalkylamine of formula (2) can be obtained at a high yield by adding a corresponding ketone and formic acid concurrently to formamide and/or ammonium formate. Such a process can be applied to not only α-phenylalkylamine (2) but also a wider variety of compounds than the α-phenylalkylamine (2).
The method is explained below.
N-formylamine represented by formula (4'):
R.sup.3 R.sup.4 CH-NH-CHO (4')
wherein R 3 represents lower alkyl group, unsubstituted or substituted aryl group or unsubstituted or substituted aralkyl group and R 4 represents unsubstituted or substituted aryl group or unsubstituted or substituted aralkyl group, can be obtained by adding ketone represented by formula (3'):
R.sup.3 R.sup.4 C═O (3')
wherein R 3 and R 4 are as defined above, and formic acid concurrently to formamide and/or ammonium formate.
R 3 represents a lower alkyl group, an optionally substituted aryl group or an optionally substituted aralkyl group. Examples of lower alkyl group are alkyl groups having 1 to 7 carbon atoms, such as methyl group, ethyl group, n-propyl group, i-propyl group, n-butyl group, i-butyl group, sec-butyl group, t-butyl group, pentyl group, and the like.
Examples of optionally substituted aryl group are unsubstituted aryl groups having 6 to 13 carbon atoms such as phenyl group, naphthyl group and the like; aryl groups, such as phenyl group, naphthyl group and the like, having 7 to 14 carbon atoms and having 1 to 3 substituents. Examples of the substituent are halogen atoms such as fluorine atom, chlorine atom, bromine atom, and the like; nitro group; the same lower alkyl groups as those described above; lower haloalkyl groups having 1 to 7 carbon atoms such as difluoromethyl group, trifluoromethyl group, and the like; lower alkoxy groups having 1 to 7 carbon atoms such as methoxy group, ethoxy group, n-propoxy group, i-propoxy group, n-butoxy group, i-butoxy group, sec-butoxy group, t-butoxy group, pentoxy group, and the like; lower haloalkoxy groups having 1 to 7 carbon atoms such as difluoromethoxy group, trifluoromethoxy group, and the like; lower aryloxy groups having 6 to 13 carbon atoms such as phenyloxy group, and the like; aralkyloxy groups having 7 to 14 carbon atoms such as benzyloxy group, and the like; and methylenedioxy group.
Examples of optionally substituted aralkyl group are unsubstituted aralkyl groups having 7 to 14 carbon atoms such as benzyl group, naphthylmethyl group and the like, and aralkyl groups, such as benzyl group, naphthylmethyl group and the like, having 7 to 14 carbon atoms and having 1 to 3 substituents. Typically, the alkyl moiety is a said lower alkyl group. Examples of the substituent are halogen atoms such as fluorine, chlorine, bromine, and the like; nitro group; the same lower alkyl groups as those described above; lower haloalkyl groups having 1 to 7 carbon atoms such as difluoromethyl group, trifluoromethyl group, and the like; lower alkoxy groups having 1 to 7 carbon atoms such as methoxy group, ethoxy group, n-propoxy group, i-propoxy group, n-butoxy group, i-butoxy group, sec-butoxy group, t-butoxy group, pentoxy group, and the like; lower haloalkoxy groups having 1 to 7 carbon atoms such as difluoromethoxy group, trifluoromethoxy group, and the like.
Examples of optionally substituted aryl group and optionally substituted aralkyl group in R 4 are the same as those described in R 3 .
When the above phenyl alkyl ketone (3) are used as the ketone (3'), α-phenylalkylformamide (4) can be obtained.
Typical examples of the ketone (3') are, in addition to the compounds described in the above phenyl alkyl ketone (3), acetophenone, 2'-nitroacetophenone, 3'-nitroacetophenone, 4'-nitroacetophenone, 4'-methoxyacetophenone, 2'-trifluoromethylacetophenone, 3'-trifluoromethylacetophenone, 4'-trifluoromethylacetophenone, 2'-trifluoromethylacetophenone, 3'-trifluoromethoxyacetophenone, 4'-trifluoromethoxyacetophenone, butyrophenone, 2'-methylacetophenone, 2'-chloro-4'-trifluoromethylacetophenone, 2'-nitrophenyl i-butyl ketone, 4'-methylphenyl propyl ketone, benzophenone, 4-chlorobenzophenone, benzyl methyl ketone, 2'-chlorobenzyl methyl ketone, 3'-methylbenzyl methyl ketone, 2'-methoxybenzyl methyl ketone, 3'-methoxybenzyl methyl ketone, 4'-methoxybenzyl methyl ketone, 3',4'-dichlorobenzyl methyl ketone, 3',4'-dimethoxybenzyl methyl ketone, 3'-bromo-4'-methoxybenzyl methyl ketone, 3'-trifluoromethylbenzyl methyl ketone, benzyl phenyl ketone, 4'-methylbenzyl phenyl ketone, 4t-methoxybenzyl phenyl ketone, 3',4'-dimethoxybenzyl phenyl ketone, 3'-benzyloxyacetophenone, 3',4'-methylenedioxyacetophenone, 3',4'-methylenedioxybenzyl methyl ketone, 1'-acetonaphthone, 2'-acetonaphthone, and the like.
Commercially available formamide or ammonium formate may be used, or formamide or ammonium formate prepared by reaction of formic acid and aqueous ammonia or ammonia gas may also be used. The amount thereof is usually 1 to 10 moles, preferably 2 to 4 moles in terms of nitrogen, per one mole of ketone (3').
The amount of formic acid to be used is usually 0.1 to 10 moles, preferably 0.5 to 5 moles, more preferably 0.7 to 4 moles, per one mole of ketone (3'). Formic acid containing water, ammonium formate and the like can be used.
This reaction is characterized in that ketone (3') and formic acid are added concurrently to formamide and/or ammonium formate. The ketone (3') and formic acid may be added separately, or a mixture thereof may be added to formamide and/or ammonium formate.
Reaction temperature is usually from about 150 to 200° C., preferably from about 155 to 175° C. The ketone (3') and formic acid are usually added over about 0.5 to 10 hours. After the addition, stirring may usually be continued for 1 to 10 hours.
It is preferred that ammonia produced from the reaction is captured with formic acid in an apparatus such as an ammonia recovering tower and recycled to the reaction and/or used in the next reaction as ammonium formate. By-product ammonia can be utilized effectively by the ammonia recycle, and as the result, the substantial amount of formamide and/or ammonium formate to be used may be reduced.
In That case, the piping from a reaction vessel to an ammonia recovering tower are preferably lagged at 80 to 120° C., whereby adhesion of ammonium carbonate to the wall can be prevented to improve the recovery rate of ammonia.
After the reaction, N-formylamine (4') thus obtained may be isolated by distilling off fractions having low boiling point from the reaction mixture.
If necessary, N-formylamine (4') may be purified by distillation, recrystallization or the like. The recovered low boiling point fractions contain formamide and the like, which may be reused.
The resultant N-formylamine (4') may be hydrolyzed in a solvent or without a solvent in the presence of dilute aqueous hydrochloric acid or sulfuric acid to obtain a corresponding amine represented by formula (2'):
R.sup.3 R.sup.4 CHNH.sub.2 (2')
wherein R 3 and R 4 are as defined above.
Of course, in the case where the raw material ketone (3') used in the preparation of N-formylamine (4') is a phenyl alkyl ketone of formula (3), the resulting amine (2') is an α-phenylalkylamine (2).
The amount of the acid used for this hydrolysis is usually 1 to 10 equivalents, preferably 1.05 to 2 equivalents of N-formylamine (4').
The amount of water including the water in the dilute aqueous acid is usually 1 to 1000 moles, preferably 20 to 100 moles, per one mole of N-formylamine (4').
When a solvent is used, the amount thereof is usually 1 to 1000 moles, preferably 20 to 100 moles, per one mole of N-formylamine (4').
Any solvent may be used as long as it does not adversely affect on the reaction. Examples thereof are alcohols such as methanol, ethanol, and the like; esters such as ethyl acetate, and the like; ethers such as dioxane, diethyl ether, and the like; aromatic hydrocarbons such as toluene, xylene, chlorobenzene, and the like.
Reaction temperature and reaction time vary depending upon the kind and amount of the solvent used. The temperature is usually from 0° C. to boiling point of the solvent, preferably from about 30 to 100° C. The reaction time is usually from 10 minutes to 5 hours.
Water-soluble salt of the corresponding amine and acetic acid, and formic acid are formed by the hydrolysis. When the hydrolysis is carried out without a solvent, amines can be isolated by adding a water-insoluble solvent to the reaction mixture to extract and separate the neutral by-products into the organic layer, adjusting the aqueous layer to alkaline with an aqueous alkaline solution such as aqueous sodium hydroxide solution or the like, extracting the alkaline aqueous layer with a water-insoluble solvent to obtain the organic layer, and then the organic layer is concentrated under reduced pressure.
When the hydrolysis is carried out using a water-soluble solvent such as alcohols or the like, after the alcohol is distilled off, the above treatment may be carried out. When a water-insoluble solvent is used, the layer of reaction mixture are separated as it is to extract the neutral by-products into the organic layer and the same treatment as that described above may be carried out.
In addition, crude amines (2') thus obtained may be treated by the conventional separation means such as distillation, column chromatography or the like to isolate the amine (2').
α-Phenylalkylamine of formula (2) may also be obtained by catalytic hydrogenation of oxime acetate represented by formula (5): ##STR6## wherein R 1 , R 2 and X are as defined above, in an organic carboxylic acid in the presence of platinum catalyst. This process has such characteristics that an α-phenylalkylamine (2) can be effectively prepared at a high yield at a low pressure almost without by-product alcohols. This process is particularly advantageous when X is a chlorine atom and R 2 is it hydrogen atom or chlorine atom in the α-phenylalkylamine (2) since the production of by-products derived from dechlorination is inhibited.
This process is explained below.
Examples of X, R 1 and R 2 in oxime acetate (5) are the is same as those described above. In this reaction, it is preferred that X is chlorine atom and R 2 is chlorine atom or hydrogen atom.
Examples of the oxime acetate (5) are oxime acetate of the above phenyl alkyl ketone (3).
Oxime acetate (5) can be easily prepared by reacting the corresponding phenyl alkyl ketone (3) with a acid salt of hydroxylamine in the same manner as that in Organic Synthesis Collective Vol. 6,278, to obtain ketoxime represented by formula (6): ##STR7## wherein R 1 , R 2 and X are as defined above, and esterifying using an acylating agent.
Examples of the acid salt of hydroxylamine are mineral acid salts such as hydrochloride, sulfate, phosphate of hydroxylamine. The amount of the salt to be used is usually 1 to 1.1 moles per one mole of phenyl alkyl ketone (3).
The reaction is usually carried out in a solvent. Examples of the solvent are a mixture of water and water-miscible alcohol such as mixture of water and methanol, a mixture of water and ethanol and the like, a mixture of water and a water-immiscible solvent such as a mixture of water with hexane, heptane, toluene, methylene chloride, dichloroethane, methyl t-butyl ether and the like- In the latter case, the reaction can be proceeded smoothly by using a phase transfer catalyst. The amount of the solvent to be used is 1 to 10 parts by weight per one part by weight of phenyl alkyl ketone (3).
Although the reaction proceeds at room temperature, it can be promoted by heating at a temperature in a range from 50 to 60° C. As the reaction proceeds, a mineral acid is released. The mineral acid is neutralized with an aqueous alkali solution such as aqueous sodium hydroxide solution, aqueous sodium carbonate solution, aqueous ammonia or the like during or after the reaction.
The resulting ketoxime (6) may be isolated by distilling the solvent off to obtain the crystals which are washed with water and dried in the case where the ketoxime (6) are obtained as crystals, or by separating the organic layer, followed by washing with water and removal of the solvent by distillation in the case where the resulting ketoxime (6) are dissolved in the organic layer.
Examples of the acylating agent used for esterifying ketoxime (6) are acetic anhydride, and acetic halides such as acetic chloride, acetic bromide and the like. The acylating agent is usually used at the amount of 1 to 1.1 moles per one mole of the ketoxime (6). When oxime acetate (5) are used for catalytic-hydrogenation as they are without isolation, the amount is preferably 1 to 1.05 moles, thereby production of by-product amide may be inhibited.
The reaction is usually carried out in a solvent. Examples of the solvent are carboxylic acids such as formic acid, acetic acid, propionic acid and the like, hexane, heptane, toluene, methylene chloride, dichloroethane, methyl t-butyl ether and the like. The amount of the solvent to be used is usually 1 to 10 parts by weight per one part by weight of ketoxime (6). Reaction temperature is usually from about 50° C. to boiling point of the solvent, preferably from about 50° C. to 120° C.
After the reaction, oxime acetate (5) can be isolated by distilling off the solvent and the acylating agent remained. When an carboxylic acid is used as a solvent, the reaction mixture may directly be catalytic-hydrogenated without isolation.
A platinum catalyst used for catalytic-hydrogenating oxime acetate (5) is not limited and may usually used the one carried on a carrier such as carbon, silica gel, alumina or the like.
The platinum catalyst is usually used at an amount of 0.05 to 1% by weight, preferably 0.1 to 0.2% by weight in term of platinum, to the oxime acetate (5).
Examples of the carboxylic acid used for catalytic-hydrogenating the oxime acetate (5) are lower carboxylic acids having 1 to 3 carbon atoms such as formic acid, acetic acid, propionic acid and the like. Among them, acetic acid is preferred.
The carboxylic acid is used at an amount of 1 to 100 parts by weight, preferably 5 to 10 parts by weight, per one part by weight of the oxime acetate (5).
The catalytic-hydrogenating reaction-is usually carried out at a temperature in a range from about 10 to 50° C., preferably from about 20 to 40° C. The reaction is preferably carried out at a temperature of not higher than 50° C. since production of by-products such as dimer, ketones and the like tends to increase when the temperature exceeds 50° C.
Since the reaction rate is decreased and production of the by-products such as dimer, amide and the like tend to increase at below 5 kg/cm 2 ·G, the hydrogen pressure is usually not lower than 5 kg/cm 2 ·G, preferably in a range from 5 to 50 kg/cm 2 ·G. The reaction proceeds sufficiently even at a range from 5 to 30 kg/cm 2 ·G.
After completion of the reaction, α-phenylalkylamine (2) thus formed can be isolated by for example, separating the catalyst, distilling the carboxylic acid off, neutralizing with an aqueous base solution such as aqueous sodium hydroxide solution or the like, extracting with an organic solvent and distilling the organic solvent off.
If necessary, the α-phenylalkylamine (2) may be purified by distillation, recrystallization or the like.
In addition, the separated and recovered catalyst can be reused.
According to the N-(α-alkylbenzylidene)-α-phenylalkylamine (1) of the present invention, a useless optically active isomer of α-phenylalkylamine (2) can easily and effectively converted to a racemate of α-phenylalkylamine (2) which is reusable as a raw material for a useful optically active compound under a mild condition.
In addition, according to the present invention, N-(α-alkylbenzylidene)-α-phenylalkylamine (1) and intermediates therefor can effectively be produced.
The following Examples and Comparative Examples illustrate the present invention in-detail but are not to be construed to limit the scope thereof.
EXAMPLE 1
155.1 g of ammonium formate was placed in a reaction vessel equipped with a Dean-Stark separating apparatus, the compound was heated to 155 ° C., and 98.5 g of acetophenone and 49.6 g of 76% formic acid were added thereto, respectively, for 3 hours under stirring, followed by stirring at 160° C. for 3 hours. During the reaction, the distillate was separated and acetophenone layer (upper layer) was returned to the reaction vessel and these procedures were repeated at interval.
After cooled to room temperature, low boiling point fraction was distilled off from the reaction mixture under reduced pressure to obtain 116.1 g of crude N-formyl-1-phenylethylamine.
Purity of the crude N-formyl-1-phenylethylamine was 87.5% as analyzed by gas chromatography.
EXAMPLE 2
In the same manner as in Example 1 except that 139.6 g of 1'-acetonaphthone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 164.5 g of crude N-formyl-1-naphthylethylamine; the purity: 82.3%.
EXAMPLE 3
In the same manner as in Example 1 except that 110.7 g of formamide was used in place of ammonium formate and 126.7 g of 4'-chloroacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 150 g of crude N-formyl-1-(4-chlorophenyl)ethylamine; the purity: 87.4%.
EXAMPLE 4
In the same manner as in Example 1 except that 155 g of 2',4'-dichloroacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 170.8 g of crude N-formyl-1-(2,4-dichlorophenyl)ethylamine; the purity: 78.9%.
EXAMPLE 5
An ammonia absorbing tower and a reaction vessel were connected and 206 g of ammonium formate was placed in the reaction vessel. 233 g of 76% formic acid was placed in a pot of the ammonia absorbing tower, and was circulated in the tower at a speed of 20 g/min. while the connecting part between the absorbing tower and the reaction vessel was lagged so as to maintain at 80° C.
The reaction vessel was heated to 155° C. with stirring, 2',4'-dichloroacetophenone and a pot solution of the ammonia absorbing tower were concurrently added to the vessel at 0.86 g/min. and at 0.48 g/min. respectively over 3 hours, followed by stirring at a temperature in a range from 155 to 160° C. for 7 hours. During the reaction, formic acid was continued to be circulated.
After the reaction, the low boiling point fraction was distilled off under reduced pressure to obtain 162.2 g of crude N-formyl-1-(2,4-dichlorophenyl)ethylamine; the purity: 86%.
The fraction obtained by distilling the low boiling point fraction was 137.9 g, which was measured by gas chromatography and found to contain 69.8% of formamide, 12.9% of formic acid and 1.7% of 2',4'-dichloroacetophenone.
The pot solution of the ammonia absorbing tower after the reaction was 229.2 g, and was found to contain 4.7% of formamide, 36.7% of formic acid, 0.2% of ammonium formate and 1.7% of 2',4'-dichloroacetophenone.
EXAMPLE 6
A mixture of 56.8 g of 27% aqueous ammonia, 137 g of distillate recovered in Example 5 and 113 g of the pot solution of the ammonia absorbing tower was distilled under reduced pressure to distill off 166 g of water.
This concentrate was placed in the reaction vessel, and the same procedures as those in Example 5 was repeated except that 130 g of 90% formic acid and 116 g of the pot solution of the ammonia absorbing tower recovered in Example 5 were placed in the pot of the ammonia absorbing tower.
165.4 g of crude N-formyl-1-(2,4-dichlorophenyl)ethylamine was obtained; the purity: 83.7%.
The distillate obtained by distilled off low boiling point fraction was 112.5 g, which was found to contain 80.1% of formamide, 15.7% of formic acid and 1.2% of 2',4'-dichloroacetophenone.
In addition, the pot solution of the ammonia absorbing tower was 265 g, which was found to contain 6% of formamide, 31.5% of formic acid, 0.2% of ammonium formate and 3% of 2'1,4-dichloroacetophenone.
EXAMPLE 7
In the same manner as in Example 1 except that 123.2 g of 2'-methoxyacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 143.7 g of crude N-formyl-1-(2-methoxyphenyl)ethylamine; the purity: 90%.
EXAMPLE 8
In the same manner as in Example 1 except that 123.2 g of 3'-methoxyacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 130.4 g of crude N-formyl-1-(3-methoxyphenyl)ethylamine; the purity: 93%.
EXAMPLE 9
In the same manner as in Example 5 except that 405 q of ammonium formate was placed in the reaction vessel, 569 g of 76% formic acid was placed in the pot of the ammonia absorbing tower, 3'-benzyloxyacetophenone and the pot solution of the ammonia absorbing tower were added to the vessel at 2.54 g/min. and 3-6 g/min. respectively over 3 hours in place of 2',4'-dichloroacetophenone at 0.86 g/min. and the pot solution of the ammonia absorbing tower at 0.48 g/min, and the stirring time after addition was 10 hours in place of 7 hours, the reaction and post treatment were carried out to obtain 497 g of crude N-formyl-1-(3-benzyloxyphenyl)ethylamine (the purity: 97.8%) in place of 2',4'-dichloroacetophenone at 0.86 g/min. and the pot solution of the ammonia absorbing tower at 0.48 g/min.
EXAMPLE 10
In the same manner as in Example 1 except that 135.5 g of 3'-nitroacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 139.8 g of crude N-formyl-1-(3-nitrophenyl)ethylamine; the purity: 91.1%
EXAMPLE 11
In the same manner as in Example 1 except that 113.3 g of 2'-fluoroacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 125.8 g of crude N-formyl-1-(2-fluorophenyl)ethylamine; the purity: 87.2%.
EXAMPLE 12
In the same manner as in Example 1 except that 147.9 g of 3',4'-dimethoxyacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 156.8 g of crude N-formyl-1-(3,4-dimethoxyphenyl)ethylamine; the purity: 96.2%.
EXAMPLE 13
In the same manner as in Example 1 except that 155.1 g of 3'-trifluoromethylacetophenone was used in place of acetophenone, the reaction and post treatment were carried out to obtain 166.5 g of crude N-formyl-1-(3-trifluoromethylphenyl)ethylamine; the purity: 85.7%.
EXAMPLE 14
In the same manner as in Example 1 except that 159.1 g of 3',4'-dimethoxybenzyl methyl ketone was used in place of acetophenone, 413.7 g of ammonium formate was used, and 41.9 g of 90% formic acid was used in place of 76% formic acid, the reaction and post treatment were carried out to obtain 165.6 g of crude N-formyl-2-(3,4-dimethoxyphenyl)-1-methylethylamine as pale yellow oil; the purity: 96.1%.
1 H-NMR: 1.15 (d,3H), 2.65 (dd,1H), 2.78 (dd,1H), 3.81 (s,3H), 3.85 (s,3H), 4.29 (m,1H), 5.52 (bs,1H), 6.55-6.82 (m,3H), 8.06 (s,1H)
EXAMPLE 15
In the same manner as in Example 14 except that 134.5 g of 4'-methoxybenzyl methyl ketone was used in place of 3',4'-dimethoxybenzyl methyl ketone, the reaction and post treatment were carried out to obtain 142.6 g of crude N-formyl-2-(4-methoxyphenyl)-1-methylethylamine; the purity: 91.0%.
COMPARATIVE EXAMPLE 1
In the same manner as in Example 1 except that a mixture of formic acid, ammonium formate and acetophenone was heated with stirring at 160° C. for 6 hours in place of the concurrent addition of acetophenone and formic acid to ammonium formate for 3 hours and keeping the mass after the addition stirred for 3 hours, the reaction and post treatment were carried out to obtain 112 g of crude N-formyl-1-phenylethylamine; the purity: 82.7%.
COMPARATIVE EXAMPLE 2
In the same manner as in Example 4 except that a mixture of formic acid, ammonium formate and 2',4'-dichloroacetophenone was heated with stirring at 160° C. for 6 hours in place of the concurrent addition of 2',4'-dichloroacetophenone and formic acid to ammonium formate for 3 hours and keeping the mass ater the addition stirred for 3 hours, the-reaction and post treatment were carried out to obtain 178.6 g of crude N-formyl-1-(2,4-dichlorophenyl)ethylamine; the purity: 70.4%.
COMPARATIVE EXAMPLE 3
In the same manner as in Example 3 except that a mixture of formamide, formic acid and 4'-chloroacetophenone was heated with stirring at 160° C. for 6 hours in place of the concurrent addition of 4'-chloroacetophenone and formic acid to formamide for 3 hours and keeping the mass after the addition stirred for 3 hours, the reaction and post treatment were carried out to obtain 144.2 g of crude N-formyl-1-(4-chlorophenyl)ethylamine; the purity: 84.6%.
COMPARATIVE EXAMPLE 4
In the same manner as in Example 14 except that a mixture of formic acid, ammonium formate and 3',4'-dimethoxybenzyl methyl ketone was heated with stirring at 160° C. for 6 hours in place of the concurrent addition of 3',4'-dimethoxybenzyl methyl ketone and formic acid to ammonium formate for 3 hours and keeping the mass after the addition stirred for 3 hours , the reaction and post treatment were carried out to obtain 182.9 g of crude N-formyl-2-(3,4-dimethoxyphenyl)-l-methylethylamine; the purity: 60%.
EXAMPLE 16
162 g of crude N-formyl-1-(2,4-dichlorophenyl)ethylamine obtained in Example 5, 96 g of hot water at 80° C. and 121 g of 36% hydrochloric acid were mixed under stirring, and the mixture was refluxed for 1 hour.
Then, 224 g of water was added thereto while maintaining at a temperature of not lower than 70° C., and the mixture was extracted twice with 80 g of toluene at 70° C. 173 g of 48% aqueous sodium hydroxide solution was added to the aqueous layer, followed by extraction twice with 100 g of toluene at 60° C.
Then, the resulting toluene layers were combined, washed twice with 80 g of water, and the toluene was distilled off to obtain 128.8 g of crude 1-(2,4-dichlorophenyl)ethylamine; the purity: 93.4%.
118 g of purified 1-(2,4-dichlorophenyl)ethylamine was obtained by distillation under reduced pressure; the purity: 99.5%.
EXAMPLE 17
(1) Preparation of chloro-substituted phenyl alkyl ketoxime
122 g of hydroxylamine hydrochloride and 400 g of water were added to a mixture of 300 g of 2',40-dichloroacetophenone and 1200 g of methanol under stirring, heated to a temperature of 60° C., and the stirring was continued at the same temperature for 3 hours while a 27% aqueous sodium hydroxide solution was added thereto to adjust to pH 4 to 5.
Then, 27% aqueous sodium hydroxide solution was added thereto to adjust to pH 8, and 1200 g of water and methanol in total were distilled off under reduced pressure. 1200 g of water was added to the residue, followed by cooled to 25° C. The precipitated crystals were filtered, washed with 1200 g of water and dried to obtain 322 g of 2',4'-dichloroacetophenone oxide as white crystals (yield: 99%); the purity: 99.5%.
(2) Preparation of chloro-substituted phenyl alkyl ketoxime acetate
36.4 g of acetic anhydride was added to a mixture of 70 g of 2',4'-dichloroacetophenone oxime and 70 g of n-heptane, followed by stirring at 70° C. for 2 hours. A portion of the reaction mixture was taken out and analysis by gas chromatography showed that the raw material was disappeared.
The reaction mixture was cooled to 25° C., and the precipitated crystals were filtered to obtain 60.2 g of 2',4'-dichloroacetophenone oxime acetate as white needle crystals; the purity: 100%.
The filtrate was concentrated under reduced pressure, and the resulting residue (crystals) was washed with 10 g of ice-cooled n-heptane to obtain another 22.5 g of 2',4'-dichloroacetophenone oxime acetate as white needle crystals; the purity: 99%.
EXAMPLE 18
2 g (purity 100%) of 2',4'-dichloroacetophenone oxime acetate obtained in Example 17-(2), 20 g of acetic acid and 0.1 g of 5% platinum-carbon (50% water content) were placed in a 100 ml autoclave, the atmosphere was replaced with nitrogen, and the mixture were heated to 30° C., followed by pressurization with hydrogen to 20 kg/cm 2 ·G.
At the same temperature, the reaction was carried out for 5 hours while maintaining at pressure of 20 kg/cm 2 ·G by feeding hydrogen.
After the reaction, the catalyst was filtered, acetic acid in the filtrate was distilled off. 5 g of toluene was added to the residue, followed by washing with 18 g of a 5% aqueous sodium hydroxide solution and removal of the solvent in the organic layer, to obtain 1.54 g of oil, which was analyzed by gas chromatography.
Content of the oil:
1-(2',4'-dichlorophenyl)ethylamine; 94.5%,
N-1-(2,,4'-dichlorophenyl)ethyl-α-(2'1,4'-dichlorophenyl)ethylamine; 0.97%,
N-acetyl-α(2',4'-dichlorophenyl)ethylamide; 0.56%,
2',4'-dichloroacetophenone; 1%,
a dechlorinated compound; below the detection limit,
an alcohol obtained by reduction of carbonyl group; below the detection limit
EXAMPLE 19
In the same manner as in Example 18 except that 2 g of 4'-chloroacetophenone oxime acetate was used in place of 2',4'-dichloroacetophenone oxime acetate, the reaction and post treatment were carried out to obtain 1.47 g of oil.
Content of the oil
1-(4'-chlorophenyl)ethylamine; 98.8%,
N-acetyl-α-(4'-chlorophenyl)ethylamide; 0.91%,
a dechlorinated compound; not detected,
an alcohol obtained by reduction of carbonyl group; not detected.
EXAMPLE 20
In the same manner as in Example 18 except that 2 g of 3',4'-dichloroacetophenone oxime acetate was used in place of 2',4'-dichloroacetophenone oxime acetate, the reaction and post treatment were carried out to obtain 1.53 g of oil.
Content of the oil
1-(3',4'-dichlorophenyl)ethylamine; 89.8%,
1-(4'-chlorophenyl)ethylamine; 1.4%,
N-1-(3',4'-dichlorophenyl)ethyl-α-(3',4'-dichlorophenyl)ethylamine; 2.9%,
N-acetyl-α-(3',4'-dichlorophenyl)ethylamide; 1.9%,
an alcohol obtained by reduction of carbonyl group; not detected.
EXAMPLE 21
In the same manner as in Example 18 except that 2 g of 3',5'-dichloroacetophenone oxime acetate was used in place of 2',4'-dichloroacetophenone oxime acetate afforded 1.54 g of oil.
Content of the oil
1-(3',5'-dichlorophenyl)ethylamine; 88.7%,
1-(3'-chlorophenyl)ethylamine; 2%,
N-1-(3',5'-dichlorophenyl)ethyl-α-(3',5'-dichlorophenyl)ethyl amine; 2.9%,
N-acetyl-α-(3',5'-dichlorophenyl)ethylamide; 2.9%,
an alcohol obtained by reduction of carbonyl group; not detected.
EXAMPLE 22
36.4 g of acetic anhydride was added to a mixture of 70 g of 2',4'-dichloroacetophenone oxime and 210 g of acetic acid, followed by stirring at 100° C. for 2 hours. A portion of the reaction mixture was taken out and analysis by gas chromatography showed that a raw material was disappeared.
The whole amount of the above reaction mixture, 210 g of acetic acid, 3.9 g of 5% platinum-carbon (50% water content) were placed in a 1000 ml autoclave, the atmosphere was replaced with nitrogen, and the mixture were heated to 30° C., followed by pressurization with hydrogen to 20 kg/cm 2 ·G. At the same temperature, the reaction was carried out for 10 hours while maintaining at pressure of 20 kg/cm 2 ·G by feeding hydrogen.
After the reaction, the catalyst was filtered, acetic acid in the filtrate was distilled off. 100 g of toluene was added to the residue, followed by washing with 180 g of a 5% aqueous sodium hydroxide solution and removal of the solvent in the organic layer, to obtain 65 g of oil, which was analyzed by gas chromatography.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 91%,
1-(4'-chlorophenyl)ethylamine 2.9%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 1.1%,
N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 1.5%,
an alcohol obtained by reduction of carbonyl group; not detected.
58.5 g of 1-(2',4'-dichlorophenyl)ethylamine was obtained by distillation; the purity: 99%, boiling point: 130-132° C./20 mmHg.
EXAMPLE 23
The same manner as in Example 22 except that 0.57 g of 5% platinum-carbon (50% water content) and the whole catalyst recovered in Example 22 were used, the reaction and post treatment were carried out to obtain 64 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 89.9%,
1-(4'-chlorophenyl)ethylamine; 1.8%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 3.4%,
N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 1.6%,
an alcohol obtained by reduction of carbonyl group; not detected.
EXAMPLE 24
In the same manner as in Example 18 except that the reaction was carried out while maintaining at the pressure of 5 kg/cm 2 ·G, the reaction and post treatment were carried out to obtain 1.52 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 78.2%,
1-(4'-chlorophenyl)ethylamine; 4.6%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 6.1%, N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 1.9%,
2',4'-dichloroacetophenone; 0.4%,
an alcohol obtained by reduction of carbonyl group; not detected.
EXAMPLE 25
In the same manner as in Example 18 except that the reaction was carried out while maintaining at the pressure of 10 kg/cm 2 ·G, the reaction and post treatment were carried Out to obtain 1.54 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 87.2%,
1-(4'-chlorophenyl)ethylamine; 3.7%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 1.1%,
N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 0.5%,
2',4'-dichloroacetophenone was 1.3%,
an alcohol obtained by reduction of carbonyl group; not detected.
COMPARATIVE EXAMPLE 5
In the same manner as in Example 18 except that 0.1 g of 5% palladium-carbon (50% water content) was used in place of platinum-carbon and the reaction was carried out for 5 hours while maintaining at the pressure of 10 kg/cm 2 ·G, the reaction and post treatment were carried out to obtain 1.49 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 53.8%, phenylethylamine; 3.1%,
1-(4'-chlorophenyl)ethylamine; 16.9%,
1-(2'-chlorophenyl)ethylamine; 13.1%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 6.2%, N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 4.7%,
2',4'-dichloroacetophenone was 0.5%.
COMPARATIVE EXAMPLE 6
In the same manner as in Example 22 except that 40.6 g of acetic anhydride was used, and the reaction was carried out while maintaining at the pressure of 10 kg/cm 2 ·G, the reaction and post treatment were carried out to obtain 68 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 51%,
1-(4'-chlorophenyl)ethylamine; 1%,
N-l-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine 1.3%,
N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 42.1%,
2',4'-dichloroacetophenone; 0.5%.
COMPARATIVE EXAMPLE 7
In the same manner as in Example 18 except that 20 g of methanol was used as a solvent, and the reaction was carried out while maintaining at the pressure of 10 kg/cm 2 ·G, the reaction and post treatment were carried out to obtain 1.52 g of oil.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 12%,
N-1-(2',4'-dichlorophenyl)ethyl-α-(2',4'-dichlorophenyl)ethylamine; 63%,
N-acetyl-α-(2',4'-dichlorophenyl)ethylamide; 15%.
COMPARATIVE EXAMPLE 8
18.9 g of 2',4'-dichloroacetophenone, 35 g of methanol, 0.15 g of bis-(2-hydroxyethyl)sulfide, 0.1 g of ammonium acetate and 1.0 g of Raney-nickel catalyst (50% content) were placed in a autoclave, the atmosphere was replaced with nitrogen, and 4.6 g of liquid ammonia was added, followed by pressurization with hydrogen to 50 kg/cm 2 ·G.
Then, the mixture was heated to 130° C., and the pressure was raised at 80 kg/cm 2 ·G by feeding hydrogen, followed by reacting at the same temperature for 4 hours while maintaining at the pressure of 80 kg/cm 2 ·G by feeding hydrogen.
After the reaction, the catalyst was filtered, and low boiling point fraction in the filtrate was distilled off under reduced pressure to obtain 19.5 g of oil, which was analyzed by gas chromatography.
Content of the oil
1-(2',4'-dichlorophenyl)ethylamine; 24.8 g,
1-(4'-chlorophenyl)ethylamine; 53.4%,
unknown ingredients; 15.9%.
EXAMPLE 26
(1) A solution consisting of 16 g of (RS)-1-(2,4-dichlorophenyl)ethylamine and 10 ml of ethanol was heated to 70° C. while stirring, a solution consisting 12.8 g of L-mandelic acid and 40 ml of ethanol was added thereto over 30 minutes, and a temperature was raised to 75° C., followed by stirring at the same temperature for 30 minutes.
After cooling to 20° C. over 5 hours, the precipitated crystals were filtered and dried to obtain 13.2 g of diastereomer salt. 10 g of a 20% aqueous sodium hydroxide solution was added to the crystals, followed by extraction twice with 20 ml of toluene. The resulting organic layer was dried over magnesium sulfate, and the solvent was distilled off to obtain 7.3 g of (R)-1-(2,4-dichlorophenyl)ethylamine. This had the optical purity of 82%ee.
(2) The low boiling point fraction was distilled off from the mother liqourd from which the diastereomer has been filtered, to obtain 15.6 g of the residue. to this was added 13 g of a 20% aqueous sodium hydroxide solution, followed by extraction twice with 30 ml of toluene. The resulting toluene layer was dried over magnesium sulfate, and the solvent was distilled off to obtain 12.7 g of (S)-1-(2,4-dichlorophenyl)ethylamine. This had the optical purity of 70%ee.
(3) The remaining aqueous layers extracted in (1) and (2) were mixed, and 36% hydrochloric acid was added thereto to adjust to pH 0.7. Then, the mixture was extracted three times with 50 ml of ethyl acetate, dried over magnesium sulfate and the solvent was distilled off to obtain 12.3 g of L-mandelic acid.
EXAMPLE 7
(1) A solution consisting of 41 g of (RS)-1-(3,4-dichlorophenyl)ethylamine and 78 g of methyl t-butyl ether was heated to 45° C. while stirring, and a mixture of 14.6 g of L-mandelic acid and 90 g of methyl t-butyl ether was added thereto over about 30 minutes, followed by stirring at the same temperature for 30 minutes. Then, after cooled to 20° C. over 6 hours, the precipitated crystals were filtered, washed twice with 40 g of methyl t-butyl ether and dried to obtain 32.9 g of diastereomer salt. 82 g of a 5% aqueous sodium hydroxide solution was added to the crystals, followed by extraction twice with 20 g of methyl t-butyl ether. The solvent was distilled off from the resulting organic layer to obtain 18.2 g of (R)-1-(3,4-dichlorophenyl)ethylamine. This had the optical purity of 87.4%ee.
(2) The mother liquor from which the diastereomer salt has been filtered and the wash were combined, and 16 g of a 5% aqueous sodium hydroxide solution was added thereto for washing. The solvent was distilled off from the resulting organic layer to obtain 22.8 q of (S)-1-(3,4-dichlorophenyl)ethylamine. This had the optical purity of 70.2%ee.
EXAMPLE 28
(1) A solution consisting of 10 g of (RS)-1-(2,3-dichlorophenyl)ethylamine and 30 g of methyl t-butyl ether was heated to 45° C. while stirring, and a mixture of 3.6 g of L-mandelic acid and 30 g of methyl t-butyl ether was added thereto over about 30 minutes, followed by stirring at the same temperature for 30 minutes. Then, after cooled to 20° C. over 6 hours, the precipitated crystals were filtered, washed twice with 20 g of methyl t-butyl ether and dried to obtain 7.2 g of diastereomer salt. 21 g of a 5% aqueous sodium hydroxide solution was added to the crystals, followed by extraction twice with 10 g of methyl t-butyl ether. The solvent was distilled off from the resulting organic layer to obtain 4 g of (R)-1-(2,3-dichlorophenyl)ethylamine. This had the optical purity of 90.4%ee.
(2) The mother liquor from which the diastereomer salt has been filtered and the wash were combined, and 2 g of a 5% aqueous sodium hydroxide solution was added thereto for washing. The solvent was distilled off from the resulting organic layer to obtain 6 g of (S)-1-(2,3-dichlorophenyl)ethy lamine. This had the optical purity of 58.8%ee.
EXAMPLE 29
(1) 0.28 g of zinc chloride was added to a mixture consisting of 62 g of (S)-1-(2',4'-dichlorophenyl)ethylamine (optical isomer ratio S/R=80.3/19.7) obtained in the same manner as in Example 26, 62 g of 2',4'-dichloroacetophenone and 130 g of toluene, followed by refluxing for 20 hours while the produced water was removed from the reaction system.
Then, the reaction mixture was washed with 10 g of a 5% aqueous sodium hydroxide solution at 25° C., and the layers were phase-separated. The resulting toluene layer was azeotropically dehydrated.
A portion thereof was taken out and analyzed by gas chromatography. As the result, it was calculated that the amount of N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dic hlorophenyl)ethylamine contained in the toluene layer was 116 g, that of unreacted 1-(2',4'-dichlorophenyl)ethylamine was 1 g and that of 2',4'-dichloroacetophenone was 0.5 g.
(2) Then, at 30° C., a solution consisting of 1.2 g of potassium t-butoxide and 10.1 g of dimethyl sulfoxide was added to the toluene solution from which the moisture has been removed in the above step (1), and the mixture was stirred at the same temperature for 10 hours, followed by washing once with 233 g of a 10% sodium chloride solution and twice with 233 g of saturated sodium chloride solution.
(3) 285 g of 5% hydrochloric acid was added to the resulting toluene solution, and the mixture was stirred at 60° C. for 1 hour, followed by phase-separation of layers at the same temperature for 30 minutes by settling to obtain aqueous and toluene layers.
194 g of toluene was added to the aqueous layer to extract at 60° C., the resulting toluene layer and the above toluene layer were combined, and the solvent was distilled off to obtain 60.7 g of 2',4'-dichloroacetophenone.
72 g of a 27% aqueous sodium hydroxide solution was added to the aqueous layer extracted with toluene, the aqueous layer was extracted with 580 g of toluene, and the toluene was distilled off to obtain 61.7 g of 1-(2',4'-dichlorophenyl)ethylamine.
A portion of the latter was taken out and analyzed by high performance liquid chromatography with the optically active column. Optical isomer ratio was S/R=52.3/47.7.
EXAMPLE 30
In the same manner as in Example 29 except that (R)-1-(2',4'-dichlorophenyl)ethylamine (optical isomer ratio S/R=1/99) was used in place of (S)-1-(2',4'-dichlorophenyl)ethylamine, the reaction and post treatment were carried out to obtain 59.7 g of 2',4'-dichloroacetophenone and 61 g of 1-(2',4'-dichlorophenyl)ethylamine.
The latter had the optical isomer ratio of S/R=45.1/54.9
EXAMPLE 31
In the same manner as in Example 29-(1), a toluene solution containing 116g of optically active N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)ethylamine was obtained.
Then, toluene and unreacted raw material were distilled off to obtain 111 g of optically active N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)ethylamine as white crystals. E/Z=8/92, m.p.: 77-85° C. 1H-NMR: 1.32 (2d,3H), 1.51 (d,3H), 2.23 (s,3H), 2.29 (2s,3H), 4.56 (m,1H), 5.18 (m,1H), 6.6-7.8.(m,12H)
EXAMPLE 32
The reaction was carried out in the same manner as in Example 29-(2) except that a solution containing 111 g of optically active N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)ethylamine and 130 g of dry toluene was used as a toluene solution.
Then, the resulting toluene solution was concentrated under reduced pressure, and the low boiling point fraction was distilled off at 100° C. at 20 mmug for 5 hours to obtain 110 g of racemic N-(α-methyl-2',4'-dichlorobenzylidene)-α-(2',4'-dichlorophenyl)ethylamine as colorless oil. E/Z=8/92
EXAMPLE 33
In the same manner as in Example 29-(3) except that a solution containing 110 g of oil obtained in Example 32 and 130 g of toluene was used as a toluene solution, the reaction and post treatment were carried out to obtain 56.9 g of 2',4'-dichloroacetophenone and 57.8 g of 1-(2',4'-dichlorophenyl)ethylamine.
The latter had optical isomer ratio of S/R=51.9/48.1.
EXAMPLE 34
In the same manner as in Example 29 except that 0.45 g of titanium tetraisopropoxide was used in place of zinc chloride, the reaction and post treatment were carried out to obtain 59.2 g of 2',4'-dichloroacetophenone and 60.8 g of 1-(2',4'-dichlorophenyl)ethylamine.
The latter had optical isomer ratio of S/R=53.3/46.7.
EXAMPLE 35
In the same manner as in Example 29 except that 0.62 g of p-toluenesulfonic acid was used in place of zinc chloride and xylene was used in place of toluene, the reaction and post treatment were carried out to obtain 59.1 g of 2', 4'-dichloroacetophenone and 60.1 g of 1-(2',4'-dichlorophenyl)ethylamine.
The latter had optical isomer ratio of S/R=53/47.
COMPARATIVE EXAMPLE 9
In the same manner as in Example 29 except that 20 g of t-butanol was used in place of dimethyl sulfoxide, the reaction and post treatment were carried out to obtain 60.3 g of 2',4'-dichloroacetophenone and 61.5 g of 1-(2',4'-dichlorophenyl)ethylamine. The latter had optical isomer ratio of S/R=80.3/19.7.
COMPARATIVE EXAMPLE 10
1.8 g of potassium t-butoxide was added to a mixture consisting of 6 g of (S)-1-(2',4'-dichlorophenyl)thylamine used in Example 29 and 9 g of dimethyl sulfoxide at 80° C., followed by stirring at the same temperature for 10 hours.
After cooled to room temperature, a portion thereof was taken out and optical isomer ratio was analyzed by high performance liquid column chromatography with optically active column.
Optical isomer ratio was S/R=80.3/19.7
EXAMPLE 36
0.05 g of zinc chloride was added to a mixture consisting of 5 g of (R)-1-(2'-chlorophenyl)ethylamine (optical isomer ratio S/R=24.8/75.2), 5 g of 2'-chloroacetophenone and 30 g of toluene, followed by reflux for 17 hours while the produced water was removed from the reaction system.
Then, in the same manner as in Example 31, the reaction and post treatment were carried out to obtain 8.9 g of optically active N-(α-methyl-2'-chlorobenzylidene)-α-(2'-chlorophenyl)ethylamine as pale yellow oil. E/Z=37/63
1H-NMR: 1.35 (2d,3H), 1.57 (d, 3H), 2.22 (s,3H), 2.31 (2s,3H), 4.65 (2m,1H), 5.2 (m,1H), 6.6-7.9 (m,8H)
EXAMPLE 37
10 g of toluene was added to 8 g of the oil obtained in Example 36. A solution consisting of 0.6 g of potassium t-butoxide and 6.8 g of dimethyl sulfoxide was added thereto at 30° C., the mixture was stirred at the same temperature for 23 hours and washed once with 20 g of a 10% sodium chloride solution and twice with 20 g of a saturated sodium chloride solution. The resulting toluene layer was concentrated under reduced pressure, and the low boiling point fraction was distilled off at 100° C. and 20 mmlg for 5 hours to obtain 7.9 g of racemic N-(α-methyl-2'-chlorobenzylidene)-α-(2'-dichloro phenyl)ethylamine as pale yellow oil. E/Z=37/63
EXAMPLE 38
10 g of toluene and 25 g of 5% hydrochloric acid were added to 7.9 g of the oil obtained in Example 37. The mixture was stirred at 60° C. for 1 hour and was phase-separated at the same temperature for 30 minutes to obtain the aqueous layer and the toluene layer. 17 g of toluene was added to the aqueous layer, followed by extraction at 60° C. The resulting toluene layer and the above toluene layer were combined, and the solvent was distilled off to obtain 4.1 g of 2'-chloroacetophenone.
6.4 g of a 27% aqueous sodium hydroxide solution was added to the aqueous layer after extracted with toluene, the aqueous solution was extracted with 50 g of toluene, and the toluene was distilled off to obtain 4.1 g of 1-(2'-chlorophenyl)ethylamine.
A portion of the latter was taken out and analyzed by high performance liquid column chromatography using the optically active column.
Optical isomer ratio was S/R=40.4/59.6.
EXAMPLE 39
0.05 g of zinc chloride was added to a mixture consisting of 5 g of (R)-1-(3',4'-dichlorophenyl)ethylamine (optical isomer ratio S/R=6.3/93.7) obtained in the same manner as in Example 27, 5 g of 3',4'-dichloroacetophenone and 30 g of toluene, followed by reflux for 27 hours while the produced water was removed from the reaction system.
Then, in the same manner as in Example 31, the reaction and post treatment were carried out to obtain 9 g of optically active N-(α-methyl-3',4'-dichlorobenzylidene)-α-(3',4'-dichlorophenyl)ethylamine as pale yellow oil. E/Z=94/6
1H-NMR: 1.35 (2d,3H), 1.47 (d,3H), 2.23 (s,3H), 2.31 (s,3H), 4.15 (m,1H), 4.77 (m,1 H), 7.25-8.0 (m,6H)
EXAMPLE 40
10 g of toluene was added to 8 g of the oil obtained in Example 39. A solution consisting of 0.25 g of potassium t-butoxide and 2.8 g of dimethyl sulfoxide was added thereto at 30° C., the mixture was stirred at the same temperature for 2 hours, and washed once with 20 g of 10% sodium chloride solution and twice with 20 g of saturated sodium chloride solution. The resulting toluene layer was concentrated under reduced pressure, and the low boiling point fraction was distilled off at 100° C. and 20 mmag for 5 hours to obtain 7.9 g of racemic N-(α-methyl-3',4'-dichlorobenzylidene)-α-(3',4'-dichlorophenyl)ethylamine as pale yellow oil. E/Z=94/6
EXAMPLE 41
10 g of toluene and 25 g of 5% hydrochloric acid were added to 7.9 g of the oil obtained in Example 40. The mixture was stirred at 60° C. for 1 hour and phase-separated at the same temperature for 30 minutes to obtain the aqueous layer and the toluene layer.
17 g of toluene was added to the aqueous layer, followed by extraction at 60° C. The resulting toluene layer and the above toluene layer were combined, and the solvent was distilled off to obtain 4 g of 3',4'-dichloroacetophenone.
6.4 g of a 27% aqueous sodium hydroxide solution was added to the aqueous layer after extracted with toluene, the aqueous solution was extracted with 50 g of toluene, and the toluene was distilled off to obtain 4 g of 1-(3',4'-dichlorophenyl)ethylamine.
A portion of the latter was taken out and analyzed by high performance liquid column chromatography using the optically active column. The optical isomer ratio was S/R=49.2/50.8.
EXAMPLE 42
0.05 g of zinc chloride was added to a mixture consisting of 5 g of (R)-1-(4'-chlorophenyl)ethylamine (optical isomer ratio S/R=20.0/80.0), 5 g of 4'chloroacetophenone and 30 g of toluene, followed by reflux for 25 hours while the produced water was removed from the reaction system.
Then, in the same manner as in Example 31, the reaction and post treatment were carried out to obtain 9 g of optically active N-(α-methyl-4'-chlorobenzylidene)-α-(4'-chlorophenyl)ethylamine as pale yellow oil. E/Z=93/7
1H-NMR: 1.35 (d,3H), 1.47 (d,3H), 2.23 (s,3H), 2.30 (s,3H), 4.32 (m,1H), 4.78 (m,1H), 6.95-7.8 (m,8H)
EXAMPLE 43
10 g of toluene was added to 8 g of the oil obtained in Example 42. A solution consisting of 0.21 g of potassium t-butoxide and 2.4 g of dimethyl sulfoxide was added thereto at 30° C., the mixture was stirred at the same temperature for 2 hours, and washed once with 20 g of 10% sodium chloride solution and twice with 20 g of saturated sodium chloride solution. The resulting toluene layer was concentrated under reduced pressure, and the low boiling point fraction was distilled off at 100° C. and 20 mmHg for 5 hours to obtain 7.9 g of racemic N-(α-methyl-4'-chlorobenzylidene)-α-(4'-chlorophenyl)ethylamine as pale yellow oil. E/Z=93/7
EXAMPLE 44
10 g of toluene and 25 g of 5% hydrochloric acid were added to 7.9 g of the oil obtained in Example 43. The mixture was stirred at 60° C. for 1 hour and phase-separated at the same temperature for 30 minutes to obtain the aqueous layer and the toluene layer.
17 g of toluene was added to the aqueous layer, followed by extraction at 60° C. The resulting toluene layer and the above toluene layer were combined, and the solvent was distilled off to obtain 4 g of 4'-chloroacetophenone.
6.4 g of a 27% aqueous sodium hydroxide solution was added to the aqueous layer afer extracted with toluene, the aqueous solution was extracted with 50 g of toluene, and the toluene was distilled off to obtain 4 g of 1-(4'-chlorophenyl)ethylamine.
A portion of the latter was taken out and analyzed by high performance liquid column chromatography using the optically active column. The optical isomer ratio was S/R=48.5/51.5
COMPARATIVE EXAMPLE 11
0.6 g of potassium t-butoxide was added to a mixture of 2 g of (R)-1-(2'-chlorophenyl)ethylamine used in Example 36 and 10 g of dimethyl sulfoxide at 80° C., and the mixture was continued to stir at the same temperature for 6 hours.
Then, 10 g of toluene was added thereto, and the reaction mixture was washed twice with 10 g of saturated sodium chloride solution, dried over anhydrous sodium sulfate, and the toluene was distilled off to obtain 2.1 g of brown oil. Purification by distillation afforded 1.58 g of 1-(2'-chlorophenyl)ethylamine. A portion thereof was taken out and optical isomer ratio was analyzed by high performance liquid chromatography with the.optically active column. The optical isomer ratio S/R=28.4/71.6
COMPARATIVE EXAMPLE 12
0.6 g of potassium t-butoxide was added to a mixture of 2 g of (R)-1-(3',4'-dichlorophenyl)ethylamine used in Example 39 and 6 g of dimethyl sulfoxide at 80° C., and the mixture was continued to stir at the same temperature for 6 hours.
Thene 10 g of toluene was added thereto, and the reaction mixture was washed twice with 10 g of-saturated sodium chloride solution, dried over anhydrous sodium sulfate, and the toluene was distilled off to obtain 2.1 g of brown oil. Purification by distillation afforded.0.6 g of 1-(3',4'-dichlorophenyl)ethylamine. A portion thereof was taken out and optical isomer ratio was analyzed by high performance liquid chromatography with the optically active column. The optical isomer ratio S/R=22.9/77.1
COMPARATIVE EXAMPLE 13
0.24 g of potassium t-butoxide was added to a mixture of 2 g of (R)-1-(4'-chlorophenyl)ethylamine used in Example 42 and 4 g of dimethyl sulfoxide at 80° C., and the mixture was continued to stir at the same temperature for 4 hours.
Then, 10 g of toluene was added thereto, and the reaction mixture was washed twice with 10 g of saturated sodium chloride solution, dried over anhydrous sodium sulfate, and the toluene was distilled off to obtain 2.1 g of brown oil. Purification by distillation afforded 1.66 g of 1-(4'-chlorophenyl)ethylamine. A portion thereof was taken out and optical isomer ratio was analyzed by high performance liquid chromatography with the optically active column. The optical isomer ratio S/R=48.5/51.5
EXAMPLE 45
0.045 g of zinc chloride was added to a mixture consisting of 5 g of (S)-1-(3'-methoxyphenyl)ethylamine (optical isomer ratio S/R=72.0/28.0), 5 g of 3'-methoxyacetophenone and 30 q of toluene, followed by reflux for 10 hours while the produced water was removed from the reaction system.
Then, in the same manner as in Example 31, the reaction and post treatment were carried out to obtain 8.7 g of optically active N-(α-methyl-3e-methoxybenzylidene)-α-(3'-methoxyphenyl)ethylamine as pale yellow oil. E/Z=78/22
1HNR: 1.38 (2d,3H), 1.53 (d,3H), 2.25 (s,3H), 2.31 (2s,3H), 3.79 (s,3H), 3.82 (s,3H), 4.09 (m,1H), 4.79 (m,1H), 6.5-7.5 (2m,8H)
EXAMPLE 46
10 g of dry toluene was added to 8 g of the oil obtained in Example 45. 1.58 g of potassium t-butoxide and 14.4 g of dizmethyl sulfoxide was added thereto at 30° C., the mixture was stirred at the same temperature for 6.5 hours, and washed once with 20 g of 10% sodium chloride solution and twice with 20 g of saturated sodium chloride solution.
The resulting toluene layer was concentrated under reduced pressure, and the low boiling point fraction was distilled off at 100° C. and 20 mmHg for 5 hours to obtain 7.9 g of racemic N-(α-methyl-3'-methoxybenzylidene)-α-(3'-methoxyphenyl)ethylamine as pale yellow oil. E/Z=78/22
EXAMPLE 47
10 g of toluene and 25 g of 5% hydrochloric acid were added to 7.9 g of the oil obtained in Example 46. The mixture was stirred at 60° C. for 1 hour and phase-separated at the same temperature for 30 minutes to obtain the aqueous layer and the toluene layer.
17 g of toluene was added to the aqueous layer, followed by extraction at 60° C. The resulting toluene layer and the above toluene layer were combined, and the solvent was distilled off to obtain 4.1 g of 3'-methoxyacetophenone.
6.4 g of a 27% aqueous sodium hydroxide solution was added to the aqueous layer after extracted with toluene, the aqueous solution was extracted with 50 g of toluene, and the toluene was distilled off to obtain 4.1 g of 1-(3'-methoxyphenyl)ethylamine.
A portion of the latter was taken out and analyzed by high performance liquid column chromatography using the optically active column.
Optical isomer ratio was S/R=54.0/46.0
EXAMPLE 48
The condensation reaction was carried out in the same manner as in Example 45 except that 5 g of (S)-1-(3',4'-dimethoxyphenyl)ethylamine (optical isomer ratio S/R=80.6/19.4) was used in place of 5 g of (S)-1-(3'-methoxyphenyl)ethylamine, 5 g of 3',4'-dimethoxyacetophenone was used in place of 5 g of 3'-methoxyacetophenone and reflux was continued for 12 hours in place of 10 hours.
Then, in the same manner as in Example 31, the reaction and post treatment were carried out to obtain 8.9 g of optically active N-(α-methyl-3',4'-dimethoxybenzylidene)-α-(3 4'-dimethoxyphenyl)ethylamine as pale yellow crystals. E/Z=76/24
1H-NMR: 1.28 (2d,3H), 1.44 (d,3H), 2.20 (s,3H), 2.28 (2s,3H), 3.79 (s,3H), 3.83 (s,3H), 3.89 (2s, 3H), 4.03 (m,1H), 4.72 (m,1), 6.7-7.5 (2m,6H)
EXAMPLE 49
7.9 g of racemic N-(α-methyl-3',4'-dimethoxybenzylidene )-α-(3',4'- dimethoxyphenyl)ethylamine as pale yellow oil was obtained according to the same manner as that in Example 46 except that 8 g of the crystals obtained in Example 48 was used in place of 8 g of the oil obtained in Example 45, potassium t-butoxide was used at an amount of 1.31 g in place of 1.58 gt dimethyl sulfoxide was used at an amount of 11.9 g in place of 14.4 g and stirring was continued for 4 hours in place of 6.5 hours. E/Z=76/24
EXAMPLE 50
In the same manner as in Example 47 except that 7.9 g of the oil obtained in Example 49 was used in place of 7.9 g of the oil obtained in Example 46, the reaction and post reatment were carried out to obtain 4 g of 3',4'-dimethoxyacetophenone and 4 g of 1-(3',4'-dimethoxyphenyl)ethylamine. The latter had optical isomer ratio of S/R=55.5/44.5.
EXAMPLE 51
The condensation reaction was performed in the same manner as in Example 45 except that 5 g of (R)-1-(2'-fluorophenyl)ethylamine (optical isomer ratio S/R13.6/86.4) was used in place of 5 g of (S)-1-(3'-methoxyphenyl)ethylamine, 5 g of 2'-fluaroacetophenone was used in place of 5 g of 3'-methoxyacetophenone, zinc chloride was used at an amount of 0.05 g in place of 0.045 g, and reflux was continued for 5.5 hours in place of 10 hours.
Then, in the same manner as in Example 31, the reaction and post treatmet were carried out to obtain 8.7 g of optically active N-(α-methyl-2'-fluorobenzylidene)-α-(2'-fluorophenyl)ethylamine as pale yellow oil. E/Z=66/34
1H-NMR: 1.39 (2d,3H), 1.56 (d,3H), 2.28 (d,3H), 2.33 (s,3H), 4.63 (m,1H), 5.17 (m,1H), 6.9-7.7 (2m,8H)
EXAMPLE 52
7.9 g of racemic N-(α-methyl-2'-fluorobenzylidene)-α-(2'-fluorophenyl)ethylamine was obtained as pale yellow oil in the same manner as in Example 46 except that 8 g of the oil obtained in Example 51 was used in place of 8 g of the oil obtained in Example 45, potassium t-butoxide was used at an amount of 0.69 g in place of 1.58 g, dimethyl oulfoxide was used at an amount of 6.3 g in place of 14.4 g, and stirring was continued for 1 hour in place of 6.5 hours. E/Z=66/34
EXAMPLE 53
In the same manner as in Example 47 except that 7.9 g of the oil obtained in Example 52 was used in place of 7.9 g of the oil obtained in Example 46, the reaction and post treatment were carried out to obtain 4.1 g of 2'-fluoroacetophenone and 4.1 g of 1-(2'-fluorophenyl)ethylamine. The latter had optical isomer ratio of S/R=49.3/50.7
COMPARATIVE EXAMPLE 44
1.34 g of potassium t-butoxide and 6.8 g of dimethyl sulfoxide were added to 2 g of (S)-1-(3'-methoxyphenyl)ethylamine (optical isomer ratio S/R=72.0/28.0), followed by stirring at 30° C. for 16 hours. After 10 g of toluene was added tereto, the mixture was washed twice with 10 g of saturated aqueous sodium chloride solution, dried over anhydrous sodium sulfate and the solvent was distilled off to obtain 2.1 g of brown oil. Purification by distillation afforded 1.9 g of 1-(3'-methoxyphenyl)ethylamine. Optical isomer ratio was S/R=72.0/28.0.
COMPARATIVE EXAMPLE 15
2.1 g of brown oil was obtained in the same manner as in Comparative Example 14 except that 2 g of (S)-1-(3',4'-dimethoxyphenyl)ethylamine (optical isomer ratio S/R=80-6/19.4) was used in place of 2 g of (S)-1-(3'-methoxyphenyl)ethylamine, potassium t-butoxide was used at an amount of 0.62 g in place of 1.34 g, dimethyl sulfoxide was used at an amount of 5.7 g in place of 6.8 g, and stirring was continued for 6 hours in place of 16 hours. Purification by distillation afforded 1.9 g of 1-(3',4'-dimethoxyphenyl)ethylamine. Optical isomer ratio was S/R=80.6/19.4.
COMPARATIVE EXAMPLE 16
2.1 g of brown oil was obtained in the same manner as in Comparative Example 14 except that 2 g of (R)-1-(2'-fluorophenyl)ethylamine (optical isomer ratio S/R=13.6/86.4) was used in place of 2 g of (S)-1-(3'-methoxyphenyl)ethylamine, potassium t-butoxide was used at an amount of 0.38 g in place of 1.34 g, dimethyl sulfoxide was used at an amount of 3.5 g in place of 6.8 g, and stirring was continued for 5 hours in place of 16 hours. Purification by distillation afforded 1.9 g of 1-(2'-fluorophenyl)ethylamine. Optical isomer ratio was S/R=13.6/86.4.
COMPARATIVE EXAMPLE 17
The reaction was performed in the same manner as in Example 46 except that 15 g of tert-butanol was used in place of dimethyl sulfoxide, and the reaction and post treatment was carried out in the same manner as in Example 47 to obtain 4.1 g of 3'-methoxyacetophenone and 4.1 g of 1-(3'-methoxyphenyl)ethylamine. The latter had optical isomer ratio of S/R=72.0/28.0 | There is disclosed an N-(α-alkylbenzylidene)-α-phenylalkylarmine represented by the general formula (1): ##STR1## wherein R 1 represents a lower alkyl group, R 2 represents a hydrogen atom, a halogen atom, a lower alkyl group or a lower alkoxy group and X represents a halogen atom or a lower alkoxy group, its use and a process for producing the same and processes for producing intermediates therefor. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/067,736, entitled “System and Methods for RFID Tag Locating Using Constructive Interference,” filed Oct. 23, 2014. The disclosure of U.S. Provisional Application No. 62/067,736 is herein incorporated by reference in its entirety and for all purposes.
TECHNICAL FIELD
[0002] This invention relates generally to the wireless communications field, and more specifically to new and useful systems and methods for using constructive interference such as use in radio frequency identification tag (RFID) tag locating.
BACKGROUND
[0003] Being able to identify and track objects as they move throughout buildings or other indoor areas with high precision is important for a wide variety of applications. Systems designed to track objects in this way, often called real-time locating systems (RTLS), find use in manufacturing, warehousing, retail inventory management, and medicine, to name a few areas. Unfortunately, current methods of tag locating used by RTLS are frequently associated with cost and/or usability issues. Thus, there is the need in the wireless communications field to create systems and methods for RFID tag locating. This invention provides such new and useful systems and methods.
SUMMARY
[0004] The present disclosure relates to a system for radio-frequency identification tag locating and associated methods.
[0005] In accordance with an aspect disclosed herein, there is set forth a method for locating a radio-frequency identification tag, comprising analyzing first and second response signals received via a plurality of antennas from the radio-frequency identification tag and determining a position of the radio-frequency identification tag based upon said analyzing. In some embodiments, the determining can be accomplished through triangulation.
[0006] In some embodiments of the method, the analyzing further comprises transmitting an initial activation signal from one of the plurality of antennas dispersed in a predefined area; and receiving a first response signal from the radio-frequency identification tag via the plurality of antennas.
[0007] In some embodiments of the method, said transmitting comprises transmitting via the selected antenna selected from among the plurality of antennas.
[0008] In some embodiments, said transmitting comprises transmitting via the selected antenna selected from among the plurality of antennas being dispersed in a predefined geographic area.
[0009] In some embodiments of the method, said analyzing comprises altering a transmission signal property of the initial activation signal, transmitting a secondary activation signal with the altered property; and receiving a second response signal from the radio frequency identification tag via the plurality of the antennas.
[0010] In some embodiments of the method, said receiving of the second response signal is conducted via the antennas.
[0011] In some embodiments, said transmitting the secondary activation signal comprises broadcasting a plurality of sub-threshold radio-frequency identification signals to create a constructive interference pattern within the predefined area.
[0012] In some embodiments, said transmitting comprises transmitting the plurality of sub-threshold radio-frequency identification signals via separate antennas.
[0013] In some embodiments of the method, said altering of the transmission signal property of the initial activation signal includes adjusting a power level of the secondary activation signal such that only a selected radio-frequency identification tag located in an area of constructive interference will transmit the second response signal. The method further comprises altering at least one of antenna power and a phase of the secondary activation signal to produce a second, but partially overlapping, area of constructive interference.
[0014] In some embodiments of the method, said receiving includes: receiving a radio signal strength indication from a plurality of radio-frequency identification tag; and identifying only a selected tag located in a first area of constructive interference due to a strength of the received radio signal strength indication.
[0015] In some embodiments of the method, said receiving includes: calculating a read probability for a selected tag to respond when queried; and using the calculated read probability to locate the selected tag.
[0016] In some embodiments, the method further comprises mapping a response pattern for the predefined area that compensates for environmental and structural interference.
[0017] In some embodiments, said mapping includes traversing the predefined area with a robot with an attached radio-frequency identification tag, transmitting a plurality of calibration signals via the plurality of antennas at respective power levels and phases, and comparing a predetermined location of the robot with a triangulated position of the attached radio-frequency identification tag.
[0018] In some embodiments, the mapping further comprises comparing the predetermined location of the robot to a predicted constructive interference zone, comparing constructive interference data to predicted interference data, and adjusting at least one of signal power or phase of the secondary activation signal until the constructive interference data matches the predicted interference data.
[0019] In some embodiments, the method further comprises disposing a calibration radio-frequency identification tag on a person; determining a location of the person as the person traverses the predetermined area; comparing the location of the person to a predicted constructive interference zone; comparing constructive interference data to predicted interference data; and adjusting at least one of signal power or phase of the secondary activation signal until the constructive interference data matches the predicted interference data.
[0020] In some embodiments, the location of the person is determined using a camera.
[0021] In some embodiments, the camera can be any one of an RGB camera, a monochrome visible light camera, a 3-dimensional camera, an infrared camera, and an ultra violet camera.
[0022] In some embodiments, the method further comprises determining a volume occupied by a person and an associated object.
[0023] In some embodiments, the volume occupied by a person and an associated object informs a targeted constructive interference pattern.
[0024] In some embodiments, the camera can identify the presence of the radio-frequency identification tag or an object with a predefined volume.
[0025] In some embodiments, the method disclosed is employed in combination with at least one of other tag locating techniques. In some embodiments, the other techniques can include at least one of time difference of arrival, frequency domain phase difference on arrival, received signal strength indication measurement, and read probability measurement.
[0026] In some embodiments, the method includes receiving environmental data including at least one of air humidity, air temperature, an environmental noise level, and a signal indicating a presence of people or objects in the preselected area, and adjusting signal power or phase of the secondary activation signal based on the environmental data to generate a constructive interference pattern. Sensors can be used to determine the background environmental radiation level.
[0027] In some embodiments, the method further comprises converting the second response signal from the radio-frequency identification tag from an analog signal into a digital signal in order to identify a radio-frequency identification tag number.
[0028] In some embodiments of the method, said altering includes changing one or more of an antenna radio pattern, an antenna orientation, a signal transmission power level, a frequency of the activation signal, a phase of the activation signal, and a beam-width of the activation signal to modify a constructive interference patterns.
[0029] In some embodiments, the method further comprises using historical radio-frequency identification tag location data to further refine the constructive interference pattern.
[0030] In some embodiments, the method further comprises calculating a velocity of a moving radio-frequency identification tag; predicting a new location of the moving radio-frequency identification tag based on the velocity of the moving radio-frequency identification tag; and altering the phase of the secondary activation signal based on the new location of the radio-frequency identification tag.
[0031] In accordance with an aspect disclosed herein, there is set forth a system for locating a radio-frequency identification tag, comprising a plurality of antennas dispersed in a predefined area; one or more radio-frequency identification tags dispersed within the predefined area; a radio-frequency transceiver in communication with said antennas; a phase modulator electrically coupled to the radio-frequency transceiver; and a system controller in communication with said transceiver and said phase modulator.
[0032] In some embodiments, the system controller enables sub-threshold superposition response mapping to calculate the location of the radio-frequency tags within the predefined area.
[0033] In some embodiments, the plurality of antennas can comprise any one of the following antenna types including a patch antenna, a reflected antenna, a wire antenna, a bow-tie antenna, an aperture antenna, a loop-inductor antenna, and a fractal antenna.
[0034] In some embodiments, the plurality of antennas can comprise more than one type of antenna. In some embodiments, the plurality of antennas are connected directly to the radio-frequency transceiver. In some embodiments of the system, the plurality of antennas are connected to the radio-frequency transceiver through one or more antenna splitters.
[0035] In some embodiments of the system, the plurality of antennas are capable of both transmission and reception of signals from the radio-frequency identification tags. In some other embodiments, the plurality of antennas are capable only of transmission or reception of signals.
[0036] In some embodiments of the system, the radio-frequency transceiver is capable of transmitting and receiving signals in a 900 megahertz frequency band.
[0037] In some embodiments, the radio frequency transceiver is capable of modulating a power level of a transmission signal.
[0038] In some embodiments, the system controller can calculate a location of a radio-frequency identification tag from radio-frequency identification response data.
[0039] In some embodiments, the system controller can store maps of constructive interference patterns of a predetermined location in a storage device.
[0040] In accordance with an aspect disclosed herein there is set forth a method for mapping a response pattern for a predefined area compensating for environmental and structural interference, comprising traversing the predefined area with a robot with an attached radio-frequency tag; transmitting a plurality of calibration signals at respective power levels and phases via a plurality of antennas disposed in the predefined area; and comparing a predetermined location of the robot with a triangulated position of the attached radio-frequency identification tag.
[0041] In some embodiments, the method further comprises comparing the predetermined location of the robot to a predicted constructive interference zone; comparing constructive interference data to predicted interference data; and adjusting at least one of signal power or phase of the secondary activation signal until the constructive interference data matches the predicted interference data.
[0042] In some embodiments, the method further comprises disposing a calibration radio-frequency identification tag on a person; determining a location of the person as the person traverses the predetermined location; comparing the location of the person to a predicted constructive interference zone; comparing constructive interference data to predicted interference data; and adjusting at least one of signal power or phase of the secondary activation signal until the constructive interference data matches the predicted interference data.
[0043] In some embodiments, the method further comprises saving constructive interference data to a database.
[0044] In accordance with an aspect disclosed herein, there is set forth a computer implemented method suitable for implementation on a processor comprising analyzing first and second response signals via a plurality of antennas from the radio-frequency identification tag; and triangulating a position of the radio-frequency identification tag based upon said analyzing, wherein said analyzing and triangulating are performed by a processor.
[0045] In some methods, said analyzing further comprises transmitting an initial activation signal from one of a plurality of antennas dispersed in a predefined area; receiving a first response signal from the radio-frequency identification tag via the plurality of the antennas.
[0046] In some embodiments of the method, said analyzing further includes altering a transmission signal property of the initial activation signal; transmitting a secondary activation signal with the altered property; and receiving a secondary response signal from the radio frequency identification tag via the plurality of the antennas.
[0047] In some embodiments of the method, said transmitting comprises transmitting the plurality of sub-threshold radio-frequency identification signals to create a constructive interference pattern within the predefined area.
[0048] In some embodiments, said transmitting comprises transmitting the plurality of sub-threshold radio-frequency identification signals via separate antennas.
[0049] In some embodiments, said altering includes adjusting a power level of the secondary activation signal such that only the selected radio-frequency identification tag located in an area of constructive interference will transmit the second response signal; and altering at least one of antenna power and a phase of secondary activation signal to produce a second, but partially overlapping, area of constructive interference.
[0050] In some embodiments, the method further comprises mapping a response pattern for the predefined area that compensates for environmental and structural interference.
[0051] In some embodiments, said mapping includes traversing the predefined area with a robot with an attached radio-frequency tag; transmitting a plurality of calibration signals via the plurality of antennas at respective power levels and phases; and comparing a predetermined location of the robot with a triangulated position of the attached radio-frequency identification tag.
[0052] In some embodiments, the method further comprises comparing the predetermined location of the robot to a predicted constructive interference zone; comparing constructive interference data to predicted interference data; and adjusting at least one of signal power or phase until the constructive interference data matches the predicted interference data.
[0053] In some embodiments, the method further comprises disposing a calibration radio-frequency identification tag on a person; determining a location of the person as the person traverses the predetermined area; comparing the location of the person to a predicted constructive interference zone; comparing constructive interference data to predicted interference data; and adjusting at least one of signal power or phase of the secondary activation signal until the constructive interference data matches the predicted interference data.
[0054] In some embodiments of the method, the location of the person is achieved using a camera.
[0055] In some embodiments of the methods, the camera can be any one of an RGB camera, a monochrome visible light camera, a 3-dimensional camera, an infrared camera, and an ultra violet camera.
[0056] One embodiment of the method, further comprises determining a volume occupied by a person and an associated object. In some embodiments, the volume occupied by a person and an associated object informs a targeted constructive interference pattern. In some embodiments of the method, the camera can identify the presence of the radio-frequency identification tag or an object with a predefined volume.
BRIEF DESCRIPTION OF THE FIGURES
[0057] FIG. 1 is a diagram view of a system of a preferred embodiment.
[0058] FIG. 2 is a diagram view of a prior-art RSSI locating technique.
[0059] FIG. 3A is an example view of constructive interference patterns generated by a system of a preferred embodiment.
[0060] FIG. 3B is another example view of constructive interference pattern generated by a system of the preferred embodiment.
[0061] FIG. 4A is an example view of constructive interference patterns generated by a system of a preferred embodiment.
[0062] FIG. 4B is another example view of constructive interference patterns generated by a system of the preferred embodiment.
[0063] FIG. 5 is a diagram view of a system of a preferred embodiment.
[0064] FIG. 6 is an example view of constructive interference patterns generated by a system of a preferred embodiment.
[0065] FIG. 7 is a chart view of a method of a preferred embodiment.
[0066] It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0067] The following description of the preferred embodiments of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.
1. RFID Tag Locating System
[0068] As shown in FIG. 1 , a radio-frequency identification (RFID) tag locating system 100 includes a plurality of antennas 110 , an RFID transceiver 120 , a phase modulator 130 , and a system controller 140 . The system 100 may additionally include one or more reference RFID tags 150 .
[0069] The system 100 functions to locate RFID tags within a three-dimensional volume of interest (or a two-dimensional plane of interest). The system 100 preferably determines tag location across time in order to track changes in tag location and/or tag movement. The system 100 is preferably designed and used to locate ultra-high frequency (UHF) passive RFID tags, but may additionally or alternatively be designed and used to locate passive RFID tags operating on any frequency spectrum. Additionally or alternatively, the system 100 may also be used with active RFID tags or any other suitable devices capable of responding selectively based on received RF signal power.
[0070] Traditional RFID tag locating systems use one of several methods for tag location, including time difference of arrival (TDOA), phase difference of arrival (PDOA), and received signal strength indication (RSSI) measurement. All three of these methods can locate tags using trilateration.
[0071] In the case of TDOA, a signal is sent to an RFID tag from one of three antennas. The tag receives the signal and transmits a signal in response. The response signal is then received at all three of the antennas at different times. The time between original signal transmission and reception of the response signal at each antenna can be used to determine the distance from the tag to each antenna, which can then be used to locate the RFID tag (relative to the antennas) using trilateration. The TDOA method is not typically used for UHF RFID tags simply because typical time differences are very small (and bandwidth available is narrow).
[0072] There are several types of PDOA, including frequency domain PDOA (FD-PDOA). In FD-PDOA, a signal is sent to a tag from one of three antennas at a first frequency; the tag responds with a first response signal. Then the same antenna sends a signal at a second frequency (preferably close to the first frequency), and the tag responds with a second response signal. The phase difference between the first response signal and the second response signal (as measured at the first antenna) can give a distance from the tag to the first antenna. This process can be repeated for the other two antennas, producing three distances, which can be used to locate the tag using trilateration.
[0073] In the case of RSSI measurement, as shown in FIG. 2 , a signal is sent to an RFID tag from one (or more) of three antennas. The tag receives the signal and transmits a signal in response. The response signal is then received at all three of the antennas, each recording a different received signal strength (e.g., RSSI). The RSSI is used to estimate distance from each antenna, which can then be used to locate the tag relative to the antennas using trilateration. Since RSSI does not typically correspond well to distance, this method may suffer from accuracy issues.
[0074] Another method for locating RFID tags is known as read probability measurement, described in U.S. Provisional Patent Application No. 61/928,303, which is incorporated in its entirety by this reference. To briefly summarize, read probability measurement takes advantage of RFID tag power-on thresholds (that is, the minimum amount of power a passive RFID tag must receive in order to transmit a readable response signal). The antennas modulate transmission power and record whether the tag responds or not at each transmission power. A number of these transmissions are used together to calculate a read probability (the probability that a tag will be read versus transmission power). By comparing this to an estimate or analysis of how transmission signal power changes with distance (and potentially direction) for each transmission power, a distance from each antenna can be determined, and trilateration can be performed.
[0075] The system 100 preferably locates RFID tags using a method henceforth referred to as sub-threshold superposition response mapping (STSRM). This technique may be used independently of the method of RFID tag locating described previously, but may additionally or alternatively be used in conjunction with those methods.
[0076] As with previously described methods, STSRM (described in more detail in the description of the method 200 ) also involves the use of multiple antennas; however, the locating process is very different from previously described methods. In STSRM, multiple antennas transmit a signal at the same time. The signals transmitted by the antennas interfere with each other, creating areas of constructive interference and areas of destructive interference. Based on the relative location of antennas, signal properties of the signal emitted by each antenna (e.g., phase, polarization, beam width, etc.), and the environment (e.g., obstacles in between antennas and tags), the interference pattern generated by signals can be predicted. The power of each antenna can be adjusted such that only areas of strong constructive interference (preferably a sparse pattern) have enough power to activate RFID tags; in other words, the individual signals are sub-activation-threshold in areas of interest. If an RFID tag is activated, it must then lie in one of these areas of constructive interference. After an RFID tag is located within a constructive interference area, the constructive interference pattern is then changed (by altering antenna power and phase) to produce a different, but partially overlapping, set of constructive interference points. This process of altering patterns may proceed until the RFID tag has been confined to a single location.
[0077] In other embodiments, instead of using power level for threshold for activation of tags inside the target zone, received signal strength indication (RSSI) measurement can be used. Outside the constructive interference zone, there will be a marked decrease in RSSI. The varied RSSI signal levels can produce a steep gradient for tags located inside and outside the zone. This difference in RSSI can be used to eliminate tags located outside the target zone. For tags that are located on the boundary of a constructive interference zone, other techniques can be utilized to determine whether the tag is located inside or outside the zone. Examples of the constructive interference patterns produced during STSRM are as shown in FIGS. 3A and 3B . FIGS. 3A and 3B include field contour plots, where field strength above a threshold is displayed as black and field strength below the threshold is displayed as white. In these examples, the plot threshold is chosen to be an RFID tag threshold; that is, RFID tags will only have enough power to respond to transmitted signals if they are in black areas. The examples shown in FIG. 3A and FIG. 3B are identical except for transmission power; P2<P1. Because P2 is lower, fewer points in the area of interest are super-threshold (and thus potential locating resolution is higher). More examples are as shown in FIGS. 4A and 4B ; in these examples, the transmission power is the same between FIGS. 4A and 4B , but the relative phase of antennas is different. Note that all of these examples assume a uniform transmission media (e.g., air) and no reflections; these factors are often important in determining real-world constructive interference patterns.
[0078] The locating process as described above discusses localization using only STSRM, but the technique may additionally or alternatively be used with other techniques to narrow the search field (i.e., how many patterns must be tested) or for other purposes. For example, read probability measurement may place an RFID tag within a 1×1 meter area with 95% accuracy, and STSRM could be used to further narrow down location within this area.
[0079] The nature of constructive interference is that with multiple signals traveling in different directions, effects can be highly localized (on order of signal wavelength). Further, altering of phase can displace interference peaks by magnitudes substantially smaller than wavelength, meaning that STSRM is capable of achieving very high accuracy in locating RFID tags.
[0080] The system 100 preferably enables the use of STSRM techniques to locate RFID tags; additionally or alternatively, the system. 100 may enable the use of other tag locating techniques in combination with or complementary to STSRM techniques.
[0081] The antennas 110 function enable the system 100 to transmit signals to RFID tags and receive signals from the RFID tags. The antennas 110 convert conducted electric power into RF waves and/or vice versa, enabling the transmission and/or reception of RF communication. The antennas 110 are preferably made out of a conductive material (e.g. metal). The antennas 110 may additionally or alternatively include dielectric materials to modify the properties of the antennas 110 or to provide mechanical support.
[0082] The antennas 110 may be of a variety of antenna types; for example, patch antennas (including rectangular and planar inverted F), reflector antennas, wire antennas (including dipole antennas), bow-tie antennas, aperture antennas, loop-inductor antennas, and fractal antennas. The plurality of antennas 110 can additionally include one or more type of antennas, and the types of antennas can include any suitable variations.
[0083] The antenna 110 structure may be static or dynamic (e.g. a wire antenna that includes multiple sections that may be electrically connected or isolated depending on the state of the antenna).
[0084] Antennas 110 may have isotropic or anisotropic radiation patterns (i.e., the antennas may be directional). If antennas 110 are directional, their radiation pattern may be dynamically alterable; for example, an antenna 110 substantially emitting radiation in one direction may be rotated so as to change the direction of radiation.
[0085] The plurality of antennas 110 are preferably connected directly to RFID transceivers 120 with conductive wires, but may additionally or alternatively be connected to transceivers through any suitable method. The antennas 110 may be connected directly to RFID transceivers 120 , or may be connected RFID transceivers 120 through one or more antenna splitters.
[0086] The system 100 preferably includes at least three antennas 110 , so as to be able to perform trilateration, but the system may additionally include any suitable number of antennas. In one implementation of the system 100 , the system 100 includes a rectangular grid of antennas 110 . Other embodiments can selectively assign antennas to various roles. In one embodiment a fixed number of antennas can be tasked with targeting a particular zone, while other antennas can be assigned to reducing secondary effects interference from other power zones which can occur some distance away from the targeted zone.
[0087] The antennas 110 of the system 100 are preferably used both for transmission of signals to and reception of signals from RFID tags, but may additionally or alternatively antennas may be used only for transmission or only for reception.
[0088] Antennas 110 are preferably located as to provide coverage for a particular indoor area. For example, antennas 110 might be oriented in a rectangle on the ceiling of a store in order to locate RFID tags contained within the rectangle. In this particular implementation, of the two solutions produced by trilateration, only one would be valid (the assumption being that no RFID tags are present above the ceiling).
[0089] The RFID transceiver 120 functions to produce signals for transmission by the antennas 110 , as well as to analyze signals received by the antennas 110 from RFID tags. In one embodiment, the RFID transceiver preferably includes an RF transmitter capable of sending signals in the 900 MHz band and an RF receiver capable of receiving signals in the 900 MHz band, but may additionally or alternatively be any suitable transceiver capable of communicating with RFID tags. The 900 MHz band supports 902-928 MHz in North America. Alternatively the transmitter can operate in the 800 MHz band. The 800 MHz band supports 865-968 MHz in Europe. Alternatively, the transceiver can operate in the industrial, scientific and medical (ISM) radio band from 2.4-2.485 (Bluetooth Band), 2.4 gigahertz (12 cm) UHF and 5 gigahertz (6 cm) SHF ISM radio bands, 3.1-10 GHz (microwave band), and other UHF RFID tag emitter bands in use or later developed.
[0090] The RFID transceiver 120 is preferably coupled directly to the antennas 110 , but may additionally be coupled to the antennas 110 through an antenna splitter or through any other components.
[0091] The RFID transceiver 120 is preferably controlled by the system controller 140 , but may additionally or alternatively be controlled by any other component of the system 100 . The RFID transceiver 120 is preferably capable of modulating power to the antennas 110 , additionally or alternatively, power modulation may be accomplished by a device external to the RFID transceiver 120 (e.g., an active splitter).
[0092] The phase modulator 130 functions to change the phase of the signal output by one or more antennas 110 . Changing the phase of any one of the antennas 110 has the effect of changing the far-field interference pattern (and thus the areas that RFID tags may be activated in). The phase modulator 130 is preferably part of the RFID transceiver 120 , but may additionally or alternatively be a component independent of the RFID transceiver 120 .
[0093] If the phase modulator 130 is part of the RFID transceiver 120 and each antenna 110 (or antenna array) is connected to the RFID transceiver 120 individually (as shown in FIG. 1 ), the phase modulator 130 preferably changes phase simply by modifying the digital signal intended for a particular antenna. For example, the carrier wave of an RF signal transmitted by an antenna 110 might have the form of cos [ωt+φ], where φ represents an alterable phase shift. The phase modulator 130 may simply adjust the value of φ to provide the signal with a particular phase.
[0094] If the phase modulator 130 is part of or after an antenna splitter, as shown in FIG. 5 , or otherwise operates on the analog signals intended for the antennas 110 (as opposed to the previous example, where the phase modulator 130 operates in the digital domain), the phase modulator 130 may consist of variable delay circuits connected to the antennas 110 . Additionally or alternatively, the phase modulator 130 may comprise any digital or analog circuit or component capable of altering the phase of the transmitted signals of one or more antennas 110 .
[0095] The system controller 140 functions to control the output of the RFID transceiver 120 and the phase modulator 130 , as well as to process the signals received by the RFID transceiver 120 . The system controller 140 includes a microprocessor; the system controller 140 may be integrated with the RFID transceiver 120 and phase modulator 130 , but may additionally or alternatively be separate of one or both of the RFID transceiver and phase modulator 130 .
[0096] The system controller 140 enables the system 100 to transform RFID response data into a location for an RFID tag. The system controller 140 preferably accomplishes this transformation by using a mapping of constructive interference patterns to physical locations to estimate the coordinates at which signal power rises above some activation threshold. This process is described in more detail in the sections on the method 200 .
[0097] The system controller 140 preferably includes a processor and storage for the above-mentioned maps, but may additionally or alternatively store map data and configuration data in any suitable location (e.g., cloud-based servers).
[0098] The system controller 140 preferably performs this transformation using stored maps. The system controller 140 may additionally or alternatively generate maps in real-time. These maps preferably allow the system controller to determine super-threshold areas of constructive interference based on transmission variables; for example, the location of antennas 110 , the angle of orientation of antennas 110 , the radiation pattern of antennas 110 , the phase, frequency, polarization, and power of signals transmitted by the RFID transceiver 120 (via the antennas 110 ), or any other applicable data. The maps may additionally or alternatively vary based on environmental variables, for example, the number of people within the area of interest.
[0099] Constructive interference patterns may be strongly dependent on environment. For example, a change in positioning of shelves in a store might cause larges changes in the constructive interference pattern generated given a certain set of transmission parameters. For this reason, it may be helpful for the system controller 140 to have a calibration reference; for example, data defining how constructive interference patterns for a particular area.
[0100] The calibration references may be static; for instance, the calibration references may be formed by a robot with an RFID tag traversing an area; the robot maps out the area while the system 100 outputs one or more constructive interference patterns. The system 100 outputs constructive interference patterns by transmitting a signal from one or more antennas 110 at particular transmission powers and phases. The robot map may be, through time synchronization, matched up to points of RFID tag activation, this data set is then compared to constructive interference data predicted by the system controller 140 . The system controller 140 may then adjust transmission variables (e.g., by adjusting transmission variable inputs to a prediction engine until prediction matches reality, or by adjusting actual transmission variable inputs until the robot output matches predictions). Static calibration processes may be performed in real-time with data gathering (e.g., as the robot moves around) or at a later time (using previously corrected data).
[0101] Similarly, a robot may be used to map read probabilities for various locations within an area. For example, a robot may be used to map out an area while the system 100 outputs signals from one antenna (or serially from multiple antennas). The robot map, through time synchronization, may be matched up to points of RFID tag activation; this data may then be used to calculate read probabilities as a function of position in the area. As in the previous process, the system controller 140 may adjust transmission variables to match predictions to reality or vice versa. Read probability calibration processes may be performed in real-time with data gathering (e.g., as the robot moves around) or at a later time (using previously corrected data).
[0102] The calibration references may additionally or alternatively be dynamic. In one example, the system 100 includes RFID reference tags 150 placed in known locations. These may be used to calibrate or recalibrate the system controller 140 mapping at any time. This allows the system 100 to be recalibrated easily when environmental factors (e.g., positioning of RF-signal-affecting objects, etc.) change. The system 100 preferably calibrates with references by predicting patterns that would activate particular reference tags, testing those patterns, and refining the patterns based on response or non-response.
[0103] Calibration may additionally or alternatively be performed with the aid of non-STSRM techniques. For example, persons in a particular area may carry RFID tags that identify them. If the position of the persons can be located with precision (e.g., by a camera, or by another method, such as detecting wireless transmissions from their cellphone), the RFID tags they carry could be used to calibrate the system 100 . Cameras or other locating methods may additionally or alternatively be used at any point in order to refine or calibrate STSRM location data or the system 100 .
[0104] For example, a camera (e.g., RGB camera, monochrome visible light camera, 3D camera, depth camera, infrared camera, or an ultra violet sensor etc.) could be used to recognize a person (either generically as a person, or as a particular person, using face recognition software, gait analysis, or another suitable technique). The camera may additionally or alternatively be used to calculate the volume occupied by the person and associated objects (e.g., a shopping cart). The location and volume occupied by the person and/or associated objects could be used to inform a particular constructive interference pattern; for example, to query RFID tags of objects contained within the person's bag or shopping cart. This could be used to determine particular items a person is carrying. Additionally or alternatively, location information, recognition data, visual data, or any other suitable camera data may be used in combination with STSRM data in any suitable manner in order to provide further information about the presence of RFID tags (or other objects) within a particular volume.
[0105] The system controller 140 may additionally or alternatively use the antennas 110 to perform calibration; for example, the system controller 140 may transmit a signal at a first antenna 110 and receive it at a second antenna 110 . Because the relative locations of the antennas 110 are preferably known, the signal can be used to determine delay or phase shift due to environmental factors in the signal path. This information can be used to refine constructive interference pattern maps.
[0106] In addition to controlling the calibration process, the system controller 140 preferably controls the transmissions used for RFID tag location. The system controller 140 preferably adjusts phase and transmission power to locate RFID tags in a small number of iterations (e.g., by optimizing for a minimum number of iterations given rough knowledge about the position of a tag). For example, the system controller 140 may know from a previous search that a tag is located in a particular area. If analysis of historical data suggests that the tag is likely to be in the same area, the system controller 140 may attempt to isolate the search to this area before trying other areas. The system controller 140 storage may analyze historical data related to tag location in a number of ways. Historical data preferably includes historical environmental data, historical absolute location data (e.g., the tag's location in coordinate space), historical relative location data (e.g., the tag's location relative to other tags or other references), behavioral data (e.g., the tag is likely to be in the middle of the area during the afternoon, but near the left edge during the evening), or any other suitable data.
[0107] The system controller 140 preferably alters phase and transmission power of antennas 110 by controlling RF transceivers 120 and phase modulators 130 , but may additionally or alternatively alter antenna phase and transmission power in any suitable manner.
[0108] The system controller 140 may locate RFID tags using only the STSRM method, but may additionally or alternatively locate RFID tags using a combination of methods; for instance, RSSI may be used to roughly locate RFID tags, and then STSRM may be used to locate RFID tags with higher resolution. If the system 100 performs multiple methods of tag locating, all methods are preferably directed by the system controller 140 , but the system controller 140 may alternatively direct only a subset of locating methods.
[0109] The reference RFID tags 150 function to provide a calibration reference to the system 100 . The reference RFID tags are preferably substantially similar to the RFID tags located by the system 100 , but may additionally or alternatively any suitable type of RFID tag. The RFID tags preferably have a known tag identifier (i.e., the signal transmitted by the tag when interrogated) and a known position. Thus, when reference RFID tags 150 transmit, the system controller 140 can infer that the activation signal was above-threshold at the location of transmitting reference RFID tags.
[0110] Reference RFID tags are preferably associated with a location that is static relative to the antennas 110 , but may additionally or alternatively be associated with a location in a different coordinate space. For example, reference RFID tags may be located with GPS coordinates, or with some particular object (e.g., a moveable cart may contain a reference RFID tag so that positions may be determined relative to that cart).
[0111] Sub-threshold superposition response mapping (STSRM) techniques are not limited to the use of UHF radio frequency radiation. STRM techniques can be applied using ultrasound radiation. Ultrasound devices operate with frequencies from 20 kHz up to several gigahertz. Sound vibration can form constructive interference patterns similar to ultrahigh frequency radiation and STSRM techniques can be applied for the selective transmission of sound waves.
[0112] In addition to using constructive interference mapping techniques for the locating of RFID tags, these methods could be used for other targeted transmission and receipt of energy. Such applications include, the targeted transmission of radiation resulting in constructive interference zones for the targeted transmission of energy for specific areas. This could be used for selected areas for transmitting radiation for wireless, remote recharging of portable electronic devices. In this way, concentration of the radiation to selective areas would reduce the harmful effects of radiation on humans with isometric radiation.
[0113] Other uses included the selected targeting of areas for concentrated bandwidth distribution. In this way some areas would have higher bandwidth capabilities in these constructive interference zones than outside the constructive interference zones. In zones outside the target zone, the data rate would be significantly reduced.
[0114] As shown in FIG. 7 , a method 200 for sub-threshold superposition response mapping (STSRM) preferably includes transmitting a plurality of sub-threshold RFID activation signals from separate antennas S 210 , receiving a response signal from an RFID tag S 220 , altering transmission signal properties S 230 , receiving an additional response signal from the RFID tag S 240 , and calculating the RFID tag position S 250 . The method 200 may additionally include calibrating interference mapping S 260 .
[0115] The method 200 functions to locate RFID tags within a specific volume (bounded by antenna range). The method 200 preferably results in a more accurate location estimate than from typical methods (e.g., TDOA, PDOA, etc.).
[0116] Step S 210 includes transmitting a plurality of sub-threshold RFID activation signals from separate antennas. Step S 210 functions to create a constructive interference pattern within an area defined by the transmitting antenna range. The constructive interference pattern is a function of antenna and signal properties including antenna radiation pattern, antenna orientation, antenna type, transmission power, frequency, phase, beam-width, and other factors.
[0117] The locations of the antennas are preferably known relative to each other. Antennas may additionally or alternatively be referenced to any coordinate frame of reference.
[0118] The transmission power and relative phase of activation signals are preferably set based on an estimated constructive interference pattern, but may additionally or alternatively be based on any suitable instructions or data. The transmission power and relative phase of activation signals are preferably set such that only a small subset of the area covered by antenna range results in super-threshold signal power; that is, most of the area covered by antenna range does not have enough constructive interference to, activate an RFID tag.
[0119] The particular power and phase settings chosen for each signal are preferably informed by historical data; that is, the interference pattern generated by Step S 210 is preferably intended to activate tags in a particular subset of in-range area where the tags are assumed to be. Additionally or alternatively, the power and phase settings chosen by Step S 210 may result from explicit settings (e.g., the first activation signals always have a relative phase of zero and a transmission power of 100 dBm), other data (e.g., data from other locating methods), or any other suitable instructions.
[0120] Step S 210 may additionally or alternatively include receiving environmental data (e.g., humidity, presence of people or objects, temperature, environmental RF noise, etc.) or previous mapping information (e.g., a mapping of particular transmission settings to a constructive interference pattern). This data may be used to inform the transmission settings in order to more accurately generate particular constructive interference patterns. Previous mapping information or other calibration information preferably results from Step S 260 , but may additionally or alternatively come from any suitable source.
[0121] Step S 220 includes receiving a response signal from an RFID tag. Step S 220 functions to provide data that can be used to generate information about the RFID tag's location. Based on the transmission settings of Step S 210 and the predicted mapping of signal strength (taking into account constructive interference), the location of the RFID tag may be confined to a set of points (or small areas) of constructive interference. Note that Step 210 may need to be iterated multiple times at different transmission settings before receiving a response signal from a particular RFID tag.
[0122] Step S 220 preferably includes receiving an analog signal over one or more antennas; these antennas are preferably the same antennas used to transmit signal in Step S 210 , but may additionally or alternatively be any suitable antennas. This analog signal is preferably converted to a digital signal and analyzed to provide the locating system with the RFID tag ID. Additionally or alternatively, if the tag identifier is not important to a particular application, the signal may not be converted (e.g., an application that only cares about locating any tag, not a specific tag).
[0123] Step S 230 includes altering transmission signal properties. Step S 230 functions to change the constructive interference pattern used to enable RFID tag responses. Step S 230 may occur after Step S 210 (if a desired tag is not located) or after Step S 220 (to refine the location of a particular tag).
[0124] Step S 230 preferably includes altering one or more of antenna radiation pattern, antenna orientation, signal transmission power, frequency, phase, and beam-width in order to alter constructive interference patterns.
[0125] The alterations made by Step S 230 preferably are informed by existing data or estimates pertaining to an RFID tag's location; additionally or alternatively, alterations may be made according to a static instruction set or in any other suitable manner. For example, if analysis of data from Step S 220 identifies an RFID tag as occupying a location in the first quadrant of a square area (i.e., x>0 and y>0) or in the third quadrant (x<0, y<0), and historical data suggests that the RFID tag is much more likely to be in the first quadrant, the alterations made by Step S 230 may produce an interference pattern more likely to provide location information on a tag located in the first quadrant.
[0126] As a specific example of data pertaining to RFID tag location, the alterations made by Step S 230 are preferably informed by the results of previous alterations. For example, as shown in FIG. 6 , a first pattern may be generated by Step S 210 , resulting in tag detection in Step S 220 . Step S 230 alters the transmission signal to produce a second pattern, which results in no detection. Assuming that the tag did not move significantly between the generation of pattern 1 and pattern 2, the tag must be located in the area found by subtracting pattern 2 from pattern 1. In this example, Step S 230 might then be run again, with the third pattern calculated to give more information about where the tag might be located within the area defined by the removal of pattern 2 area from pattern 1. While this example includes a detection and a non-detection, the same principles apply to two detections in a row. For example, if an RFID tag were detected in both pattern 1 and pattern 2, the RFID tag would be located within the intersection of pattern 1 and pattern 2 (again assuming no substantial movement between responses).
[0127] Preferably, tags read by the method 200 do not move significantly while being located; but if it is expected that tags will move significantly while being located, the method 200 may include detecting tag velocity and adjusting locating techniques appropriately (e.g., predicting where a tag will be based on previously measured velocity and attempting to locate it at the predicted location). Tag velocity may be detected in any number of ways, including by the steps previously mentioned. Altering antenna phase only slightly has an effect of essentially shifting the constructive interference pattern without substantially altering it; by shifting constructive interference patterns slightly tag velocity can be determined even if tag location is not definitely known. For example, if the method 200 confines tag location to a first set of points defined by a constructive interference pattern, generates a shifted pattern and detects the tag in a second set of points defined by a second constructive interference pattern, the average velocity of the tag between the generation of those two patterns falls into a bound set of solutions. By performing additional pattern generations and/or by including some assumptions (e.g., maximum velocity the tag can move at, direction of velocity, etc.) the tag velocity can be determined.
[0128] Step S 240 includes receiving an additional response signal from the RFID tag. Step S 240 is preferably substantially similar to Step S 220 . The results of the second response signal are preferably used in determining RFID tag position; the results may additionally be used to direct Step S 230 (e.g., by identifying an area of interest to search in).
[0129] Steps S 230 and Steps 240 are preferably iterated until RFID tag location has been suitably confined. In some cases, Steps S 230 and S 240 may be iterated a set number of times; for instance, there may be a set of constructive interference patterns that can, to a desired resolution, locate any tag within an area of interest (regardless of tag location within the area of interest) and Steps S 230 and S 240 may be iterated until this set has been completed. Additionally or alternatively, Steps S 230 and Steps S 240 are iterated along with an intermediate iteration of Step S 250 ; for example, after each iteration of Step S 230 and Step S 240 , Step S 250 uses the results to further confine tag location and to direct parameters of the next iteration of Step S 230 , the iteration cycle continuing until Step S 250 has suitably determined tag location (e.g., by reducing possible tag location area to an area below some threshold area).
[0130] Step S 250 includes calculating the RFID tag position. Step S 250 functions to determine or estimate where RFID tags are located based on responses to particular interference patterns. Step S 250 is preferably iterated along with steps S 230 and S 240 , but may additionally or alternatively be performed only after several iterations of Steps S 230 and S 240 or at any suitable time.
[0131] Step S 250 preferably calculates RFID tag position by correlating RFID tag response or non-response to locations defined by constructive interference patterns. Step S 250 preferably produces RFID tag position data from RFID tag response data and transmission parameter sets (e.g., whether a tag responded or not for a particular transmission parameter set) by generating a transmission power field estimate (or other distribution correlated to RFID response rates) based on the transmission parameter set.
[0132] The mapping between transmission parameter sets and transmission power fields is preferably set by Step S 260 , but may additionally or alternatively be set in any suitable manner. As described in Step S 260 , the mapping may vary solely on transmission power and phase (i.e., all other transmission parameters, including antenna location, and environmental variables are considered static) or the mapping may vary based on additional variables. For example, the mapping algorithm might also vary based on the number of people known to be in a particular area (changing the permittivity of the area, and thus the interference pattern) or based on antenna direction, if antenna direction is variable.
[0133] Step S 250 may additionally or alternatively include calculating RFID tag position based on a combination of multiple locating methods (e.g., by locating an RFID tag to a particular area using a read probability method and then locating the tag within that area using STSRM).
[0134] Step S 260 includes calibrating interference mapping. Step S 260 functions to increase the accuracy of the mapping between antenna fields (specifically, super-threshold and sub-threshold areas) and location (relative to antennas or otherwise).
[0135] Step S 260 preferably calibrates interference mapping by generating calibration references, which are then used to predict antenna fields (or a related metric, such as areas of super-threshold power). Calibration references may be pre-generated; for instance, calibration references may be formed by a robot with an RFID tag traversing an area; the robot maps out the area while one or more constructive interference patterns are generated by antennas. The robot map may be, through time synchronization, matched up to points of RFID tag activation, this data set is then compared to predicted data. Transmission parameters may then be adjusted (e.g., by adjusting transmission variable inputs to a prediction engine until prediction matches reality, or by adjusting actual transmission variable inputs until the robot output matches predictions). Pre-generated calibration references may be calculated in real-time with data gathering (e.g., as the robot moves around) or at a later time.
[0136] The calibration references may additionally or alternatively be generated in real-time (during operation of the method 200 ). In one example, RFID reference tags are placed in known locations. These may be used to generate calibration references at any time. This allows for easy recalibration when environmental factors (e.g., positioning of RF-signal-affecting objects, etc.) change.
[0137] These calibration references are preferably measured for a range of transmission parameters. In particular, calibration references preferably contain enough information to accurately calculate antenna fields for significantly varying transmission parameters (e.g., transmission phase and power from each antenna). In some cases, this may not mean actually measuring fields for wide ranges of all parameters. For instance, if the phase delay of signals is independent of transmission power for a particular environment, and the antenna transmission characteristics are well-known, an accurate calibration may not require many data points at different transmission powers.
[0138] Predicted fields are preferably generated by a modeling of the constructive interference fields based on calibration data collected as part of the method 200 ; additionally, the modeling may also be based on additional data. In one example, antenna fields for a particular set of transmission parameters not exactly sampled as part of calibration data may be predicted by interpolating calibration data. In another example, calibration data is used to model the permittivity (vs. coordinates) of a volume of interest, which are then used to predict antenna fields at any transmission power and phase.
[0139] Calibration may additionally or alternatively be performed with the aid of non-STSRM techniques. For example, persons in a particular area may carry RFID tags that identify them. If the position of the persons can be located with precision (e.g., by a camera, or by another method, such as detecting wireless transmissions from their cellphone), the RFID tags they carry could be used to generate calibration data. Cameras or other locating methods may additionally or alternatively be used at any point in the method 200 in order to refine or calibrate STSRM location data.
[0140] Step S 260 may additionally include calibrating read probabilities by generating read probability references. Read probability references may be pre-generated; for instance, read probability references may be formed by a robot with an RFID tag traversing an area; the robot maps out the area while signals are output from one antenna (or serially from multiple antennas). The robot map, through time synchronization, may be matched up to points of RFID tag activation; this data may then be used to calculate read probabilities as a function of position in the area. As in the previous process, the transmission variables may be adjusted to match predictions to reality or vice versa. Read probability calibration processes may be performed in real-time with data gathering (e.g., as the robot moves around) or at a later time (using previously corrected data).
[0141] The description of the method 200 above provides examples directed to locating particular tags or of tags in a sparse environment; that is, scenarios where some amount of search is required to find a tag. A person skilled in the art will recognize that the method 200 is also applicable to systems where a large number of tags are located in some area, and the locations of many or all of those tags are of interest. In examples applying to such a situation, constructive interference patterns may not be generated to find a particular tag, but rather to provide the locations of all tags within a certain area; the strategy to locate all tags in an area (e.g., what patterns are generated and in what order) may be significantly different than a strategy to locate a single tag.
[0142] The method 200 is preferably performed by the system 100 but may additionally or alternatively be performed by any suitable system.
[0143] The methods of the preferred embodiment and variations thereof can be embodied and/or implemented at least in part as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions are preferably executed by computer-executable components preferably integrated with an RFID tag locating system. The computer-readable medium can be stored on any suitable computer-readable media such as RAMs, ROMs, flash memory, EEPROMs, optical devices (CD or DVD), hard drives, floppy drives, or any suitable device. The computer-executable component is preferably a general or application specific processor, but any suitable dedicated hardware or hardware/firmware combination device can alternatively or additionally execute the instructions.
[0144] The disclosed embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and herein described in detail. It should be understood, however, that the disclosed embodiments are not meant to be limited to the particular forms or methods disclosed, but to the contrary, the disclosed embodiments are to cover all modifications, equivalents, and alternatives. | A system and method for locating radio-frequency identification tags within a predetermined area. The method can incorporate sub-threshold superposition response mapping techniques, alone, or in combination with other methods for locating radio-frequency identification tags such as but not limited to time differential on arrival (TDOA), frequency domain phase difference on arrival (FD-PDOA), and radio signal strength indication (RSSI). The system can include a plurality of antennas dispersed in a predefined area; one or more radio-frequency identification tags; a radio-frequency transceiver in communication with said antennas; a phase modulator coupled to the ra-dio-frequency transceiver; and a system controller in communication with said transceiver and said phase modulator. Calibration techniques can be employed to map con-structive interference zones for improved accuracy. | 6 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/656,514, filed 6 Jun. 2012, the contents of which are incorporated herein by reference in their entirety.
FIELD
[0002] The present embodiments relates generally to detecting at least one variable associated with the formation of at least one joint and/or a machine during assembly of a pipeline system.
BACKGROUND
[0003] 1. Technical Field
[0004] The present disclosure relates to pipeline systems and more specifically to detecting and tracking variable data associated with the formation of joints of an assembled pipeline system, and to archiving and subsequently retrieving the variable data at a later date in the event of a failure.
[0005] 2. Introduction
[0006] Pipeline systems are used for transfer of various industrial fluids, such as oil, coolant, lubricants, water, or other fluids. Given the relatively large size and weight of such industrial pipeline systems, assembly of industrial pipeline systems typically occurs at remote locations that are convenient to processing facilities, such as rural fields for oil drilling, deep ocean floors, etc. Additionally, these pipeline systems are typically situated at locations that alternatively support both origination and receipt of shipment of such industrial commodities, such as ports supporting transport by truck, railway, and water shipment.
[0007] Such pipeline systems typically include an assembly of individual pipe sections, which are assembled by hydraulically pulling a pipe section having a pin end into another pipe section having a bell end, thereby creating an interference fit at the joint. Manufacturers will typically supply these pipe sections with some form of unique part identifier, such as a pipe section serial number, and these pipe sections will be delivered to a particular geographic location for subsequent on-site pipeline assembly.
[0008] Numerous environmental variables or pipeline system assembly parameters can influence its mechanical outcome and performance, as well as the resulting physical integrity of such assembled pipeline systems. Such variables can include, for example, any combination of one or more of variations in mechanical tolerances associated with the respective pin end and bell end of mating pipe sections, ambient temperature and humidity conditions at time of assembly, hydraulic pressing or pulling forces generated by pipeline assembly equipment while mating the pipe sections, as well as other variations affecting pipe quality or reliability.
[0009] Because of the remote locations where these pipeline systems are typically assembled and deployed for use, experienced or qualified machine operators and related equipment are frequently unavailable. Given the complex nature and enormous capital expense for installation of such pipeline systems, as well as the high value associated with the commodities potentially being piped therein, it is desirable that such pipeline systems perform for several years without failure or required maintenance. Thus, determining whether the interference fit is proper during the pipeline assembly process and that a fluid-tight joint is established before these resources leave the pipeline assembly location can be important.
[0010] In the event of a pipeline system failure, such as a failed connection (i.e., leakage) between a particular pin end and bell end of adjacent pipe sections, establishing some form or archival record during original assembly which documents the various assembly parameters and variables may be desirable. This would allow for both dynamic and retrospective analyses of the pipeline.
[0011] Therefore, a need exists for detecting and tracking multiple variables associated with the formation of at least one joint of an assembled pipeline system at the time of assembly. A need also exists for archiving and subsequently retrieving variable data associated with the formation of at least one joint at a later date in the event of a subsequent failure of the at least one joint. The embodiments described below are believed to meet these needs.
SUMMARY
[0012] Additional features and advantages of the disclosure will be set forth in the description that follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein. The steps outlined in these methods can be arranged in any order, combination, or permutation thereof. The methods can include fewer steps or more steps.
[0013] Disclosed herein is a method of detecting at least one variable associated with at least one joint and/or a machine of an assembled pipeline system. A system configured to practice this method can assemble, via the machine including at least one pulling cylinder, at least two pipe sections to form at least one joint of the assembled pipe system. The system can measure, by at least one sensor, at least one variable selected from the group consisting of time, temperature and hydraulic pressure of the pulling cylinder during assembly of the pipe system. The system can determine a location of the at least one joint of the assembled pipeline system. The system can record a serial number associated with each of the at least two pipe sections of the assembled pipeline system.
[0014] In another aspect, a system for detecting at least one variable associated with at least one joint and/or a machine of an assembled pipeline system, includes a machine including at least one sensor for measuring at least one of a variable selected from the group consisting of time, temperature and hydraulic pressure of a pulling cylinder during assembly of the pipe system. The system can include a data controller communicatively coupled to the at least one sensor, the data controller configured to receive information from the sensor. The system can include a processor for executing computer-executable instructions for analyzing information obtained from the data collector.
[0015] Also disclosed herein is a non-transitory computer-readable medium for use on a computer system, the computer-readable medium including computer-executable instructions for performing, when executed by a processor, a method for detecting at least one variable associated with at least one joint and/or a machine. The method can include receiving a measurement, via at least one sensor, of at least one variable selected from the group consisting of time, temperature, and hydraulic pressure during assembly of a pipe system. The method can include determining a location of at least one joint. The method can include generating a notification, status, or alert regarding the received measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Various embodiments of the invention will be understood from the following description, the appended claims and the accompanying drawings, in which:
[0017] FIG. 1 provides a schematic diagram of a working environment of the present invention.
[0018] FIG. 2 provides a schematic diagram illustrating certain components associated with the embodiments of FIG. 1 ; and
[0019] FIG. 3 provides a flowchart depicting an exemplary method for detecting at least one variable, consistent with the disclosed embodiments of FIGS. 1-2 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular embodiments and that they can be practiced or carried out in various ways. The steps and modules outlined and illustrated herein are exemplary, and can be combined in multiple configurations, including configurations in different orders, with different functional links, or with more or fewer steps or modules.
[0021] FIG. 1 illustrates pipeline assembly equipment 100 for assembling a first tubular pipe section 102 together with a second tubular pipe section 104 . While the examples provided herein refer to tubular pipe sections 102 , 104 , the same principles can be applied to other, non-tubular pipe sections as well, including but not limited to square, rectangular, octagonal, or trigonal pipes. These pipe sections will be typically be fabricated with specially-formed, mating ends for assembly by interference fit, and will be shipped in such form to the site for assembly using the present invention. The pipe sections can be fabricated of any suitable material, including but not limited to steel, ductile iron, PVC, non-rigid plastic, copper, and other materials.
[0022] In one example, the first pipe section 102 incorporates an expanded bell end 102 a , and further includes an interior region 102 b defined within the bell end. Prior to assembly of the two pipe sections, the interior region 102 b may be coated with a fast setting epoxy compound, or other adhesive material or materials, disposed along its interior surface, which can include a smooth powder fusion epoxy, or alternatively can include a multi-layer (e.g., three-layer) polyethylene coating.
[0023] The second pipe section 104 incorporates a pin end 104 a which is tapered inwardly at the tapered portion 104 b in order to provide a mating seal with the interior region 102 b of the first pipe section 102 . Adjacent the pin end 104 a , an annular groove 104 b may be pre-formed into the outer surface of the second pipe section, such as by a hydraulic groover or otherwise machined into the pipe, in order to receive additional epoxy for an improved fluid seal following pipe assembly. The pin end 104 a may be coated with a fast setting epoxy compound disposed along its interior surface, which can include a smooth powder fusion epoxy, or alternatively can include a multi-layer (e.g., three-layer) polyethylene coating. However, it may be desirable that the most distal portion of the pin end 104 a remains partially uncoated with the polyethylene coating to optimize the coupling of the first and second pipe sections.
[0024] The pipe assembly equipment 100 includes a housing 106 . The housing incorporates inwardly-projecting pipe guides 108 and 109 which can be positioned after insertion of the bell end 10 of the first pipe section 102 into the housing, to stabilize the first pipe section for assembly. Additionally, the housing incorporates inwardly-projecting pipe guides 110 and 111 which can be positioned after insertion of the pin end 10 of the second pipe section 104 into the housing, to stabilize the second pipe section for assembly.
[0025] Additionally, each of the projecting pipe guides 108 , 109 , 110 and 111 are respectively provided with sensors 108 a , 109 a , 110 a and 111 a , for purposes of monitoring and acquiring at least one of several variables representative of pipe assembly conditions, including without limitation, hydraulic pressing or pulling forces generated by pipe assembly equipment while mating the pipe sections, time of assembly, and the like. Additionally, these sensors may also monitor and acquire at least one of several variables representative of pipe assembly conditions in the environment during pipeline installation, including without limitation, ambient temperature, barometric pressure and humidity conditions at time of assembly, and the like. The sensors can be incorporated into the projecting pipe guides 108 , 109 , 110 , and 111 , or can be incorporated at other locations, such as the exterior surface of the housing 106 , within the pipe sections 102 , 104 , or in the cavity within the housing 106 between the projecting pipe guides 108 , 109 , 110 and 111 . In one embodiment, the sensors are of different types. In another embodiment, multiples sensors of a same type at several positions or locations can detect a difference or a gradient in sensed values.
[0026] During assembly, the first pipe section 102 and the second pipe section 104 are concentrically aligned within the housing 106 of the pipe assembly equipment 100 with respect to a common longitudinal axis, and are stabilized by the pipe guides 108 , 109 , 100 and 111 , to ensure effective assembly at the mating joint.
[0027] As a result, the pin end 104 a is inserted into the bell end 102 a , such as by a hydraulic press (not shown), or in the alternative a hydraulic pulling cylinder (not shown), which moves the pin end in the general direction depicted by arrow A toward the bell end. In this manner, the two pipe sections are coupled together to create an interference fit. When in an interference fit, the interior surface of the bell end 102 a exerts a compressive force upon the exterior surface of the pin end 104 a , which force is engineered by choice of design and materials to be less than the yield strength of the pin end.
[0028] The pipeline assembly equipment 100 is illustrated in FIG. 1 as being situated in an environment 112 for assembly and installation of pipeline systems, and is coupled to a pipeline machine management system 114 via a wired or wireless network 116 . In one example, the sensors 108 a , 109 a , 110 a and 111 a communicate with a central data collector, discussed below with respect to FIG. 2 , which gathers the sensor data and reports the sensor data to the pipeline machine management system 114 .
[0029] The subscriber 118 is depicted as connected to the pipeline machine management system 114 , to receive updates on information being acquired during pipeline assembly, as hereinafter described below. Subscriber 118 may be one or more entities with an interest or stake in the performance or electromechanical condition of pipeline assembly equipment 100 , and the subscriber may have duties or responsibilities to maintain the performance of or condition of pipeline assembly equipment 100 . Subscriber 118 may receive information on the at least one variable, such as the hydraulic pressure of the pulling cylinder (not shown) on pipeline assembly equipment 100 . Subscriber 118 may receive the information from pipeline machine management system 114 . Subscriber 118 may include, for example, operators of pipeline assembly equipment 100 , project managers, repair technicians, shift managers, human resource personnel, or any other person or entity that may be designated.
[0030] In one variation, the subscriber 118 is a human entity, but the subscriber 118 can also be an electronic repository, such as a log file or a pipeline machine management history or record repository. The log file can include information such as a date, time, sensor readings, serial numbers of the pipe sections, sensor status, or any other available and relevant information. The subscriber 118 can enroll with the pipeline machine management system 114 to receive notifications of sensor data that exceeds a threshold, such as a sensed temperature outside of a desired temperature range for safe operation of the resulting pipe joint. Thus, while the pipeline machine management system 114 can record a large set of data, which can be made available upon request of the subscriber 118 , the pipeline machine management system 114 may only generate notifications for the subscriber 118 based on one or more conditions or sensor data ranges. The subscriber 118 can also enroll with the pipeline machine management system 114 to receive a periodic update or report of all data performed within a certain time period or within a certain number of pipe join operations, such as a daily report or a report for every 500 pipe join operations.
[0031] The location of the at least one joint associated with each such pipeline assembly can be dynamically determined. According to one embodiment, GPS or another positioning system, alone or in combination with an internal tracking system of the pipeline machine management system 114 , may track or periodically update the position of pipeline assembly equipment 100 . In another exemplary embodiment, RFID tags located on-board the pipeline assembly equipment 100 may be detected by RFID receivers distributed throughout work environment 112 to determine relative positions of such equipment 100 . In another exemplary embodiment, a combination of GPS and RFID methodologies may be employed to determine the location of pipeline assembly equipment 100 in work environment 112 . In another embodiment, unique serial numbers can be imprinted directly on the pipeline assembly equipment which can be recognized and retrieved from a database to identify the equipment 100 . In yet another embodiment, some optically readable code, such as a QR code or other form of barcode, is affixed to or included on the equipment 100 for identification via an automatic means or via a human manually scanning the code, such as with a handheld barcode scanner.
[0032] As illustrated in FIG. 2 , the pipeline assembly equipment 100 is connected via network 116 to pipeline machine management system 114 , which is described in more detail below.
[0033] Pipeline assembly equipment 100 can further incorporate a data collector 120 which may be configured to receive, collect, package, format, and/or distribute variable data acquired by each of the respective pipe sensors 108 a , 109 a , 110 a and 111 a . In one embodiment, pipeline assembly equipment 100 may include on-board data collection and communication equipment to monitor, collect, and/or distribute information associated at least one variable sensed by at least one of the sensors 108 a , 109 a , 110 a and 111 a . In particular, pipeline assembly equipment 100 may include electronic sensors 108 a , 109 a , 110 a and 111 a and control modules that are coupled to one or more data collectors 120 via communication lines 122 . Additionally, the data collector 120 may include one or more transceiver devices 124 and/or any other components for monitoring, collecting, and communicating information associated with the operation of pipeline assembly equipment 100 .
[0034] Pipeline assembly equipment 100 may also be configured to receive information, warning signals, operator instructions, or other messages or commands from off-board systems, such as from pipeline machine management system 114 . The components described above are exemplary and not intended to be limiting. Accordingly, the disclosed embodiments contemplate pipeline assembly equipment 100 including additional and/or different components than those listed above.
[0035] Referring to FIG. 2 , pipeline machine management system 114 may include one or more hardware components and/or software applications that cooperate to improve performance of pipeline assembly equipment 100 in work environment 112 by monitoring, analyzing, and/or measuring variables during assembly of at least one joint during assembly of a pipeline system. For example, pipeline machine management system 114 may include a variable monitoring system 126 for collecting, distributing, analyzing, and/or otherwise managing variable data collected from pipeline assembly equipment 100 . In one exemplary embodiment, variable monitoring system 126 may determine hydraulic pressure of at least two pipe sections during assembly of at least one joint.
[0036] Variable monitoring system 126 may include any computing system configured to receive, analyze, transmit, and/or distribute variable data associated with pipeline assembly equipment 100 . Variable monitoring system 126 may be communicatively coupled to pipeline assembly equipment 100 via communication network 116 . Data collector 120 may receive variable data from at least one of the sensors 108 a , 109 a , 110 a and 111 a via communication lines 122 during operation of the pipeline assembly equipment 100 , and may transmit the received data to pipeline machine management system 114 via communication network 116 . Alternatively or additionally, data collector 120 may store the received data in memory for a predetermined time period, for later transmission to pipeline machine management system 114 . For example, if a communication channel between the pipeline assembly equipment 100 and pipeline machine management system 114 becomes temporarily unavailable, the performance data may be stored in memory for subsequent retrieval and transmission when the communication channel has been restored.
[0037] In an alternate embodiment, variable monitoring system 126 may be located on pipeline assembly equipment 100 . Variable monitoring system 126 may embody a centralized server and/or database adapted to collect and disseminate variable data associated with forming at least one joint of the assembled pipeline system and/or pipeline assembly equipment 100 .
[0038] Variable monitoring system 126 may include hardware and/or software components that perform processes consistent with certain disclosed embodiments. For example, as illustrated in FIG. 2 , variable monitoring system 126 may include one or more transceiver devices 128 , a central processing unit (CPU) 130 , a communication interface 132 , one or more computer-readable memory devices, such as a storage device 134 , a random access memory (RAM) 136 and a read-only memory (ROM) 138 , a common information bus 140 , a display unit 142 , and/or an input device 144 . The components described above are exemplary and not intended to be limiting. Furthermore, variable monitoring system 126 may include alternative and/or additional components than those listed above.
[0039] CPU 130 may be one or more processors that execute instructions and process data to perform one or more processes consistent with certain disclosed embodiments. For instance, CPU 130 may execute software that enables variable monitoring system 126 to request and/or receive variable data from data collector 120 of pipeline assembly equipment 100 . CPU 130 may also execute software that stores collected variable data in storage device 134 . In addition, CPU 130 may execute software that enables variable monitoring system 126 to analyze variable data collected from pipeline assembly equipment 100 , perform diagnostic and/or prognostic analysis to identify potential problems with the at least one joint formed from at least two pipe sections, notify a machine operator or subscriber 118 of any potential problems, and/or provide customized analysis reports.
[0040] CPU 130 may be connected to a common information bus 140 that may be configured to provide a communication medium between one or more components associated with variable monitoring system 126 . For example, common information bus 140 may include one or more components for communicating information to a plurality of devices. According to one embodiment, CPU 130 may access, using common information bus 140 , computer program instructions stored in memory. CPU 130 may then execute sequences of computer program instructions stored in computer-readable medium devices such as, for example, storage device 134 , RAM 136 , and/or ROM 136 , in order to perform methods consistent with certain disclosed embodiments, as will be described below.
[0041] Communication interface 132 may include one or more elements configured for two-way data communication between variable monitoring system 126 and remote systems (e.g., pipeline assembly equipment 100 ) via transceiver device 128 . For example, communication interface 132 may include one or more modulators, demodulators, multiplexers, demultiplexers, network communication devices, wireless devices, antennas, modems, or any other devices configured to support a two-way communication interface between variable monitoring system 126 and remote systems or components.
[0042] One or more computer-readable medium devices may include storage device 134 , a RAM 136 , ROM 138 , and/or any other magnetic, electronic, flash, or optical data computer-readable medium devices configured to store information, instructions, and/or program code used by CPU 130 of variable monitoring system 126 . Storage device 134 may include magnetic hard-drives, optical disc drives, floppy drives, flash drives, or any other such information storing device. RAM 136 may include any dynamic storage device for storing information and instructions by CPU 130 . RAM 136 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by CPU 130 . During operation, some or all portions of an operating system (not shown) may be loaded into RAM 136 . In addition, ROM 138 may include any static storage device for storing information and instructions by CPU 130 .
[0043] Variable monitoring system 126 may be configured to analyze variable data associated with at least one joint formed by assembling at least two pipe sections. According to one embodiment, variable monitoring system 126 may include diagnostic software for analyzing variable data associated with at least one joint based on threshold levels (which may be factory set, manufacturer recommended, and/or user configured). For example, diagnostic software associated with variable monitoring system 126 may compare an ambient temperature measurement received from a particular machine with a predetermined threshold temperature. If the measured ambient temperature exceeds the threshold temperature, variable monitoring system 126 may generate an alarm and notify one or more of the machine operator, job-site manager, repair technician, dispatcher, or any other appropriate entity, such as subscriber 118 .
[0044] Variable monitoring system 126 may determine a physical location for the at least one joint of the assembled pipeline system. The physical location may be determined based on monitored GPS data associated with the machine, or other positioning systems, such as an internal machine system. For example, the physical location may be determined using the latitude, longitude, and elevation of the machine derived from GPS data gathered from on-board GPS equipment. Four or more remote positioning devices (or GPS satellites) may be used to determine elevation.
[0045] FIG. 3 provides a flowchart 200 depicting an exemplary method for detecting at least one variable, consistent with the disclosed embodiments.
[0046] As described above, the pipeline assembly equipment 100 is used to assemble a pipeline consisting of at least a first pipe section 102 and a second pipe section 104 , thereby forming at least one pipe joint therebetween (Step 210 ).
[0047] Pipeline machine management system 114 records at least one sensor variable associated with the pipeline assembly process, such as hydraulic pressing or pulling parameters, pipeline temperature, ambient temperature, barometric pressure, humidity, time of assembly, etc. (Step 220 ). These measured pipeline assembly variables may be expressed as a number, a range of values around a number, a range of values between two numbers, a range of values, a maximum value, a minimum value, and the like. The range of values, for example, may include a predetermined amount or percentage of a value, or may be determined at the time the variable is measured. The range of values can be determined in advance and established in a memory, firmware, or other storage location of the system. Alternatively, an operator, administrator, or other user can enter or modify ranges of values.
[0048] The location of the at least one pipe joint associated with each such pipeline assembly can then be dynamically determined (Step 230 ).
[0049] A serial number associated with each of the at least two pipe sections of the assembled pipe system may then be recorded (Step 240 ). A subscriber 118 may use an input device 144 , such as a keyboard, to enter the serial number as the pipe section are fitted to form the at least one pipe joint. The serial number can be associated with the material, location and date of manufacturer of the respective pipe sections. Alternatively, Step 240 may be performed prior to any of Steps 210 , 220 and 230 , or in any order therebetween.
[0050] After the variables have been acquired in Step 220 , the variables are compared to standard and/or threshold values (Step 250 ). As an example to illustrate use of an embodiment of the present invention, the measured hydraulic pressure associated with the pulling cylinder of pipeline assembly equipment 100 can be compared to a standard hydraulic pressure, in order to determine whether the formed pipe joint, or the respectively-joined pipe sections, are faulty. For example, if the measured hydraulic pressure is greater or less than the standard value, then the data may suggest a variety of problems, such as a defect in the material of the pipe section (i.e., steel pipe section), improper dimensional tolerances in the bell and/or pin ends of the pipe sections, defective coatings or epoxy adhesives at the joint, and the like.
[0051] Variable monitoring system 126 may be configured to generate a status or alert and provide the status or alert to pipeline machine management system 114 and/or one or more subscribers 118 (Step 260 ). A status or alert may indicate the comparison of Step 250 was out of tolerance, or may be information, such, as for example, the hydraulic pressure of the pulling cylinder during formation of the at least one joint was normal. A status or alert may embody any type of signal or message notifying pipeline machine management system 114 and/or one or more subscribers 118 of a variable measured by at least one sensor. For example, variable monitoring system 126 may output hydraulic pressure data on a display console 142 associated with the variable monitoring system 126 . Alternatively or additionally, variable monitoring system 126 may provide an electronic message (e.g., electronic page, text message, fax, e-mail, etc.) indicative of the status or alert to a respective machine operator and/or a project manager, or any other person or entity established as a subscriber 118 . In response to the status notification, subscribers 118 may take appropriate responsive action to investigate the variable to ensure that the at least one joint of the assembled pipe system is properly formed.
[0052] In another embodiment, variable monitoring system 126 may be configured to archive at least one of the following, namely: the measured variables; the location of the at least one joint; the recorded serial number of each of the at least two pipe sections of the assembled pipe, and the like (Step 135 ). This archived data may later be retrieved in order to evaluate a cause of a latter failure of at least one joint.
[0053] While certain aspects and features associated with the method described above may be described as being performed by one or more particular components of pipeline machine management system 114 , it is contemplated that these features may be performed by any suitable computing system. Also, while the method may describe variable monitoring system 126 as being part of pipeline machine management system 114 , variable monitoring system 126 may instead be located on-board pipeline assembly equipment 100 . Furthermore, the order of steps in FIG. 3 is exemplary only, and that certain steps may be performed before, after, or substantially simultaneously with other steps illustrated in FIG. 3 . | The present disclosure is directed to a method of detecting at least one variable associated with at least one joint or a machine of an assembled pipeline system ( 100 ). The example method includes assembling, via the machine having at least one pulling cylinder, at least two pipe sections to form at least one joint of the assembled pipeline system. The example method includes measuring, by at least one sensor ( 102,104 ), at least one variable selected from the group consisting of time, temperature and hydraulic pressure of the pulling cylinder during assembly of the pipelines system ( 100 ). The example method includes determining a location of the at least one joint of the assembled pipeline system. The example method includes recording a serial number associated with each of the at least two pipe sections of the assembled pipeline system. Corresponding systems and a computer-readable media are also disclosed. | 5 |
BACKGROUND
1. Field of the Disclosure
The embodiments described herein relate to a method and apparatus for a downhole device connected to coiled tubing to obtain diagnostic information of a wellbore. The downhole device may be connected to the interior of the coiled tubing. Alternatively, the downhole device may be connected to an exterior carrier portion of the coiled tubing.
2. Description of the Related Art
Natural resources such as gas and oil may be recovered from subterranean formations using well-known techniques. For example, a horizontal wellbore may be drilled within the subterranean formation. After formation of the horizontal wellbore, a string of pipe, e.g., casing, may be run or cemented into the well bore. Hydrocarbons may then be produced from the horizontal wellbore.
In an attempt to increase the production of hydrocarbons from the wellbore, the casing may be perforated and fracturing fluid may be pumped into the wellbore to fracture the subterranean formation. The fracturing fluid is pumped into the well bore at a rate and a pressure sufficient to form fractures that extend into the subterranean formation, providing additional pathways through which fluids being produced can flow into the well bores. The fracturing fluid typically includes particulate matter known as a proppant, e.g., graded sand, bauxite, or resin coated sand, that may be suspended in the fracturing fluid. The proppant becomes deposited into the fractures and thus holds the fractures open after the pressure exerted on the fracturing fluid has been released.
A production zone within a wellbore may have been previously fractured, but the prior fracturing may not have adequately fractured the formation leading to inadequate production from the production zone. Even if the formation was adequately fractured, the production zone may no longer be producing at adequate levels. Over an extended period of time, the production from a previously fractured horizontal wellbore may decrease below a minimum threshold level. One technique in attempting to increase the hydrocarbon production from the wellbore may be the re-fracturing of some of the previously fractured locations of the horizontal wellbore. However, it may not be beneficial to re-fracture every previously fractured location. It may be beneficial to use a diagnostic tool to analyze the production zones in a horizontal wellbore to determine which zones should be re-fractured.
FIG. 8 shows a prior art diagnostic tool 22 conveyed into a wellbore 10 on coiled tubing 40 via a wellhead 16 . The coiled tubing 40 moves the diagnostic tool 22 down the wellbore 10 along the casing 18 until the diagnostic tool 22 is positioned at a desired location. The diagnostic tool 22 is connected to the surface via a cable 14 , which transmits diagnostic information obtained from the device 22 . The cable 14 and diagnostic tool 22 are connected to the end of the coiled tubing 40 via a cable head 20 and connector 21 . Prior to running the diagnostic tool 22 into the wellbore 10 , coiled tubing 40 may be run into the wellbore 10 to conduct a clean-out procedure. The coiled tubing 40 is then tripped out of the wellhead 16 and the diagnostic tool 22 and cable 14 may be connected to the coiled tubing 40 for a second trip into the wellbore 10 with the coiled tubing 40 . The positioning of the cable 14 outside of the coiled tubing 40 as well as the diagnostic tool 22 being connected to end of the coiled tubing 40 may present an increased chance the coiled tubing 40 becomes stuck within the wellbore 10 . It may also be beneficial to permit a cleanout procedure and conveyance of a diagnostic tool 22 into a wellbore in a single trip of coiled tubing 40 .
SUMMARY
The present disclosure is directed to a downhole device connected to coiled tubing that substantially overcomes some of the problems and disadvantages discussed above.
One embodiment is a method of determining information about the production from a zone of a wellbore comprising running a downhole device into a wellbore. The device comprises an electronic device positioned inside of a housing within an interior of coiled tubing. The method includes positioning the downhole device adjacent a first zone of the wellbore, determining diagnostic information of the first zone of the wellbore, and storing the determined diagnostic information of the first zone in a memory device.
The method may include connecting the housing to the interior of coiled tubing. The method may include pumping fluid down the interior of the coiled tubing past the downhole device while determining diagnostic information of the first zone. The method may include positioning the downhole device adjacent a second zone of the wellbore, determining diagnostic information of the second zone of the wellbore, and storing the determined diagnostic information of the second zone in the memory device. The electronic device may be a logging tool. The method may include pulling the downhole device out of the wellbore and analyzing the diagnostic information of the first zone stored in the memory device.
One embodiment is a method of determining information about the production from a zone of a wellbore comprising running a downhole device into a wellbore. The downhole device comprises an electronic device positioned inside of a housing connected to a recess in an exterior of coiled tubing. The method includes positioning the downhole device adjacent a first zone of the wellbore, determining diagnostic information concerning the first zone of the wellbore, and storing the determined diagnostic information of the first zone in a memory device.
The electronic device may be a logging tool. The method may further comprise positioning the downhole device adjacent a second zone of the wellbore, determining diagnostic information of the second zone of the wellbore, and storing the determined diagnostic information of the second zone in the memory device. The method may include pulling the downhole device out of the wellbore and analyzing the diagnostic information of the first zone stored in the memory device.
One embodiment is a system to monitor a zone of a wellbore. The system comprises a string of coiled tubing and a housing having a first end and a second end. The housing is closed at the first end and is closed at the second end and at least one of the ends being selectively closed to permit access into the housing. The system includes an electronic device positioned within the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The housing is connected to a portion of an interior of the string of coiled tubing with a flow path between the housing and the interior of the string of coiled tubing.
The electronic device may be a logging tool. The system may include a memory storage device connected to the electronic device. The housing may be welded to the interior of the string of coiled tubing. The housing may be positioned between an end of the string of coiled tubing and a location ten feet from the end of the string of coiled tubing, the location being along the string of coiled tubing.
One embodiment is a system to monitor a zone of a wellbore. The system comprises a string of coiled tubing and a housing having a first end and a second end. The housing is closed at the first end and is closed at the second end and at least one of the ends being selectively closed to permit access into the housing. The system includes an electronic device positioned within the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The housing is connected to a recess in a portion of an exterior of the string of coiled tubing with a flow path in an interior of the string of coiled tubing past the recess.
The electronic device may be a logging tool. The system may include a memory storage device connected to the electronic device. The housing may be welded to the exterior of the string of coiled tubing. The housing may be positioned between an end of the string of coiled tubing and a location ten feet from the end of the string of coiled tubing, the location being along the string of coiled tubing.
One embodiment is a system to monitor a wellbore. The system comprises a string of coiled tubing and a housing having a first end, a second end, at least one inner wall forming a cavity, and a flow path from the first end to the second end. The cavity is selectively sealed from the flow path. The housing is connected to an end of the string of coiled tubing. The system includes an electronic device positioned within the selectively sealed cavity of the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The system includes a memory storage device connected to the electronic device. The memory storage device is positioned within the selectively sealed cavity of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an embodiment of a downhole device positioned within a housing inside of coiled tubing;
FIG. 2 shows an end cross-section view of an embodiment of a downhole device positioned within a housing inside of coiled tubing;
FIG. 3 shows an end cross-section view of an embodiment of a downhole device positioned within a housing inside of coiled tubing within casing;
FIG. 4 shows an embodiment of a downhole device positioned adjacent a first zone of a wellbore;
FIG. 5 shows an embodiment of a downhole device positioned adjacent a second zone of a wellbore;
FIG. 6 shows an embodiment of a downhole device positioned within a housing connected to the outside of coiled tubing;
FIG. 7 shows an embodiment of a downhole device that may be connected to the end of coiled tubing; and
FIG. 8 shows a prior art downhole device connected to coiled tubing.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
FIG. 1 shows an embodiment of a downhole device 100 that may be connected to the interior of coiled tubing 40 . The downhole device 100 may include a housing 50 that is connected to the inside of the coiled tubing 40 . The housing 50 may be connected to the inside of the coiled tubing 40 by various mechanisms such as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the housing 50 could be welded to the interior of the coiled tubing 40 . An electronic device 60 configured to monitor various aspects of a production zone (e.g. 30 a or 30 b shown in FIG. 4 and FIG. 5 ) of a wellbore 10 is positioned within the housing 50 . The coiled tubing 40 is used to run the device 100 down a wellbore 10 within casing or tubing 18 and position the electronic device 60 of the downhole device 100 at a desired location within the wellbore 10 . The ends of the housing 50 are closed so that fluid flows around the housing through a flow area 45 (shown in FIG. 2 ) between the housing 50 and the coiled tubing 40 as shown by arrows 41 in FIG. 1 . The positioning of the downhole device 100 inside of the coiled tubing 40 may permit the attachment of a bottom hole assembly to the bottom of the coiled tubing 40 that is adapted for other purposes. A conventional logging tool connected to the bottom of the coiled tubing 40 may prevent the connection of an additional bottom hole assembly to the coiled tubing 40 .
The downhole device 100 is preferably connected to the interior of the coiled tubing 40 near the downhole end of the coiled tubing. For example, the downhole device 100 may be positioned flush with the end of the coil or between the end of the coiled and ten (10) feet from the end of the coiled tubing 40 . FIG. 1 shows a distance, D, from the end of the coiled tubing 40 within which the downhole device 100 is preferably positioned within. The distance, D, may be various lengths. For example, D may be two (2) feet, which is approximately shown in FIG. 1 . However, this distance is for illustrative purposes only and may be varied as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Preferably, the distance D may be approximately ten (10) feet. Coiled tubing 40 is often inserted into a wellbore 10 to perform a cleaning operation prior to other wellbore operations. The insertion of the downhole device 100 inside of the coiled tubing 40 permits the transmittal of an electronic device 60 , which may be a diagnostic tool, into the wellbore 10 during the cleaning trip into the wellbore 10 . The housing 100 connected inside of the coiled tubing 40 may provide added protection as the electronic device 60 , which may be fragile, is tripped in and out of the wellbore 10 . The addition of the housing 50 to the end of the coiled tubing string 40 may provide higher rigidity at the end of the coiled tubing string 40 , which may aid in the insertion of the coiled tubing string 40 into a wellbore 10 , in particular if the wellbore 10 is a horizontal wellbore.
FIG. 2 shows an end cross-section view of the downhole device 100 connected to an interior portion of the coiled tubing 40 creating a flow path 45 between the housing 50 of the device 100 and the rest of the interior of the coiled tubing 40 that is not connected to the housing 50 . The outer diameter of the housing 50 may be configured to permit an adequate flow path past the housing 50 . The housing 50 encloses an electronic device 60 that may be used to analyze the condition of the wellbore 10 and its surroundings. For example, the electronic device 60 may be a logging tool also referred to as a diagnostic tool. The diagnostic information gathered from the electronic device 60 may be stored on a memory device 70 also positioned within the housing 50 . The diagnostic information stored on the memory device 70 may then be analyzed after the device 100 is removed from the wellbore 10 . FIG. 3 shows an end cross-section view of a downhole device 100 connected to coiled tubing 40 positioned within casing, or tubing, 18 of a wellbore. The device creates a flow area 45 between the housing 50 of the device 100 and the coiled tubing 40 . Likewise, the coiled tubing 40 creates a flow area 25 between the exterior of the coiled tubing 40 and the casing 18 . The flow area 45 between the housing 50 and the coiled tubing 40 may permit the pumping of fluid down the coiled tubing 40 during the capturing of diagnostic information from the electronic device 60 . The housing 50 may also act as a fluid displacer, which may enhance the response on neutralizing wellbore fluids.
FIG. 4 shows the downhole device 100 connected to coiled tubing 40 being positioned adjacent a first zone 30 a of a wellbore 10 . The electronic device 60 of the downhole device may be used to determine whether the first zone 30 a should be re-fractured during a re-fracturing procedure. For example, the downhole device 100 may be run into the wellbore 10 to determine which locations of the wellbore should be re-fractured by the process disclosed in related and commonly owned U.S. patent application Ser. No. 14/091,677 filed on Nov. 27, 2013 entitled System and Method for Re-fracturing Multizone Horizontal Wellbore, which is incorporated by reference herein in its entirety.
The electronic device 60 of the downhole device may be adapted to obtain various information about a desired location of a wellbore 10 . The diagnostic device 60 of the downhole device 100 may provide information concerning the temperature, pressure, fluid flow, and formation. The electronic device 60 may use various mechanisms to obtain diagnostic information as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For instance, the device 60 may generate pulsed neutrons that penetrate the housing 50 and reflect off the wellbore fluid as well as the wellbore 10 and surrounding formation measuring its activity. All of the diagnostic information gathered by the electronic device 60 may be stored in the memory device 70 for later analysis.
The coiled tubing 40 may be used to position the downhole device 100 adjacent a first zone 30 a of a wellbore 10 so that the electronic device 60 may obtain diagnostic information concerning the first zone 30 a . This diagnostic information is stored in the memory device 70 and may be used later to determine whether it would be beneficial to re-fracture the first zone 30 a during a re-fracturing process. After storing the diagnostic information for the first zone 30 a , the coiled tubing 40 may be used to position the downhole device 100 adjacent a second zone 30 b of the wellbore 10 as shown in FIG. 5 . The electronic device 60 may then obtain diagnostic information concerning the second zone 30 b , which may be stored in the memory device 70 . This process may be repeated until all desired locations within the wellbore 10 have been analyzed by the electronic device 60 .
FIG. 6 shows an end cross-section view of an embodiment of a downhole device 100 connected to the exterior of coiled tubing 140 . The coiled tubing 140 includes a carrier portion 141 , which is a concave portion that creates a recess for the placement of downhole device 100 . The housing 50 of the downhole device 100 may be connected to the recess in the coiled tubing 140 by various means. For example, the housing 50 may be welded to the carrier portion 141 of the coiled tubing 140 . The carrier portion 141 may be connected to coiled tubing 140 at connection points 142 . For example, the carrier portion 141 may be welded to the coiled tubing at connection points 142 . The carrier portion 141 may be formed from crimping the coiled tubing 140 to form bends at connection points 142 forming a recess for the positioning of the downhole device 100 . The coiled tubing 140 includes a flow path 145 between the interior of the coiled tubing 140 and the carrier portion 141 . The downhole device 100 includes an electronic device 60 used to diagnose conditions of the wellbore 10 and memory device 70 protected by housing 50 . The coiled tubing 140 may be used to positioned the downhole device 100 at desired locations within the wellbore 10 to obtain diagnostic information as detailed herein. As shown in FIG. 6 , the addition of the downhole device 100 to the coiled tubing 140 may result in substantially the same outer diameter of the coiled tubing 140 if it did not contain the carrier portion 141 .
FIG. 7 shows an exploded view of an embodiment of a downhole device 200 that may be connected to the end of a coiled tubing string 240 by a connector 270 . The downhole device 200 includes an electronic device 60 that is configured as a wellbore diagnostic tool and a memory device 70 positioned within a cavity 205 within the downhole device 200 . As disclosed herein, the electronic device 60 may be positioned at various locations within the wellbore to obtain information concerning the wellbore 10 that may be stored in the memory device 70 for later analysis. The downhole device 200 may be formed by machining a housing 201 that includes an flow path 245 that is in communication with the interior of the coiled tubing 240 and a cavity that is formed by inner wall 202 and end caps 210 and 215 . End caps 210 and 215 seal the cavity 205 from fluids flowing through the flow path 245 of the downhole device. One or both of the end caps 210 and 215 may be selectively disconnected form the cavity 205 to permit access to the cavity 205 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. The end caps 210 and 215 may be connected to the cavity 205 by various mechanisms as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Various mechanisms may be used to selectively seal the chamber 205 from the flow path 245 within the device 200 . For example, one end may be permanently closed with the other including a removable plugging element.
Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Accordingly, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof. | A method and system for determining information about a wellbore with coiled tubing. A downhole device may be positioned within coiled tubing and run down the wellbore to determine diagnostic information about a location with the wellbore. The downhole device may store diagnostic information in a storage device that may be analyzed when the device is returned to the surface. A downhole device may be connected to the end of a string of coiled tubing that includes a diagnostic device and memory sealed in a chamber. A flow path past the chamber is in communication with the coiled tubing string permitting the flow of fluid past the chamber. A downhole device including a diagnostic device may be connected to a recess in an exterior of a coiled tubing string. | 4 |
TECHNICAL FIELD
The present invention relates to a method for visualizing a protein or nucleic acid contained in a matrix, particularly an electrophoresis matrix such as polyacrylamide.
BACKGROUND OF THE INVENTION
Electrophoresis is a well known analytical technique in biochemistry. A sample is placed in a matrix and exposed to an electric field which causes various components in the sample to migrate within the matrix at different rates depending on the component's charge, molecular weight and other physical and chemical properties. After migration has occurred, the resulting migration pattern is ascertained. Various methods to ascertain the migration pattern have been developed. These include autoradiography and staining for visual or densitomeric determination. Typical stains include the dyes Coomassie Brilliant Blue and Ponceau S. Silver staining has been used to increase sensitivity over that provided by dyes. A widely used silver staining technique is that described by Merril et al., Methods in Enzymology, Volume 96, p. 230 (1983). An electrophoresis matrix, specifically polyacrylamide, is immersed in either an acid or an acid/alcohol solution for about one hour to fix the protein in the matrix. The matrix is then washed, typically for thirty minutes. The matrix is then soaked for about five minutes in a dichromic acid solution to oxidize the protein. Next, the gels are soaked in a silver nitrate solution for twenty minutes and then rinsed with a sodium carbonate/formaldehyde buffer to reduce silver ion bound to proteins and nucleic acids. A silver pattern is then allowed to develop. Development is stopped with acetic acid. The pattern is then analyzed either by direct visualization or by instrumental techniques.
The method of Merril et al. was simplified by Oakley et al. ([Analytical Biochem., Volume 105, p. 361 (1980)]. Electrophoresis gels were treated with unbuffered glutaraldehyde to cross-link proteins. Following rinsing, the gels were treated with ammoniacal silver solution. A combination of citric acid and formaldehyde was used to reduce silver ion to silver.
It has been found that the sensitivity of the silver staining technique for the optical detection of proteins and nucleic acids can be improved substantially if the matrix is treated with a fixing agent comprising a highly aromatic compound having at least one sulfonic acid group and at least one aromatic, tertiary amine, preferably as part of an oxazole group. Preferred compounds are selected from the group consisting of ##STR1## wherein R is H, CH 3 , C 2 H 5 or CH 2 N + (CH 3 ) 3 , ##STR2## Optionally, the matrix is treated with a sensitizing agent selected from the group consisting of sodium sulfide, dithiothreitol, thiourea and sodium thiosulfate.
In addition, the sensitivity of the silver staining technique for the optical detection of nucleic acids can be improved substantially if the matrix is treated with a fixing agent comprising a compound of the formula: ##STR3##
The increase in sensitivity for both protein and nucleic acids is believed to result from the ability of these fixing agents to cross-link proteins and nucleic acids while, at the same time, providing an aromatic ring containing a tertiary amine which is capable of forming a coordination complex with silver.
SUMMARY OF THE INVENTION
In a first aspect, the present invention is a method for detecting a protein or nucleic acid in a matrix, comprising:
(a) contacting the matrix with a fixing agent selected from the group consisting of ##STR4## wherein R is H, CH 3 , C 2 H 5 or CH 2 N + (CH 3 ) 3 , ##STR5##
(b) optionally contacting the matrix with a sensitizing agent selected from the group consisting of sodium sulfide, thiourea, dithiothreitol and sodium thiosulfate,
(c) contacting the matrix with silver ion, and
(d) contacting the matrix with a developer capable of reducing silver ion to metallic silver.
The present invention also comprises a kit for the optical detection of proteins and nucleic acids comprising the fixer, sensitizing agent, source of silver ions, and developer of steps (a)-(d) and further including a stopper capable of stopping reduction of silver ions to metallic silver.
In a second aspect, the present invention is a method for detecting a nucleic acid in a matrix, comprising:
(a) contacting the matrix with an intercalating agent comprising a compound of the formula ##STR6## wherein n is an integer from 3 to 10,
(b) contacting the matrix with a washing agent to remove excess intercalating agent,
(c) contacting the matrix with silver ion, and
(d) contacting the matrix with a developer capable of reducing silver ion to metallic silver.
DETAILED DESCRIPTION OF THE INVENTION
Techniques for electrophoretically separating protein and nucleic acids in a matrix are well known. A particularly preferred matrix is polyacrylamide gel. Other matrices include paper, agarose, nitrocellulose, etc. The present method is not limited to the optical detection of proteins and nucleic acids in electrophoresis matrices, but can be used to measure protein and nucleic acid patterns in other matrices such as those used in thin layer chromatography.
For the optical detection of proteins and nucleic acids, the matrix is immersed in a solution containing a fixing agent selected from the group consisting of compounds of the formulae: ##STR7## wherein R is H, CH 3 , C 2 H 5 or CH 2 N + (CH 3 ) 3 , ##STR8## Compound (i) of the formulae above is preferred and will be referred to hereinafter as POPOP-disulfonic acid. A preferred solution comprises 0.05% (w/v) of POPOP-disulfonic acid in 50% methanol, 12% acetic acid and 38% distilled water by volume. Incubation time is determined empirically and depends primarily on the thickness of the matrix. For example, for a polyacrylamide matrix of dimensions 14×16×0.15 cm, the optimum fixing time is about forty five minutes with constant agitation.
Next, the matrix can be immersed in a sensitizing solution. The sensitizing solution contains a compound selected from the group consisting of dithiothreitol, thiourea, sodium thiosulfate and sodium sulfide. The preferred compound is dithiothreitol. A preferred solution comprises 5 ng/mL of dithiothreitol in distilled water. Typical incubation for the previously described matrix is about fifteen minutes.
Next, the matrix is immersed in a silver nitrate solution, generally 0.1% silver nirate in distilled water. The matrix is incubated with agitation for about thirty minutes.
Next, the protein or nucleic acid pattern in the matrix is developed. In general, the matrix is washed quickly in distilled water and rinsed quickly in developer solution. The developer is a basic buffer solution whose pH is between 11 and 12 and which contains formaldehyde. Preferred buffers are sodium carbonate and sodium phosphate, the latter being most preferred. A preferred solution is 3% (w/v) sodium carbonate or 0.5% (w/v) sodium phosphate and 0.5 mL formaldehyde (37% by weight) per liter of distilled water. The matrix is then rinsed again with the developer solution. Finally, the matrix is developed for about five minutes to an hour in the developer solution. The optimum time depends upon the extent of sample loading and background staining attributable to matrix characteristics.
Finally, the reaction in the matrix is stopped by lowering the pH of the developer to about 3 in the case of a carbonate-based developer, or 7 for a phosphate-based developer. A convenient method comprises the addition of citric acid directly to the developer solution.
The present invention differs from the prior art in that the first step, fixing, leads to a chemical interaction between amino groups present in the protein molecules and sulfonic acid groups in the POPOP-disulfonic acid or other fixing agent. Precipitation of basic and neutral amino acids by aromatic mono-sulfonic acids has been reported. [Suida, W., Z. Physiol. Chem. 50, 174, (1906)]. The aromatic sulfonic acids are sufficiently strong acids that they may be expected to form salts with all types of amino acids. It apparently has not been recognized generally that many of the sulfonic acid salts of the neutral or basic proteins are sparingly soluble. The amino groups in the protein molecule form coordination complexes with metals such as silver. However, when the amino groups in protein interact with sulfonic acids, the ability of nitrogen atoms to complex with metal ions is lost. But if the aromatic sulfonic acid itself contains amino groups, the coordinating property of the protein sulfonic acid salts is not affected.
Most of the polyamino aromatic sulfonic acid derivatives are either black or very dark colored materials and find little use in silver staining procedure. The sulfonic acids disclosed herein are either yellow or brown colored in the solid state. However, dilute solutions used in the fixing step are colorless. The process of chemical interaction leading to insoluble salt formation gives this present process its sensitivity advantage over other silver staining methods, particularly for low molecular weight proteins.
Silver complexed with protein is more readily reduced in the presence of sulfur. Thiourea and its derivatives are strongly adsorbed to the surface of silver halides, then decompose to form sulfide. [James, T. H. and Vanselow, W., J. Photo. Sci 1, 133, (1953)]. Sodium thiosulfate is also known to act as a sensitizer. [Wood, H. W., J. Phot. Sci. 2, 154, (1954)]. The silver deposited on the protein or nucleic acid in the matrix is more easily reduced due to the presence of the sulfur containing compounds. It is believed that the silver sulfide acts as a catalyst for the reduction of silver ions. Sodium sulfide, thiourea, dithiothreitol and sodium thiosulfate in 0.01 to 0.05% concentration can be used to sensitize silver ion.
The preparation of suitable fixing agents used in accordance with the present invention is described below.
(I) Preparation of 4,4'-[1,4-phenylenebis(2,5-oxazolediyl)]-bisbenzenesulfonic acid (POPOP-disulfonic acid) ##STR9##
POPOP-disulfonic acid is prepared by the sulfonation of POPOP [1,4-bis(5-phenyloxazole-2-yl)-benzene] with fuming sulfuric acid as described below.
One hundred milliliters of 20% fuming sulfuric acid (oleum) is charged into a 500 mL flask. Stirring is begun, and 50.0 g of POPOP is added in small portions. The reaction is exothermic. After the addition is complete, the reaction mixture is heated at about 90°-100°C. with stirring for two hours. The reaction is then quenched by pouring the reaction mixture onto 500 g of crushed ice with stirring. A bright-yellow product precipitates as a very fine powder. The resulting suspension is allowed to stand overnight. The product is then collected on a medium-porosity fritted-glass Buchner funnel. It should not be washed at this point, nor should the filter cake be disturbed. As much liquid is removed from the filter cake as possible. The pasty filter cake is then washed by stirring it in 200 mL of 2/1 (v/v) water/methanol or 1/20/10 concentrated hydrochloric acid/water/methanol. Water alone should not be used, as a very thick paste will form. Stirring is continued until the product is finely dispersed. The suspension is then allowed to settle briefly, and the solid is collected by vacuum filtration. The washing process should be repeated once. The product is then dried in a vacuum oven at 60°-70° C. Typical yields are 67-73 g (90-94%).
(II) Preparation of 4,4'-[1,4-phenylenebis(4-methyl-2,5-oxazolediyl)]-bisbenzenesulfonic acid (dimethyl-POPOP-disulfonic acid) ##STR10##
Dimethyl-POPOP-disulfonic acid is prepared by the sulfonation of dimethyl POPOP with fuming sulfuric acid by using the same procedure for the preparation of POPOP-disulfonic acid.
(III) Preparation of 2,2'-(2,5-thiophenediyl)bis[5-(1,1-dimethylethyl)-7-benzoxazole-sulfonic acid](BBOT-disulfonic acid) ##STR11##
BBOT-disulfonic acid is prepared by the sulfonation of BBOT [2,5-bis(5-t-butyl-2-benzoazolylthiophene)] with fuming sulfuric acid as described below.
One hundred milliliters of 20% fuming sulfuric acid is charged into a 500 mL Erlenmeyer flask. With magnetic stirring, 60 g of BBOT is added in small portions. The reaction is exothermic. After the addition is complete, the reaction mixture is heated to 90°-100° C. for two hours. The reaction is then quenched by pouring the reaction mixture onto 500 g of crushed ice. A brown product precipitates as a fine powder. The product is collected on a fritted-glass Buchner funnel. The product is then washed by stirring it in 200 mL of 1N hydrochloric acid. Washing is prepared several times. The product is then dried in a vacuum oven at 60°-70° C. Typical yields are 75-80 g (89-93%).
(IV) Preparation of N,N,N-Trimethyl-2-phenyl-5-(4-sulfophenyl)-4-oxazolemethanamonium hydroxide (inner salt) ##STR12##
One hundred grams (613 mM ) of isonitrosopropiophenene (Eastman Organic Chemicals) and 65 grams (613 mM) of benzaldehyde were dissolved in glacial acetic acid. Hydrogen chloride gas as bubbled through the solution with stirring until a yellow precipitate was formed. The precipitate was collected and washed with ether until it was white. This product as dissolved in methanol with heating and neutralized with sodium hydroxide. The product, 2,5-diphenyl-4-methyloxazole-N-oxide, was dissolved in ethanol, placed in a Paar hydrogenation bottle with freshly activated Raney-nickel catalyst and degassed by vacuum. The system was then charged to a pressure of about 3 atmospheres with hydrogen gas. The reaction was continued with supplemental hydrogen being added until hydrogen was no longer consumed and thin layer chromatography using 8:1 hexane/ethyl acetate on silica gel showed no starting material. The catalyst was filtered, the solvent distilled, and the resulting white crystals of 2,5-diphenyl-4-methyloxazole were dried in a vacuum oven. Yield was 110 g (80%).
Fifty grams of 2,5-diphenyl-4-methyloxazole (0.21 moles) was dissolved in 250 mL of carbon tetrachloride. A catalytic amount (about 25 mg) of benzoyl peroxide was added, and the solution was heated to reflux. Sulfuryl chloride (17 mL; 0.21 moles) was added dropwise to the refluxing mixture, and refluxing was continued for about an hour. The mixture was allowed to cool to room temperature. The solvent was removed under reduced pressure, and the remaining product, 4-chloromethyl-2,5-diphenyloxazole, was recrystallized from ethanol. Yield was 47 g (80%); melting point 138°-139° C.
Sixty milliliters of 20% fuming sulfuric acid was charged into a 250 mL flask. With stirring, 40 grams of 4-chloromethyl-2,5-diphenyloxazole was added in small portions. The reaction is exothermic. After the addition was completed, the reaction mixture was heated at 90°-100° C. for two hours. The reaction was then quenched by pouring the reaction mixture onto 300 g of crushed ice with stirring. The product precipitated as a fine powder. The resulting suspension was allowed to stand overnight. The product was then filtered on a medium porosity fritted-glass Buchner funnel. The precipitate was washed with 1/1 (v/v) water/methanol. The product, 4-chloromethyl-2-phenyl-5-(4-sulfophenyl)oxazole, was then dried in a vacuum oven at 60°-70° C. Yield was 40 g (80%); melting point >300° C.
Into 500 mL of ethanol was stirred 20.6 g (56 mM) of 4-chloromethyl-2-phenyl-5-(4-sulfophenyl)oxazole. Trimethylamine was bubbled into the stirred solution. At first, all the material went into solution, then a white precipitate began to form. Bubbling of trimethylamine into the reaction mixture was continued until thin layer chromatography using 1:1 methanol/ethyl acetate (v/v) on silica gel showed no starting material. The precipitate was collected and washed with ethanol. Yield was 17.0 g (83%).
(V) Preparation of 2,2'-(1,4-phenylene)bis[N,N,N-trimethyl-5-(4-sulfophenyl)]-4-oxazole methanaminium dihydroxide, (bis inner salt) ##STR13##
In 500 mL of carbon tetrachloride, 23 g (60 mM) of 1,4-bis(4-methyl-5 phenyloxazol-2-yl)benzene was dissolved. A catalytic amount of benzoyl peroxide was added, and the solution was heated to reflux. Sulfuryl chloride (10 mL; 63 mM), dissolved in 10 mL of carbon tetrachloride, was added dropwise to the refluxing solution. The refluxing was continued for about 4 hours. After the addition of the sulfuryl chloride was completed, the mixture was allowed to cool to room temperature overnight. The precipitated product was collected by filtration and recrystallized from methylene chloride. Yield was (18.7 g; 65%). TLC using 1:8 acetone/chloroform showed no starting material, but several small spots.
1,4-Bis(4-chloromethyl-5-phenyloxazol-2-yl)benzene (18.7 g; 40 mM) was added in small portions to 75 mL of 20% fuming sulfuric acid with stirring. The reaction as exothermic. After the addition, the reaction mixture was heated at about 95°-110° C. The reaction was then quenched by pouring the reaction mixture onto 200 g crushed ice. The yellowish brown precipitate was allowed to stand overnight. The product was then collected on a fritted-glass Buchner funnel and washed several times with water. The product was then dried in a vacuum oven at 60°-70°. Yield was 12 g (60%).
For the optical detection of nucleic acids in a matrix, the matrix is immersed in a solution containing an intercalating, cross-linking reagent of the formula: ##STR14## wherein n is an integer from 3 to 10.
A preferred solution comprises 0.05% of the reagent, 50% (v/v) methanol, 12% (v/v) acetic acid and water. Incubation time is determined empirically. For a polyacrylamide matrix of dimensions 14×16×0.15 cm, the matrix is incubated for about 45 minutes with agitation.
Next, the matrix is washed in a solution comprising 10% (v/v) ethanol and 5% (v/v) acetic acid in water. The matrix is incubated in the solution for about 15 minutes with agitation.
Next, the matrix is washed in distilled water with agitation for about 15 minutes. The matrix is washed with fresh water two additional times.
Next, the matrix is incubated in a silver nitrate solution. A preferred solution comprises 0.1% AgNO 3 in distilled water. Typical incubation time is 30 minutes.
Next, the nucleic acid pattern is developed by washing the matrix quickly in distilled water; rinsing the matrix in a developer solution comprising typically 3% Na 2 CO 3 and 0.5 mL formaldehyde per liter of distilled water; rinsing again in developer; and, finally immersing the matrix in developer for five minutes to an hour depending on nucleic acid loading and background staining.
Finally, the development is stopped by lowering the pH of the developer solution to about 3. A convenient method comprises the addition of a solution of citric acid in distilled water directly to the developer solution. A preferred solution for use with the developer solution described above is 2.3M citric acid.
It was recognized that the acridine derivative proflavine binds to double-stranded DNA primarily by intercalation of the aromatic chromophore between the base pairs. [Lerman, L. S., J. Mol. Biol. 3, 18, (1961)]. Two or more chromophores joined by various linker groups were shown to have much greater DNA and RNA affinity than the corresponding single chromophores. [King, H. D., Wilson, W. D. and Gabby, E., J. Biochem. 21, 4982. (1982)]. Diacridines in which the connecting paraffinic chain has six or more methylene groups have proved more effective in intercalation studies than those with fewer than six methylene groups. [Canellakis et al., Biochim. et al., Biophys. Acta., Volume 418, p. 277 (1976)]. Suitable diacridines for use in the present invention are those in which the two aromatic chromophores are connected by a paraffinic chain of three to ten carbon atoms length. Preferred diacridines are those separated by four to eight carbon atoms. More preferred are those separated by five to seven. Most preferred is the diacridine whose synthesis is described below, namely one in which the two chromophores are separated by a paraffinic chain of six carbon atoms length.
The silver staining method of the present invention for nucleic acids differs from the prior art in that the fixing step is a combination of fixing and chemical modification by inter or intra-strand intercalation, resulting in cross-linking. The cross-linked strands are retained preferentially in the matrix leading to greater sensitivity. This process of intercalation gives the present method its sensitivity advantage over other staining methods. The intercalating capacity of the fixing solution is responsible for enhanced sensitivity, particularly for low molecular weight nucleic acids. The most preferred intercalating agent, N,N'-di-(9-acridyl)-1,6-diaminohexane, has two acridinium moieties which are separated by a straight chain of six methylene groups, it is capable of interacting with two distinct DNA strands. This obviously helps retain smaller molecules in the matrix.
N,N'-Di-(9-acridyl)-1,6-diaminohexane can be prepared as follows: ##STR15##
A solution of 21.35 g (0.1 mole) of 9-chloroacridine and 5.8 g (0.05 mole) of 1,6-diaminohexane in 100 mL of ethanol as refluxed for 2 hours under nitrogen. The reaction mixture was concentrated to one-third of the original volume and poured into 120 mL of 1M aqueous NaOH solution. The product was extracted with methylene chloride. The dried methylene chloride solution was evaporated to dryness, and the residue was crystallized from EtOH/CHCl 3 to give yellow crystals. M.P. was 178°-180° C. Yield was 67%. | A method and kit for the optical detection of proteins and nucleic acids in a matrix, such as polyacrylamide electrophoresis gels. The method comprises fixing the proteins and nucleic acids in the matrix using aromatic sulfonic acids having tertiary amines capable of forming coordination complexes with silver ion. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to structural members generally and, more particularly, but not by way of limitation, to a novel tubular column of high resistance to buckling.
2. Background Art
The maximum compressive load that structural bars or slender columns can resist, for a given material of construction and length, is generally a function of its diameter or width and the thickness of the material of construction, with the maximum load increasing with increased width and/or thickness. As a result, structural bars or slender columns for large loads tend to be heavy and expensive.
Accordingly, it is a principal object of the present invention to provide a structural bar or slender column that is lighter in weight than a structural bar or slender column of conventional construction.
It is a further object of the invention to provide such a structural bar or slender column that is simply and economically constructed.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figure.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in a preferred embodiment, a device for sustaining longitudinal compressive loads applied to the ends thereof, comprising: a longitudinally extending tube; means to seal the ends of said tube; a pressurized fluid within said tube, said pressurized fluid having a pressure greater than the external pressure on said tube.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figure, submitted for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is a side elevational view, in cross-section, of a tubular column constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic essence on which the present invention rests is a tubular column subjected to extremely high internal pressures, which internal pressures bring about internal longitudinal tensile stresses of high values. These high internal stresses of longitudinal traction stress the column, with the particularity that they are internal forces which tend to stiffen the column and to preserve its original form.
Following are the mathematical comparative calculations which are the mathematical proof that illustrates the advantage of this invention by comparing it with conventional designs. It will be understood that this mathematical proof is simplified, in that it does not consider second-order effects and that it does not enter into what is called the mathematical theory of elasticity in a totally rigorous and academic manner.
The critical buckling load of a slender bar, according to Euler, is given by:
Pcr=(PI.sup.2 ×E×I)/L.sup.2,
in which
Pcr is the critical buckling load expressed in kilograms,
E is the modulus of elasticity of the material of the bar expressed in kilograms per square centimeter,
I is the minimum moment of inertia of the section normal to the axis of the piece expressed in centimeters to the fourth power, and
L is the equivalent length of the bar expressed in centimeters.
The assumed conditions of the anchoring of the bar are that the bar is articulated at both ends, so that the equivalent Euler length, L, coincides with the actual length of the bar.
The section of the bar under consideration is annular, so the moment inertia of the bar is given by:
I=[PI×(B.sup.4 -A.sup.4)]/4,
in which
I is the moment of inertia expressed in centimeters to the 4th power,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
The surface of the annular section is given by:
F=PI×(B.sup.2 -A.sup.2),
in which
F is the surface of the annular section expressed in square centimeters,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
The tangential stress in the tubular body is given by:
St=[P×(B.sup.2 -A.sup.2)]/(B.sup.2 +A.sup.2),
in which
St is the tangential or circumferential stress to which the wall of the tube that forms the bar is subjected, brought about in the internal pressure, expressed in kilograms per square centimeter,
P is the internal manometric pressure to which the tubular body of the bar is subjected, expressed in kilograms per square centimeter,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
It is considered that the external pressure is atmospheric pressure.
The longitudinal stress in the tubular body is given by:
Sl=(P×A.sup.2)/(B.sup.2 -A.sup.2),
in which
Sl is the longitudinal tensile stress in the tubular body, brought about by the internal pressure, expressed in kilograms per square centimeter,
P is the internal manometric pressure to which the tubular body of the bar is subjected, expressed in kilograms per square centimeter,
B is the outside radius of the tube in centimeters, and
A is the inside radius of the tube in centimeters.
It is considered that the distribution of longitudinal stress is uniform.
The maximum permissible pressure in the interior of the tube is given by:
P=Sf×(B.sup.2 -A.sup.2)/(B.sup.2 +A.sup.2),
in which
Sf is the flow stress of the material of the tube expressed in kilograms per square centimeter,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
For the following calculations, it will be assumed that the tube under consideration has the following characteristics and properties:
Tube: seamless, one-inch diameter, Schedule 40 pipe of low-alloy steel, API Standard 5LX65,
DE outside diameter=3.34 cms,
DI inside diameter=2.07 cms,
ES wall thickness=6.35 mms,
L length=1000 cms,
E modulus of elasticity=2,100,000 kgs/cm2,
B outside radius=1.67 cms,
A inside radius=1.035 cms,
Sf flow stress=4.570 kgs/cm2, and
Sr rupture stress=5,410 kgs/cm2.
First will be calculated the critical buckling load of the tubular bar without internal pressurization, that is, the conventional calculation of resistance/strength.
Inserting the formula for the moment of inertia in the formula for critical buckling load gives:
Pcr=[PI.sup.3 ×E×(B.sup.4 -A.sup.4)]/(4×L.sup.2).
Replacing values gives:
Pcr=[PI.sup.3 ×2,100,000×(1.67.sup.4 -1.035.sup.4)]/(4×1000.sup.2),
or
Pcr=107.9 kilograms.
This value of compressive load is the limit value above which failure of the tubular bar is reached, with the concomitant loss of the stability thereof.
Now, assume that the interior of the tubular bar is pressurized with a working fluid which preferably will be hydraulic, but not excluding at least partially a pneumatic fluid. The maximum permissible internal pressure is:
P=4,570×(1.67.sup.2 -1.035.sup.2)/(1.67.sup.2 +1.035.sup.2),
or
P=2,033 kg/cm 2 .
This very high internal pressure, the limitation of which is controlled by geometric dimensions and the magnitude of the permissible maximum stress of the material, not only brings about circumferential or tangential stresses in the wall of the tube, but also brings about radial stresses, which are of no use in the present invention, and longitudinal stresses, which bring about the mechanical principle of the present invention. The latter stresses stiffen the piece as a whole and are of critical importance when the tubular bar is subjected to a longitudinal compressive external load.
In fact, when the tubular bar is subjected to a high internal, longitudinal tensile stress, produced by the internal pressure, and subsequently when subjecting the bar to an external compressive load, the resultant state of stress will be the composition of both states considered independently, as deduced from the principle of superposition.
The longitudinal tensile stress is:
Sl=(2033×1.035.sup.2)/(1.67.sup.2 -1.035.sup.2),
or
Sl=1,267 kg/cm 2 .
The high internal pressure causes an internal tensile force, N, which is equivalent to the product of the longitudinal stress and the section normal to the axis of the tubular bar, or:
N=Sl×F=Sl×PI×(B.sup.2 -A.sup.2).
Replacing values gives:
N=1,276×PI×(1.67.sup.2 -1.035.sup.2),
or
N=6,837 kilograms.
According to the principle of superposition, if the tubular bar is pressurized to the maximum permissible pressure and the ends of the tubular bar are compressed longitudinally, the failure of the bar will occur when a stress value is reached which is the resultant of the composition of both independent states. That is to say, the new value of the critical buckling load of the tubular bar will be the sum of the value of the critical buckling load of the unpressurized tubular bar plus the value of the internal traction in the pressured tubular bar, or:
Failure load=6,837+107.9=6,944.9 kilograms.
Thus, the compressive strength of the pressurized tubular bar has been increased by a factor of 64 over that of the unpressurized tubular bar.
The above demonstration has disregarded secondary and second-order effects and does not pretend to be academic text, but it is eloquent enough to demonstrate the technological advantage of the present invention. The calculations also do not include the provision of outer circumferential reinforcement of high-strength synthetic fibers bonded to the tubular pipe to sustain the high circumferential stresses which normally double the value of the longitudinal stress that is of use and benefit.
FIG. 1 illustrates a tubular column according to the present invention, generally indicated by the reference numeral 10. Column 10 includes a cylindrical tube 12 having its ends sealed by means of first and second end pieces 14 and 16. End pieces 14 and 16 are constructed of the same material as tube 12, preferably a suitable metallic material (i.e., seamless steel or aluminum), are welded to the ends of tube 12, and have defined therein channels 20 and 22 for the application therethrough of a pressurized fluid to the interior of tube 12. Other means of attaching end pieces 14 and 16 to the ends of tube 12 may be employed as well, including threaded joints.
Surrounding the exterior surface of tube 12 is a layer 30 of synthetic fibers, for example, Kevlar or Araldit fibers, which cooperates in absorbing tangential forces in the tube to increase the maximum permissible pressure thereof, as is described above. The synthetic fibers referred to herein produced from long-chain polyamides (nylons) in which 85% of the amide linkages are attached directly to two aromatic rings called aramids. Nomex and Kelvar from Du Pont Co. and Twaron from Akzo NV are examples of fibers that can be used. Layer 30 is applied to tube 12 and bonded with a suitable resin using known techniques for fabricating such a reinforced structure. The source (not shown) of the pressurized fluid may be any conventional mechanical element, pump or compressor, or from any special installation that keeps tube 12 pressurized. Check valves (not shown) may be provided to maintain pressurization of tube 12.
In use, a fluid (not shown) under pressure "P" is applied to the interior of tube 12 through channels 20 and 22 from external piping (not shown) to assist the tube in resisting compressive forces "F" applied longitudinally to column 10, in the manner described above.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | In a preferred embodiment, a device for sustaining longitudinal compressive loads applied to the ends thereof, the device including: a longitudinally extending tube; devices to seal the ends of the tube; pressurized fluid within the tube, the pressurized fluid having a pressure greater than the external pressure on the tube. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 13/837,209, filed Mar. 15, 2013, which is a continuation-in-part of U.S. patent application Ser. No. 13/483,852, filed May 20, 2012, now issued as U.S. Pat. No. 9,044,342, which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present disclosure relates to embodiments of devices and methods for treating one or more damaged, diseased, or traumatized portions of the spine, including intervertebral discs, to reduce or eliminate associated back pain. In one or more embodiments, the present disclosure relates to an expandable interbody spacer. In addition, the present disclosure describes tools and methods for implanting the disclosed devices.
BACKGROUND OF THE INVENTION
The vertebrate spine is the axis of the skeleton providing structural support for the other body parts. In humans, the normal spine has seven cervical, twelve thoracic and five lumbar segments. The lumbar spine sits upon the sacrum, which then attaches to the pelvis, and in turn is supported by the hip and leg bones. The bony vertebral bodies of the spine are separated by intervertebral discs, which act as joints but allow known degrees of flexion, extension, lateral bending, and axial rotation.
The typical vertebra has a thick anterior bone mass called the vertebral body, with a neural (vertebral) arch that arises from the posterior surface of the vertebral body. The centra of adjacent vertebrae are supported by intervertebral discs. Each neural arch combines with the posterior surface of the vertebral body and encloses a vertebral foramen. The vertebral foramina of adjacent vertebrae are aligned to form a vertebral canal, through which the spinal sac, cord and nerve rootlets pass. The portion of the neural arch which extends posteriorly and acts to protect the spinal cord's posterior side is known as the lamina. Projecting from the posterior region of the neural arch is the spinous process.
The intervertebral disc primarily serves as a mechanical cushion permitting controlled motion between vertebral segments of the axial skeleton. The normal disc is a unique, mixed structure, comprised of three component tissues: the nucleus pulpous (“nucleus”), the annulus fibrosus (“annulus”) and two vertebral end plates. The two vertebral end plates are composed of thin cartilage overlying a thin layer of hard, cortical bone which attaches to the spongy, richly vascular, cancellous bone of the vertebral body. The end plates thus act to attach adjacent vertebrae to the disc.
The spinal disc and/or vertebral bodies may be displaced or damaged due to trauma, disease, degenerative defects, or wear over an extended period of time. One result of this displacement or damage to a spinal disc or vertebral body may be chronic back pain. A common procedure for treating damage or disease of the spinal disc or vertebral body may involve partial or complete removal of an intervertebral disc. An implant, which may be referred to as an interbody spacer, can be inserted into the cavity created where the intervertebral disc was removed to help maintain height of the spine and/or restore stability to the spine. An example of an interbody spacer that has been commonly used is a cage, which typically is packed with bone and/or bone-growth-inducing materials. However, there are drawbacks associated with conventional interbody spacers, such as cages and other designs. For instances, conventional interbody spacers may be too large and bulky for introduction into the disc space in a minimally invasive manner, such as may be utilized in a posterior approach. Further, these conventional interbody spacers may have inadequate surface area contact with the adjacent endplates if sized for introduction into the disc space in a minimally invasive manner. In addition, conventional interbody spacers designed for introduction into the disc space in a minimally invasive manner may lack sufficient space for packing of bone-growth-inducing material, thus potentially not promoting the desired graft between the adjacent endplates.
Therefore, a need exists for an interbody spacer that can be introduced in a minimally manner that provides a desired amount of surface area contact with the adjacent endplates and has an increased space for packing of bone-growth-inducing material.
SUMMARY OF THE INVENTION
Embodiments of the present disclosure relates to an expandable interbody spacer. The expandable interbody spacer may comprise a first jointed arm comprising a plurality of links pivotally coupled end to end. The expandable interbody spacer further may comprise a second jointed arm comprising a plurality of links pivotally coupled end to end. The first jointed arm and the second jointed arm may be interconnected at a proximal end of the expandable interbody spacer. The first jointed arm and the second jointed arm may be interconnected at a distal end of the expandable interbody spacer. The first jointed arm and the second jointed arm may each be configured to fold inward in opposite directions to place the expandable interbody spacer in an expanded position.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure will be more readily understood with reference to the embodiments thereof illustrated in the attached drawing figures, in which:
FIG. 1 is a top view of an expandable interbody spacer shown in a collapsed position in accordance with embodiments of the present disclosure;
FIG. 2 is a side view of the expandable interbody spacer of FIG. 1 shown in a collapsed position;
FIG. 3 is a proximal end view of the expandable interbody spacer of FIG. 1 shown in a collapsed position;
FIG. 4 is a distal end view of the expandable interbody spacer of FIG. 1 shown in a collapsed position;
FIG. 5 is an exploded view of the expandable interbody spacer of FIG. 1 ;
FIG. 6 is a top view of the expandable interbody spacer of FIG. 1 shown in an expanded position;
FIG. 7 is a right side view of the expandable interbody spacer of FIG. 1 shown in an expanded position;
FIG. 8 is a left side view of the expandable interbody spacer of FIG. 1 shown in an expanded position;
FIG. 9 is a proximal end view of the expandable interbody spacer of FIG. 1 shown in an expanded position;
FIG. 10 is a distal end view of the expandable interbody spacer of FIG. 1 shown in an expanded position;
FIG. 11 is a view showing disc space between adjacent vertebrae in accordance with embodiments of the present disclosure;
FIG. 12 is a view of a tool for insertion of an expandable interbody spacer in accordance with embodiments of the present disclosure;
FIG. 13 is a view showing the tool of FIG. 12 introducing an expandable interbody spacer into a disc space in a collapsed position in accordance with embodiments of the present disclosure;
FIG. 14 is a view showing the tool of FIG. 12 expanding an expandable interbody spacer in a disc space in accordance with embodiments of the present disclosure;
FIG. 15 is a view showing a funnel for introduction of bone-growth-inducing material into a disc space in accordance with embodiments of the present disclosure;
FIG. 16 is an exploded view of another embodiment of an expandable interbody spacer;
FIG. 17 is a top view of another embodiment of an expandable interbody spacer shown in a collapsed position;
FIG. 18 is a top view of the expandable interbody spacer of FIG. 17 shown in an expanded position;
FIG. 19 is an exploded view of the expandable interbody spacer of FIG. 17 ;
FIG. 20 is an exploded view of a link of a jointed arm of the expandable interbody spacer of FIG. 17 ;
FIG. 21 is a top view of another embodiment of an expandable interbody spacer shown in a collapsed position;
FIG. 22 is a top view of the expandable interbody spacer of FIG. 21 shown in an expanded position;
FIG. 23 is a view of the expandable interbody spacer of FIG. 21 shown in a disc space in a collapsed position;
FIG. 24 is a view of the expandable interbody spacer of FIG. 21 shown in a disc space in an expanded position;
FIG. 25 is a top view of a tool shown engaging the expandable interbody spacer of FIG. 21 in accordance with embodiments of the present disclosure;
FIG. 26 is a view showing the tool of FIG. 24 expanding the expandable interbody spacer of FIG. 24 in a disc space in accordance with embodiments of the present disclosure;
FIG. 27A is an isometric view of an exemplary expandable interbody spacer in an expanded position, in accordance with a further embodiment of the disclosure;
FIG. 27B is an isometric view of the expandable interbody spacer of FIG. 27A in the collapsed position;
FIG. 28 is an exploded view of the expandable interbody spacer of FIG. 27A .
FIG. 29 depicts a cross-sectional view of the expandable interbody spacer of FIG. 27A in the collapsed position;
FIG. 30 depicts an embodiment of an exemplary tool for implanting an embodiment of an exemplary expandable interbody spacer, in accordance with the principles of the present disclosure;
FIG. 31 depicts a partially-exploded view of various components of the tool shown in FIG. 30 ;
FIG. 32A depicts a cross-sectional view of a proximal portion of the tool of FIG. 30 ;
FIG. 32B depicts a cross-sectional view of an actuator assembly;
FIG. 32C depicts an exploded view of the actuator assembly;
FIGS. 33-43 depict various views of components of the exemplary tool of FIG. 30 and their interaction with an exemplary interbody spacer; and
FIG. 44 depicts a final implanted configuration of an exemplary embodiment of an expandable interbody spacer.
Throughout the drawing figures, it should be understood that like numerals refer to like features and structures.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiments of the disclosure will now be described with reference to the attached drawing figures. The following detailed description of the invention is not intended to be illustrative of all embodiments. In describing preferred embodiments of the present disclosure, specific terminology is employed for the sake of clarity. However, the embodiments described herein are not intended to be limited to the specific terminology so selected. It is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
As used herein, the term “proximal” may refer to a portion of a device or component thereof disposed closest to an operator or healthcare professional during an implantation procedure. Conversely, the term “distal” may refer to a portion of a device or component thereof disposed opposite the proximal portion and disposed farther from the operator or healthcare professional during an implantation procedure. As discussed below, the embodiments of expandable interbody spacers described herein may be implanted via any suitable approach known in the art. It is contemplated, however, that the disclosed embodiments may be implanted via an offset (e.g., 20-40 degree offset) posterior approach. Accordingly, solely for orientation purposes, a “proximal” portion of the device, when implanted, may be disposed posteriorly relative to a patient, if implanted via a posterior approach.
Referring to FIGS. 1-10 , an expandable interbody spacer 10 is shown in accordance with embodiments of the present disclosure. In the illustrated embodiment, the expandable interbody spacer 10 has a proximal end 20 and a distal end 30 . The expandable interbody spacer 10 may include a first jointed arm 40 and a second jointed arm 50 positioned on either side of longitudinal axis 15 of the spacer 10 . The first and second jointed arms 40 , 50 may be interconnected at the proximal end 20 , for example, by a proximal connection member 60 . The first and second jointed arms 40 , 50 may be interconnected at the distal end 30 , for example, by a distal connection member 70 . The first and second jointed arms 40 , 50 of the expandable interbody spacer 10 may be made from a number of materials, including titanium, stainless steel, titanium alloys, non-titanium alloys, polymeric materials, plastic composites, polyether ether ketone (“PEEK”) plastic material, ceramic, elastic materials, and combinations thereof. While the expandable interbody spacer 10 may be used with a posterior, anterior, lateral, or combined approach to the surgical site, the spacer 10 may be particularly suited with a posterior approach.
The first jointed arm 40 has a proximal end 80 and a distal end 90 . The proximal end 80 may be pivotally coupled to the proximal connection member 60 . The distal end 90 may be pivotally coupled to the distal connection member 70 . Any of a variety of different fasteners may be used to pivotally couple the proximal end 80 and the distal end 90 and the proximal connection member 60 and the distal connection member 70 , such as pins 100 , for example. In another embodiment (not illustrated), the connection may be a hinged connection. As illustrated, the first jointed arm 40 may comprise a plurality of links that are pivotally coupled to one another. In the illustrated embodiment, the first jointed arm 40 comprises first link 110 , second link 120 , and third link 130 . When the spacer 10 is in a collapsed position, the first link 110 , second link 120 , and third link may be generally axially aligned. As illustrated, the first link 110 , second link 120 , and third link 130 may be connected end to end. When the spacer 10 is in a collapsed position, the first link 110 , second link 120 , and third link 130 may be generally axially aligned. The first link 110 and the second link 120 may be pivotally coupled, and the second link 120 and the third link 130 may also be rotatably coupled. Any of a variety of different fasteners may be used to pivotally couple the links 110 , 120 , 130 , such as pins 100 , for example. In another embodiment (not illustrated), the coupling may be via a hinged connection.
As best seen in FIGS. 1, 5-7, 9, and 10 , an upper surface 140 of the first jointed arm 40 may be defined by the links 110 , 120 , 130 . The upper surface 140 should allow for engagement of the first jointed arm 40 with one of the adjacent vertebral bodies. In some embodiments, the upper surface 140 may include texturing 150 to aid in gripping the adjacent vertebral bodies. Although not limited to the following, the texturing 150 can include teeth, ridges, friction-increasing elements, keels, or gripping or purchasing projections.
As best seen in FIGS. 7, 9, and 10 a lower surface 160 of the first jointed arm 40 may be defined by the links 110 , 120 , 130 . The lower surface 160 should allow for engagement of the first jointed arm 40 with one of the adjacent vertebral bodies. In some embodiments, the lower surface 160 may include texturing 170 to aid in gripping the adjacent vertebral bodies. Although not limited to the following, the texturing 170 can include teeth, ridges, friction-increasing elements, keels, or gripping or purchasing projections.
The second jointed arm 50 has a proximal end 180 and a distal end 190 . The proximal end 180 may be pivotally coupled to the distal connection member 70 . The distal end 190 may be pivotally coupled to the distal connection member 70 . Any of a variety of different fasteners may be used to pivotally couple the proximal end 180 and the distal end 190 and the proximal connection member 60 and the distal connection member 70 , such as pins 100 , for example. In another embodiment (not illustrated), the connection may be a hinged connection. As illustrated, the second jointed arm 50 may comprise a plurality of links that are pivotally coupled to one another. In the illustrated embodiment, the second jointed arm 50 comprises first link 200 , second link 210 , and third link 220 . When the spacer 10 is in a collapsed position, the first link 200 , second link 210 , and third link 220 may be generally axially aligned. As illustrated, the first link 200 , second link 210 , and third link 220 may be connected end to end. The first link 200 and the second link 210 may be pivotally coupled, and the second link 210 and the third link 220 may also be pivotally coupled. Any of a variety of different fasteners may be used to pivotally couple the links 200 , 210 , 220 , such as pins 100 , for example. In another embodiment (not illustrated), the coupling may be via a hinged connection.
As best seen in FIGS. 1, 2, 6, and 8-10 , an upper surface 230 of the second jointed arm 50 may be defined by the links 200 , 210 , 220 . The upper surface 230 should allow for engagement of the second jointed arm 50 with one of the adjacent vertebral bodies. In some embodiments, the upper surface 230 may include texturing 240 to aid in gripping the adjacent vertebral bodies. Although not limited to the following, the texturing 240 can include teeth, ridges, friction-increasing elements, keels, or gripping or purchasing projections.
As best seen in FIGS. 8-10 , a lower surface 250 of the second jointed arm 50 may be defined by the links 200 , 210 , and 220 . The lower surface 250 should allow for engagement of the second jointed arm 50 with one of the adjacent vertebral bodies. In some embodiments, the lower surface 250 may include texturing 260 to aid in gripping the adjacent vertebral bodies. Although not limited to the following, the texturing 260 can include teeth, ridges, friction-increasing elements, keels, or gripping or purchasing projections.
With reference now to FIGS. 3, 5, and 9 , a bore 270 extends through proximal connection end 60 . The bore 270 may extend generally parallel to the longitudinal axis 12 (see FIG. 1 ) of the spacer 10 . The first jointed arm 40 and the second jointed arm 50 may define a hollow interior portion (not shown) that extends axially through the spacer 10 . The bore 270 in the proximal connection end 60 may communicate with this hollow interior portion. As best shown on FIG. 5 , the distal connection end 70 may include an opening 280 . As illustrated, the opening 280 may face inward and may not extend all the way through the distal connection 70 . In one embodiment, the opening 280 may be generally aligned with the bore 270 in the proximal connection end 60 such at a tool (e.g., tool 340 shown on FIG. 12 ) inserted into the bore 270 may be received in the opening 280 for placement of the spacer 10 into a disc space and/or expansion of the spacer 10 .
FIGS. 1-4 illustrate the expandable interbody spacer 10 in a collapsed position. In accordance with present embodiments, the expandable interbody spacer 10 may be laterally expanded to an expanded position. FIGS. 6-10 illustrate the expandable interbody spacer 10 in an expanded position. In the expanded position, the first arm 40 and the second arm 50 have each been folded inward in opposite directions. For example, the proximal end 80 and the distal end 90 of the first arm 40 may be folded closer together. The links 110 , 120 , 130 should pivot with respect to one another when the first arm 40 is folded inward. The proximal end 80 should pivot at the proximal connection end 60 , and the distal end 90 should pivot at the distal connection end 70 . By way of further example, the proximal end 180 and the distal end 190 of the second arm 50 may also be folded together. The links 200 , 210 , 220 should pivot with respect to another when the second arm is folded inward. The proximal end 180 should pivot at proximal connection end 60 , and the distal end 190 should pivot at the distal connection end 70 . After placement in the expanded position, the expandable interbody spacer 10 can be secured in the expanded position to prevent collapse of the expandable interbody spacer 10 upon application of spacer. Any of a variety of different techniques may be used to secure the expandable interbody spacer 10 , including pins or other suitable locking mechanism, for example.
As illustrated by FIG. 6 , the first and second jointed arms 40 , 50 define an interior cavity 290 when in an expanded position. The interior cavity 290 may be filled with a bone-growth-inducing material, such as bone material, bone-growth factors, or bone morphogenic proteins. As will be appreciated by those of ordinary skill in the art, the bone-growth-inducing material should induce the growth of bone material, thus promoting fusion of the adjacent vertebra.
The expandable interbody spacer 10 may be sized to accommodate different applications, different procedures, implantation into different regions of the spine, or size of disc space. For example, the expandable interbody spacer 10 may have a width W 1 (as shown on FIG. 1 ) prior to expansion of about 8 mm to about 22 mm and alternatively from about 10 mm to about 13 mm. By way of further example, the expandable interbody spacer 10 may be expanded to a width W 2 (as shown on FIG. 6 ) in a range of about 26 mm to about 42 mm and alternatively from about 16 mm to about 32 mm. It should be understood that the width W 1 or W 2 whether prior to, or after, expansion generally refers to the width of the expandable interbody spacer 10 extending transverse to the longitudinal axis 12 of the spacer 10 . In general, the width W 2 of the expandable interbody spacer 10 after expansion should be greater than the width W 1 of the expandable interbody spacer 10 prior to expansion.
In accordance with present embodiments, the expandable interbody spacer 10 may be used in the treatment of damage or disease of the vertebral column. In one embodiment, the expandable interbody spacer 10 may be inserted into a disc space between adjacent vertebrae in which the intervertebral disc has been partially or completely removed. FIG. 11 illustrates a spinal segment 300 into which the expandable interbody spacer 10 (e.g., FIGS. 1-10 ) may be inserted. The spinal segment 300 includes adjacent vertebrae, identified by reference numbers 310 and 320 . Each of the adjacent vertebrae 310 , 320 has a corresponding endplate 315 , 325 . The disc space 330 is the space between the adjacent vertebrae 310 , 320 . FIG. 12 illustrates a tool 340 that may be used in the insertion of the expandable interbody spacer 10 into the disc space 330 . The tool 340 includes a shaft 350 having an elongated end portion 360 for coupling to the expandable interbody spacer 10 . The elongated end portion 360 has a distal tip 370 .
FIGS. 13 and 14 illustrate introduction of an expandable interbody spacer 10 into the disc space 330 using tool 340 . For illustrative purposes, the upper vertebra 330 shown on FIG. 11 has been removed from FIGS. 13 and 14 . As illustrated, the spacer 10 may be secured to the tool 340 . For example, the elongated end portion 360 of the tool 340 may be disposed through the bore 270 (e.g., see FIG. 5 ) in the proximal connection end 60 with the distal tip 370 (e.g., see FIG. 12 ) of the end portion 360 secured in the opening 280 (e.g., see FIG. 5 ) in the distal connection end 70 . As illustrated by FIG. 13 , the tool 340 may introduce the spacer 10 into the disc space 330 through an access cannula 380 . After introduction into the disc space 330 , the spacer 10 may be laterally expanded. In accordance with present embodiments, the spacer 10 can be laterally expanded by folding the first arm 40 and the second arm 50 inward. By expanding laterally, the spacer 10 has an increased surface area contact with the endplate 325 . In addition, the spacer 10 may engage harder bone around the apophyseal ring. As previously mentioned, an interior cavity 290 should be formed in the spacer 10 when in the expanded position. The tool 340 may then be detached from the spacer 10 and removed from the cannula 380 . As illustrated by FIG. 15 , a funnel 390 may then be placed on the cannula 380 . Bone-growth inducing material may then be placed into the interior cavity 290 through the cannula 380 . Because the spacer 10 has been laterally expanded, the interior cavity 290 should have a desirable amount of space for packing of the bone-growth-inducing material.
FIG. 16 illustrates an expandable interbody spacer 10 in accordance with an alternative embodiment. In the illustrated embodiment, the expandable interbody spacer 10 comprises a first jointed arm 40 and a second jointed arm 50 . The first jointed arm 40 has a proximal end 80 and a distal end 90 . The first jointed arm 40 comprises a plurality of links 110 , 120 , 130 connected end to end, for example, by pins 100 . The first jointed arm 40 further may comprise washers 105 (e.g, PEEK washers) that may be disposed between the links 110 , 120 , 130 at their connections. The second jointed arm 50 has a proximal end 180 and a distal end 190 . The second jointed arm 50 comprises a plurality of links 200 , 210 , 220 connected end to end, for example, by pins 100 . The second jointed arm 50 further may comprise washers 105 (e.g, PEEK washers) that may be disposed between the links 200 , 210 , 220 at their connections. Washers 105 may also be disposed between the first arm 40 and the proximal connection member 60 and the distal connection member 70 at their respective connections. Washers 105 may also be disposed between the second arm 50 and the proximal connection member 60 and the distal connection member 70 at their respective connections. The washers 105 should have an interference fit to cause friction such that the spacer 10 may hold its shape in the entire range of the expanded implant.
The proximal ends 80 , 180 may be pivotally coupled, for example, by pin 100 , as shown on FIG. 19 . The distal ends 90 , 180 may also be pivotally coupled, for example, by pin 100 , as shown on FIG. 19 . The first jointed arm 40 comprises first link 110 and third link 130 , the first link 110 and the third link 130 being pivotally coupled. In contrast to the first jointed arm 40 of FIGS. 1-10 , there
Referring now to FIGS. 17-19 , an expandable interbody spacer 10 is illustrated in accordance with another embodiment of the present disclosure. In the illustrated embodiment, the expandable interbody spacer 10 comprises a first jointed arm 40 and a second jointed arm 50 . The first jointed arm 40 has a proximal end 80 and a distal end 90 . The second jointed arm 50 has a proximal end 180 and a distal end 190 . The proximal ends 80 , 180 may be pivotally coupled, for example, by pin 100 , as shown on FIG. 19 . The distal ends 90 , 180 may also be pivotally coupled, for example, by pin 100 , as shown on FIG. 19 . The first jointed arm 40 comprises first link 110 and third link 130 , the first link 110 and the third link 130 being pivotally coupled. In contrast to the first jointed arm 40 of FIGS. 1-10 , there is no second link 120 . As shown by FIG. 20 , the third link 130 may comprise a first link segment 400 and a second link segment 410 , which may be secured to one another by pins 420 , for example. First link segment 400 and second link segment 410 may also have a tongue-and-groove connection, for example a groove 430 in the first link segment 400 may receive a tongue 440 of the second link segment 410 . The second jointed arm comprises first link 200 and third link 220 , the first link 200 and the third link 220 being pivotally coupled. In contrast to the second joint arm 50 of FIGS. 1-10 , there is no second link 210 .
In accordance with present embodiments, lateral expansion of the expandable interbody spacer 10 of FIGS. 17-19 may include folding the first arm 40 and the second arm 50 inward. For example, the proximal end 80 and the distal end 90 of the first arm 40 may be folded together, and the proximal end 180 and the distal end 190 of the second arm 50 may also be folded together.
Referring now to FIGS. 21 and 22 , an expandable interbody spacer 10 is illustrated in accordance with another embodiment of the present disclosure. In the illustrated embodiment, the expandable interbody spacer 10 has a proximal end 20 and a distal end 30 . The expandable interbody spacer 10 may include a first jointed arm 40 and a second jointed arm 50 positioned on either side of longitudinal axis 12 of the spacer 10 . As illustrated, the expandable interbody spacer 10 further may comprise an internal screw 450 . The internal screw 450 may comprise a head 460 and an elongated body 470 , which may extend generally parallel to the longitudinal axis 12 of the spacer 10 . In some embodiments, the internal screw 450 may extend from the proximal end 20 to the distal end 30 of the spacer 10 . In one embodiment, the elongated body 470 may be retractable. For example, the elongated body 470 may retract into the head 460 , as shown on FIG. 22 .
As illustrated by FIGS. 23 and 24 , the spacer 10 may be introduced into the disc space 330 , wherein the spacer 10 can be laterally expanded. In accordance with present embodiments, the spacer 10 can be laterally expanded by folding the first arm 40 and the second arm 50 inward. In some embodiments, the elongated body 470 may be retracted into the head 460 to cause folding of the first arm 40 and the second arm 50 inward, as the first arm 40 and the second arm 50 are secured to the distal end 480 of the internal screw 450 .
FIG. 25 shows attachment of a tool 490 to the expandable interbody spacer 10 of FIGS. 22 and 23 in accordance with embodiments of the present disclosure. As illustrated, the tool 490 may have an attachment end 500 , which can be secured to the head 460 of the internal screw 450 . As shown by FIG. 26 , the tool 40 can be used to introduce the spacer 10 into the disc space 330 , wherein the spacer 10 can be laterally expanded.
Turning now to FIG. 27A-29 , there are depicted multiple views of a further embodiment of an expandable interbody spacer 2700 , in accordance with an aspect of the present disclosure. The expandable interbody spacer 2700 may include one or more features of any of the other interbody spacers discussed herein. For example, although the spacer 2700 and its components may be made of titanium, any suitable biocompatible material known in the art may be used.
With reference to FIG. 27A , for example, spacer 2700 may include, among other things, a proximal portion 2702 . Proximal portion 2702 may include a substantially cylindrical portion 2703 . Cylindrical portion 2703 may include a complete cylindrical shape or a partial cylindrical shape. In addition, cylindrical portion 2703 may define a lumen 2704 therethrough. A surface of the lumen 2704 may include one or more geometric features, such as, for example, screw threads 2705 , as described in greater detail below. In one embodiment, lateral surfaces of cylindrical portion 2703 may include one or more geometric features 2706 to facilitate engagement by a tool 3000 , as discussed below in greater detail. The geometric features 2706 may include any suitable shape and/or configuration. In one embodiment, the geometric features 2706 may include elongate notches disposed in the side walls that define cylindrical portion 2703 . Further, the elongate notches may extend into the side walls in a direction that is substantially perpendicular.
A plurality of cantilevered ledges 2707 may extend distally from a distal portion of cylindrical portion 2703 . Aside from being disposed in an opposing relation to one another, the cantilevered ledges 2707 may be substantially similar to one another. The ledges 2707 may include any suitable configuration, shape, and/or size known in the art. In one embodiment, the ledges 2707 may define a space 2708 therebetween for receiving a plurality of links (as described below) of spacer 2700 . External surfaces (e.g., inferior and superior surfaces) of ledges 2707 may include texturing 150 to aid in gripping adjacent vertebral bodies, as described herein. The external surfaces may also be configured to promote bone ingrowth. For example, in one embodiment, the external surfaces of ledges 2707 may include a porous configuration or may include a coating of, e.g., hydroxyapatite. External edges of ledges 2707 may include any suitable configuration for matingly coupling with corresponding portions of the plurality of links discussed below. In one embodiment, the external edges of ledges 2707 may be curved to facilitate the plurality of links pivoting relative to each of ledges 2707 . Further, each of ledges 2707 may include one or more openings 2707 a for receiving a pivot pin 2709 therethrough, as described below in greater detail.
With continued reference to FIGS. 27A-29 , proximal portion 2702 may be rotatably coupled via a plurality of pivot pins 2709 to links 2710 and 2712 . Links 2710 and 2712 may be substantially similar to one another. Indeed, as depicted in, e.g., FIG. 27A , links 2710 and 2712 may be positioned as mirror images of each other. Thus, for the purposes of brevity, similar portions of links 2710 and 2712 will be described together. Proximal portions 2714 of links 2710 and 2712 may be received in space 2708 . The proximal portions 2714 of links 2710 , 2712 may be appropriately configured and dimensioned to fit between ledges 2707 . In addition, each of proximal portions 2714 includes a through-hole 2716 for receiving a pivot pin 2709 . The through-hole 2716 may be disposed in a scalloped cut-out on proximal portions 2714 of each of links 2710 , 2712 .
Pivot pin 2709 may include any suitable fastener known in the art for movably coupling links 2710 and 2712 to proximal portion 2702 . In one embodiment, pivot pin 2709 may be inserted and retained within openings 2707 a and through-holes 2716 via an interference or friction fit.
In some embodiments, an interface between one or both of links 2710 and 2712 and proximal portion 2702 may be configured to retain one or both of links 2710 and 2712 in a predetermined position relative to proximal portion 2702 . For example, an edge of ledge 2707 may interact with a wall 2717 to frictionally retain in a predetermined position relative to proximal portion 2702 . In one embodiment, the wall 2717 may include a raised portion (not shown), such as, e.g., a rounded bump, or other suitable feature against which the edge of ledge 2707 may engage.
Superior and inferior surfaces of links 2710 and 2712 may also include suitable texturing 150 as described above. In addition, the superior and inferior surfaces may be configured to promote bone ingrowth, as described above. Each link 2710 and 2712 also may define one more openings 2718 therethrough. The openings 2718 may include any suitable configuration known in the art. In one embodiment, openings 2718 may include a substantially rectangular configuration. In other embodiments, openings 2718 may include other shapes. In one embodiment, the openings 2718 may be disposed distally of wall 2717 . Openings 2718 may be configured as bone graft windows, allowing facilitating bone ingrowth into an interior of spacer 2700 through openings 2718 An edge of opening 2718 may be appropriately beveled, chamfered, and/or rounded, as is known in the art. Further, opening 2718 may be generally disposed in a central portion of each of links 2710 and 2712 .
A distal end portion of links 2710 , 2712 may be configured to be movably coupled to another link, as discussed herein. In one embodiment, the distal end portions of links 2710 , 2712 may define a male hinge 2719 that includes a hole 2720 therethrough. The hole 2720 may be configured to receive a pivot pin 2709 for rotatable coupling the links 2710 , 2712 to adjacent links described below. In one embodiment, a wall perpendicular to hinge 2719 may define one or more position retaining features 2721 . As will be described below, the position retaining features 2721 may be configured to interact with corresponding features on an adjacent link to frictionally retain links in a predetermined position.
The ends of each of links 2710 , 2712 that are opposite to the ends coupled to proximal portion 2702 may be movably coupled to links 2722 and 2724 . Each of links 2722 and 2724 may be substantially similar to one another. Thus, those of ordinary skill in the art will understand that either link 2722 or link 2724 may include features of the other link 2722 or link 2724 . A proximal end portion of each of links 2722 and 2724 may define a recess 2725 for receiving hinge 2719 . The recess 2725 may be disposed between a pair of proximally extending arms 2725 a and 2725 b . Each of arms 2725 a , 2725 b may be substantially similar to one another and, thus, for the purposes of efficiency, only one arm 2725 a will be discussed.
Arm 2725 a may include any suitable shape and/configuration known in the art. In one embodiment, an external surface of arm 2725 a may be rounded to facilitate rotating relative to link 2712 or 2710 . A lateral surface of arm 2725 a may include one or more position retaining features 2727 for engaging position retaining features 2721 . In use, as links 2724 and 2712 may rotate relative to one another, for example, position retaining features 2721 and 2727 may frictionally engage one another to retain links 2724 and 2712 in a desired position. Position retaining features 2727 may be similar to position retaining features 2721 . For example, in one embodiment, position retaining feature 2727 may be a bump that is raised relative to a remaining surface of arm 2725 a.
Each link 2722 and 2724 may also include one or more openings 2718 disposed generally in a central portion of links 2722 and 2724 . As discussed above, openings 2718 may be configured to extend through each respective link 2722 , 2724 , and may be configured to facilitate bone-ingrowth. One or more edges of openings 2718 may be beveled, rounded, and/or chamfered as known in the art.
A distal end of each link 2722 and 2724 may include a plurality of extensions 2729 , 2730 . Extensions 2729 , 2730 may be configured to extend away from a central portion of the links 2722 , 2724 , and may be configured to define a space 2732 therebetween. The space 2732 may be configured to receive a distal component of spacer 2700 . Each of extensions 2729 , 2730 may include a through-hole 2734 therein. The through-hole 2734 may include any suitable configuration known in the art. The through-hole 2734 may be configured to receive a respective pivot pin 2709 for movably coupling links 2722 , 2724 to the distal component discussed in greater detail below.
Inward facing surfaces of one or both of extensions 2729 , 2730 may be configured to interact or engage with corresponding surfaces of the extensions 2729 , 2730 of an opposing link. For example, as shown in FIG. 28 , the inward facing surfaces of extensions 2729 , 2730 of one of links 2722 , 2724 may include a plurality of teeth, recesses, protrusions, notches, or the like, that may be configured to engage corresponding geometry disposed on the inward facing surfaces of the extensions disposed on the other of links 2722 , 2724 . In the preferred embodiment, the inward facing surfaces of extensions 2729 , 2730 may include a plurality of gear teeth 2736 . The gear teeth 2736 of each extension 2729 , 2730 may engage gear teeth 2736 of the opposing link to facilitate rotating one link relative to the other in a single plane.
Each of links 2722 and 2724 may be movably coupled to a distal component 2740 . Distal component 2740 may include a substantially trapezoidal configuration. That is, distal component 2740 may taper in the distal direction from a larger width dimension to a smaller width dimension. With reference to FIG. 28 , a proximal face of distal component 2740 may include an opening 2742 in communication with a hole 2744 through distal component 2740 . As shown in, e.g., FIG. 27A , hole 2744 extends completely through distal component 2740 . Hole 2744 may include any suitable configuration known in the art. In one embodiment, hole 2744 may include a substantially conical configuration as it tapers towards a smaller diameter in its distal portion. As will be discussed below, hole 2744 may include internal threads for engaging with an implantation tool.
Superior and inferior surfaces of distal component 2740 may be configured to receive extensions 2729 , 2730 . Accordingly, as best shown in FIG. 28 , for example, these surfaces may include a stepped portion 2746 for receiving extensions 2729 , 2730 of each link 2722 , 2724 . Stepped portion 2746 may include a plurality of openings 2748 for receiving a pivot pin 2709 therein to rotatably couple the links 2722 , 2724 to distal component 2740 . Those of ordinary skill in the art will understand that links 2722 , 2724 may be coupled to distal component 2740 by any suitable means known in the art. Distal component 2740 may include a raised portion disposed distally of stepped portion 2746 . The raised portion 2750 may include any suitable configuration known in the art. In one embodiment, the raised portion 2750 may include a distally tapering configuration, as shown in FIG. 27A . As also shown in FIG. 27A , distal component 2740 may include a curved external configuration.
With reference now to FIGS. 28-29 , the spacer 2700 may be maintained in an expanded configuration (shown in FIG. 27A ) by any suitable mechanism known in the art. As discussed above, the spacer 2700 may include certain position retaining features. To more permanently retain an expanded configuration of spacer 2700 , the spacer 2700 may include a locking feature 2760 . Those of ordinary skill in the art will understand that locking feature 2760 may include any suitable configuration known in the art. In one embodiment, locking feature 2760 may include a substantially cylindrical configuration. In addition, locking feature 2760 may define a lumen 2762 therethrough. In one embodiment, the walls of the lumen 2762 may include a plurality of geometric configurations 2762 a to allow a tool (described in greater detail below) to engage and rotate locking feature 2760 . Further, locking feature 2760 may be configured and dimensioned to be received within lumen 2704 of proximal portion 2702 , as shown in FIG. 29 . In one embodiment, an external surface of locking feature 2760 may include suitable geometric features for engaging lumen 2704 . In the embodiment where lumen 2704 includes threads 2705 , the external surface of locking feature 2760 may include corresponding threads 2764 . The threads 2705 in lumen 2704 and threads 2764 may cooperate to only allow locking feature 2760 to be advanced into lumen 2704 without being withdrawn, regardless of whether locking feature is rotated clockwise or counter-clockwise. For example, in one embodiment, threads 2705 may terminate short of the opening to lumen 2704 . In addition, or alternatively, one or more raised circumferential or partially circumferential protrusions 2705 a may be formed just inside of the opening to lumen 2704 . In such embodiments, locking feature 2760 may be pre-disposed within lumen 2704 during a manufacturing or assembly process and before delivery to a user or healthcare professional. Thus, the user or healthcare professional is only able to rotate locking feature 2762 to advance it further into lumen 2704 and is unable to remove locking feature 2762 from 2704 .
With reference to FIG. 29 , and as will be discussed in greater detail below, locking feature 2760 may be configured to be advanced into lumen 2704 and protrude out of cylindrical portion 2703 into space 2708 , which, as shown in FIG. 29 , is occupied by proximal portions 2714 of links 2710 and 2712 when the spacer 2700 is in the collapsed configuration. When the spacer 2700 is in the expanded position, the proximal portions 2714 may be moved out of the space 2708 . Accordingly, locking feature 2760 may be rotated and consequently advanced further into lumen 2704 so that a distal portion of locking feature 2760 extends out of lumen 2708 and into the space 2704 . In this position, the locking feature 2762 may be configured to prevent links 2710 and 2712 from returning to their collapsed positions.
The components of spacer 2700 may be fabricated from any suitable material known in the art, including, but not limited to those described above. In one embodiment, one or more components of spacer 2700 may be fabricated from titanium. Further, portions of spacer 2700 may include any suitable coating known in the art, including, but not limited to, coatings of suitable therapeutic, antiseptic, anesthetic, and/or antibiotic. In addition, as alluded to above, portions of spacer 2700 may be configured to promote bone ingrowth into the structure of spacer 2700 .
Turning now to FIGS. 30-31 , there is depicted an exemplary embodiment of a tool 3000 for effecting implantation, removal, and otherwise manipulation of the various embodiments of expandable interbody spacers described herein. Tool 3000 may include a plurality of components, each of which will be discussed in greater detail below. Those of ordinary skill in the art will recognize that any of the individual components discussed herein may be combined with other components or may be omitted altogether without departing from the principles of the present disclosure.
Tool 3000 may include a handle assembly 3001 . Handle assembly may include an elongate structure 3002 configured to be held in the hand of an operator or healthcare professional. As such, the elongate structure 3002 may be appropriately configured and dimensioned as is known in the art. In some embodiments, elongate structure 3002 may include a plurality of geometric configurations or features 3004 , such as, e.g., bumps, grooves, indentations, ridges, knobs, cut-outs, etc. for gripping by an operator. In addition, elongate structure 3002 may include a constant cross-sectional dimension throughout its length, or elongate structure 3002 may include varying dimensions throughout its length. Further, elongate structure 3002 may include a substantially circular cross-sectional configuration. In some embodiments, however, elongate structure 3002 may include any suitable cross-sectional configuration, including, but not limited to, square, rectangular, triangular, etc.
A generally cylindrical extension member 3006 may extend away from a superior surface 3005 . For the purposes of FIGS. 30-31 only, the orientation depicted is presumed to be an orientation during operation. Thus, terms such as “superior,” “anterior,” “proximal,” “distal,” “inferior,” and “posterior” are used relative to this orientation. The extension member 3006 may serve to rotatably connect elongate structure 3002 to holder 3008 .
Holder 3008 may include any suitable configuration known in the art. In one embodiment, holder 3008 may be configured, shaped, and sized to receive and frictionally engage a proximal portion of an inserter fork described in greater detail below. In one embodiment, for example, holder 3008 may include a substantially U-shaped configuration. The inserter fork may be received with the “U” portion 3008 a of the holder 3008 . The U-shaped holder 3008 may include a base portion, and two superiorly extending arms 3009 . One or more of arms 3009 may be provided with one or more geometric features for frictionally engaging and retaining the inserter fork. For example, the geometric features may include dents, indents, recesses, apertures, protrusions, ribs, and the like. In one embodiment, an inner surface of an upper portion of each arm 3009 may include a rib 3010 . In some embodiments, the U-shaped holder 3008 may include a securing member for retaining (by, e.g., friction) the inserter fork within holder 3008 . In one embodiment, the securing member may be selectively actuatable. For example, the base portion of the holder 3008 may include a set screw (not shown) or other similar mechanism that may selectively engage a portion of the inserter fork to retain the inserter fork relative to the holder 3008 . The set screw may be configured to transition between a first configuration and a second configuration. In the first configuration, the set screw may be received substantially completely or completely within the base portion of holder 3008 . In the second configuration, the set screw may be advanced out of the base portion 3008 and into the “U” portion 3008 a . The set screw may be configured to transition between the first and second configurations by rotating elongate structure 3002 relative to holder 3008 in the directions shown by arrow A. For example, rotating elongate structure 3002 may rotate a head (not shown) of the set screw, thereby advancing the set screw out of the base portion of holder 3008 .
With continued reference to FIG. 31 , the inserter fork may include a generally elongate structure 3012 . In some embodiments, the elongate structure 3012 may define one or more lumens therein. For example, as shown in FIG. 32A , the elongate structure 3012 may define a lumen 3014 therethrough. Elongate structure 3012 may include any suitable cross-sectional structure known in the art. For example, in some embodiments, the elongate structure 3012 may be a generally tubular structure. In other embodiments, elongate structure 3012 may include a substantially rectangular cross-sectional configuration. In a further embodiment, the cross-sectional configuration of elongate structure 3012 may vary along its length. For example, as shown in FIG. 31 , a distal portion of elongate structure 3012 may include a substantially square or rectangular cross-sectional configuration and a proximal portion of elongate structure 3012 may include a substantially circular cross-sectional configuration.
With reference to FIGS. 31 and 33 , a distal portion of elongate structure 3012 may be configured in a fork-like configuration. More particularly, a distal portion of elongate structure 3012 may include a vertical slit 3016 defining two arms 3018 and 3020 . Although only two arms 3018 , 3020 are shown, those of ordinary skill in the art will understand that a greater or lesser number of arms may be contemplate in accordance with the principles of the present disclosure. For example, the distal portion of elongate structure 3012 may include only a single arm. Alternatively, elongate structure 3012 may include two longitudinal slits disposed in perpendicular planes, thereby creating four arms (not shown). As a result of one or more of the configuration of the elongate structure 3012 , the configuration of slit 3016 , and the material properties of elongate structure 3012 , the arms 3018 and 3020 may exhibit resiliency or other spring-like characteristics. For examples, the arms 3018 and 3020 may be biased away from one another. In another embodiment, the arms 3018 and 3020 may be biased toward one another.
The arms 3018 and 3020 may be substantially similar to one another. Accordingly, for the purposes of efficiency, only the features of arm 3020 will be described. Those of ordinary skill will understand that arm 3018 may include one or more features of arm 3020 . With specific reference to FIG. 33 , a distal end 3022 of arm 3020 may be configured to releasably engage proximal portion 2702 of spacer 2700 via features 2706 . More particularly, the distal end 3022 of arm 3020 may include a projection 3024 configured and shaped to be received within feature 2706 . For example, as shown in FIG. 33 , projections 3024 may be configured to extend towards each other. In some embodiments, feature 2706 may include a projection, and the distal end 3022 of arm 3020 may include a notch or other recess for releasably engaging the projection. Furthermore, a distal end portion of arm 3020 proximate to projections 3024 may include one or more geometric features configured for assisting in urging arm 3020 towards arm 3018 and vice versa. More particularly, an external surface of arm 3020 may include a rib 3026 , which may be engaged by sleeve 3030 to urge arm 3020 toward arm 3018 . The rib 3026 may include any suitable configuration known in the art. For example, in one embodiment, the rib may extend generally transverse to a longitudinal axis of the elongate structure 3012 . In some embodiments, a proximal portion of rib 3026 may be configured to transition smoothly to an external surface of the remainder of arm 3020 . That is, a proximal portion of rib 3026 may include a tapering or a generally ramp-like configuration. Further, although only one rib 3026 is depicted on arm 3020 , those of ordinary skill will understand that any suitable number of ribs 3026 may be provided. Furthermore, the rib 3026 may include a height dimension that correlates to an amount of travel needed to move arm 3020 toward arm 3018 (and vice versa) so as to effectively engage spacer 2700 .
With renewed reference to FIGS. 31 and 32A -B, a proximal end portion 3013 of elongate structure 3012 may be configured as follows. In one embodiment, the proximal end portion 3013 may include a horizontal slit 3028 , which may extend from the proximal end of elongate structure 3012 distally to a position just proximal of knob 3032 on elongate structure 3012 . The slit 3028 may define two arms 3028 a , 3028 b , which may be configured to be either biased away or toward one another. A proximal end of each arm 3028 a , 3028 b may be configured to assist securing the inserter fork to an actuator assembly, which will be discussed in greater detail below. In an embodiment, the proximal end of at least one of arms 3028 a , 3028 b may include a raised flange 3027 .
As alluded to above, elongate structure 3012 may include a knob 3032 disposed thereon. Knob 3032 may include any suitable configuration. In one embodiment, knob 3032 may be disposed distally of slit 3028 . An outer surface of knob 3032 may include suitable geometric features for securing knob 3032 within holder 3008 . For example, an outer surface of knob 3032 may include a plurality of knurls, indents, recesses, and/or projections thereon. In one embodiment, knob 3032 may include a plurality of channels 3031 disposed thereon. The channels 3031 may be configured to receive at least one of ribs 3010 to facilitate securing knob 3032 with holder 3008 . In some embodiments, elongate structure 3012 may include a mechanism for limiting longitudinal movement of elongate structure 3012 relative to holder 3008 . For example, elongate structure 3012 may include a radially extending flange 3033 configured to abut one of arms 3009 or the base portion of U-shaped holder 3008 so as to prevent elongate structure 3012 from moving proximally relative to handle 3001 . Furthermore, elongate structure 3012 may include a plurality of screw threads 3029 disposed on an external surface thereof. In one embodiment, the threads 3029 may be disposed proximally of slit 3016 but distally of flange 3033 . As shown in FIG. 31 , threads 3029 may be disposed substantially closer to flange 3033 than slit 3016 .
Elongate structure 3012 may be configured to be received within a lumen 3030 a of sleeve 3030 . Sleeve 3030 may include any suitable configuration known in the art. For example, sleeve 3030 generally may include a configuration corresponding to an outer periphery of elongate structure 3012 . More particularly, sleeve 3030 may include a distal portion having a substantially rectangular cross-sectional configuration, and a proximal portion having a substantially circular cross-sectional configuration. The lumen 3030 a within sleeve 3030 may be similarly configured. That is, lumen 3030 a may include a configuration that corresponds to an outer periphery of elongate structure 3012 . That is, lumen 3030 a may include a distal portion having a substantially rectangular cross-sectional configuration, and a proximal portion having a substantially circular cross-sectional configuration. A proximal portion of lumen 3030 a may include a width dimension larger than a similar width dimension at a distal portion of lumen 3030 a . In addition, a distal end of lumen 3030 a may be configured to urge arms 3018 and 3020 towards one another so that they may engage spacer 2700 , as discussed herein. Further, in one embodiment, sleeve 3030 may be a substantially elongate hollow member having a neck portion 3034 and a proximal lip 3036 at a proximal end thereof. Instead of lip 3036 , those of ordinary skill in the art will understand that any suitable geometric configuration may be used within the principles of the present disclosure.
Prior to being received over elongate structure 3012 , a proximal portion of sleeve 3030 may be operably coupled to an inserter knob 3038 . Inserter knob 3038 may be any suitable knob known in the art and may include any suitable configuration. In one embodiment, knob 3038 may include a generally cylindrical configuration. However, any suitable configuration may be used in accordance with the principles of the present disclosure. Knob 3038 may include at least one lumen 3040 . Lumen 3040 may extend completely through knob 3038 or partially therethrough. A distal portion of an inner surface of lumen 3040 may include at least one geometric feature 3042 for interacting with lip 3036 so as to retain inserter knob 3038 on sleeve 3030 . In one embodiment, geometric feature 3042 may include a circumferential channel configured to receive lip 3036 therein. With reference now to FIG. 32A , lumen 3040 may include a plurality of screw threads 3044 for cooperating with threads 3029 on elongate structure 3012 . Although the depicted embodiment illustrates that screw threads 3044 are disposed at a proximal portion of lumen 3040 , threads 3044 may be disposed along any portion of lumen 3040 . For example, in one embodiment, threads 3044 may extend from a midpoint of lumen 3040 to a proximal end thereof.
With reference now to FIGS. 31-32C , actuator assembly 3050 will be described. Actuator assembly 3050 may include a plurality of components operably coupled together and operable to facilitate expanding spacer 2700 , as discussed below in greater detail. Although the plurality of components are described individually, those of ordinary skill in the art will appreciate that any of the described components may be combined with one or more of the other components and/or eliminated altogether without departing from the principles of the present disclosure.
Actuator assembly 3050 may include a central portion 3052 , which may include a proximal head 3054 and an elongate tubular member 3056 extending therefrom. Central portion 3052 may define a lumen 3058 . Lumen 3058 may extend completely through central portion 3052 . Lumen 3058 may include any suitable configuration known in the art. For example, as shown, lumen 3058 may include a substantially circular cross-sectional configuration. In one embodiment, proximal end 3054 may include a channel 3060 for receiving a locking tab 3062 therein, which will be discussed in greater detail below. Channel 3060 may include any suitable configuration, and may be dimensioned and shaped to correspond to locking tab 3062 . Further, channel 3060 may be configured to cut through lumen 3058 , as shown in FIG. 32B . In addition, a portion of lumen 3058 may include a plurality of screw threads 3064 . The screw threads 3064 may be disposed along any portion of lumen 3058 . For example, in the depicted embodiment, screw threads 3064 may be disposed along only a proximal portion of lumen 3058 . Screw threads 3064 may be disposed in lumen 3058 on either side of channel 3060 . The screw threads 3064 may extend until a proximalmost end of lumen 3058 .
Externally, proximal head 3054 may include any suitable configuration. In the depicted embodiment, for example, proximal head 3054 may include a substantially planar proximal end face 3066 . The end face 3066 may include an opening 3067 in communication with lumen 3058 . In addition, end face 3066 may include a second opening 3068 for receiving a retention pin 3069 therein. Opening 3068 include a diameter that is smaller than opening 3067 . As will be discussed below, retention pin 3067 may be disposed in opening 3068 for retaining tab 3062 in channel 3060 . Proximal head 3054 may include a generally circular cross-sectional configuration. In one embodiment, however, proximal head 3054 may include substantially planar superior 3070 and inferior (not shown) surfaces. As depicted in FIG. 32C , planar superior surface 3070 may include an opening 3071 in communication with channel 3060 for receiving tab 3062 therein. With continued reference to FIGS. 32B-32C , central portion 3052 may include any suitable external configuration known in the art. In one embodiment, central portion 3052 may include a substantially uniform external configuration. In the depicted embodiment, central portion 3052 may include a step 3072 . Step 3072 may be located at any portion along a length of central portion 3052 . In one embodiment, step 3072 may be located at a midpoint of central portion 3052 . Step 3052 may include any suitable configuration. For example, step 3052 may be the interface between a relatively smaller diameter distal portion 3052 a of central portion 3052 and a relatively larger diameter proximal portion 3052 b of central portion 3052 . As shown in, e.g., FIG. 32C , step 3072 may include a ramped surface in some embodiments. Further, a portion of proximal portion 3052 b may be configured to receive sleeve member 3076 thereon. Accordingly, proximal portion 3052 b may include one or more suitable geometric configurations, such as, e.g., screw threads 3074 , for coopering with corresponding screw threads 3077 within sleeve member 3076 , as described in greater detail below. Screw threads 3074 may extend along any portion of proximal portion 3052 b . For example, screw threads 3074 may extend along a substantial entirety of proximal portion 3052 b or only for a portion thereof.
Distal portion 3052 may be configured, sized, and dimensioned to be received within a lumen defined by arms 3028 a and 3028 b . In one embodiment, distal portion 3052 may include a diameter (or if not tubular, a width dimension) that is larger than a diameter (or width dimension) of the lumen defined by arms 3028 a , 3028 b , so as to spread apart arms 3028 a , 3028 b when distal portion 3052 is received therebetween. In this manner, distal portion 3052 may be frictionally retained by the inherent resilient properties of arms 3028 a , 3028 b acting on distal portion 3052 . To facilitate with orientation and guiding distal portion 3052 into the lumen defined by arms 3028 a , 3028 b , distal portion 3052 may include one or more projections 3075 , which may be configured to be slidably received within slit 3028 .
As noted above, opening 3071 and channel 3060 may be configured to receive therein a locking tab 3062 for receiving a tool within lumen 3058 of actuator 3050 . Tab 3062 may include any suitable configuration known in the art. In one embodiment, tab 3062 may be resiliently biased in a direction out of channel 3060 by one or more springs or spring like members 3063 . Further, tab 3062 may be retained in channel 3060 by retention pin 3069 , described above. Tab 3062 may further define a passageway 3062 a therethrough. Passageway 3062 a may include any configuration known in the art. As discussed below, passageway 3062 a may be configured (e.g., may include one more projections) to engage channel 3206 of threaded shaft 3200 for retaining threaded shaft within actuator assembly 3050 .
Sleeve 3076 may include a generally cylindrical member defining a lumen 3078 therethrough. Sleeve 3076 may include any suitable configuration known in the art. In one embodiment, sleeve 3076 may include a generally circular cross-sectional configuration. However, sleeve 3076 may include any suitable cross-sectional configuration. Further, a distal end of sleeve 3076 may include a generally tapered configuration. Lumen 3078 may include a generally circular cross-sectional configuration, and may be configured to receive proximal portion 3052 b therein. Indeed, as alluded to above, lumen 3078 may include a plurality of threads 3077 configured to mate with threads 3074 to retain sleeve 3076 on central portion 3052 . Threads 3077 may extend along any suitable portion of lumen 3078 . In one embodiment, for example, threads may extend an entirety of lumen 3078 . In another embodiment, threads 3077 may extend along only a portion of lumen 3078 .
An overall maximum diameter of sleeve 3076 may be less than a diameter or width of proximal head 3054 . In addition, sleeve 3076 may include a step 3079 that defines an interface between a relatively larger diameter distal portion 3076 b of sleeve 3076 and relatively smaller diameter proximal portion 3076 a of sleeve 3076 . Step 3079 may be disposed at any suitable location along sleeve 3076 . Further, sleeve 3076 may include one or more longitudinal grooves 3080 extending distally from a proximal end thereof. The grooves 3080 may be configured to receive rods 3081 therein, which may be configured to prevent sleeve 3076 from rotating within housing 3090 of actuator 3050 , as described below in greater detail.
A washer 3082 may be configured to be frictionally retained on proximal portion 3076 a , as shown in FIG. 32B . Washer 3082 may include a generally cylindrical structure that defines a lumen 3084 therethrough. In addition, washer 3082 may define a proximal ledge 3085 configured to abut a distal face of proximal head 3054 . Washer 3082 may also include a plurality of external threads 3086 for securing housing 3090 thereon.
Housing 3090 may include a generally cylindrical structure defining a lumen 3092 therethrough. Lumen 3092 may include any suitable configuration known in the art. For example, lumen 3092 may include a generally circular cross-sectional configuration. However, any suitable cross-sectional configuration may used within the principles of the present disclosure. In embodiments where lumen 3092 includes a circular cross-sectional configuration, lumen 3092 may include a generally constant diameter throughout its length or a diameter that varies over the length of lumen 3092 . For example, a proximal portion of lumen 3092 may include a counter bore and therefore may include a larger diameter than a remainder of lumen 3092 . A proximal portion of lumen 3092 may also include screw threads 3093 for threadingly engaging threads 3086 of washer 3082 to retain housing 3090 thereon. Threads 3093 may extend along any suitable portion of lumen 3092 . Walls of lumen 3092 may include one or more grooves 3094 , which may correspond to grooves 3080 and be configured to receive rods 3081 . Rods 3081 , grooves 3904 , and grooves 3080 cooperate to prevent sleeve 3076 from rotating within housing 3090 . Further, housing 3090 may be made of any suitable biocompatible material known in the art, including, for example, PEEK.
Externally, housing 3090 may include any suitable configuration known in the art. In the depicted embodiment, housing 3090 may include a raised proximal portion 3095 . Proximal portion 3095 may include any suitable configuration. In one embodiment, proximal portion 3095 may include a hexagonal configuration (e.g., a hexagonal cross-sectional configuration) for being engaged by an appropriately configured tool. Similarly, proximal portion 3095 may include one or more geometric features 3096 configured to assist with retaining a tool (discussed below) on proximal portion 3095 . The geometric features 3096 may include a plurality of indentations, bumps, recesses, channels, etc. Housing 3090 may further include a raised distal portion 3097 . Raised distal portion 3097 may define a channel 3098 through housing 3090 . Channel 3098 may include any suitable configuration. For example, in one embodiment, channel 3098 may extend in a direction that is substantially perpendicular to a longitudinal axis of lumen 3092 . Channel 3098 may be configured to receive catch 3100 slidably therein. Further, raised distal portion 3097 may include one or more openings 3099 for receiving fasteners 3099 a therein. In embodiments where fasteners 3099 include threaded fasteners such as, e.g., screws, openings 3099 may include corresponding threads.
Catch 3100 may include any suitable configuration, and may be dimensioned and shaped to be received within channel 3098 . Catch 3100 may be made of any suitable material known in the art, including, e.g., PEEK. In one embodiment, catch 3100 may include a substantially rectangular configuration. As shown in FIG. 31C , lateral surfaces 3102 of catch 3100 may be radiused or curved so that an outer profile of catch 3100 may correspond to raised distal portion 3097 when catch 3100 is received within channel 3098 . Further, superior 3104 and/or inferior surfaces of catch 3100 may include one or more openings corresponding to openings 3099 . As shown in FIG. 32C , opening 3104 may include any suitable configuration. For example, opening 3104 may include a substantially elongate configuration, whereby fastener 3099 a may be slidably disposed in opening 3104 . Consequently, catch 3100 may be configured to slide back and forth relative to channel 3098 without becoming disengaged when fasteners 3099 are disposed in openings 3104 . Moreover, catch 3100 may define a passageway 3106 therethrough for receiving flange 3027 (at the proximal end of the inserter fork shown in FIG. 31 ) and/or distal portion 3052 a therethrough. Passageway 3106 may include any suitable configuration known in the art. In one embodiment, a wall of passageway 3106 may define a circumferential channel 3108 (shown in FIG. 32B ) configured to engage flange 3027 . The circumferential channel 3108 may be disposed completely around passageway 3106 or only partially around passageway 3106 .
With reference now to FIGS. 34-44 a method of operating tool 3000 and its various components to implant an exemplary embodiment of spacer 2700 will be described. As shown in FIG. 34 , sleeve 3030 may be advanced distally to squeeze arms 3018 , 3020 towards one another so that projections 3024 may engage features 2706 to secure spacer 2700 to tool 3000 . Sleeve 3030 may be moved distally by rotating knob 3038 relative to elongate structure 3012 . As a result of the coupling via threads 3044 and 3029 , rotating knob 3038 relative to elongate structure 3012 may result in knob 3038 and sleeve 3030 moving longitudinally relative to elongate structure 3012 .
Once the spacer 2700 is secured to tool 3000 , the spacer 2700 may be ready for implantation within a patient. As discussed above, spacer 2700 may be delivered to the interbody disc space within a patient via any suitable procedure known in the art. For example, in one embodiment, the spacer is delivered via an anterior approach. In another embodiment, the spacer may be delivered via a posterior approach. Further, the approach angle may be any suitable angle known in the art. For example, the spacer 2700 may be delivered by tool 3000 inserted via a posterior approach at an angle of 20-40 degrees offset from a center line of a patient.
Once spacer 2700 is secured to the distal end of the inserter fork, a threaded shaft 3200 may be inserted into a proximal end of actuator assembly 3050 and all the way through the distal end of sleeve 3030 into lumen 2705 of proximal portion 2702 and threaded into lumen 2744 of distal component 2740 of spacer 2700 . With reference to FIG. 35 , threaded shaft 3200 may include any suitable configuration. In one embodiment, threaded shaft 3200 may include an elongate member 3202 . Elongate member 3202 may include any suitable configuration. In embodiment, elongate member 3202 may include a generally cylindrical configuration. For example, elongate member 3202 may include a generally circular cross-sectional configuration. Further, elongate member 3202 may be configured to gradually taper toward its distal end. That is, a proximal portion of elongate member 3202 may include a diameter that is relative larger than a distal portion of elongate member 3202 .
In one embodiment, a distal portion, e.g., a distal end, of elongate member 3202 may be configured to engage distal component 2740 of spacer 2700 . For example, a distal portion of elongate member 3202 may include one or more geometric configurations configured to cooperate with geometric configurations disposed within lumen 2744 of distal component 2740 . In embodiments where lumen 2744 may include threads, for example, a distal portion of elongate member 3202 may also include threads 3208 .
A proximal end of elongate member 3202 may include an actuating member 3204 . Actuating member 3204 may include any suitable configuration known in the art. In one embodiment, actuating member 3204 may be removably coupled to a proximal portion of elongate member 3202 . In another embodiment, actuating member 3204 may be integrally formed with elongate member 3202 . Actuating member 3204 may include a knob or a handle in some embodiments. Accordingly, actuating member 3204 may include one or more geometric configurations 3210 to facilitate gripping by an operator. Geometric configurations 3210 may include ridges, channels, protrusions, projections, dents, bumps, recesses, surface texturing, etc. Further, elongate member 3202 may include a channel 3206 . Channel 3206 may be disposed at any suitable position along elongate member 3202 . In one embodiment, channel 3206 may be disposed closer to a proximal end of elongate member 3202 than a distal end. Channel 3206 may be defined by a portion of elongate member 3202 including a relatively smaller diameter than immediately adjacent portions of elongate member 3202 . Channel 3206 may be positioned at a location on elongate member 3202 suitable for being engaged by passageway 3062 a (shown in FIG. 32C ). Further, actuating member 3204 may include one or more markings 3212 (shown in FIG. 38A ) for indicating a degree of expansion of spacer 2700 , as described further below. The markings 3212 may include any suitable markings known in the art and may include numerical values corresponding to a percentage of expansion of spacer 2700 .
Turning now to FIG. 36 , tool 3000 may be secured to spacer 2700 and threaded shaft 3200 may be received within tool 3000 . Tool 3000 may be then inserted into a patient to effect implantation of spacer 2700 within the patient. In some embodiments, however, tool 3000 and spacer 2700 may be already positioned within a patient when threaded shaft 3200 is inserted into tool 3000 and secured to spacer 2700 .
Turning now to FIG. 37 , an expanding hex cap 3700 may be positioned over a proximal end of tool 3000 and actuating member 3204 . In one embodiment, hex cap 3700 may include a generally cylindrical member defining a lumen 3702 therein. Lumen 3702 may extend completely through hex cap 3700 or may be blind, such that hex cap 3700 includes a closed proximal end. A distal end portion 3704 of hex cap 3700 may be configured to be received over and engage proximal portion 3095 . Accordingly, distal end portion 3704 may include a configuration that corresponds to proximal portion 3095 . For example, distal end portion 3704 may be shaped as a hexagonal tool. Further, an inner surface of lumen 3702 in distal portion 3704 may include one or more geometric features 3706 configured to engage geometric features 3096 on proximal portion 3095 . In one embodiment, geometric features 3706 may include a plurality of bumps while geometric features 3096 may include a plurality of recesses, or vice versa. In addition, as depicted in FIG. 37 , distal end portion 3704 may include a diameter relatively larger than a proximal portion 3708 of hex cap 3700
Further, a proximal portion 3708 of hex cap 3700 may include a plurality of windows or openings 3710 disposed radially thereabout. The openings 3710 may include any suitable configuration known in the art and may facilitate visualizing the markings 3212 disposed on actuating member 3204 . Proximal portion 3708 may include any suitable number of openings desired.
In operation, and while spacer 2700 is appropriately positioned (e.g., by moving hex cap 3700 in the direction of arrow 3712 ) within a patient, hex cap 3700 may be positioned over a proximal end of tool 3000 so that distal end portion 3704 may engage proximal portion 3095 of actuator assembly and actuating member 3204 may be visible to an operator through openings 3710 . Next, the operator may rotate hex cap 3700 to expand spacer 2700 until the desired amount of expansion if achieved. Rotating hex cap 3700 causes proximal portion 3095 (and, consequently, housing 3090 ) to be rotated via its engagement with distal end portion 3704 . As a result of the various components and their connections of actuator assembly 3050 described above, when housing 3090 is rotating, sleeve 3076 is also rotated because it is fixed relative to housing 3090 via rods 3081 . Consequently, sleeve 3076 and housing 3090 are translated longitudinally relative to central portion 3052 . Further, because a proximal end flange 3027 is secured to housing 3090 via catch 3100 , the entire inserter fork also translates longitudinally relative to central portion 3052 when hex cap 3700 is rotated. And, since threaded shaft 3200 is secured to central portion 3052 via catch 3206 and tab 3062 , the distal threads 3208 threaded into distal component of spacer 2700 may move relative to proximal portion 2702 of spacer 2700 as the inserter fork is moved when hex cap 3700 is rotated. Such relative movement between the distal end of the inserter fork and the threaded shaft 3200 causes proximal portion 2702 to move towards distal component 2740 , thereby effecting expansion of spacer 2700 as the various components of spacer are rotated from the positions depicted in FIG. 27B to the positions depicted in FIG. 27A or any suitable, desired intermediate position. As alluded to above, a degree of travel of, e.g., housing 3090 relative to actuating member 3054 may correspond to a degree of expansion of spacer 2700 . Accordingly, actuating member 3054 may include a plurality of markings to assist an operator in determining a degree of expansion of spacer 2700 .
After desired expansion of spacer 2700 is achieved and spacer 2700 is appropriated positioned within the patient, hex cap 3700 may be removed. Subsequently, tab 3062 may be actuated (e.g., depressed) so that it may temporarily be disengaged from channel 3206 and threaded shaft 3200 may be also removed from tool 3000 . In the meantime, position retaining features 2721 and 2727 may interfere with one another to frictionally retain an expanded configuration of spacer 2700 . Subsequently, a locking instrument 3900 may be inserted into lumen 3058 and advanced through tool 3000 until it engages within locking feature 2760 .
Locking instrument 3900 (see FIG. 39 ) may include a generally elongate member 3902 having a distal portion 3904 including one or more geometric configurations 3906 configured to engage with geometric configurations 2762 a in such a manner that when locking instrument 3900 is rotated, locking feature 2760 will be rotated. As its proximal end, locking instrument may include a suitable actuating member, such as, e.g., a handle or knob 3908 . Handle or knob 3908 may be secured to elongate member 3902 by any suitable means known in the art. In one embodiment, handle or knob 3908 may be removably coupled to elongate member 3902 . In other embodiments, handle or knob 3908 may be integrally formed with elongate member 3902 . In some embodiments, locking instrument 3900 may be a torque limiting tool. That is, locking instrument 3900 may be configured to prevent application of torque above a predetermined limit. For example, once a predetermined limit of applied torque is exceeded, handle or knob 3908 may rotate freely relative to elongate member 3902 . Handle or knob 3908 may include any suitable configuration known in the art to facilitate gripping and operation by a user. In one embodiment, handle or knob 3908 may include one or more geometric features 3909 (e.g., detents, recesses, protrusions, etc.) configured to allow manipulation by a user.
In operation, distal portion 3904 may be inserted into lumen 2762 so as to engage geometric configurations 2762 a , as shown in FIG. 40 . Next, handle or knob 3908 may be rotated to advance locking feature 2760 into space 2708 to prevent links 2710 from returning to their collapsed position, thereby locking spacer 2700 in the expanded configuration.
Next, locking instrument 3900 may be removed from tool 3000 and a funnel tube 4100 (see FIG. 41 ) having a funnel 4200 removably coupled thereto may be inserted into tool 3000 via lumen 3058 . Funnel tube 4100 may include any suitable configuration known in the art. In one embodiment, funnel tube 4100 may include an elongate member 4102 defining a lumen 4104 therethrough. Elongate member 4102 may include any suitable configuration. For example, elongate member 4102 may include a generally circular cross-sectional configuration. In some embodiments, however, other cross-sectional configurations, such as, e.g., rectangular, may be used. Similarly, lumen 4104 may include a substantially circular cross-sectional configuration, but any suitable configuration may be employed within the principles of the present disclosure. Elongate member 4102 may have a length sufficient to extend from outside a proximalmost end of tool 3000 to beyond a distal end of locking feature 2760 , so as to deliver material into a center of spacer 2700 when it is in the expanded configuration, as discussed below in greater detail.
A proximal end portion 4106 of elongate member 4102 may be configured to be removably secured within lumen 3058 . More particularly, proximal end portion 4106 may include threads 4108 configured to engage threads 3064 in proximal head 3054 so as to retain funnel tube 4100 therein. Funnel tube 4100 may further include a knob 4110 disposed proximally of threads 4108 . In some embodiments, knob 4110 may include a diameter that is relatively larger than a diameter of a remainder of funnel tube 4100 . In addition, knob 4110 may define a lumen (not shown) therethrough. In some embodiments, the lumen of knob 4110 may include a diameter that is relatively larger than a diameter of the lumen 4104 through a remainder of funnel tube 4100 . Knob 4110 may also include a plurality of geometric configurations 4112 located on an external surface thereof. The geometric configurations 4112 may include any suitable configuration known in the art. In one embodiment, the geometric configurations may include a plurality of raised ridges, bumps, notches, recesses, detents, etc.
Funnel 4200 may be any suitable funnel known in the art. For example, funnel 4200 may include a conical portion 4202 having a tapering cavity therein. The conical portion 4202 may be secured to or integrally formed with a neck portion 4204 having a lumen defined therethrough. The lumen in neck portion 4204 may be in communication with conical portion 4202 . Neck portion 4204 may be removably secured to proximal end portion 4106 by any suitable means known in the art. In one example, neck portion 4204 may include threads configured to matingly engage corresponding threads 4113 (shown in FIG. 43 ) disposed on proximal end portion 4106 . In one embodiment, a portion of proximal end portion may be received within neck portion 4204 . In another embodiment, a portion of neck portion 4204 may be received within proximal end portion 4106 .
In use, funnel tube 4100 may be advanced into lumen 3058 and secured therein by engaging threads 4108 with threads 3064 , such that a distal opening of lumen 4104 is disposed through locking feature 2760 within spacer 2700 , as shown in FIG. 42 . Next, the space within spacer 2700 may be filled with morcellated bone (e.g., autograft) or any other suitable material into the center of spacer 2700 when it is in the expanded position. Subsequently, funnel 4200 may be decoupled from funnel tube 4100 by, e.g., unscrewing it. Next, a bone funnel pusher 4300 may be inserted through funnel tube 4100 to push or advance any morcellated bone graft or other material remaining in funnel tube 4100 out of funnel tube 4100 and into a center of spacer 2700 .
As shown in FIG. 43 , bone funnel pusher 4300 may include a generally elongate member 4302 having a proximal end 4304 and a distal end 4306 . Pusher 4300 may include any suitable configuration known in the art. Elongate member 4302 may include any suitable configuration known in the art. For example, elongate member 4302 may include a generally circular cross-sectional configuration. However, elongate member 4302 may include any suitable configuration known in the art. In one embodiment, pusher 4300 may be sized to be advanced through tool 3000 to spacer 2700 . At its proximal end 4304 , pusher 4300 may include a handle 4305 . Handle 4305 may include any suitable configuration. For example, handle 4305 may include a generally tubular structure. Handle 4305 may include a diameter that is relatively larger than a diameter of elongate member 4302 . At its distal end 4306 , elongate member may include a pushing member 4307 . Pushing member 4307 may include any suitable configuration. For example, pushing member 4307 may be substantially tubular. In one embodiment, pushing member 4307 may include a diameter that is relatively larger than a diameter of elongate member 4302 , but relatively smaller than a diameter of handle 4305 .
In use, the bone funnel pusher 4300 may be used to fill spacer 2700 with, e.g., finely milled autogenous bone graft material to tightly pack spacer 2700 . Once the graft material is tightly packed within spacer 2700 , the inserter knob 3038 may be rotated to withdraw sleeve 3030 to disengage the inserter fork from spacer 2700 . Prior to final disengagement, however, a user may choose to verify a final positioning of the spacer 2700 via radiographic visualization, such as, e.g., fluoroscopy, X-ray, or any other suitable imaging technique, as shown in FIG. 44 .
If necessary, the spacer 2700 may be removed or otherwise manipulated by first inserting a removal tool (not shown) through a distal end of lumen 2744 in distal component 2740 . The removal tool may engage locking feature 2760 and advance it completely back into cylindrical portion 2703 of proximal portion 2702 , thereby removing the impediment to links 2710 and 2712 returning to their collapsed position. Next, projections 3024 of arms 3018 , 3020 may engage features 2706 as described above. Threaded shaft 3200 may then be inserted through tool 3000 to engage threads 3208 within distal component 2740 . Subsequently, hex cap 3700 may be provided over a proximal end of tool 3000 for rotation so as to collapse 2700 for removal from within the patient.
As described above, the devices, tools, and methods described herein may be used to provide an interbody spacer for positioning between adjacent vertebral bodies. Prior to performing the above-described steps, those of ordinary skill in the art will understand that a patient's native intervertebral disc may be first removed via a conventional discectomy, for example. Alternatively, scrapers may be used for disc distractions and to loosen the disc space without damaging vertebral endplates. In one embodiment, an operator may begin distraction with a relatively small scraper and proceed with increasingly larger scrapers. Next, the disc space may be prepared for receiving, for example, spacer 2700 as known in the art. Subsequently, measurements may be made of a height and width of the interbody disc space to ensure a spacer of correct dimensions is selected for implantation. The measurements may be made by any suitable means known in the art. For example, a user may conduct one or more adjustable footprint trials. In particular, one or more trials may be inserted into the prepared disc space in a collapsed configuration and expanded. The trial may be observed under suitable imaging means, such as, e.g., fluoroscopy, to identify appropriate sizing suitable for the prepared disc space.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations can be made thereto by those skilled in the art without departing from the scope of the invention as set forth in the claims. | Embodiments of the present disclosure relate to devices and methods for treating one or more damaged, diseased, or traumatized portions of the spine, including intervertebral discs, to reduce or eliminate associated back pain. In one or more embodiments, the present disclosure relates to an expandable interbody spacer. The expandable interbody spacer may comprise a first jointed arm comprising a plurality of links pivotally coupled end to end. The expandable interbody spacer further may comprise a second jointed arm comprising a plurality of links pivotally coupled end to end. The first jointed arm and the second jointed arm may be interconnected at a proximal end of the expandable interbody spacer. The first jointed arm and the second jointed arm may be interconnected at a distal end of the expandable interbody spacer. | 0 |
BACKGROUND OF THE INVENTION
Pulmonary embolism is the commonest preventable cause of death in hospitalized patients. Early detection of its most common precursor, venous thrombosis of the lower extremities, would permit prompt anticoagulant therapy and reduce the frequency of embolism. However, the potential for successful treatment of established pulmonary embolism is limited by the short time between onset of symptoms and death in the majority of patients who die of massive pulmonary embolism. Secondly, most patients with massive pulmonary embolism do not have preceding clinical signs of minor venous thromboembolism, even though postmortem examination shows that most of them do have associated leg vein thrombosis. Unfortunately, clinial diagnosis of venous thrombosis and phlebographic technique are neither specific nor reliable during acute phase of thrombophlebitis. There is an urgent need for a simple, rapid and reliable means of detecting venous thrombosis. A number of techniques for screening large numbers of high-risk patients are being evaluated at present. The most promising appears to be radioiodinated fibrinogen labeled with 125 I. Because of low energy gamma photon and long physical half life, the use of 125 I-fibrinogen is limited to surface monitoring technique. It is not a scintillation imaging agent. Other limitations include high percentage of false positive results due to its inability to distinguish between superficial and deep vein thrombi, and its sensitivity to fibrin in hematoma and inflammatory exudate. Autologous human fibrinogen labeled with 131 I has been advocated recently as a thrombi scanning agent.
Another important group of plasma protein which may have significant clinical applications in Nuclear Medicine is immunoglobulins or antibodies. The immunoglobulins are protein molecules that carry antibody activity against specific antigens. With the possible exception of natural antibody, antibodies arise in response to foreign substances such as microorganisms, toxin or other foreign matter introduced into the body. The immunoglobulins comprise a heterogeneous group of proteins, chiefly gamma or beta globulins, which account for approximately 20% of the total plasma proteins. The presence of malignant tumors can also cause the production of antibodies within the host in response to the insult. Thus, radiolabeled autologous immunoglobulin isolated from patient's own serum which contains the specific antibody offers the best and specific means of detecting infectious foci or tumors. Early detection of these leisons is extremely important in reducing the high morbidity and mortality rate. The use of 131 I-labeled antigen or antibody for tumor imaging in man have been reported in the literature.
Various methods of labeling plasma proteins with 125 I or 131 I have been published in recent years. The most commonly used chemical method is radio-iodination of the protein in the presence of chloramine-T or iodine monochloride. The labeling yield, however, is low and varies from 50-70%. In order to be clinically useful, the desired radiolabeled protein must undergo a long and tedious separation and purification process. The radionuclide 131 I has other disadvantages. Among these are: emission of high energy beta and gamma photons which is not compatible with existing commercial display means; a long physical half life of 8 days; excessive irradiation to the patients; and finally, the dosage of any 131 I-labeled compounds must be given in very minute microcurie(uCi) quantity.
Compounds labeled with 99m Tc which eliminate most of the undesirable properties of the radioiodinated radiopharmaceuticals have been found extremely useful in biological studies and medical diagnosis. The radionuclide, 99m Tc-technetium, has many advantages. It is a pure gamma emitter with a relative short half life of 6 hours. The gamma photon of 140 KeV energy is compatible with existing conventional scintillation imaging equipments. 99m Tc-labeled radiopharmaceuticals can be safely administered to the patients with a much larger dose than radioiodinated compounds but produces a minimal amount of radiation health hazard. Human proteins such as serum albumin labeled with 99m Tc has been used clinically in placenta localization, cardiac scan and cisternography. More recently, there is increasing scientific and medical interest in 99m Tc-labeled human fibrinogen and antibody for the localization and detection of thrombi, infectious foci and tumors. Unfortunately, a more wide spread use of these radioactive tracer materials has been restricted because; (1) a simple and reliable chemical method of labeling protein with 99m Tc at physiological condition which preserves the physiobiological properties of the protein has not been developed; (2) current .sup. 99m Tc-labeling technology using acid reduction of the radionuclide in the presence of a reducing agent causes complete denaturation of the proteins; (3) the labeling yield is low with many radioactive impurities as well as free or unbound 99m Tc: (4) the possibility of hepatitis transmission and antigenic reactions.
Recent literature mention labeling serum albumin with 99m Tc by a chemical process in the presence of a reducing agent such as stannous chloride (SnCl 2 .2H 2 O) or stannous tartrate (see U.S. Pat. No. 3,725,295 to Eckelman et al and U.S. Pat. No. 4,042,676 to Molenski et al), but the results have never been very satisfactory. According to the labeling methodology, 99m Tc(+7) in the stable form of sodium pertechnetate(Na 99m TcO 4 ) is first reduced to a chemically active +4 or +5 valence state with a reducing agent in 0.5-1 N HCl at a pH of less than 2. A diluted solution of the albumin is added to the reduced 99m Tc/SnCl 2 acidic mixture with subsequent binding of the radionuclide to the protein ligand. The final mixture is than readjusted to pH 6-7 with a suitable buffer. The labeling mechanism is not known. Since the optimal condition of preserving the physiobiological properties of the protein is at a very narrow pH range of 7-7.4, proteins labeled by the above described chemical method is completely denatured.
The enzymes streptokinase and urokinase which are proteins, have been labeled with 99m Tc using similar technique. (see U.S. Pat. No. 3,812,245 to Dugan and Dugan, MA, Kozzar, JJ, et al, J. Nucl. Med. 14 233, 1973) The labeling yields of these proteins are extremely low. Purification of these radioactive proteins requires a tedious process of removing large amount of free or unbound 99m Tc, insoluble tin particles in the form of 99m Tc-stannous hydroxide( 99m Tc-Sn(OH) 4 ), and other protein degradation products. (see Duffy MJ and Duffy GJ, J. Nucl. Med. 18: 483, 1977 and Person, BRR and Kempe, V. J. Nucl. Med. 16: 474, 1975) 99m Tc-streptokinase and 99m Tc-urokinase have claimed to be effective in localizing preformed clots of the deep veins. However, they are ineffective in documenting early stage of acute thrombophlebitis. Both enzymes are antigenic in man.
An alternate approach for labeling proteins by chemical means has been patented in 1978 but has never been reported in any scientific scientific literature (see U.S. Pat. No. 4,057,617 to Abramovici et al). According to this invention, the proteins antibody and fibrinogen are labeled with 99m Tc at pH 11.6. A careful analysis of the labeling methodology reveals many flaws. Stannous chloride dissolved in dilute hydrochloric acid(HCl) or acetic acid is known to be a powerful reducing agent for the reduction of 99m TcO 4 - . Increasing the pH from 2 to 11.6 will not cause further reduction of 99m Tc. On the contrary, during the process of pH adjustment, insoluble radioactive collodial particles, stannous hydroxide, will form when alkali such as 0.1 N NaOH is added to a solution containing SnCl 2 and reduced 99m Tc. The problems encountered by labeling proteins at alkaline pH condition is similar to the acidic chemical method, namely; protein denaturation, formation of insoluble stannous particles, protein degradation byproduct, free or unbound 99m Tc and low yield.
Significant protein denaturation occurs with earlier electrolytic method of labeling serum albumin and fibrinogen with 99m Tc using zirconium electrodes in acid medium (see U.S. Pat. No. 3,784,453 to Dworkin et al; Benjamin, PP, Int. J. Appl. Rad. Isotopes 20: 187, 1969; Dworkin, HJ and Gutkowski, RF, J. Nucl. Med. 12: 562, 1971 and Wong, DW and Mishkin, F, J. Nucl. Med. 16: 347, 1975). The labeling methodology requires the addition of the protein to be labeled to an acidic medium (pH 1.8) during electrolysis which leads to subsequent decomposition of the labeled product. Recently, an improved electrolytic method of labeling plasma proteins has been developed (see Wong, DW, J. Labeled Comp. Radiopharmaceuticals 14: 603, 1978 and Wong, DW and Huang, TT, Int. J. Appl. Rad. Isotopes 28:719, 1977). These proteins are labeled at physiological conditions, thus avoiding harsh treatment of the protein molecules and preserving the physiobiological properties. The labeling mechanism is not well understood. The tagging of 99m Tc to pure protein appears to involve a chemically active 99m Tc-(Zr)citrate complex species with high protein binding capacity. The latter is formed following initial reduction of 99m TcO 4 - by Zr ++ ions as a result of electrolysis and by the addition of trisodium citrate/NaOH buffer during pH adjustment. In the presence of a pure protein, such as fibrinogen or immunoglobulin, 99m Tc quickly binds to the protein ligand. Whether the entire complex binds to the protein ligand or acts only as a transferring agent for reduced 99m Tc for the final labeling has not been determined. Further investigation of the improved electrolytic technique indicates that similar complex species can be prepared by chemical means with stannous chloride or stannous tartrate under similar conditions. The resultant 99m Tc-(Sn)citrate complex species is effective in tagging plasma proteins with superior labeling efficiency and reproducibility. The labeling mechanism of the chemical method has not been determined. It is assumed that protein binding involves the reaction of the 99m Tc-(Sn)-citrate complex species with the protein ligand similar to the 99m Tc-(Zr)-citrate reaction (see Wong, DW, Mishkin, F and Lee, T, Int. J. Appl. Rad. Isotopes 29: 251, 1978).
SUMMARY OF THE INVENTION
Human plasma proteins are labeled with 99m Tc-pertechnetate by a novel chemical process at physiologic pH 7.4. Autologous human fibrinogen and immune gamma globulin extracted by glycine precipitation and the salting-in action of rivanol respectively have been tagged by the same technique with similar high yields. The labeling methodology requires the initial reduction of 99m Tc-pertechnetate in normal saline by stannous chloride in 0.05 N HCl solution. Following pH adjustment to 7.4 with a solution of trisodium citrate and NaOH, a stable 99m Tc-(Sn)citrate complex species with high protein binding capacity is formed. In the presence of pure protein, the radionuclide 99m Tc quickly binds to the protein ligand at ambient temperature. Greater than 95% of the initial radioactivity is found to be associated with the labeled protein; 3-4% unbound 99m Tc(Sn) complex and less than 1% free or unbound 99m TcO 4 - as assessed by paper radiochromatography and instant thin layer radiochromatography. Since these proteins are labeled at optimal physiological condition, the problems of protein denaturation normally associated with earlier labeling technology have been significantly reduced. In vitro experimental data indicate no significant loss of physiobiological properties. The entire labeling process which requires less than 1 hour of time produces a sterile pyrogen-free solution of 99m Tc labeled tracer material ready for patient administration. No further purification of the final labeled product is necessary. This novel labeling technique will provide a simple mean of tagging autologous fibrinogen or antibodies with 99m Tc for scintillation imaging which may allow visualization of thrombi, infectious lesions or tumors by scanning techniques.
DETAILED DESCRIPTION OF THE INVENTION
The labeling methodology in the present invention requires (1) initial reduction of 99m Tc-pertechnetate to a chemically active +4 or +5 valence state by a reducing agent such as stannous chloride; (2) the formation of a stable chemically active 99m Tc-(Sn)citrate complex species and (3) the covalent binding of radionuclide to the protein ligand. Chemical reduction of 99m Tc-pertechnetate can be effectively carried out with any suitable reducing agents such as SnCl 2 , SnF or stannous tartrate. However, stannous chloride (SnCl 2 .2H 2 O) is preferred in the present embodiment. The stannous chloride reagent is freshly prepared by dissolving the desired amount of SnCl 2 .2H 2 O powder or crystals in 6 N HCl and diluted with distilled water to a final concentration of 0.2 mg SnCl 2 /ml 0.05 N Hcl slution. After dissolving, the stannous chloride solution is sterilized by passage through a 0.22 nm biological filter and injected into individual sterile and non-pyrogenic serum vials. Each vial contains 0.5 ml of the sterilized reducing agent which can be stored under refrigeration at 2°-8° C. until needed. These vials are preferably lyophilized by conventional freeze-drying techniques to remove water. This provides a solid mixture of stannous chloride and 0.05 N HCl which aids in shipping and storage and is more stable than in liquid reagent form. The lyophilized reducing agent can be reconstituted by the addition of 2-3 ml 99m Tc-pertechnetate in normal saline without losing its reducing activity. The concentration of the reducing agent can be varied from 0.2-5 mg/ml depending upon the amount of 99m Tc radioactivity used in the labeling process. The concentration of 0.1 mg SnCl 2 in 0.5 ml 0.05 N HCl is sufficient to reduce 60-100 mCi of 99m TcO 4 - .
In the preferred embodiment, 2-3 ml of 99m Tc-pertechnetate in normal saline which provides 60-100 mCi of 99m Tc radioactivity is aseptically injected into the reaction vial containing the stannous chloride reducing agent in either liquid or lyophilized form. The radioactive content of the reaction vial is then shaken for 1-10 minutes to allow complete reduction of 99m Tc-pertechnetate. The source of 99m Tc-technetium is preferably obtained in the form of fresh sodium pertechnetate in normal saline eluted from a 99m Tc generator.
In accordance with the principles of this invention, a sufficient amount of 2% trisodium citrate solution previously adjusted to pH 12.4-12.6 with 1 N NaOH is used to react with the reduced 99m Tc ions. The addition of this reagent not only cause the formation of the radioactive complex species but also raise the acidic 99m Tc-SnCl 2 -HCl mixture from pH 1.8 to 7.4. Experimental data indicate that the reduced 99m Tc ion in the form of 99m Tc-(Sn)citrate complex is stable and chemically active at a pH range of 5-9 indefinitely in the absence of air or any oxidizing agents. However, to preserve the physiobiological properties of the protein and to obtain high labeling yield, a pH 7.4 condition is preferred. Any of the commonly used alkaline buffer systems with a pH of greater than 7 can be utilized to form the radioactive complex species with 99m Tc. Among these are sodium acetate, sodim bicarbonate or sodium phosphate. Sodium citrate is preferred in the present formulation because it is physiobiochemically compatible with many biological preparations and because sodium citrate is an excellent biological preservative.
While it is preferred that a solution of trisodium citrate/NaOH with a pH of 12.4 is used to produce the radioactive complex species and to raise the pH to 7.4 condition as an one-step process, this chemical reaction can be separated into two successive steps. The radioactive 99m Tc-(Sn)citrate complex species can be formed by the addition of 1 ml of a 2% solution of trisodium citrate(pH 8.5) to the reduced 99m Tc-SnCl 2 -HCL mixture prior to pH adjustment. After thorough mixing, the pH of the admixture is then raised to 7.4 with 0.1-1 N NaOH solution. The amount of NaOH solution needed can be determined by routine experimentation to those skilled in the art.
Following pH adjustment and the formation of the radioactive complex, a diluted solution of the protein to be labeled is added to the mixture. The radionuclide is quickly bound to the protein ligand and is stablized at 37° C. or at room temperature for 30 minutes. The amount of protein that can be labeled varies from 0.1-100 mg. In the present invention, a concentration of 3-4 mg of protein in 1 ml diluent is adequate to bind up to 100 mCi of 99m Tc. Diluents such as distilled water, normal saline or any pharmacologically acceptable buffer systems such as Sorenson's phosphate buffer or Veronal buffer can be used to reconstitute or to dilute the protein to the desired concentration.
Exogenous protein preparations are commercially available in sterile apyrogenic solutions or in lyophilized forms. In order to demonstrate the efficacy of the present labeling technique for tagging plasma proteins, the following representative agents are used;
(A) Plasma proteins:
Human fibrinogen, 20 mg/ml
Human serum albumin, salt poor, 25%
Human immune gamma globulin, 16%
(B) Enzyme:
Thrombin, bovine, 1000 units/ml normal saline
(C) Hormone:
Thyrotropin, bovine, 10-50 units/ml normal saline
(D) Autologous plasma proteins:
Human fibrinogen
Canine fibrinogen
Human immune gamma globulin
All exogenous protein preparations are prepared according to manufacturer's direction. The amount of protein to be labeled is limited to 1-20 mg in less than 1 ml diluent.
Autologous human or canine fibrinogen and human immune γ-globulin are obtained from plasma or serum by the modified methods of Kazai (Kazai LA, Amesl S, Miller OP et al, Proc Soc. Exptl. Biol. Med. 113: 989, 1963) and Horejsi and Smetana (Horejsi, J and Smetana, R, Acta Medica Scand. 155: 65, 1956) respectively. Qualitative analysis of the extracted proteins using protein electrophoresis demonstrate absence of any contaminants. The extracted autologous proteins are dissolved in Sorenson phosphate pH 7.4 buffer to a final concentration of 3-4 mg/ml. No significant loss of biological property occurs following extraction procedure as indicated by biochemical determinations.
The binding efficiency of the labeled proteins is assessed by ascending paper and instant thin layer radiochromatography with silica gel plates in 85% methanol. The actual amount of labeled protein content is determined by trichloroacetic acid(TCAA) protein precipitation method. In case of 99m Tc-labeled fibrinogen, topical thrombin solution is added prior to TCAA protein precipitation in order to determine the actual amount of clottable protein present after labeling. Qualitative radiolabeled protein identification is determined by protein electrophoresis using cellulose polyacetate support medium.
Results from analysis of a series of at least 12 trials for each labeled protein indicate that an average binding efficiency of greater than 95% (range 95-99%) is achieved as assessed by radiochromatography with less than 1% free or unbound 99m TcO 4 - . TCAA protein precipitation determinations demonstrate the existance of a reduced unbound species, presumably, 99m Tc(Sn) complex which accounts for 3-4% of the radioactivity. Electrophoris protein profiles are identical for both labeled or unlabeled protein fractions. Greater than 95% of the radioactivity is firmly bound to the protein. Thrombin clottability assays indicate that 99m Tc-fibrinogen retains most of its biological activity after labeling. The final labeled fibrinogen contains greater than 85% clottable protein with an average clottability of 95%. Similary, the labeling process does not affect the enzymatic property of 99m Tc-thrombin. All 99m Tc-labeled proteins are stable at room temperature up to 6 hours after tagging process as determined by radiochromatography and protein electrophoresis. The final labeled product is sterile, apygrogenic up to seven days without any evidence of microorganism contamination.
Since proteins are essential constituents in animal and plant, a physiological chemical method of labeling these substances with a radioactive tracer offers unlimited potential in biological investigations and medical uses. 99m Tc-labeled autologous human fibrinogen, for example, is extremely useful for the localization and detection of thrombi or emboli in man by scintillation imaging techniques. Similarly, infectious foci or tumors can be specifically detected using 99m Tc-labeled autologous immunoglobulins. A dose of 3-20 mCi in 1-3 ml volume of the radiolabeled autologous proteins administered intravenously to patients is sufficient to detect these lesions. Whole body scans are then taken at various time intervals, e.g. 0.5-24 hrs post administration of the dose using a rectilinear scanner or Anger scintillation camera. Increased radioactivity at the site of the lesions indicates the presence of thrombi, emboli, infectious foci or tumors.
The present invention is far superior to earlier reported labeling techniques. All components used in the composition are prepared in bulk quantity and sterilized by passage through a 0.22 nm biological filter into sterile, apyrogenic serum vials. An instant "cold" labeling kit comprising a stannous reducing agent and an alkaline trisodium citrate/NaOH reagent can be prepared in advance prior to labeling of the protein with 99m Tc-pertechnetate. The following examples illustrate the simiplicity and usefulness of the present invention for labeling different types of plasma proteins.
EXAMPLE 1
Labeling procedure for 99m Tc-exogenous or autologous fibrinogen
1. Inject up to 2 ml (60-100 mCi) 99m Tc-pertechnetate in normal saline into a sterile evacuated serum vial containing 0.5 ml of a solution of 0.1 mg SnCl 2 in 0.05 N HCl solution. Mix the content of the vial vigorously for one minute and allow to stand at room temperature for a total of 10 min. for the complete reduction of 99m TcO 4 - .
2. Raise the pH of the mixture to 7.4 by adding 0.5-0.75 ml 2% (0.068 M) trisodium citrate solution previously adjusted to pH 12.4-12.6 with 1 N NaOH.
3. Immediately, inject 0.2 ml (4 mg) reconstituted exogenous fibrinogen solution or 1 ml (3-4 mg) of autologous human fibrinogen dissolved in pH 7.4 (0.007 M) Sorenson's phosphate buffer into the vial slowly with gentle swirling to avoid foaming.
4. Incubate the content of the vial at room temperature for 30 min. The final labeled product is clear, sterile and ready for use. Additional purification process of the labeled protein is unnecessary.
5. Perform complete qualitative and quantitative radioactive assays. The final concentration should be in the range of 15-25 mCi labeled protein per ml.
6. For scintillation imaging, a dose of 3-15 mCi 99m Tc-autologous fibrinogen is sufficient to detect presence of blood clots in pulmonary embolism or thrombophlebitis.
EXAMPLE 2
Procedure for labeling 99m Tc-Human serum albumin
1. Following labeling procedure steps 1 & 2 of example 1, inject 0.1 ml (25 mg) normal serum albumin (25%, salt poor) into the vial slowly with gentle swirling to avoid foaming.
2. Complete steps 4 & 5 of example 1. A dose of 3-15 mCi is sufficient for placenta localization, cardiac scan or cisternography.
EXAMPLE 3
99m Tc-Exogenous or autologous human immune gamma globulin(Antibody)
1. Following steps 1 & 2 of example 1, inject 0.1 ml(16.5mg) of exogenous human immune gamma globulin or 1 ml(1-20 mg) of autologous human gamma globulin(antibody) dissolved in pH 7.4 phosphate buffer into the vial slowly with gentle swirling. Complete steps 4 & 5 of example 1.
2. A dose of 3-15 mCi of the immunoglobulin is sufficient for the localization and detection of tumors or infectious foci.
EXAMPLE 4
Procedure for labeling enzyme with 99m Tc-pertechnetate
1. Dissolve lyophilized thrombin(bovine) in 5 ml normal saline or pH 7.4 phosphate buffer to a final concentration of 1000 units/ml.
2. Label 10-1000 units of the enzyme with 60-100 mCi 99m Tc-pertechnetate according to the labeling procedure described in example 1.
EXAMPLE 5
Procedure for labeling hormone with 99m Tc-pertechnetate
1. Dissolve 10 or more units of the hormone thyrotropin in 1 ml normal saline or pH 7.4 phosphate buffer.
2. Labeled the desired amount of the hormone according to example 1.
The above examples and detailed described procedures are for illustration purposes only and are not intended to be limiting of the scope of the invention. It will be apparent to those skilled in the art that both may be modified within the scope of the invention defined in the following claims: | A novel rapid chemical method of labeling exogenous and autologous plasma proteins, other compound and/or substance containing proteins with 99m Tc-Technetium at physiologic pH 7.4 condition, producing a sterile apyrogenic radioactive tracer material which is suitable for biological and medical uses. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 722,291 filed on Jun. 27, 1991, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a surface coating member and, more in particular, it relates to a surface coating member prepared by applying a lubricating coating to tile surface of a rubber or plastic member such as wiper blade, seal packing, O-ring, weather strip, glass run, timing belt, rubber bellows, gear and door catcher. More in particular, the present invention relates to a surface coating member suitable as a surface-coated sliding member such as a wiper blade, glass run, weather strip and O-ring whose surface is in sliding contact with other members.
2. Description of the Prior Art
For a wiper blade rubber, a molding product of natural rubber or synthetic rubber has been employed so far. However, the wiper rubber of this kind has the following drawbacks and hence is not always satisfactory.
That is, since an adhering phenomenon occurs between the wiper blade rubber and a glass surface in the damp-drying state or under cold climate condition, to bring about a so-called "locking phenomenon" in which the wiper operation is blocked, or a so-called "trembling phenomenon", that is, self-exciting vibration due to the negative characteristics of the velocity dependency of tile frictional coefficient. This leads to problems such as (1) unsatisfactory wiping, (2) abnormal abrasion at the surface of the blade rubber, (3) shortening for the life in each of connection portions of the wiper system, (4) increase of power consumption for the operation motor and (5) eyesore and grating due to the trembling phenomenon.
For overcoming such problems, Japanese Patent Laid-Open Sho 55-15873 proposes to coat on the rubber surface of a wiper blade with a silicone composition containing molybdenum disulfide.
However, in the wiper blade rubber having such a coating as described in the above-mentioned patent publication, it has been found that the durability of the coating layer becomes poor. The problem also occurs in the weather strip or the glass run.
Further, the following drawbacks are also caused between the metal surface and the rubber material and the coating material not always has a satisfactory property.
That is, in an oil seal or gasoline cap seal, sticking occurs between the rubber and the metal surface to increase torque upon opening and closure. In an O-ring, packing or timing belt, there happens abnormal abrasion, stick slip or generation of ringing owing to high sliding resistance between the rubber and the metal surface. Also in rubber bellows, puncture occurs due to the abnormal abrasion. Further, in a gear or door catcher made of polyacetal, nylon resin, etc. abnormal abrasion, ringing or creaking occurs.
For overcoming the foregoing problems, although a countermeasure such as coating of grease has been applied, this lacks in durability.
OBJECT AND SUMMARY OF THE INVENTION
The object of the present invention is to overcome the foregoing problems and provide a surface coating member having excellent sliding property and also high durability of the coating layer.
The surface coating member according to the present invention comprises a surface coating member in which a coating layer containing a solid lubricant and a resin matrix is formed at the surface, in which the resin matrix comprises a fluoro-olefin vinyl ether polymer resin and/or a fluoro-olefln vinyl ether vinyl ester copolymer resin.
There is no particular restriction to rubber or plastic constituting the main body portion of the coating member according to the present invention but various kinds of rubber and plastic can be employed. The rubber may be either of natural or synthetic rubber. As an example of the synthetic rubber, there can be mentioned, for instance, styrene butadiene rubber, butaxdiene rubber, isoprene rubber, ethylene propylene rubber (EPM, EPDM), acrylonitrile butadiene rubber, chloroprene rubber, isobutylene isoprene rubber, alfin rubber, polyether rubber, polysulfide rubber, silicone rubber, acrylic rubber, fluoro rubber, halogenated polyethylene rubber, urethane rubber, ethylene vinyl acetate rubber, high styrene rubber and acrylonitrile isoprene rubber. Among them, IEPDM is particularly, preferred.
As the plastic material, either of a thermosetting resin or a thermoplastic resin may be used.
As an example of the plastic, there can be mentioned, for instance, ABS resin, ABS blend, acetal resin (homopolymer), acryl resin, ACS resin, alkyd resin, amino resin, ASA resin, cellulose type resin, chlorinated polyether, diallyl phthalate resin, epoxy resin, ethylene - vinyl acetate copolymer, fluoro resin, ionomer, methyl pentene polymer, phenol resin, polyamide (nylon), polyallyl ether, polyallyl sulfone, polybutene-1, polycarbonate, unsaturated polyester resin, polyethylene, polyethylene terephthalate (tetron), polyimlde, polyamidemide, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polysulfone, polyether sulfone, polyurethane, vinyl chloride resin and polyallylate.
The coating layer coating the rubber or plastic comprises a solid lubricant and a resin matrix.
As the resin matrix, a fluoro-olefin vinyl ether polymer resin and/or a fluoro-olefin vinyl ether vinyl ester copolymer resin may be used.
As the solid lubricant, there can be used, for example, sulfide such as molybdenum disulfide and tungsten disulfide, fluoride such as polytetrafluoro ethylene and fluorinated graphite, graphite and silicone powder. The solid lubricant described above may be used alone or as a combination of two or more of them. In the present invention, combined use of the sulfide, fluoro compound and graphite is preferred in view of the excellent lubrication resistance, fitness and feeling. In this case, the blending ratio for the sulfide, fluoro compound and graphite is preferably from 10 to 1500 parts by weight of the sulfide and 100 to 3000 parts by weight of the fluoro compound based on 100 parts by weight of the graphite.
It is desirable that the solid lubricant has an average grain size of less than 10 μm, preferably, less than 5 μm, particularly, preferably, less than 3 μm. The blending ratio of the solid lubricant and resin matrix is preferably from 50 to 95 parts by weight of the solid lubricant and 50 to 5 parts by weight of the resin matrix and, more preferably, from 70 to 90 parts by weight of the solid lubricant and 30 to 10 parts by weight of the resin matrix.
For forming the coating on the surface of the rubber or the plastic in the present invention, the solid lubricant, the resin matrix and a curing agent may be coated while being dispersed or dissolved in an organic solvent.
As the curing agent, there can be used, for example, polyisocyanate and melamine resin.
As the organic solvent, methyl ethyl ketone, toluene, xylene, isopropyl alcohol, isobutanol, n-butanol, butyl acetate, MIBK and cellosolve acetate are preferred, for example.
As the coating method, various method such as brushing, spraying or dipping may be employed. Prior to the coating, the surface of the rubber or plastic may be cleaned or a surface treatment may be applied for improving the fitness with the resin matrix. For the surface treatment, a primer treatment can be mentioned.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is a schematic side elevational view for illustrating the method of experiment.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present will now be explained with reference to examples and comparative examples.
Compositions shown in the following (Comparative Example 1) - (Comparative Example 4), as well as (Example 1) - (Example 9) were sprayed on the surface of rubber pieces, and the compositions were cured under the curing conditions (heating conditions) shown in each of them, to form a coating Layer at a thickness of 10 μm on the surface of each of the rubber pieces. Each rubber piece was cut into a size of 10 mm×6 mm×2 mm to prepare a test piece. The coating surface was formed on the 10 mm×6 mm surface of the test piece.
The test piece was mounted no FALEX No. 1 Tester (Faville-Levally Corporation) and the durability of the coating layer was examined.
FIG. 1 is a schematic side elevational view illustrating the state of the test, in which a test piece was held to a test piece holder 2 and urged to the outer circumferential surface of a ring 3 of 35 mm diameter under a load of 9.06 kg (20 LBS). The outer circumferential surface of the ring 3 was made of SAE 4620 steel and the surface roughness was 6-12 rms. The ring 3 was reciprocally rotated around the axial center as shown by arrows within a rotational range of 90° at a rate of 100 cycle/min.
The number of cycles at which tile frictional coefficient reached 0.2 was measured as a life cycle. In a case where the coating layer was abraded to expose the rubber layer before the frictional coefficient reached 0.2, the number of cycles up to that time was defined as the life cycle.
The life cycle for each off the comparative examples and the examples is shown in Table-1. The static frictional coefficient and the dynamic frictional coefficient at the surface of the coating layer for each of the test pieces before the sliding movement with the ring 3 were measured and the results are also shown together in Table-1.
From Table-1, it can be seen that the test pieces of Examples 1-9 according to the present invention have low friction coefficient and the durability of the coating layer was remarkably high.
The average grain size of the solid lubricant used hereinafter is less than 5 μm in each of the cases.
In the following descriptions, "parts" means "parts by weight".
(Comparative Example 1)
______________________________________(Polyurethane resin) Nipporan 5185 100 parts(manufactured by Nippon Polyurethane Industry co.)(Isocyanate curing agent) Coronate HL 10.0 partsCuring conditions: 80° C. - 30 min.______________________________________
(Comparative Example 2)
______________________________________(Polyurethane resin) Nipporan 5185 26.0 parts(manufactured by Nippon Polyurethane Industry co.)(Molybdenum disulfide) Technical grade 30.0 parts(manufactured by Climax Molybdenum Co.)(Polytetrafluoroethylene) Lubron L-5 42.0 parts(manufactured by Daikin Industry Co.)(Graphite) ACP 1000 2.0 parts(manufactured by Nippon Graphite Industry Co.)(Isocyanate curing agent) Coronate HL 2.6 partsCuring conditions: 80° C. - 30 min.______________________________________
(Comparative Example 3) (corresponding to Example 3 in Japanese Patent Laid-Open Sho 55-15873)
______________________________________KM-765 (Emulsion with 20% silicone content) 45 parts(manufactured by Juetsu Chemical Co.)C-PM-4F (catalyst, manufactured by Juetsu 4.5 partsChemical Co.)Molybdenum disulfide (4.5 μm average grain size) 4.0 partsWater 52.0 partsCuring condition: After leaving at a roomtemperature for 10 min, a cured layer was obtainedat 150° C. - 10 min______________________________________
(Comparative Example 4)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 100 partsFluonate K702(manufactured by Dainippon Ink ChemicalIndustry Co.)(Isocyanate curing agent) Barnock DN980 24 parts(manufactured by Dainippon Ink ChemicalIndustry Co.)Curing condition: 80° C. - 10 min.______________________________________
(Example 1)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 26 partsFluonate K702(manufactured by Dainippon Ink ChemicalIndustry Co.)(Molybdenum disulfide) Technical grade 30 parts(manufactured by Climax Molybdenum Co.)(Polytetrafluoro ethylene) Lubron L-5 42 parts(manufactured by Daikin Industry Co.)(Graphite) ACP 1000 2 parts(manufactured by Nippon Graphite Industry Co.)(Isocyanate curing agent) Barnock DN980 6.2 parts(Dainippon Ink Chemical Industry Co.)Curing condition: 80° C. - 10 min.______________________________________
(Example 2)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 28 partsFluonate K702(manufactured by Dainippon Ink ChemicalIndustry Co.)(Molybdenum disulfide) Technical grade 10 parts(manufactured by Climax Molybdenum Co.)(Polytetrafluoro ethylene) Lubron L-5 60 parts(manufactured by Daikin Industry Co.)(Graphite) ACP 1000 2 parts(manufactured by Nippon Graphite Industry Co.)(Isocyanate curing agent) Barnock DN980 6.7 parts(Dainippon Ink Chemical Industry Co.)Curing condition: 80° C. - 10 min.______________________________________
(Example 3)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 28 partsFluonate K702(manufactured by Dainippon Ink ChemicalIndustry Co.)(Molybdenum disulfide) Technical grade 47 parts(manufactured by Climax Molybdenum Co.)(Polytetrafluoro ethylene) Lubron L-5 23 parts(manufactured by Daikin Industry Co.)(Graphite) ACP 1000 2 parts(manufactured by Nippon Graphite Industry Co.)(Isocyanate curing agent) Barnock DN980 6.7 parts(Dainippon Ink Chemical Industry Co.)Curing condition: 80° C. - 10 min.______________________________________
(Example 4)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 49 partsFluonate K702(manufactured by Dainippon Ink ChemicalIndustry Co.)(Molybdenum disulfide) Technical grade 39 parts(Polytetrafluoro ethylene) Lubron L-5 10 parts(Graphite) ACP 1000 2 parts(Isocyanate curing agent) Barnock DN980 6.7 partsCuring condition: 80° C. - 10 min.______________________________________
(Example 5)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 49 partsFluonate K702(Molybdenum disulfide) Technical grade 47 parts(Polytetrafluoro ethylene) Lubron L-5 2.5 parts(Graphite) ACP 1000 1.5 parts(Isocyanate curing agent) Barnock DN980 12.0 partsCuring condition: 80° C. - 10 min.______________________________________
(Example 6)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 49 partsFluonate K702(Molybdenum disulfide) Technical grade 49 parts(Graphite) ACP 1000 2 parts(Isocyanate curing agent) Barnock DN980 12 partsCuring condition: 80° C. - 10 min.______________________________________
(Example 7)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 39 partsFluonate K702(Molybdenum disulfide) Technical grade 59 parts(Graphite) ACP 1000 2 parts(Isocyanate curing agent) Barnock DN980 9.4 partsCuring condition: 80° C. - 10 min.______________________________________
(Example 8)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 28 partsFluonate K702(Molybdenum disulfide) Technical grade 70 parts(Graphite) ACP 1000 2 parts(Isocyanate curing agent) Barnock DN980 6.7 partsCuring condition: 80° C. - 10 min.______________________________________
(Example 9)
______________________________________(Fluoro-olefin vinyl ether vinyl ester copolymer) 20 partsFluonate K702(Molybdenum disulfide) Technical grade 78 parts(Graphite) ACP 1000 2 parts(Isocyanate curing agent) Barnock DN980 4.8 partsCuring condition: 80° C. - 10 min.______________________________________
TABLE 1__________________________________________________________________________ Comp. Comp. Comp. Comp. Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- Exam- ple 1 ple 2 ple 3 ple 4 ple 1 ple 2 ple 3 ple 4 ple 5 ple 6 ple 7 ple ple__________________________________________________________________________ 9Static 0.7 0.25 0.13 0.23 0.10 0.09 0.10 0.13 0.13 0.14 0.1 0.1 0.09frictionalcoefficient(μo)dynamic 0.5 0.35 0.18 0.38 0.14 0.16 0.15 0.17 0.17 0.17 0.16 0.16 0.14frictionalcoefficient(μ)Endurance life 10 200 1000 100 45000 42000 44000 33000 35000 35000 37000 37000 39000(sliding cycles)__________________________________________________________________________
As has been described above, the surface coating member according to the, present invention has an extremely low friction coefficient For the coating surface and the durability of the coating layer is remarkably high. | The present invention concerns a surface coating sliding member made of rubber or plastic applied with a coating of excellent durability and high sliding property, in which the coating contains a solid lubricant such as molybdenum disulfide and a resin matrix, wherein the resin matrix comprises a fluoro-olefin vinyl ether polymer resin and/or fluoro-olefin vinyl ether vinyl ester copolymer. | 2 |
FIELD OF THE INVENTION
The present invention relates to a method of providing selenium, in the form of selenate, in a nutritional product, and to nutritional products which contain selenate.
BACKGROUND OF THE INVENTION
The element selenium (Se) occurs in four common oxidation states. Two of these oxidation states, selenite, which is Se (IV), and selenate which is Se (VI), are believed to be acceptable for use in a nutritional product from a biochemical and medical perspective. Elemental selenium, Se (O), is not bioavailable as a source of selenium. Selenite is readily reduced to selenide, with is Se (II), and elemental selenium, be relatively mild reducing agents such as glucose, phosphorus acid, and iodide. In contrast, selenate is more difficult to reduce than selenite and thus, is less likely to form free selenium or selenides, including hydrogen selenide. This stability of selenate makes a selenate salt the preferred chemical form for the addition of selenium to a nutritional product.
However, selenite has been employed in nutritional products for the purpose of adding selenium to nutritional products. The incorporation of sodium selenite in a premixed combination of ingredients for use in a nutritional product has created several problems. These problems were manifested by the incomplete solubility of the premixed combination of ingredients and by a repulsive odor that emanated from the premixed combination of ingredients. The source of these problems stemmed from the interactions of sodium selenite with ferrous sulfate and cupric sulfate. Either or both of these salts, when ground together with sodium selenite, caused the reduction of sodium selenite to an insoluble reddish material, which is believed to be metallic selenium. A repugnant odor emitted from this mixture is believed to be hydrogen selenide which was formed as a byproduct of the same redox reactions. The problems may be significantly reduced by using special mixing techniques and/or the use of selenate in a premixed combination of ingredients for use in a nutritional product.
PRIOR ART
Numerous reports in the literature have examined the bioavailability of sodium selenite compared to other forms of selenium (sodium selenate, selenomethionine, selenocysteine). Groce et al, Journal of Animal Science, 33, 1149 (1971) and Olson et al, Poultry Science, 53, 403 (1973) comment upon the instability of selenite salts in premixed combinations of ingredients for nutritional products when premixes contain sugars or other organic substances.
Shils et al, 22nd Annual Meeting of the American Society for Clinical Nutrition, 1982, abstract published in The American Journal of Clinical Nutrition, 35, 829 (1982) teach that selenium added to total parenteral nutrition (hereinafter referred to as TPN), solutions as sodium selenite is reduced to an elemental form which is insoluble and biologically unavailable. Interactions with ascorbic acid and mineral components, such as copper (II) of multiple mineral and vitamin solutions added to TPN were shown to be responsible for selenium losses.
Levander, Bulletin New York Academy of Medicine, 50, 144 (1984) compares properties of various forms of selenium (sodium selenite, sodium selenate, selenomethionine) suitable for supplementation of TPN solutions. This publication teaches that the main disadvantage of selenite is a high chemical reactivity that renders selenite unstable in certain formulations. High concentrations of ascorbic acid reduce selenite to elemental selenium, which is almost totally unavailable as a nutritional source. This reaction can be accelerated by cupric ion, and has been shown to be of practical significance when selenite solutions are mixed with a multiple-vitamin solution in the presence of copper (II). Sodium selenate appears to have most of the best features of both selenite and selenomethionine because it is a nutritionally available source of selenium and has good chemical stability. This publication teaches that the main drawbacks of selenate are that this form of selenium has not been extensively studied and its metabolic behavior is not well characterized when given intravenously.
Korpela, Annals of Nutrition and Metabolism, 32, 347 (1988) teaches that the effects of selenite and selenate on concentrations of selenium in serum of selenium-depleted animals were similar for both forms in his studies. Consequently, he recommends that selenate be regarded as an appropriate form for selenium supplementation because it is more stable and less toxic than selenite.
Postaire et al., International Journal of Pharmaceutics, 55, 99 (1989) teaches that ascorbic acid, particularly in the presence of copper (II) ions reduced selenite to elemental selenium. These reactions were held responsible for the complete loss of selenite in TPN solutions. Reduction of selenite was also observed to occur in dextrose solutions, and results indicated a detectable change in selenium recovery when a solution contains electrolytes as phosphate salts.
Ganther et al, Journal of Parenteral and Enteral Nutrition, 13, 185 (1989) relates an investigation of the reduction of selenite to elemental selenium by ascorbic acid with regard to the stability of selenite in TPN solutions. While complete reduction of selenite occurred in ascorbic acid solutions, there was little or no reduction of selenium in complete TPN formulas. This publication teaches that the amino acid component of the TPN formula prevented the reduction of selenite in buffered solutions having a pH of 5 or greater. Selenate is not reduced by ascorbic acid under any of the above described experimental conditions.
DETAILED DESCRIPTION OF THE INVENTION
A first example of a premix used in the practice of the present invention is set forth in Table 1, which is followed by a description of how to manufacture the premix.
TABLE 1______________________________________COMPOSITION OF NUTRITIONAL ULTRA TRACE/TRACE MINERAL PREMIXIngredient Amount for 1000 Kg______________________________________Ferrous Sulfate, Dried, USP 197.0 KgZinc Sulfate, Monohydrate, USP 204.6 KgCupric Sulfate, USP 29.2 KgManganese Sulfate, Monohydrate, USP 54.12 KgSodium Selenate 0.610 KgChromic Chloride Hexahydrate 1.434 KgSodium Molybdate Dihydrate 1.475 KgCitric Acid, USP, Anhydrous 61.72 KgSucrose or Maltodextrin (diluent) 449.65 Kg______________________________________
Manufacturing Procedure
Dry blend zinc sulfate, chromic chloride, sodium selenate and sodium molybdate with the diluent. Mill the premix through a No. 4 band using a suitable mill, such as a Fitzmill, at high speed. Discharge the premix into a V-Blender and blend for 15 minutes. Discharge the premix from the V-Blender through a No. 0 band using a suitable mill, such as a Fitzmill, at high speed, impact forward into a polyethylene lined container (Blend A). Dry blend ferrous sulfate, cupric sulfate, manganese sulfate and citric acid using a blender for 15 minutes. Discharge materials in blender through a No. 0 band using a suitable mill, such as a Fitzmill, at high speed and impact forward into a polyethylene lined container (Blend B). Dry mix Blends A and B for one hour in V-Blender. Discharge premix into a fiber drum.
A second example of a premix used in the practice of the present invention is set forth in Table 2, which is followed by a description of how to manufacture the premix.
TABLE 2______________________________________COMPOSITION OF NUTRITIONAL ULTRA TRACE/TRACE MINERAL PREMIXIngredient Amount for 1000 Kg______________________________________Taurine (food supplement) 305.600 KgSodium Selenate 217.200 KgZinc Sulfate, USP, Monohydrate 91.970 KgBiotin, USP 363.000 gNiacinamide, USP 66.500 KgCalcium Pantothenate, USP 36.000 KgThiamine Hydrochloride, USP 10.180 KgPyridoxine Hydrochloride, USP 4.130 KgRiboflavin, USP 4.497 KgFolic Acid, USP 1.265 KgFerrous Sulfate, Dried, USP 35.030 KgCupric Sulfate, USP 18.940 KgInositol, FCC 222.000 KgManganese Sulfate, USP Monohydrate 862.700 gCyanocobalamin powder in starch 30.240 Kg1000 mcg/gm (vitamin B12)Dextrose, USP, Anhydrous 172.205 Kg______________________________________
Manufacturing Procedure
Dry blend approximately one-half of the taurine with sodium selenate, zinc sulfate, biotin, and manganese sulfate and approximately one-half of the dextrose. Mill through a No. 4 band using a suitable mill, such as a Fitzmill at high speed, discharge the blend into a V-Blender. Mill the remainder of the taurine through a No. 4 band using a suitable mill, such as a Fitzmill at high speed and impact forward to a V-Blender and blend for 30 minutes. Discharge blender contents through an 0 band using a suitable mill, such as a Fitzmill at high speed, impact forward into a polyethylene lined container (Blend A). Mill the niacinamide, calcium pantothenate, thiamine hydrochloride, pyridoxine hydrochloride, riboflavin, folic acid, ferrous sulfate, cupric sulfate, inositol, Vitamin B12 and remainder of the dextrose through a No. 4 band using a suitable mill, such as a Fitzmill at high speed and impact forward into a V-Blender and blend for 30 minutes. Discharge blender contents through a 0 band using Fitzmill at high speed and impact forward into a polyethylene lined container (Blend B). Speed sift the milled material (Blend A and Blend B) through a 16 mesh screen into a V-Blender and blend for 60 minutes. Package the premix.
Selenite has been found to be equally as bioavailable as selenate. However, selenite is known to be more readily reduced than selenate to elemental selenium which is not bioavailable. In an attempt to determine the preferred form of selenium for fortification of nutritional products, the absorption and retention of selenite and selenate from a vitamin/mineral premix and from two processed nutritional products as studied using a rat model.
A study was designed to assess independently the potential reactivity of selenite and selenate from a mineral/vitamin premix, and formulas prepared with the premix when freshly made and over 3 to 9 months of shelf life in rats. In the presence of reducing substances in the premix both selenite and selenate theoretically could be reduced to elemental Se. Normally, both selenite and selenate are well absorbed. Thus, short-term retention of 75 Se by the animals is likely reflective of the selenite/selenate ingested that is present in a bioavailable form.
Selenate/selenite, zinc and copper were incorporated into a vitamin/mineral premix similar to that set forth in Table 2 in the following quantities:
______________________________________Component Per 1 g Premix______________________________________Selenium, mcg 71-111Zinc, mg 33-41Copper, mg 4.4-5.2______________________________________
Sufficient amounts of premix were added to the infant nutritional products Similac® with Iron and Isomil® to provide approximately 12-30 mcg Se/L of finished product (added plus inherent). Similac® with Iron and Isomil® are commercially available nutritional products for infants and both are manufactured by Ross Laboratories, a Division of Abbott Laboratories, Columbus, Ohio.
The results of the study showed that the apparent absorption of selenate as estimated by whole-body retention 1 day post-dose was significantly greater (4% to 15%) than that of selenite from both the premix and products throughout the study. Whole body retention at 10 days post-dose of both selenite and selenate in rats fed all diets decreased significantly during the first 3 months of shelf-life. Whole-body retention of selenite and selenate from formula diets was also examined at 9 months of storage and did not appear to decrease further from that at 3 months. Overall, whole-body retention 10 days post-dose of rats fed selenate ranged from 51% to 61% for premix and formula diets over shelf-life compared to retentions of 42% to 49% for selenite. These data confirmed that selenate remained more bioavailable to rats when incorporated into premix and processed formulas. Due to the inability to incorporate the radioisotope ( 75 Se) during commercial manufacture of the premix, it is believed that the effects observed for this portion of the study underestimated those likely occurring during commercial manufacture. The results suggest that some reaction(s) is taking place, particularly in nutritional products during processing and early storage, which reduces the apparent absorption and retention of selenite and selenate by rats. This was a surprising finding for selenate because it has been assumed to be relatively nonreactive compared to selenite. Although some reaction(s) involving both selenite and selenate appear to be occurring during premix and product manufacture and over shelf-life, the results of the study suggest that selenate is the preferred form in which to provide Se, a mineral required by animals and humans.
Improved stability and reduced reactivity in a nutritional premix similar to that set forth in Table 2 was confirmed via testing of two pediatric premixes by different analytical methods. Total Se was measured by the dissolution in 2% HCl (HCl method) whereas soluble Se, or that believed to be soluble and bioavailable after incorporation into the vitamin/mineral premix, was assessed by the dissolution in citric acid solution (citric acid method) method. Estimations of the amount of bioavailable Se present in each freshly made premix prepared with both selenite and selenate is shown in Table 3.
TABLE 3______________________________________ HCl CITRIC ACID PERCENT SOLUBLE SOLUBLE BIOAVAILABLE*______________________________________Premixwith Selenite 52.9 mcg/g 44.2 mcg/g 83.5%with Selenate 62.2 mcg/g 59.8 mcg/g 96.1%Premixwith Selenite 89.8 mcg/g 70.3 mcg/g 78.2%with Selenate 89.3 mcg/g 95.6 mcg/g 107%______________________________________ *Amount determined by citric acid method divided by amount determined by HCl method.
The results confirmed that when selenate was added to a premix similar to the set forth in Table 2, a significantly greater percent of the added selenium was bioavailable after manufacture of the premix. Less than 5% of the selenate appeared to have been rendered as insoluble Se compared to 16% to 22% of the selenite.
In the practice of the present invention a premix of selenate and iron (II) and/or copper (II) salts which are water soluble is combined with a source of proteins and/or carbohydrates and/or fats to form a nutritional product. It is understood that this invention may be practiced by making a nutritional product which contains, for example, only carbohydrates but no proteins or fats. Such a product may be consumed in such a state or possibly could be supplemented with additional nutrients at the time of consumption. The most preferred iron (II) salt is iron sulfate. The most preferred copper (II) salt is copper sulfate. In a most preferred embodiment the premix contains selenate, iron sulfate, copper sulfate and zinc sulfate.
While certain representative embodiments and details have been set forth for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention. | Selenium is provided in a nutritional product by incorporating selenate into a premix with an zinc and/or copper (II) salt which is water soluble and then combining the premix with a source of nutrition to form a nutritional product. | 0 |
This application is a continuation in part of application Ser. No. 09/039,751, filed Mar. 16, 1998 now abandoned, and claims the priority of this application.
BACKGROUND OF THE INVENTION
The present invention relates to a front end loader attachment for utility tractors, and more specifically, to a front end loader attachment having multi-purpose tools for use on skid steer loaders or other similar vehicles.
Often times, industries such as factory yards, building sites, and farms utilize skid steer loaders. Skid steer loaders are small vehicles, typically having four wheels, which steer the vehicle by varying the speed of each individual wheel. Due to the unique steering method, skid steers are easily maneuverable in tight quarters. Thus, skid steer loaders have proven to be very efficient and necessary in many work situations having limited space.
As skid steers have increased in popularity, manufacturers have found it profitable to make large numbers of attachments for the front of skid steer loaders. These attachments include: snow blowers, sandbagging devices, log moving equipment, buckets, hole drilling equipment, and the like. The various attachments are limited only by the ability of the skid steers and the user's needs.
A prime example of the use of skid steers is in the farm yard. A farmer may typically need to move large barrels of chemicals, oil, and fuel from location to location. These needs may also include finding an easy way to tip the barrel to empty its contents. Farmers may also use an attachment for moving logs, telephone poles and large fence posts. It may be necessary in this situation to have some type of attachment that will articulate so a pole may be picked up if laying on its side, moved to proper location and rotated so that it may be placed, for example in a fence post hole or a telephone pole hole.
Though skid steer loaders have the convenience of attachment devices, users have encountered difficulties when utilizing several front end loader attachments at a job site. Some of these problems include: down time between connecting a new tool, connecting the hydraulics and control lines to the skid steer, and familiarizing the driver of the skid steer with the new controls of each different device. Users at a given location often may need several attachments to complete a given job.
In the past, a user would need to buy all of the attachments individually. The attachments are costly and each attachment may have redundant parts located on existing attachments, such as hydraulic cylinders, control lines and an attachment means for connecting to the skid steer loader. Often times, a user may spend a large sum of money on parts he may not need.
From this discussion, it can be seen that it would be desirable to provide a structure for skid steer loaders. This structure would need to readily attach to the skid steer loader, have a power means such as hydraulic cylinders and control lines that could be reused from attachment to attachment, and have a means of easily, quickly and inexpensively attaching various implements to the attachment means. Further, it may be desirable to provide such an attachment that provides many directions of movement for the attachment, including the ability to rotate. This problem has been solved by supplying a universal attachment mechanism for skid steers, having a hydraulically controlled cylinder, which may attach to the skid steer at an attachment point to which various tools may be affixed. Further, this attachment point is supplied with a control cylinder which allows the attachment point to rotate. Thus, the attachment point is able to minimize the expense while maximizing the number of tools a given user may have.
SUMMARY OF THE INVENTION
It is the primary objective of the present invention to provide a means of pivotally mounting a plurality of tools to the forward end of a front end loader to be used in a number of applications that would allow a single person to handle and move heavy or bulky objects that would normally require the assistance of two or more persons.
It is an additional objective of the present invention to provide such a means that is configured in a manner that would allow a single individual to easily change and secure the tools to the front end loader, thus, allowing him to accomplish a number of tasks without the aid of other people.
It is a further objective of the present invention to provide such a means that will allow an individual operator to not only manipulate an object in a vertical manner but also to change its orientation by rotating it around the central axis of the attachment.
It is a still further objective of the present invention to provide such a means of enabling an individual to manipulate heavy objects that is not only effective, but also inexpensive to own and operate.
These objectives are accomplished by the use of a frame apparatus that fits on the loader arms of a skid steer tractor. The frame apparatus serves as a platform upon which a plurality of hydraulically driven tools can be employed to grasp, lift and transport heavy objects such as oil drums and telephone poles. The hydraulically driven tools are designed in a manner that allows them to be easily installed on, and removed from, the frame apparatus by one person. This is accomplished by having a frame member as part of the tool that slides over the end of the attached frame apparatus and is held in place by passing a pin through both of the attached frame members. This design enables a single person to lift and move objects that would normally require two or more persons to accomplish.
Additionally, the present invention employs a pivotal mounting system in the attachment of the tools to the front end of the skid steer loader. This configuration allows the operator of the loader to not only pick up and transport large and heavy objects, but also to manipulate them rotationally around the central axis of the invention. The design of this feature is especially useful in working with objects such as telephone poles as it allows the operator to pick up a pole that is oriented in the horizontal plane and rotate to the vertical plane. Once the pole has rotated into position, it can then be placed into position vertically within a hole that has been dug specifically for that purpose. Additionally, the rotational ability of the present invention also enhances the flexibility of the plurality of tools that can be attached to the front end of a skid steer loader.
The rotation of the pivotal attachment plate component of the present invention is accomplished through the use of the pivot hydraulic cylinder. The pivot hydraulic cylinder is attached at its inner end to the lower inside edge of the pivot plate and at its outer end to the attachment bracket located at the outside edge of the attachment plate. This hydraulic cylinder is controlled by the skid steer operator through the skid steer's hydraulic system and the pressure and return hydraulic lines that are connected to it. By activating the cylinder it expands and forces the bottom of the pivot plate to rotate. This rotation of the pivot plate forces the central beam to also rotate which in turn imparts this rotational force to any of the tools attached to the present invention. Conversely, the retraction of the pivot hydraulic cylinder brings the pivot plate and any tool connected to it back to its original upright position.
The individual tools attached to the present invention are driven by a hydraulic cylinder which is mounted to the upper surface of the central beam and is also supplied with hydraulic pressure from the skid steer's system. The hydraulic cylinder is used generally to articulate the upper member of the attached tool. Thus, for example the skid steer operator controls the the hydraulic cylinder which in turn articulates the components of the attachment which allows the operator to accomplish the desired job.
For a better understanding of the present invention, reference should be made to the drawings and the description in which there are illustrated and described preferred embodiments of the present invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a typical skid steer loader being shown as equipped with the present invention which is configured with the barrel handler apparatus attached to the arms of the skid steer loader.
FIG. 2 is a front elevation view of the present invention showing it as configured with the grasping claw apparatus and illustrating the orientation of its major components in relation to the mounting plate.
FIG. 3 is a side elevation view of the present invention showing it as configured with the grasping claw apparatus and illustrating the manner of construction of the invention and the grasping claw apparatus.
FIG. 4 is a side elevation view of the present invention illustrating the manner in which a tool, in this case the grasping claw apparatus, is both fitted to and operated by the present invention.
FIG. 5 is a front elevation view of the major components of the present invention and illustrates the position of the pivot plate and pivot hydraulic cylinder when the invention is in the normal position.
FIG. 6 is a front elevation view of the major components of the present invention and illustrates the position of the pivot plate and pivot hydraulic cylinder when the invention is in the rotated position.
FIG. 7 is a side elevation view of the tree claw apparatus, an additional attachment tool that may be used with the present invention, illustrating the manner of construction when the tree claw is in the open position.
FIG. 8 is a side elevation view of the tree claw apparatus, illustrating the manner of construction when the tree claw is in the closed position, allowing for grasping and holding.
FIG. 9 is a top view of the tree claw apparatus, illustrating the manner of construction of the components of the attachment articulation hydraulic cylinder with the tree claw arms.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more specifically to FIG. 1 , the pivoting skid steer loader attachment 10 is an accessory item intended to be used in conjunction with front end skid steer loaders 12 . Front end skid steer loaders 12 are typically highly maneuverable motor driven vehicle used to pick up and transfer raw materials having skid steer wheels 22 and loader arms 14 which are driven and controlled through the use of the loader arm hydraulic cylinders 20 . The front end skid steer loaders 12 also generally consist of a loader body 16 to which all of its components are attached and which also contains the loader cab 18 within which the operator sits during the use of the present invention.
The pivoting skid steer loader attachment 10 consists of an attachment plate 24 which is easily mounted to and dismounted from the forward most portion of the loader arms 14 . The operator of the front end skid steer loader 12 can control the present invention and any of its plurality of attachments through the front end skid steer loader 12 by manipulating the loader arms 14 . Thus, he can lift and carry large items, such as full oil barrels 30 , with only the effort of operating the hydraulic control and steering mechanisms of the front end skid steer loader 12 .
The hydraulic power needed to operate the present invention and its associated tools is supplied by the front end skid steer loader 12 through the primary hydraulic assembly 26 located st the front of one of the loader arms 14 . The primary hydraulic lines 28 span the space between the front of the loader arms 14 and the attachment plate 24 and are long enough to provide enough slack to allow for the changing position of the invention during operation.
The pivot assembly mount 54 extends forward from the face of the attachment plate 24 and provides the point at which the pivot assembly 31 is attached. The pivot plate assembly 31 consists primarily of the pivot plate 32 and the central beam 34 . The pivot plate 32 has attached to one of its lower corners the pivot hydraulic cylinder 42 by use of the inside cylinder attachment fitting 44 and it is the combination of these components which provide the rotational force for the operation of the invention. Additionally, the central beam 34 is the portion of the pivot assembly 31 to which one of the plurality of tools can be attached to by the skid steer loader operator to perform a desired job.
One of the tools most commonly used with the present invention is the barrel handler assembly 36 which is illustrated in FIG. 1 . The barrel handler assembly 36 is primarily made up of the barrel handler arms 38 which are pivotally mounted hemispherical claw-like components and, in their closed position, having their most forward ends not quite joining to form a near circle with a forward facing gap. The pivotal attachment of the barrel handler arms 38 is accomplished at the arm mount assembly 40 at their inward end. The arm mount assembly 40 also serves to tie the barrel handler arms 38 to the forward end of the central beam 34 and, therefore, the present invention. This configuration allows the operator to open and close the barrel handler arms 38 which enables him to manipulate the barrel handler assembly 36 to grasp and lift large cylindrical objects such as oil barrels.
The orientation of an attachable tool, in this example a claw assembly 48 , in relation to the attachment plate 24 and the pivot hydraulic cylinder 42 is further illustrated in FIG. 2 . The pivot assembly 31 is located and mounted at the center of the attachment plate 24 which positions the claw assembly 48 in the position at which it can be most easily controlled and manipulated by the operator. The pivot plate 32 then extends downward from the central beam 34 so that its lowest edge is a relatively large distance from its point of attachment. This distance provides a greater amount of rotational leverage through the expanding and contracting action of the pivot hydraulic cylinder 42 to the claw assembly 48 (or other attached tool) while the present invention is in use. The additional leverage created by this design enables the invention to rotate and manipulate greater loads without the need to increase the amount of power that is readily available from the hydraulic system of the front end skid steer loader 12 .
One of the lower corners of the pivot plate 32 is equipped with a protruding pivot tab 43 to which the inside cylinder attachment fitting 44 of the pivot hydraulic cylinder 42 is attached. From this point of attachment, the pivot hydraulic cylinder then extends outward to the edge of the attachment plate 24 where it is attached to the pivot cylinder attachment bracket by means of the outside cylinder attachment fitting 46 . The pivot cylinder attachment bracket 50 is a vertical plate located at one of the lower corners of the attachment plate 24 and is braced by a pair of horizontally extending bracket braces 52 that connect and help to secure the pivot cylinder attachment bracket 50 to the attachment plate 24 .
This FIG. also illustrates the manner in which hydraulic pressure is supplied to the present invention by the primary hydraulic lines 28 . The primary hydraulic lines 28 enter the attachment plate 24 behind the hydraulic control valve 60 which is located at the upper corner of the attachment plate 24 that is directly above the pivot cylinder attachment bracket 50 . The purpose of the hydraulic control valve 60 is to serve as switching point between the pivot hydraulic cylinder 42 and the attachment articulation hydraulic cylinder 72 .
From the point of entry behind the hydraulic control valve 60 , a portion of the hydraulic pressure is diverted by hydraulic control valve 60 through the pivot hydraulic cylinder 42 through the pivot cylinder hydraulic feed line 62 and the pivot cylinder hydraulic return line 64 . The use of these components allows the operator to control the pivot hydraulic cylinder 42 which in turn allows him to control the rotational orientation of the claw assembly 48 or other attached tool. Additionally, a portion of the hydraulic pressure supplied by the primary hydraulic lines 28 is similarly diverted through the articulation cylinder hydraulic feed line 74 and the articulation cylinder hydraulic return line 76 . This system provides for the control of individual components of the claw assembly 48 or other attached tool and will be explained in further detail below.
Additionally, the manner in which the present invention is constructed to provide the pivoting ability that is central to the purpose of the invention is further illustrated in FIGS. 5 and 6. As previously stated, the pivot assembly 31 is connected to the attachment plate 24 through the pivot hydraulic cylinder 42 . The pivot hydraulic cylinder 42 is connected to the pivot tab 43 located at the lower inside corner of the pivot plate 32 by means of the inside cylinder attachment fitting 44 . The opposite end of the pivot hydraulic cylinder 42 is connected to the attachment plate 24 through the pivot cylinder attachment bracket 50 by means of the outside cylinder attachment fitting 46 . Additionally, these attachments are all pivotal in nature which allows the orientation of the pivot hydraulic cylinder 42 to change in relation to the other components of the invention during operation. Finally, the hydraulic pressure necessary to expand and contract the pivot hydraulic cylinder 42 is supplied though the pivot cylinder hydraulic feed and return lines, 66 and 68 .
When the pivot hydraulic cylinder 42 is contracted (as illustrated in FIG. 5 ), the pivot plate 32 is oriented in the upright position with its wider and lower end positioned in a downward manner. This orientation transfers to any tool that is connected to the central beam 34 which means that it remains in the relative position at which it was fixed to the invention. Conversely, when the pivot hydraulic cylinder 42 is expanded (as illustrated in FIG. 6 ), the bottom of the pivot plate 32 is forced away from the pivot cylinder attachment bracket 50 which rotates the entire pivot assembly, and any tools attached to it, as much as one hundred twenty-seven degrees. This design allows the operator of a front end skid steer loader 12 to rotate an object in this fashion which greatly increases the flexibility of such vehicles when used for these purposes.
The manner in which tools such as the claw assembly 48 are attached to and controlled by the present invention are further illustrated in FIGS. 3 and 4. The attachment plate 24 is the component of the invention which connects it to the loader arms 14 of the front end skid steer loader 12 . The attachment plate 24 not only serves as the mounting mechanism for the present invention, but also provides the base upon which the other components of the present invention are built. Extending forward from the front of the attachment plate 24 is the pivot assembly mount 54 . The pivot assembly mount 54 is structurally braced in its initial portion by the horizontal mount brace 56 and the vertical mount brace 58 . These braces consists of four right triangles that are permanently attached to all four of the outer surfaces of the pivot assembly mount 54 on one side and to the front surface of the attachment plate 24 on the other. This configuration provides a more than adequate amount of structural integrity for the mounting of the pivot plate assembly 31 on its outer most surface.
The configuration of the pivot assembly mount 54 fixedly attaches it to the face of the attachment plate 24 which means that the rotational nature of the present invention come from the manner in which the pivot assembly 31 is mounted to the pivot plate mount 54 . Appropriately, the mounting of the pivot assembly 31 to the pivot assembly mount 54 is accomplished in such a manner that allows the pivot assembly 31 to rotate freely around the central axis of the pivot assembly mount 54 and the central beam 34 . Again, this rotational ability is controlled and limited by attachment of the pivot hydraulic cylinder 42 on the lower edge of the pivot plate 32 .
The end of the central beam 34 also provides the attachment point for the plurality of tools that can be used in conjunction with the present invention. This attachment is accomplished by using an attachment sleeve 90 , as illustrated by the rearward portion of the claw assembly 48 , which is slightly larger in its inside diameter than the outside diameter of the forward portion of the central beam 34 . Therefore, the attachment of the claw assembly 48 to the central beam 34 is accomplished by the user sliding the larger attachment sleeve 90 over the forward portion of the central beam 34 . Once this has been accomplished, the claw assembly is fixed in position by the inserting attachment retainer pin 82 , which is a large handled metal pin, through the attachment retainer pin holes 86 located in corresponding locations on the forward portion of the central beam 34 and the attachment sleeve 90 . Once the attachment retainer pin 82 has passed completely through these components, it is secured in place by the use of a retainer clip 80 which prevents attachment retainer pin 82 from slipping back through the attachment retainer pin holes 86 . This design provides for the secure attachment of a plurality of hydraulically articulated tools, such as the claw assembly 48 , to the central beam 34 of the present invention.
Additionally, the space between the pivot assembly 31 and the attached tool, in this case the claw assembly 48 , provides the point of attachment for the attachment articulation hydraulic cylinder 72 . The attachment articulation hydraulic cylinder 72 is the component of the invention which is used to control the positioning of individual components of the attached tool. The attached articulation hydraulic cylinder 72 is pivotally attached to one of the central beam braces 59 (which provide structural integrity to the pivot assembly 31 ) from where it extends diagonally forward and upward to terminate at the cylinder pin receptor 88 . The cylinder pin receptor 88 is the device by which the attachment articulation hydraulic cylinder 72 is connected to the upper jaw 66 of the claw assembly 48 . This connection is possible as the cylinder pin receptor 88 is equipped with a hole that can be positioned to correspond in location to the upper claw retainer pin hole 84 which is located at the rearward portion of the upper claw 66 . Once this positioning has been accomplished, the two components are held together by passing the upper claw retainer pin 78 through these aligned holes in much the same fashion as described for the attachment retainer pin 82 above where it is again held in place by the use of a retainer clip 80 .
The design of the claw assembly 48 in conjunction with the attachment articulation hydraulic cylinder 72 allows the upper claw 66 to open and close in relation to the lower claw 68 . The pivoting ability of the upper claw 66 in relation to the lower claw 68 is facilitated by the use of the claw pivot mount 70 which is used to attach the upper and lower claws, 66 and 68 , and allows the upper claw 66 to freely pivot around this point of attachment when the attachment articulation hydraulic cylinder 72 is activated by the operator.
The opening and closing action of the claw assembly 48 is controlled by the attachment articulating hydraulic cylinder 72 which is controlled in turn through the articulation cylinder hydraulic feed and return lines, 74 and 76 . As the attachment articulation hydraulic cylinder 72 is contracted, its connection to the rear portion of the upper claw 66 pulls it back around the claw pivot mount 70 which in turn opens the space between the forward portions of the upper and lower claws, 66 and 68 . This opening allows the operator to slip the claw assembly 48 over objects such as poles and the like whereupon the operator reverses the process by expanding the attachment articulation hydraulic cylinder 72 which forces the upper and lower claws, 66 and 68 , together and firmly grasps any object in between. With this accomplished, the operator can then manipulate the object into the position which is necessary to complete the job at hand with little physical effort.
An additional attachable tool that can be used in conjunction with the present invention and a front end skid steer loader 12 is illustrated in FIGS. 7, 8 , and 9 . This tool is referred to as a tree claw 92 and is most commonly employed to grasp the trunk portion of a tree to move it around during landscaping operations. The tree claw 92 is fitted to the forward portion of a front end skid steer loader 12 through the attachment plate 24 in much the same manner as described above with the other tools.
The tree claw 92 is primarily made up of the central claw body 94 and the two claw arms 96 that are pivotally attached to it forward edge. The claw body 94 is the portion of the tree claw 92 that attaches to the other components of the present invention. This attachment is accomplished by the use of an attachment sleeve 90 which is generally the most rearward portion of the claw body 94 and is held in the proper location by the use of the attachment retainer pin 82 which passes through the attachment sleeve from one side to the other. With this accomplished, the tree claw 92 is securely held in place on the present invention.
The inner edges of the claw arms 96 are lined with relatively thick plates made of a hard rubber or other similar material and are called the tree protection bumpers 98 . The purpose of these tree protection bumpers 98 is too keep the claw arms from digging too far into the bark of a tree while it is being transported by the use of the present invention. This is an important feature of the tree claw 92 tool because if the bark of a tree is damaged too severely during handling it will cause the tree to die. This potential result occurs because the water and other nutrients needed by the tree to live are gathered by the root system and are transported to the remainders of the tree by a thin layer of cells located just beneath the interior surface of the bark. If this layer is damaged or destroyed the flow of water and nutrients will be cut off and the tree will then wither and die.
The pivotal mounting of the claw arms 96 to the claw body 94 is accomplished by the use of the arm pivot mount bolts 100 which pass through both the width of the claw arms 86 and the forward end of the claw body 94 . This method of attachment allows the claws arms 96 to pivot around their mounting which allows them to be manipulated through hydraulic articulation. Additionally, the two claw arms 96 are designed in such a way that when their forward tips are forced to close by the hydraulic articulation, they can function much like a pair of common house scissors in that their tips can slide past one another in relation to the center longitudinal plane. This aspect of the design of the claw arms 96 is clearly illustrated in FIG. 8 and is important to the tree grasping function of the claw arms 96 as it allows the tree claw 92 to grab and effectively hold onto trees that are of relatively small diameters.
The opening and closing of the claw arms 96 is controlled by the use of attachment articulation hydraulic cylinders 72 which are supplied with hydraulic pressure by the articulation cylinder hydraulic feed and return lines, 74 and 76 , in much the same manner as previously described. The difference in the illustrated example is that there are two such attachment articulation hydraulic cylinders 72 used but the principles involved are the same as when a single unit is used. The attachment articulation hydraulic cylinders 72 are attached at their rearward end to the claw body 94 by the use of the rear cylinder mount pin 102 and at its forward end to the claw arms 96 by the front cylinder mount pin 104 . Additionally, these mountings are all pivotal in nature which allow the attachment articulation hydraulic cylinders 72 to change their orientation during claw arm 96 articulation. These design features of the tree claw 92 allow a user to easily pick up and move trees of varying sizes around a work site without damaging the delicate inner bark of the tree.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, the type of tractor used may vary greatly. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | A frame apparatus that fits on the loader arms of a skid steer front loader. This frame apparatus serves as a platform upon which a plurality of hydraulically driven tools can be employed to grasp, lift, rotate, and transport heavy objects such as oil drums and telephone poles. The hydraulically driven tools are designed in a manner that allows them to be easily installed on, and removed from, the frame apparatus by one person. This is accomplished by having a frame member as part of the tool that slides over the end of the attached frame apparatus and is held in place by passing a pin through both of the attached frame members. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a sanitizing and/or disinfecting apparatus for use in sanitizing and/or disinfecting a target space by spraying a sanitizing and/or disinfecting chemical including high-concentration alcohol into the target space.
[0003] 2. Description of Related Art
[0004] As one example of a method of efficiently sanitizing and/or disinfecting spaces where high cleanliness is required, such as clean rooms of pharmaceutical companies, food factories, wards of hospitals, the inside of ambulances and kitchens of food shops, for example, Japanese Examined Patent Application Laid-Open No. 6-84287 (1994) and Japanese Unexamined Patent Application Laid-Open No. 2000-237288 propose methods in which a sanitizing and/or disinfecting chemical including alcohol as a main component is sprayed in the form of fine particles.
[0005] These methods use a spray gun which is widely used for various painting operations. A chemical tank containing the above-mentioned chemical is attached to the spray gun, and a gas cylinder containing a carrier gas for spraying is connected to the spray gun. The carrier gas supplied from the gas cylinder is injected from the end nozzle of the spray gun, and the chemical in the chemical tank is sucked by a function of the negative pressure created at this time and is sprayed together with the carrier gas.
[0006] At this time, by using a carrier gas that does not react with alcohol, such as carbon dioxide gas and nitrogen gas, so as to isolate the sprayed alcohol from oxygen in the space, a high sanitizing and/or disinfecting function of alcohol can be obtained while avoiding the risk of ignition immediately after spraying. Moreover, by setting an injecting pressure of the carrier gas to control the particle size of the sprayed chemical, it is possible to optimize the settling velocity of the chemical particles in the sprayed space. It is therefore possible to spread the chemical particles throughout the target space including the corners of the space by short-time spraying, and to evenly and satisfactorily sterilize and disinfect the target space. Furthermore, since the sprayed chemical in the form of fine particles includes high-concentration alcohol with quick dry characteristics as a main component, the chemical will evaporate rapidly after adhering to the wall surface, floor surface and the like in the target space without remaining for a long time, and thus there is no need to perform a post treatment including wiping.
[0007] On the other hand, when spraying a chemical including alcohol, care must be taken so that the concentration of alcohol in the sprayed space does not exceed the explosion limit. According to the above-described method, however, since the sprayed chemical diffuses evenly throughout the target space, it is possible to achieve the object under a sufficiently low concentration than the explosion limit. Moreover, even in the periphery of the end nozzle of the spray gun, it is possible to maintain an appropriate mixed ratio of the chemical and the carrier gas, and to realize a sprayed condition in which the chemical particles are covered with the carrier gas, by optimizing the design of the end nozzle. It is therefore possible to completely eliminate the risk of explosion, and perform the sanitizing and/or disinfecting operation without taking into account the presence or absence of fire in the target space.
[0008] As described above, the sanitizing and/or disinfecting methods disclosed in Japanese Examined Patent Application Laid-Open No. 6-84287 (1994) and Japanese Unexamined Patent Application Laid-Open No. 2000-237288 are excellent methods capable of sanitizing and/or disinfecting any target space in a highly efficient and satisfactory manner. However, these methods use a liquefied gas cylinder filled with carbon dioxide gas or nitrogen gas in a liquefied state as the gas source of carbon dioxide gas or nitrogen gas that serves as a carrier gas, and the liquefied gas supplied from the liquefied gas cylinder is heated and vaporized by a heater and then decompressed to a required injecting pressure to obtain a desired carrier gas. These methods have the following problems.
[0009] First, heating with the heater is performed so as to prevent the peripheral part from freezing due to a decrease in temperature caused by volume expansion resulting from the decompression afterward. For this purpose, it is necessary to have the heater and control means for controlling the temperature of the heater and also an anti-freezing mechanism, such as a fin for absorbing heat from outside air in the periphery of the decompression section, and consequently the configuration of the apparatus is complicated.
[0010] Second, it is essential to secure a power supply for supplying power to the heater, and thus the place where the apparatus can be used is limited. Besides, if the apparatus comprises an internal power supply, the configuration of the apparatus is further complicated.
[0011] Third, a liquefied gas cylinder designed to supply a liquefied gas, i.e., a so-called siphon type liquefied gas cylinder, is originally manufactured to utilize low temperatures of the liquefied gas, and is commercially sold as a large cylinder with a content capacity of 10 Kg or more and a total weight of 20 Kg or more. It is difficult to move a conventional sanitizing and/or disinfecting apparatus using such a liquefied gas cylinder, even when the apparatus is mounted on a transport truck. Therefore, for example, when sanitizing and/or disinfecting a plurality of wards of a hospital or the inside of a plurality of ambulances, hard work is required to move the sanitizing and/or disinfecting apparatus to the respective locations.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention has been made with the aim of solving the above problems, and it is an object of the present invention to provide an apparatus for sanitizing and/or disinfecting a target space by spraying a chemical including alcohol, which can operate with a simple structure requiring no power supply and is significantly lighter in weight than conventional apparatuses.
[0013] A sanitizing and/or disinfecting apparatus of the present invention supplies a carrier gas that does not react with alcohol to a spray gun to which a chemical container containing a sanitizing and/or disinfecting chemical including the alcohol is attached, and sprays the chemical into a target space by the function of the carrier gas injected from the end nozzle of the spray gun. This sanitizing and/or disinfecting apparatus is characterized by comprising: a gas cylinder filled with the compressed carrier gas; a pressure reducing valve, attached near an outlet of the gas cylinder, for decompressing the gas discharged from the outlet to a predetermined pressure; and a gas hose directly connected to the pressure reducing valve and the spray gun.
[0014] According to the present invention, a gas cylinder filled with a compressed carrier gas is used. The carrier gas discharged in a vaporized state from the gas cylinder is decompressed by the pressure reducing valve without heating, fed to the spray gun through the gas hose and injected from the end nozzle, so that the chemical in the chemical container attached to the spray gun is sprayed by the function of the injected gas. Such spraying can be realized by optimally designing the gas pressure and flow rate on the outlet side of the decompressing valve, the gas hose, the spray gun and the end nozzle. Thus, it is possible to achieve a light-weight apparatus by a decrease in the weight of the gas cylinder; simplify the configuration of the apparatus by the omission of a heater for heating and temperature control means; and achieve improved handling by the elimination of the necessity of securing a power supply. Besides, the apparatus can be used in any place.
[0015] Moreover, in the sanitizing and/or disinfecting apparatus of the present invention, the gas cylinder, pressure reducing valve and gas hose may be mounted on a common truck shared by the spray gun and chemical container.
[0016] According to the present invention, since the light-weight gas cylinder, the pressure reducing valve and the gas hose are mounted on the truck together with the spray gun and the chemical container, it is possible to move the apparatus easily between places of use, thereby achieving improved handling.
[0017] Furthermore, in the sanitizing and/or disinfecting apparatus of the present invention, the chemical container may be detachably attached to the spray gun.
[0018] According to the present invention, the chemical container is detachably attached to the spray gun, so that replacement or supply of chemical is easily and safely performed by replacing the container as a unit.
[0019] The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] FIG. 1 is a side view showing the entire configuration of a sanitizing and/or disinfecting apparatus of the present invention;
[0021] FIG. 2 is a plan view showing the entire configuration of the sanitizing and/or disinfecting apparatus of the present invention;
[0022] FIG. 3 is a side view showing the structure of a spray gun; and
[0023] FIG. 4 is a vertical cross-sectional view of a spray nozzle.
[0024] FIG. 5 is a view of the nozzle.
[0025] FIG. 6 is a view of the nozzle.
[0026] FIG. 7 is a view of the nozzle.
[0027] FIG. 8 is a view of the nozzle.
[0028] FIG. 9 is a view of the nozzle.
[0029] FIG. 10 is a view of the nozzle.
[0030] FIG. 11 is a view of the nozzle.
[0031] FIG. 12 is a view of the nozzle.
[0032] FIG. 13 is a view of the nozzle.
[0033] FIG. 14 is a view of the nozzle.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The following description will explain in detail the present invention, based on the drawings illustrating an embodiment thereof. FIG. 1 is a side view showing the entire configuration of a sanitizing and/or disinfecting apparatus of the present invention, and FIG. 2 is a plan view of the apparatus seen from above.
[0035] As shown in FIGS. 1 and 2 , the sanitizing and/or disinfecting apparatus of the present invention comprises a gas cylinder 1 filled with a compressed carrier gas; a pressure reducing valve 2 connected through a joint 20 to an outlet formed in the upper end of the gas cylinder 1 ; a gas hose 3 connected through a joint 21 to the discharge side of the pressure reducing valve 2 ; and a spray gun 4 attached to the other end of the gas hose 3 . The gas cylinder 1 , pressure reducing valve 2 , gas hose 3 , and spray gun 4 are mounted on a truck 5 which is movably supported by a pair of right and left wheels 50 (only one side is illustrated).
[0036] The truck 5 comprises a pedestal 52 having the right and left wheels 50 attached to the lower portion on one side thereof and a supporting leg 51 protruding from the lower portion on the other side. On the top face of the pedestal 52 supported in parallel to the floor surface as shown in FIG. 1 by the wheels 50 and the supporting leg 51 , a grip pipe 53 that has a suitable length and can be stretched upward is mounted at a position above the wheels 50 . A supporting box 54 is mounted between the legs of this grip pipe 53 .
[0037] The gas cylinder 1 is mounted at the center of the above-described pedestal 52 , and fixed in an upright position as shown in FIG. 1 by supporting a middle portion in a height direction with a projecting supporter 55 positioned on the same side of the supporting box 54 . As shown in FIG. 2 , the supporter 55 comprises a recessed portion capable of accepting the trunk portion of the gas cylinder 1 , and the gas cylinder 1 accepted in this recessed portion is fixed while maintaining a stable posture by being supported at three points on the circumferential surface of the trunk portion.
[0038] Note that it may be possible to place a belt (not illustrated) between the tops on both sides of the supporter 55 , to securely fix the gas cylinder 1 by tightening the belt. Moreover, in order to protect the gas cylinder 1 from a colliding object and improve the appearance, it is preferred to cover the outside of the thus fixed gas cylinder 1 with a box-shaped cover C as shown by the two dotted dash rule in FIGS. 1 and 2 .
[0039] The inside of the gas cylinder 1 is filled with a carrier gas, such as carbon dioxide gas and nitrogen gas, compressed under a predetermined pressure. The carrier gas is discharged in a vaporized state from an outlet that is formed in the upper end of the gas cylinder 1 and can be opened and closed by a valve 10 . If carbon dioxide is used as the carrier gas, most of carbon dioxide is in a liquefied state inside the gas cylinder 1 , and a vaporized gas residing in the upper part of the gas cylinder 1 is discharged from the outlet. If the nitrogen gas is used as the carrier gas, it is not liquefied by the compression under the above-mentioned pressure, is in a vaporized state even in the gas cylinder 1 , and is discharged as it is from the outlet.
[0040] As the carrier gas, any gas that does not react with alcohol included in a later-described chemical 8 used for sterilization and disinfection can be employed, and it is possible to use an inert gas such as neon gas and argon gas as well as the above-mentioned carbon dioxide gas and nitrogen gas. However, since the gas will remain in the air after spraying, it is preferred to use carbon dioxide gas or nitrogen gas which is widely present in the air. Besides, the carbon dioxide gas and the nitrogen gas have the advantages of low costs.
[0041] As shown by the broken line in FIG. 1 , the pressure reducing valve 2 is fixed and supported in a chamber formed in the upper part of the supporting box 54 , and the joints 20 and 21 connected to the inlet side and the outlet side of the pressure reducing valve 2 protrude from both side surfaces of the supporting box 54 . The outlet formed in the upper end of the gas cylinder 1 is connected to the inlet-side joint 20 .
[0042] Further, one end of the gas hose 3 having flexibility is connected to an outlet-side joint 21 protruding from the other face of the supporting box 54 . Connected to the other end of the gas hose 3 is the spray gun 4 which is to be described later. A gun hook 56 is attached to the upper part of the other face of the supporting box 54 , and the spray gun 4 in a non-use state is kept while being caught with the gun hook 56 as shown in FIG. 1 . Note that, in FIG. 2 , illustration of the gas hose 3 and spray gun 4 is omitted.
[0043] The pressure reducing valve 2 is a known valve performing the function of decompressing high-pressure gas fed from the inlet side to a predetermined pressure and feeding it to the outlet side. The pressure reducing valve 2 according to this embodiment is designed to decompress the carrier gas fed from the gas cylinder 1 to a fixed pressure of around 0.2 to 0.5 Mpa and feed it into the gas hose 3 and the spray gun 4 . A pressure gauge 22 for detecting the pressure on the outlet side of the pressure reducing valve 2 is mounted on the top surface of the supporting box 54 so that it can be seen from above as shown in FIG. 2 .
[0044] FIG. 3 is a side view showing the structure of the spray gun 4 . The spray gun 4 comprises a barrel portion 40 , a grip portion 41 and a trigger 42 , and has a known structure in which the gas supplied from the gas hose 3 connected to the end of the grip portion 41 is supplied from the front end of the barrel portion 40 by operating the trigger 42 . A spray nozzle 6 is attached to the front end of the barrel portion 40 .
[0045] The spray nozzle 6 comprises a nozzle body 60 in the form of a cylinder with a hexagonal cross section, and a nozzle head 61 fixed to the front end of the nozzle body 60 . A communication pipe 62 is connected to the circumferential surface of the nozzle body 60 at the middle part in a direction substantially orthogonal to the nozzle body 60 , and a chemical container 7 is attached to the front end of the communication pipe 62 .
[0046] As shown by the cross section in FIG. 3 , the chemical container 7 comprises a container body 70 in the shape of a bottle having an opening on one side, a cover plate 71 for covering the opening of the container body 70 by being screwed on the circumferential edge, and a siphon 72 that passes in and out through the cover plate 71 at the center and is extended to the vicinity of the bottom face of the container body 70 . The chemical container 7 is detachably attached to the communication pipe 62 with a coupler 73 attached to the end of the communication pipe 62 and the outside end of the siphon 72 .
[0047] A sanitizing and/or disinfecting chemical 8 is contained in such a chemical container 7 . The chemical 8 , for example, has a composition prepared by mixing a solution including alcohol as a main component with a suitable amount of water-soluble sanitizing and/or disinfecting agent for improving the sterilization and disinfection effects so that the alcohol concentration is between 65 to 80% by volume. The sanitizing and/or disinfecting agent to be mixed can be suitably selected depending on the bacterial species subjected to sterilization. Since the sanitizing and/or disinfecting agent is water soluble, it is well mixed with alcohol as the main component.
[0048] Note that, as the alcohol to be included in the chemical 8 , it is possible to use alcohol having high volatility and high sterilization and disinfection effects, such as ethyl alcohol, methyl alcohol and isopropyl alcohol. It is also possible to suitably mix these alcohols, or use a denatured alcohol obtained by mixing a predetermined denaturant (perfume or the like). The alcohol to be used may be selected by taking into account the safety and cost in addition to the above-mentioned volatility and sterilization and disinfection effects.
[0049] The chemical container 7 containing such a chemical 8 can be easily attached and detached with the use of the coupler 73 . It is possible to prepare a plurality of chemical containers containing the above-mentioned different types of sanitizing and/or disinfecting agents and suitably replace them according to the target space or target bacterial species. Note that it is also possible to use a single chemical container 7 by opening the cover plate 71 and supplying or replacing the chemical 8 in the chemical container 7 as occasion arises. In the case of using a plurality of chemical containers 7 , as shown in FIG. 1 , it is possible to provide, in the supporting box 54 on the truck 5 a, a storage room for storing the chemical containers 7 before or after use, thereby enabling highly efficient sanitizing and/or disinfecting operations against a plurality of types of bacteria in a plurality of places.
[0050] FIG. 4 is a vertical cross-sectional view of the spray nozzle 6 . As shown in FIG. 4 , a connecting pore 63 for connecting the spray gun 4 is formed in the axial center portion of one end face of the nozzle body 60 , and a coupling pore 64 for connecting the communication pipe 62 is formed in the outer circumferential surface of the middle portion of the nozzle body 60 . The coupling pore 64 communicates with the other end face of the nozzle body 60 to which the nozzle head 61 is attached, through a chemical passage 65 formed in the axial center portion of the nozzle body 60 . The connecting pore 63 communicates with said other end face of the nozzle body 60 through a plurality of gas passages 66 formed at equal intervals outside the chemical passage 65 .
[0051] The nozzle head 61 comprises an inner nozzle 67 screwed into and fixed at a screw hole formed in an end of the chemical passage 65 , and an outer nozzle 68 surrounding the outside of the inner nozzle 67 . The outer nozzle 68 is fixed by sandwiching a stopper portion provided on the circumference thereof between the end face of the nozzle body 60 and a stopper ring 69 fastened to the outer circumference of the nozzle body 60 on the same side. Each of the inner nozzle 67 and outer nozzle 68 has a shape with a diameter narrowing toward the tip thereof like a funnel. A liquid jet orifice 67 a of a small diameter is formed in the tip of the inner nozzle 67 , and an annular gas jet orifice 68 a is formed in the tip of the outer nozzle 68 so that it is located between the outer nozzle 68 and the liquid jet orifice 67 a . The chemical passage 65 communicates with the inside of the inner nozzle 67 . The gas passages 66 communicate with an annular space between the outer nozzle 68 and the inner nozzle 67 .
[0052] The sanitizing and/or disinfecting apparatus of the present invention constructed as described above is used by opening the valve 10 in the upper end of the gas cylinder 1 , holding the spray gun 4 with the tip of the spray nozzle 6 directed into a target space, and pulling the trigger 42 of the spray gun 4 . Thus, after the carrier gas inside the gas cylinder 1 is decompressed to a predetermined pressure by the pressure reducing valve 2 , it is fed to the spray nozzle 6 through the gas hose 3 and the spray gun 4 , introduced into the outer nozzle 68 through the gas passages 66 formed in the nozzle body 60 , and jetted out from the gas jet orifice 68 a formed in the tip of the outer nozzle 68 .
[0053] In the process of injecting the carrier gas as described above, there is a possibility that volume expansion due to decompression in the pressure reducing valve 2 causes the peripheral part to freeze. However, it is possible to delay the time to freeze by appropriately determining the feed rate of the carrier gas.
[0054] The carrier gas feed rate is determined by the pressure on the outlet side of the pressure reducing valve 2 that is set as described above and the strength of the internal resistance of the gas passage on the outlet side of the pressure reducing valve 2 , namely, the gas hose 3 , spray gun 4 and spray nozzle 6 , whereas the necessary continuous injection time of the carrier gas under the condition of use to be described later is around several minutes, except for an excessively large target space. By appropriately designing the gas hose 3 , spray gun 4 and spray nozzle 6 , the continuous injection for such a period of time can be realized without causing freezing. It was confirmed by experiments that continuous injection for 15 minutes or more is possible by optimally designing the gas hose 3 , spray gun 4 and spray nozzle 6 .
[0055] It has been determined that in one embodiment the following conditions lead to optimal results.
[0056] Gas pressure at the outlet side of the pressure reducing value 2 may be set to between 10-80 psig. The pressure at the inlet of the spray gun 4 may also be between 10-80 psig. In one embodiment, the optimal relationship between the area of the liquid jet orifice 67 a and the gas jet orifice has been determined to be such that the area of the liquid jet orifice 67 a is 36% as large as the gas jet orifice 68 a. This relationship is plotted in Chart F. In a preferred embodiment the gas pressure at the outlet side of the pressure reducing value 2 is set to 30 psig.
[0057] Chart E shows a second embodiment where satisfactory results may be achieved with relative liquid passage area and gas passage area in a 10% higher and a 10% lower range.
[0058] A negative pressure is created around the liquid jet orifice 67 a in the tip of the inner nozzle 67 by the injection of the carrier gas as described above, and the inside of the inner nozzle 67 , the chemical passage 65 , the coupling pore 64 , and the inside of the communication pipe 62 have negative pressure. As a result, the chemical 8 in the chemical container 7 connected to the communication pipe 62 is sucked into the siphon 72 , reaches the inside of the inner nozzle 67 through the coupling pore 64 and the chemical passage 65 , is jetted out from the liquid jet orifice 67 a opened in the tip of the inner nozzle 67 , and sprayed as small diameter particles by the function of the carrier gas injected from the gas jet orifice 68 a.
[0059] The particle size of the chemical 8 sprayed in this manner is determined by the design of the nozzle head 61 , particularly the sizes of the gas jet orifice 68 a and liquid jet orifice 67 a. In the sanitizing and/or disinfecting apparatus of the present invention, the nozzle head 61 is designed so that the particle size is between 15 and 20 .mu.m under the above-mentioned conditions of the pressure and volume of carrier gas.
[0060] In the sanitizing and/or disinfecting apparatus of the present invention, as the gas source of a carrier gas, a gas cylinder 1 filled with the compressed gas is used. As this type of gas cylinder 1 , gas cylinders with various content capacities such as 1 Kg, 3 Kg and 5 Kg are commercially available, and even a relatively large gas cylinder 1 with a content capacity of 5 Kg has a total weight of 24 Kg or so. Besides, the carrier gas fed from the gas cylinder 1 is designed to be delivered to the spray gun 4 without heating and injected from the spray nozzle 6 , and therefore it is not necessary to use heater for heating and temperature control means for the heater.
[0061] The chemical 8 sprayed with such a particle size is widely spread throughout the target space, drifts while gradually settling, and then adheres to the inside surface (floor surface, wall surface, etc.) in the target space. During this time, the target space is sterilized and disinfected by the functions of the alcohol as the main component and the added water-soluble sanitizing and/or disinfecting agent. At this time, since the carrier gas that does not react with alcohol, such as carbon dioxide gas and nitrogen gas, is used, it is possible to isolate the alcohol in the chemical 8 sprayed from the spray nozzle 6 from oxygen in the target space, thereby obtaining a high sanitizing and/or disinfecting function of alcohol while avoiding the risk of ignition immediately after spraying. Moreover, since the spayed chemical 8 in the form of fine particles includes high-concentration alcohol with quick dry characteristics as the main component, it rapidly evaporates after adhering to the inside surface in the target space without residing for a long time. Thus, there is no possibility of new breeding of various types of bacteria by the remaining moisture, and a post treatment including wiping is unnecessary.
[0062] Therefore, even when a relatively large carbon dioxide gas cylinder having a content capacity of 5 Kg is used, the total weight of the apparatus including the pressure reducing valve 2 , gas hose 3 , spray gun 4 and spray nozzle 6 is within 24 Kg or so. Such an apparatus can be freely moved by mounting the apparatus as a unit on the truck 5 having a simple structure as shown in FIG. 1 , holding and inclining the grip pipe 53 , and turning the left and right wheels 50 . Furthermore, since this apparatus does not include a heater for heating, the power supply for the heater is unnecessary. Hence, for example, a plurality of wards of a hospital and the inside of a plurality of ambulances can be easily sterilized and disinfected by quickly moving the apparatus to the respective locations.
[0063] For sterilization and disinfection of the inside of an ambulance, a satisfactory result is obtained by 2 minutes spraying or so. With the use of a gas cylinder having a content capacity of 5 Kg, it is possible to sterilize and disinfect approximately 25 ambulances. In this sanitizing and/or disinfecting process, since spraying is stopped while moving the apparatus from one location to another, if the apparatus is designed to inject the carrier gas continuously for 15 minutes or more as described above, the process can be performed substantially continuously.
[0064] Besides, the gas cylinder 1 filled with compressed nitrogen gas is constructed using a high-strength resin such as Kevlar (product name) fiber reinforced resin so as to withstand the internal pressure of the nitrogen gas in a vaporized state. With the use of such a gas cylinder 1 , it is possible to further decrease the total weight of the apparatus, and, for example, the user can use the apparatus while holding the gas cylinder 1 on his/her back.
[0065] As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalence of such metes and bounds thereof are therefore intended to be embraced by the claims.
[0066] The following are a series of chart that shows the relationship of the parameters.
Chart A
Carrier Gas Volume Flow Rates
Regulator 1
[0067] 1 lb of CO 2 liquid=8.741 ft 3 of gas
0.028 (Inch Diameter) liquid orifice with corresponding gas passage
1.0 lb of CO 2 liquid×8.741=8.741 ft 3 of gas/5 min
1.2 lb of CO 2 liquid×8.741=10.489 ft 3 of gas/5 min
Regulator 1
[0068] 0.040 (Inch Diameter) liquid orifice with corresponding gas passage
2.4 lb of CO 2 liquid×8.741=20.978 ft 3 of gas/5 min
2.6 lb of CO 2 liquid×8.741=22.727 ft 3 of gas/5 min
2.8 lb of CO 2 liquid×8.741=24.475 ft 3 of gas/5 min
Regulator 2
[0069] 0.040 (Inch Diameter) liquid orifice with corresponding gas passage
2.6 lb of CO 2 liquid×8.741=22.727 ft 3 of gas/5 min
2.4 lb of CO 2 liquid×8.741=20.978 ft 3 of gas/5 min
2.2 lb of CO 2 liquid×8.741=19.230 ft 3 of gas/5 min
2.0 lb of CO 2 liquid×8.741=17.480 ft 3 of gas/5 min
1.8 lb of CO 2 liquid×8.741=15.734 ft 3 of gas/5 min
3.0 lb of CO 2 liquid×8.741=26.223 ft 3 of gas/5 min
[0000]
CHART B
CO 2 Consumption Rates
CO 2 cylinder outlet
CO 2 Cylinder
CO 2 Cylinder
CO 2 Cylinder
pressure (inlet pressure
Time
Time
Time
Start Weight
Weight Stop
Weight
full tank 850 psi)
Start
Stop
Change
(lbs)
(lbs)
Change (lbs)
Regulator 1 Liquid Orifice 0.028 inches ID, 0.050 inches OD; circumferential gas orifice 0.070 inches ID
20
10:20
10:25
0:05
44.4
43.4
1.0
20
10:27
10:35
0:08
43.4
42.2
1.2
20
10:35
10:40
0:05
42.4
41.0
1.2
20
10:50
10:55
0:05
41.0
39.0
1.0
0
10:57
11:02
0:05
39.0
Regulator 1 Liquid Orifice 0.040 inches ID, 0.100 inches OD; circumferential gas orifice 0.120 inches ID
20
39.0
20
11:10
11:15
0:05
39.0
36.2
2.8
20
11:18
11:23
0:05
36.2
33.6
2.6
20
11:27
11:32
0:05
33.6
31.0
2.6
20
11:35
11:40
0:05
31.0
28.6
2.4
0
11:44
11:47
0:03
28.6
27.6
1.0
Regulator 1 Liquid Orifice 0.060 inches ID, 0.150 inches OD; circumferential gas orifice 0.180 inches ID
30
9:20
9:25
0:05
44.0
42.0
2.0
30
9:26
9:31
0:05
42.0
40.6
1.4
30
9:32
9:37
0:05
40.6
38.6
2.0
30
9:38
9:43
0:05
38.6
34.4
4.2
30
9:44
9:49
0:05
34.4
32.2
2.2
28 ↓
9:49
10:04
0:05
32.2
29.4
3.2
8 ↓
10:05
10:08
0:03
29.4
28.8
0.6
Regulator 1 Liquid Orifice 0.028 inches ID, 0.050 inches OD; circumferential gas orifice 0.070 inches ID
30
10:04
10:09
0:05
45.6
44.8
.8
0.8
30
10:10
10:15
0:05
44.8
44.0
.8
0.8
30
10:16
10:21
0:05
44.0
43.4
1.6
0.6
30
10:22
10:27
0:05
43.4
42.4
2.2
1.0
30
10:28
10:33
0:05
42.4
41.6
3.3
0.8
31
10:33
10:38
0:05
41.6
41.0
4
0.6
33
10:39
10:44
0:05
41.0
40.0
4.6
1.0
34
10:45
10:50
0:05
40.0
39.4
5.6
0.6
34
10:51
10:56
0:05
39.4
38.8
6.2
0.6
35
10:57
11:02
0:05
38.8
37.7
6.8
0.9
35
11:03
11:08
0:05
37.7
36.8
7.9
0.9
36.8
8.8
Regulator 2
28
12:01
12:06
0:06
45.0
42.4
2.6
28
12:10
12:15
0:05
42.4
39.4
3.0
28
12:17
12:22
0:05
39.4
37.0
2.4
28
1:18
1:23
0:05
37.0
34.8
2.2
28
1:25
1:30
0:05
34.8
33.0
1.8
28
1:31
1:36
0:05
33.0
30.6
2.4
28
1:35
1:38
0:03
30.6
28.6
2.0
0
1:39
1:40
0:01
28.6
27.2 | An apparatus for sterilizing and disinfecting a target space by spraying a chemical including alcohol includes a spray gun to which a chemical container containing a sterilizing and disinfecting chemical including alcohol is attachable, a gas cylinder filled with a compressed carrier gas that does not react with alcohol, and a pressure reducing valve for decompressing the carrier gas discharged in a vaporized state from the gas cylinder to a predetermined pressure, and is constructed so that the pressure reducing valve and the spray gun are directly connected with a gas hose and mounted on a common truck. The sterilizing and disinfecting apparatus can operate with a simple structure requiring no power supply, and is much lighter in weight compared to conventional apparatuses. | 0 |
FIELD OF THE INVENTION
The, present invention relates to an apparatus for coating a substrate in general and to a short dwell coater apparatus in particular.
BACKGROUND OF THE INVENTION
Paper is formed of a mat of fibers, typically cellulose fibers from wood, produced by draining fibers from stock in a papermaking machine. The fibers making up a sheet of paper influence the paper's surface finish or texture. The surface attributes of the paper may be modified by calendering or chemically treating the paper. However, for many applications, such as for the paper employed in magazines and printed advertising in flyers, a desirable glossy high brightness finish can best be achieved by coating the paper.
The coating material is typically comprised of a mixture of clay or fine particulate calcium carbonate which provides a flat filled surface, titanium dioxide for white coloring, and a binder. Coated papers come in a number of weights and grades depending on the weight of the paper and the thickness of the coating.
One type of coater, called a flooded nip coater, is particularly suitable for heavier grades of coated paper, and employs a roll partly submerged in a bath of coating. The roll transfers a film of coating to one side of the paper web. The coated web is wrapped around a backing roll which forms a nip with the coating roll. Following contact with the coating roll the web passes around the backing roll to a metering blade which contacts the applied coating and controls the overall thickness of the coating.
For lightweight paper grades, which may be run at higher machine speeds, the short dwell coater has been developed. The short dwell coater maintains a pond of coating which is held against a backing roll. A paper web is directed about the backing roll through the pond. The web's short dwell time in the pond of coating results in a relatively thin layer of coating on the web.
An improved coater known as the BA 1500 coater by Beloit Corporation employs a combination of a short dwell coater with a wiping blade similar to the flooded nip coater and has proven practical at a wide range of paper weights and paper speeds.
Short dwell coaters are advantageously used for coating fluids on lightweight and other grades of paper. The short dwell coater employs a pond of coating material. The pond is formed in a feed cavity and fed with an excess of coating material. The pond is caused to overflow in the up machine direction thereby flooding the web and pre-wetting it as it approaches the pond. On the downstream side, a metering blade controls the amount of coating material which is applied to the moving web. The coating material is fed into the pond and against the moving web at relatively low velocity. However, upon contact with the web, the coating material becomes entrained in a boundary layer attached to the web which is moving at a velocity of 75 to 100 feet per second or more. The high velocity boundary layer impinges on the doctoring blade and is turned downwardly into the pond creating a recirculating zone between the down machine end of the pond and the coating feed at the up machine end of the pond where the excess coating overflows. The paper web as it enters the pond and is wetted by the pond pulls along a boundary layer of air which penetrates some distance into the pond as the web moves through the pond.
The location where the paper becomes wetted by the coating material is defined as the dynamic contact line. As the speed of the machine increases beyond forty-five hundred feet per minute, the fluid flow in the pond tends to destabilize. A result of destabilized flow is that the dynamic contact line oscillates both in the machine direction and in the cross-machine direction. Further, air from the boundary layer is entrained at the oscillating dynamic contact line and is eventually entrapped in the vortex formed by the recirculating fluid flow within the pond. The vortex periodically becomes overcharged with air and expels coating out of the pond. These two phenomena, the destabilization of the flows and the accumulation of air in the vortex within the pond results in coating defects which can manifest themselves as streaks on the coated paper. At the same time that increasing the paper web speed in a papermaking machine can have deleterious effects on coating quality, increased machine speed is essential to increased productivity and reduced costs. A papermaking machine is a very substantial capital investment which must be amortized over the quantity of paper manufactured thereon. Therefore, increasing the machine speed is critical to continued increase in papermaking productivity.
What is needed is a film applicator capable of functioning at higher speeds without inducing defects in the paper produced.
SUMMARY OF THE INVENTION
The film applicator of this invention employs a backing roll over which substrate is drawn. An applicator head is positioned below the backing roller and forms a pond of coating material between an up machine overflow lip and a down machine metering element. Coating material at a relatively low velocity flows into the pond adjacent to the overflow lip. Whereas in a conventional short dwell coater, the down machine edge of the pond is terminated by a metering element or blade, in the applicator of this invention, an extraction plate is disposed between the pond and the metering element. The plate extends from the coating inlet to a position proximate to and converging with the backing roll, where it premeters the amount of coating applied to the substrate. The extraction or premetering plate is spaced from the metering element and a low pressure area is constructed therebetween. The extraction plate preferably has perforations and works to remove a large portion of air and excess coating away from the substrate preventing instabilities from propagating to the metering element. The extraction plate minimizes the mixing problem between the feed and recirculating coating in the pond, thus reducing the macroscopic scale flow variations. It is these flow variations adjacent to the metering element which are strongly suspected as the root cause of the streaking or incomplete coating of a substrate.
It is a feature of the present invention to provide a film applicator which may operate at higher machine speeds.
It is another feature of the present invention to provide a film applicator which applies a more uniform coating to a substrate.
It is a yet further feature of the present invention to provide a film applicator wherein entrained air within the pond is removed.
It is a still further feature of the present invention to provide a film applicator wherein flow instabilities are prevented from propagating to the applicator metering element.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view partly cut away in section of the applicator of this invention.
FIG. 2 is a cross-sectional elevational view of the applicator of FIG. 1.
FIG. 3 is a fragmentary view of a paper web passing through a prior art coater, and the resultant coating disposition on the web.
FIG. 4 is a cross-sectional view of an alternative embodiment applicator of this invention having recirculation openings.
FIG. 5 is a fragmentary elevational view of the recirculation opening pattern in the applicator of FIG. 4.
FIG. 6 is a fragmentary elevational view of the recirculation opening patern of an alternative embodiment applicator of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to FIGS. 1-6 wherein like numbers refer to similar parts, film applicator 20 is shown in FIGS. 1 and 2. An uncoated substrate 36 passes through the applicator 20 for application of the desired surface coating. The applicator 20 has an applicator head 22 which extends at least the width of the web and which is positioned beneath a backing roll 24. The applicator head 22 has a rigid housing 23 which extends in the cross machine direction and which has an inlet 26 through which coating is introduced to a pond 28 formed between an upstream baffle plate 30 and an angled rigid premetering plate 32.
The coating 34 is applied from the pond 28 to the substrate 36 as it passes between the backing roll 24 and the applicator head 22. A gap 38 is defined between the upper lip 40 of the baffle plate 30 and the substrate 36. The coating 34 overflows the baffle plate 30 and is allowed to escape the pond 28 through the gap 38. The gap 38, which is typically between zero and one inch and preferably between one-sixteenth and three-sixteenths of an inch high, is used to decrease the amount of air which is brought by the boundary layer of the substrate 36 into the pond 28. The overflow or flood of coating 34 which flows through the gap 38 displaces a portion of the air boundary layer. The overflow then flows into a trough 42 which is positioned upstream of the baffle plate 30. The overflowing coating 34 is collected in the trough 42 and recycled. A dynamic contact line 44 is formed where the coating 34 displaces the boundary layer.
The advantages of the film applicator 20 of this invention for applying coating fluids on lightweight and other grades of paper are its superior runnability and ease of operation for machine speeds up to forty-five hundred feet per minute or higher. As machine speeds are constantly increased, sheet quality becomes a problem as coating uniformity deteriorates. At machine speeds above thirty-five hundred feet per minute on the short dwell coater, certain formulations of coating develop low coat weight streaks and blotches, marring the appearance of the base sheet and thereby reducing the operation window within which the product may be made. Experimental data show that this uniformity problem can be attributed to a complex interplay of variables in the coating pond, including the existence of vortexes being generated in the pond, air entrained at the dynamic contact line, mixing difficulties between the low velocity incoming and high velocity recirculating coating, and flow variations from the feed in the cross-machine direction.
The difficulties in achieving an even coating on the web are illustrated by the view of a prior art coater 45 shown in FIG. 3. The exemplary prior art coater has a metering blade 52 downstream of a coating pond. As the paper web 47 passes through the pond to the metering blade 52, air trapped in the boundary layer is drawn with the web. At a particular instant, the boundary layer 46 defines a dynamic contact line 46 which is wavy and unpredictable. In FIG. 3 the coated paper 48 is shown shaded and the uncoated paper web 47 is shown as unshaded. Fingers of air 50 extend into the pond toward the blade 52 and on occasion prevent coating from reaching the paper's surface forming an uncoated streak 54 on the coated paper. The applicator 20 reduces the problems associated with this unwanted air by using a low pressure region to extract air from the pond.
When run at high speeds, some prior art coaters are subject to two problems related to the boundary layer of air which is pulled into the pond. The first relates to the flow regime created by the paper web. When a papermaking machine is run at high machine speeds, that is at four-and-a-half to six thousand feet per minute, the web can induce unstable fluid flow within the pond. The unstable flow can be chaotic in nature. A chaotic system is one in which the future state of the system cannot readily be predicted from the past states of the system. In practice, it means, as shown in FIG. 3, that air fingers and streaks appear and disappear and move over time in a way that is not readily predictable. Thus it is difficult to find an applicator design which will eliminate the streaks in a chaotic environment.
A second problem caused by the interface of the rapidly moving substrate 36 and the pond 28 is that a vortex is created as shown by arrows 55 in FIG. 2. The vortex is created by the recirculation of coating within the pond caused by the rapidly flowing boundary layer of coating adjacent the moving web. This movement sets up a recirculation zone in the pond 28. The vortex can induce a region 56 of lower pressure at its center within the pond. This region of lower center 56 attracts air bubbles which have been incorporated in the recirculating pond coating by induction from the web air boundary layer. The air typically continues to accumulate in the vortex until it reaches a critical amount, at which point the accumulated air is liable to expel the coating out of the pond and collapse. This explosive breakdown of the coating flow leads to streaking and uneven coating of the paper.
The film applicator 20 of this invention solves the problem of unstable flow and air accumulation in the vortex with the premetering plate 32. The premetering plate 32 extends from the coating inlet wall 57 to an engagement point or a nip 58 adjacent to the substrate 36 and the backing roll 24. The premetering plate defines a region 60 of the pond which is narrowly tapered. The region 60 tapers in the machine direction and defines a narrow wedge of coating where the boundary layer attached to the substrate is gradually reduced. Once it has been sufficiently reduced, the flow adjacent to the substrate approaches a stable uniform flow condition. At this point, it is no longer subject to cross machines fluctuations and may be adjusted to produce a smooth coating. Between the premetering plate 32 and a final metering element 62 which can be a blade, rod (smooth or grooved), plate or roll, a low pressure cavity 64 is formed. The cavity is drained through one or more valves 66 which control the pressure in the cavity 64 which is typically maintained below the pressure next to the substrate or below atmospheric pressure if vacuum is applied.
Reduction of the vortex instability and the air entrained therein is achieved by creation of a region of low pressure along the inside surface 68 of the premetering plate 32. Low pressure on the surface 68 is produced by holes 72 in the premetering plate 32 which are connected with the low pressure cavity 64. The holes 72 preferably have a random or pseudo-random pattern concentrated in the middle one-third of the plate 32. The holes 72 serve two functions. By partially or completely removing the recirculating flow along the inside 68 of the premetering plate 32, the severity of the vortex is considerably reduced or eliminated. Secondly, by creating regions of low pressure on the inside of the premetering plate, the air is drawn from the vortex and from the coating generally to the low pressure regions adjacent to the inside 68 of the premetering plate 32, where the air is then drawn along with coating through the holes into the low pressure cavity 64.
In operation, the substrate 36, shown in FIG. 1, is brought into engagement with the backing roll 24 and thence through the flooded gap 38 into the pond 28. As the substrate approaches the premetering plate nip 58, a condition approaching a stable uniform flow regime is established and a relatively thick coating is applied to the substrate. The heavily coated substrate then proceeds past the nip 58 into the low pressure region where all fluid dynamic forces are removed from the coating. The heavily coated substrate then approaches and passes over the metering blade 62 where the majority, typically ninety percent, of the coating is scraped away leaving a uniform layer of coating on the substrate 36. The coated substrate 36 then leaves the backing roll 24 and passes over a turning roll 78 and enters a dryer section (not shown).
The paper coating is typically comprised of a plate-like filling material such as clay or calcium carbonate; a whitening agent, typically titanium dioxide; and a binder such as casein hide glue or a synthetic glue. The coating is typically applied in a slurry containing forty to seventy percent dry weight of coating materials. It should be understood, however, that the applicator 20 can be employed with coatings of various viscosity and dry solid content depending on the type of substrate being coated and the thickness of the coating being formed.
It should be understood that although the holes in the premetering plate are shown and described as being distributed in the middle third of the plate, they could be located across the entire plate or in various selected regions. Further it should be understood that the holes could be eliminated altogether and that the tapered region formed by the premetering plate and the low pressure cavity can form an improved coating on the substrate without the employment of the premetering plate with holes.
It should be understood that by feeding the coating into the pond 28 along the baffle plate 30 so that the coating enters the back of the pond cavity, the amount of air entrained into the coating is reduced. Air and excess coating which enters into the application zone defined by the tapered region 60 are removed by the holes in the premetering plate into the low pressure cavity. The removal of the circulating flow prevents instabilities from propagating into the application zone, eliminating the mixing problems between the coating entering the inlet 26 and the recirculating coating in the pond. The reduction of the macroscopic scale fluctuation variations results in a substrate with a more even coat.
An alternative embodiment applicator 80 is shown in FIGS. 4 and 5. The applicator 80 is similar to the applicator 20, but is provided with an array of holes 90 in a wall 85 which defines the infeed channel 87 with respect to the housing 82. The coater 80 is positioned to apply coating material 34 to a web 86 which passes over a backing roll 84. The holes 90 allow a portion of the metered coating 34 to be recirculated by allowing access to the feed channel from the coating chamber 83. This recirculation of coating allows a reduction in pump rate requirements. The openings or perforations 90 may be an array of elongated slots which overlap as shown in FIG. 5. The slots are overlapped to ensure equal open area in a given cross-machine orientation. The overlapping of the slots can result in 0 to 20 percent more open area than an alternative hole pattern of simple circular openings 98 in a recirculation channel wall 96 shown in FIG. 6. Other hole patterns may also be employed. It should be noted that the applicator 80 may also be employed in a size press.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. | An applicator head is positioned beneath a backing roll over which a substrate can be drawn. The applicator head has a housing which contains a pond of coating material between an up machine overflow lip and a down machine extraction plate or premetering plate. Coating material at a relatively low velocity flows into the pond adjacent to the overflow lip. The premetering plate extends radially from the coating inlet to a position proximate to and converging with the backing roll, where it premeters the amount of coating applied to the substrate. The premetering plate preferably has a plurality of holes through which coating and air are drawn. A metering element is spaced downstream of the premetering plate, and a low pressure area is constructed therebetween. Air and coating are drawn from the low pressure area through a valve, and the pressure thereby controlled. | 3 |
This invention relates to an apparatus for liquid treatment of a lengthy woven or knitted cloth band of an endless form.
The invention is particularly intended for liquid treating such cloth in a treating liquid for scouring, dyeing and desizing purposes.
According to the apparatus of the invention, a cloth band of a preferred length is provided to helically wind and depend from cylindrical drum which are longitudinally connected and axially mounted on a shaft, such cylindrical drum being rotated at peripheral speeds progressively reduced from one end to other end, wherein each helical part of the cloth band is depended downwardly from drum at a uniform length and thereafter the cylindrical drum are rotated at an equal speed thereby circulating the cloth through a treating liquid in a tub to apply a desired treatment to the cloth band such as scouring, dyeing and desizing.
BACKGROUND OF THE INVENTION
Prior art methods of the kind for liquid treatment of a cloth band included the steps of providing a cloth band of an endless form depended upon a cylindrical drum, suspending the cloth band from the drum and passing it repeatedly through a treating liquid in a tub below the cylindrical drum. One usual method was provided such that a cloth band of a preferred length and in endless connection is depended from the cylindrical drum, the depending lower part of the cloth band being dipped in a treating liquid in a treating tub, thereafter the cylindrical drum are rotated to permit the cloth band depended from the drum to pass through the treating liquid continuously. The method as described however is very cumbersome and therefore not desirable for use because separate cloth bands must be prepared in a large number to meet the need and much troubles are entailed from the necessity of suspending each cloth band on the drum or removing each used cloth band from the drum.
In alternate case, the cloth band was formed in a lengthy band with the ends connected to each other, the connected cloth band being helically depended from the drum with the lower parts drooping in a loose condition. The lower parts of the cloth band helically depending are dipped in a treating liquid. The cylindrical drum is then rotated in the similar way to treat the cloth band in like manner as described in the first example.
According to the above prior art methods, the cloth band may be taken out of the tub after treatment but as the entire band is formed in a serial connection, it is rather convenient for drawing out the cloth band from the tub simply by disconnecting the joints of ends of the cloth band so that the cloth band can be readily taken out continuously from the drum and also from the treating tub. However the suspension of the cloth band helically on the cylindrical drum so as to get uniform lengths of dipped parts in the treating liquid or of parts drooping from the drum to be dipped in the treating liquid in a loosened way has been a difficult problem to solve.
BRIEF SUMMARY OF THE INVENTION
The invention provides an apparatus for liquid treatment of a lengthy woven or knitted cloth band of an endless form for scouring, dyeing and desizing purposes. Normally the cylindrical drums are consisted of one or more drum members having same diameters mounted on a same shaft and arranged axially in a longitudinal connection. On the cylindrical drums is wound a cloth band which may be helically suspended downwardly of the drums with a number of helical parts of the cloth band depended from the cylindrical drums. By rotation of the cylindrical drums with the peripheral speeds progressively reduced from a first drum toward a last one, each helical part of the cloth band may depend downwardly at a uniform length. All cylindrical drums in serial connection are rotated at equal speeds thereafter.
It is a primary object of the invention to provide an apparatus for liquid treatment of a lengthy cloth band of woven or knitted material for scouring, dyeing and desizing purposes, which apparatus is simple and efficient for practice and brings no troubles in charging the cloth band and treating and drawing out the product.
It is a further object of the invention to provide a novel mechanism for use in the apparatus for liquid treatment of a lengthy cloth band of woven or knitted material for scouring, dyeing and desizing, which can apply a desired uniform treatment for the manufacture of a product before charging a material cloth band, that is, in the initial stage of liquid treatment.
It is a further object of the invention to provide a novel mechanism most adapted for the apparatus for liquid treatment of a lengthy cloth band of woven or knitted material which can apply an equal speed to the cylindrical drum after a material cloth is charged onto the cylindrical drum which are uniform in shape and suited for manufacture of a product.
It is an additional object of this invention to provide an apparatus for liquid treatment of a lengthy cloth band of woven or knitted material, which has a simple and efficient construction.
These and other objects and advantages of the invention will be achieved by application of the mechanism and also by the process and operation of the apparatus of the present invention, of which specific embodiments of the invention will be illustrated with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an example of a conventional apparatus showing a part thereof being cut away;
FIG. 2 is a cross section taken along the line II--II of FIG. 1;
FIG. 3 is a perspective view of other example of a prior art apparatus showing a part thereof being cut away;
FIG. 4 is a view illustrating an essential portion of the apparatus according to the invention;
FIG. 5 is a front view of a preferred mechanism used in the apparatus of the invention, showing its cross section being partly cut away;
FIGS. 6 and 7 are other embodiments of the apparatus of this invention illustrating the apparatus in practical use;
FIG. 8 is a view of FIG. 6 illustrating the condition of a lengthy cloth band in the initial stage of operation;
FIG. 9 is a view illustrating a preferred example of treatment of a lengthy cloth band of FIG. 6; and
FIG. 10 is a front view showing other construction of the cylindrical drum according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Previous to illustration of an embodiment of the invention, one example of the prior art technique is now described with reference to FIG. 1. In the drawing, a preferred number of cloth bands, 11, 12, 13 and 14 are shown connected in an endless form and arranged to be depended in parallel from a longitudinal cylindrical drum 15 axially mounted on a shaft 16. A guide plate 17 is provided for guiding the cloth band. Each cloth band 11, 12, 13 and 14 has a downwardly drooping part 18, 19, 20 and 21, which is arranged to dip in a treating liquid 22 (shown in FIG. 2) of a treating tub 23. The cylindrical drum 15 is rotated to continuously pass over the cloth bands 11, 12, 13 and 14 through the treating liquid 22. This type of the conventional apparatus is required a number of endless cloths, each of which is suspended from the cylindrical drum 15 as shown and removed from the drum after it is treated with liquid. It has been found that this treating operation has been extremely troublesome in practice. A cross section of the apparatus taken along the line II--II of FIG. 1 is shown in FIG. 2.
Another example of the prior art technique is shown in FIG. 3, in which ends of a cloth are previously connected for subsequent treatment. The cloth band is formed in a lengthy endless band 24, the lower part of which is loosend and helically applied on the cylindrical drum 15. The loosend lower parts 25, 26, 27 and 28 are dipped in the treating liquid. By rotation of the cylindrical drum 15, the endless band 24 is passed through the treating liquid. As shown in the drawing, a guide ring 29 is provided for the endless band. In the apparatus of the type, the endless band is taken out of the cylindrical drum and treating means after treatment is carried out in a manner different from that of the apparatus shown in FIGS. 1 and 2. The entire cloth band is formed in a serial connection, which cloth can be taken out all in succession in a relatively simple way. When one of the connection parts of the cloth band is detached from other and one end of the detached cloth is pulled out, the cloth can be pulled out continuously very simply and conveniently. In this occasion, however, it is quite difficult to preferably helically put the cloth band in endless connection upon the cylindrical drum 15 so that the lower parts 25, 26, 27 and 28 of the cloth band each depending in the treating liquid may have substantially uniform lengths. It is essentially important though to provide an arrangement of cloth bad depending at uniform lengths and substantially helically wound on the cylindrical drum.
The present invention has eliminated the above-mentioned drawbacks of the prior arts as shown in FIG. 3. In the first embodiment of the invention, as shown in FIG. 4, the apparatus is consisted of composite cylindrical drum 30 which is longitudinally connected and disposed on a same shaft 16, which composite cylindrical drum consisting of a number of cylindrical drum members each having a same diameter. The composite cylindrical drum 30 thus being formed in a serial connection, each drum may have a peripheral speed of a preferred ratio of rotation relative to the rotation of other drums. Thus, the drums may respectively be rotated at progressively reduced peripheral speeds from a first drum A through a last one D, that is, from the nearest drum A through the farthest drum D relative to a housing 31. The cloth band in serial connection and contained in the housing 31 can be drawn out of the housing and put on the serially connected drums having each helical part of the cloth band depending from each and one cylindrical drum. In this arrangement, the cylindrical drums may be rotated respectively at various peripheral speeds in the order of progressively reduced ratios as preferred. After rotation of the drums in a certain period of time, there may be obtained cloth bands of uniform lengths with loosened parts 32, 33, 34 and 35 of a lengthy cloth band 36 depending from the drums A, B, C and D. In this occasion, two ends 37 and 38 of the lengthy cloth band as shown in FIG. 4 are connected in an endless form. Preferably the connected cloth band may be formed endless in shape before it is suspended from each drum.
Thus, the drums may be rotated at the same peripheral speeds. It will result that each part of the cloth band on each drum will droop from the drum having a preferred form always in continuity.
Below is illustrated an example of a mechanism with reference to FIG. 5 which is employed for varying the speed of each drum mounted on a shaft for all drums in connection.
The drawing shows for illustration a combination of two small cylindrical drums A and B formed into a composite cylindrical drum 30. In FIG. 5 is shown a drum A located closest to the housig 31 of FIG. 4 and secured to a shaft 16, which shaft is journalled on bearings 39 and 40. On the shaft 16 is mounted a rotary sprocket wheel 41. A chain 42 is provided between the rotary sprocket wheel 41 and a first driving sprocket wheel 43 attached to one end of a drive shaft 44 as separately provided. The shaft 16 is rotated through rotation of the drive shaft 44. A clutch 45 is provided on a shaft 16 to slidably move to left and right. The drum B may be located adjacent to the drum A on the shaft 16, an internal drum 46 is rotatably attached to the shaft 16, which internal drum 46 is secured with the drum B. The internal drum 46 is further attached with a rotary sprocket wheel 47, which is connected by chain 48 to a second driving sprocket wheel 49 fixed to other end of the drive shaft 44. It will be seen that the rotary sprocket wheel 47 of the second drum B has a diameter relatively larger than that of the rotary sprocket wheel 41 of the first drum A. The two driving sprocket wheels 43 and 49 as described and mounted on the drive shaft 44 have the same diameter. The second driving sprocket wheel 49 which rotates the second drum B may preferably be provided with a freewheel means (not shown).
A pawl 50 is provided on an outer side of the rotary sprocket wheel 47 of the second drum B, which pawl is located opposite to the engaging part 51 of the clutch 45 as above described.
Operation of the mechanism according to the invention is now described.
When the drive shaft 44 is rotated, the first and second drums A and B are rotated and at this moment the second drum B is rotated slower than the first drum A.
Thereafter, the lengthy cloth band 36 of the lower part of each drum having equal loosening and being dipped in the treating liquid.
During this operation, the clutch 45 is moved as in FIG. 5 to the right (as shown by the arrow). Then an engaging part 51 is engaged to a pawl 50 of the rotary sprocket wheel 47 of the drum B to transmit the rotation of the shaft 16 to the drum B which was rotating at a lower speed relative to the drum A so that the first and second drums A and B are integrally and simultaneously rotated.
The rotary sprocket wheel 47 giving rotation to the second drum B is idly rotated by the freewheel of the second driving sprocket wheel 49 as above described.
This embodiment provides such that the first, second and third small drums of the same diameter may be mounted in parallel on the same shaft. It is also provided that the small drum located farther from the housing 31 relative to other small drums on the same axis is so much reduced in frequency of rotation and when lengths of dependency of the cloth bands from respective small drums become equal, rotation of the small drums becomes equal.
In another case shown in FIG. 6, a cylindrical drum 52 of a known cone-shape is located in the upper part and a cylindrical drum 53 of a right shape is provided below in parallel to the abovementioned cone-shaped cylindrical drum. Each shaft 16 on which each drum is carried by support frames 54 and 55 is provided in vertical direction of the shaft 16.
In this arrangement, the lengthy cloth band 36 leading from the housing 31 is brought to a large diameter part of the cone-shaped cylindrical drum 52, the cloth band then being successively wound helically on the drum rotating at a preferred frequency of rotation. As the result, the depending portion of the cloth band is produced a loosening of an approximately same length while staying in the treating liquid. Then, as shown in FIG. 7, the support frames 54 and 55 are turned over with the upper support frame changed for the lower support frame. The portion which has been depended on the cone-shaped cylindrical drum 52 is moved to the right shaped cylindrical drum 53. Liquid treatment is thus carried out by rotation of this right shaped cylindrical drum. FIG. 8 shows the cone-shaped cylindrical drum 52 depending the lengthy cloth band 36 in the initial stage of liquid treatment. FIG. 9 illustrates the lengthy cloth band 36 in a preferred proper condition of treatment.
FIG. 10 shows a mechanism of an essential portion of another embodiment. In the mechanism, the shaft 16 is journalled on bearings 39 and 40, the shaft being slidably fitted with the slidable member 56 on which arms 57 and 58 are provided are rotatably carried at ends by pins 59 and 60 with other ends of the arms 57 and 58 rotatably connected by pins 61 and 62 to ends of frame bars 63 and 64. The ends of the frame bars 63 and 64 are attached free to open or close to supports 65 and 66 so designed as to allow the ends of the frame bars 63 and 64 to open outwardly larger than other ends of the frame bars relative to the shaft 16 when the arms 57 and 58 are turned to vertical as shown. The frame bars 63 and 64 are provided several in number surrounding the shaft 16 (the other frame bar is partly shown at 67 in a cutaway view of FIG. 10).
Thus, when the arms 57 and 58 are turned to vertical, there is produced a same configuration as that of the cone-shaped cylindrical drum 52 as shown in FIGS. 6, 7, 8 and 9. The lengthy cloth band leading from the housing 31 is then depended from the cone formed by the above described frame bars successively from a large diameter portion to a smaller one of the cone. When the lengths of loosened parts in the lower part of the cloth band becomes equal to each other, the slidable member 56 is drawn out (shown on the right) and the frame bars are mounted in parallel on the shaft 16 with the slidable member rigidly fixed to the shaft 16 by a set screw 68. As shown in the drawing, outer configuration formed by the frame bars parallel to the shaft 16 have same diameters both in the front and rear parts, which configuration is similar to that of the cylindrical drum of the right cylindrical shape (as shown in FIGS. 6 and 7). In this position, the shaft 16 is rotated to carry out the liquid treatment as desired for the cloth band.
The above-mentioned mechanism does not need the provision of two cylinders of conical and right cylindrical shape as shown in FIGS. 6 and 7. This gives much convenience for the treatment operation.
As many apparently widely different embodiments of this invention may 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. | Method and apparatus for liquid treatment of a lengthy woven or knitted cloth band of an endless form for scouring, dyeing and desizing of cloths. A cloth band is helically wound on plurality of cylindrical drums disposed axially in longitudinal arrangement with helical parts thereof depending from the cylindrical drums. Rotation of the cylindrical drums at progressively reduced peripheral speeds causes the helical parts of the cloth to depend at uniform lengths from the drums and thereafter all cylindrical durms are rotated at an equal speed. | 3 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an advertisement system and methods for video-on-demand (VOD) services, and particularly to the means and steps of synchronizing and coordinating between the invented advertisement system and a VOD system with fast-forward functions to assure viewing of advertisements by viewers.
[0002] VOD services are becoming more and more popular in US and other parts of the world. Currently there are two kinds of VOD technologies: Internet-protocol (IP) based VOD technologies and non-IP-based VOD technologies. The non-IP-based VOD technologies include VOD, near VOD (NVOD), digital VOD or analog VOD technologies.
[0003] It is well-known that most of conventional non-VOD TV services are supported by advertisement revenues. It is expected that some of the new VOD services also may be supported by advertisement revenues. For example, free TV news, sports, shows and movies with advertisement commercials may be offered over VOD services. Most of existing digital VOD players, including software players or hardware players, have the capability to play fast-forward for consumers' convenience. On the other hand, the fast-forward-play feature also allows viewers to be able to skip the advertisement commercials of any VOD programs in existing VOD systems. This would dramatically reduce the advertisement revenue for VOD service providers and content providers.
[0004] In U.S. Pat. No. 4,506,387 by Walter, a method is disclosed to make VOD services possible by downloading video files from a central data station to a data receiving station through a fiber optic line and broadcasting the video to a viewer according to his demand. No methods in Walter are disclosed to offer fast-forward, pause, backward functions for this kind of VOD services.
[0005] In U.S. Pat. No. 5,206,722 by Kwan assigned to AT&T Bell Laboratories (now Lucent Technologies Bell Labs), a method is disclosed to make VOD services possible over a conventional analog TV network by designating a number of analog channels (e.g., channel #611-#999) for VOD services. In this kind of VOD services, a viewer can choose to watch a video program at a specified time. No methods in Kwan are disclosed to offer fast-forward, pause, backward functions for this kind of VOD services.
[0006] In U.S. Pat. No. 5,508,732 by Bottomley et al assigned to IBM, U.S. Pat. No. 5,561,456 by Yu assigned to IBM, U.S. Pat. No. 5,583,937 by Ullrich et al assigned to GTE, and U.S. Pat. No. 5,682,597 by Ganek et al assigned to IBM, a method is disclosed to increase the throughput of a VOD system by allowing a number of viewers requesting for the same video program to wait for a tolerable length of time before being served by a single stream. The methods disclosed in Bottomley et al do not provide any fast-forward, pause, backward functions for this kind of VOD services.
[0007] In U.S. Pat. No. 5,357,276 by Banker et al assigned to Scientific-Atlanta, U.S. Pat. No. 5,517,257 by Dunn et al assigned to Microsoft, U.S. Pat. No. 5,606,359 by Youden, et al assigned to Hewlett-Packard Company, U.S. Pat. No. 5,720,037 by Biliris et al assigned to Lucent Technologies, U.S. Pat. No. 5,815,146 by Youden et al assigned to HP, U.S. Pat. No. 5,899,582 by DuLac assigned to Hyundai, methods are disclosed to provide the fast-forward and fast-reverse play capabilities for VOD or NVOD services. However, they do not provide any advertisement methods for the VOD/NVOD systems with the capabilities of preventing viewers from skipping commercial advertisements.
[0008] An object of this invention is to design a VOD system with fast-forward functions and the capability to assure advertisement commercials being viewed by the VOD viewers and prevent viewers from skipping the advertisement commercials.
[0009] Another object of this invention is to design an IP-based VOD system with the fast-forward, slow-forward, and backward functions and the capability to assure advertisement commercials being viewed by the VOD viewers and prevent viewers from skipping the advertisement commercials.
SUMMARY OF THE INVENTION
[0010] The goal of this invention is to design a VOD system with fast-forward functions and the capability to assure advertisement commercials being viewed by the VOD viewers and prevent viewers from skipping the advertisement commercials.
[0011] The VOD system in one embodiment of this invention comprises at least one hardware server and a plurality of clients. Each hardware server comprises an advertisement server and a VOD server. Each Client comprises a playing unit, a VOD unit, an advertisement unit, a scheduling unit, and an optional storage unit. The clients are connected to the hardware server through IP connections.
[0012] In one embodiment of the invention, the hardware server is a general-purpose computer hardware server, such as an IBM hardware server or a Dell hardware server both running a Linux operating system. The hardware server could also be an application-specific hardware server particularly designed for VOD services. In one embodiment of the invention, both the advertisement server and the VOD server are a suite of software programs running in the hardware server. The advertisement server and the VOD server may also reside in different hardware servers.
[0013] The client is a hardware personnel computer (PC), a set-top-box connected to a TV set, or a wireless device. The playing unit, VOD unit, advertisement unit, scheduling unit and optional storage unit in the client are interconnected to each other and are communicating to the advertisement server and the VOD server in the hardware server.
[0014] The VOD server, the client's VOD unit and scheduling unit together provide VOD functions for the client, including but not limited to ordering movies/TV programs, downloading movies to client using a TCP or UDP protocol, scheduling a VOD play, collecting billing information and transporting the billing information to a billing server.
[0015] The advertisement server, the client's advertisement unit and scheduling unit together provide advertisement functions for the client, including but not limited to downloading advertisement files using a TCP or UDP protocol, scheduling and coordinating the advertisement play/VOD play, collecting advertisement play information and reporting the advertisement play information to a billing server.
[0016] When a VOD play is scheduled to start, a VOD file is played either offline from the storage unit, or played real-time when the VOD file is being downloaded from the file server. When an advertisement play is scheduled by the advertisement server and the scheduling unit, the regular VOD play is interrupted and paused and the advertisement file is played on the client's screen. The advertisement play is preferably uninterruptible to assure the advertisement being viewed by viewers. After the advertisement play ends, the regular VOD play starts again from the point where the VOD play was paused.
[0017] In one embodiment of the invention, the fast forward VOD play is implemented by storing the VOD files in the storage unit and dropping some of the VOD frames when the file is being played. The slow forward VOD play is implemented by repeating each VOD frame by a given number of times when the file is being played. The fast backward VOD play is implemented by playing the VOD frames in a backward fashion and dropping some of the VOD frames when the file is being played.
[0018] Since the advertisement files are different than the VOD files and the advertisement play is controlled separately than the VOD play, the fast-forward play of the VOD files cannot skip the advertisement play. The advertisement and VOD method disclosed in this invention assure the advertisement being viewed by viewers and allow service providers to generate advertisement revenues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic diagram illustrating one embodiment of the advertisement system and methods for VOD services with fast-forward functions.
[0020] [0020]FIG. 2 illustrates a logic flow chart of the software program in the client implementing the advertisement function for the VOD services.
DETAILED DESCRIPTION
[0021] Referring to FIG. 1, VOD system in one embodiment of this invention comprises at least one hardware server 120 and a plurality of clients 100 , 102 , 104 , et al. Each hardware server 120 comprises an advertisement server 122 and a VOD server 124 . Each Client 100 comprises a playing unit 112 , a VOD unit 110 , an advertisement unit 114 , a scheduling unit 118 , and an optional storage unit 116 . The clients 100 , 102 , 104 are connected to the hardware server 120 through IP connections.
[0022] In one embodiment of the invention, the hardware server 120 is a general-purpose computer hardware server, such as an IBM hardware server or a Dell hardware server both running a Linux operating system. The hardware server 120 could also be an application-specific hardware server particularly designed for VOD services. In one embodiment of the invention, both the advertisement server 122 and the VOD server 124 are a suite of software programs running in the hardware server 120 . The advertisement server 122 and the VOD server 124 may also reside in different hardware servers.
[0023] The client 100 is a hardware personnel computer (PC), a set-top-box (STB) connected to a TV set, or a wireless device. The playing unit 112 , VOD unit 110 , advertisement unit 114 , scheduling unit 118 and optional storage unit 116 in the client are interconnected to each other and are communicating to the advertisement server 122 and the VOD server 124 in the hardware server 120 . The playing unit 112 , VOD unit 110 , advertisement unit 114 , scheduling unit 118 may be implemented by using software only, or by using a combination of software and hardware chips. For PCs and STBs, the storage unit 116 is generally included to provide better VOD services. For wireless and personnel-digital-assistance (PDA) devices, the optional storage unit 116 may not be included due to power-consumption, size and cost reasons.
[0024] The VOD server 124 , the client's VOD unit 110 and scheduling unit 118 together provide VOD functions for the client 100 , including but not limited to ordering movies/TV programs, downloading movies to client using a TCP or UDP protocol, scheduling a VOD play, collecting billing information and transporting the billing information to a billing server. A typical process of the VOD function is as follows. When a client logs into the VOD system after passing authentication, he is able to search for any one of the movies/TV programs. When he decides to order a movie/TV program, he clicks this movie/TV program and a message is sent to the VOD server 124 . Then the VOD file for the movie/TV program is downloaded from the VOD server 124 to the client 100 . If the storage unit 116 is available, the VOD file is stored in the storage unit 116 while it is being downloaded and played. If the storage unit 116 is not available for wireless or PDA devices, the VOD file is played in real-time while it is being downloaded.
[0025] The advertisement server 122 , the client's advertisement unit 114 and scheduling unit 118 together provide advertisement functions for the client 100 , including but not limited to downloading advertisement files using a TCP or UDP protocol, scheduling and coordinating the advertisement play/VOD play, collecting advertisement play information and reporting the advertisement play information to a billing server.
[0026] In one embodiment of the invention, the coordination of the VOD play and the advertisement play is implemented as follows. When a VOD play is scheduled to start, a VOD file is played either offline from the storage unit 116 , or played real-time when the VOD file is being downloaded from the VOD server 124 . When an advertisement play is scheduled by the advertisement server 122 and the scheduling unit 118 , the regular VOD play is interrupted and paused and the advertisement file is played on the client's screen. The advertisement play is preferably uninterruptible to assure the advertisement being viewed by viewers. After the advertisement play ends, the regular VOD play starts again from the point where the VOD play was paused.
[0027] In one embodiment of the invention, the fast forward VOD play is implemented by storing the VOD files in the storage unit 116 and dropping some of the VOD frames when the file is being played. The slow forward VOD play is implemented by repeating each VOD frame by a given number of times when the file is being played. The fast backward VOD play is implemented by playing the VOD frames in a backward fashion and dropping some of the VOD frames when the file is being played.
[0028] Since the advertisement files are different than the VOD files and the advertisement play is controlled separately than the VOD play, the fast-forward play of the VOD files cannot skip the advertisement play. In addition, the client can only control the VOD play and cannot control the advertisement play. The advertisement and VOD method disclosed in this invention assures the advertisement being viewed by viewers and allow service providers to generate advertisement revenues.
[0029] [0029]FIG. 2 illustrates a logic flow chart of a software program residing inside the client 100 coordinating the VOD play and the advertisement play. At the initial step 2 - 1 the software program starts and then proceeds to step 2 - 2 . Then at step 2 - 2 it is checked if an advertisement is scheduled. If the advertisement is not scheduled, the VOD play continues at step 2 - 3 . If the advertisement is scheduled, the program goes to step 2 - 4 to interrupt and pause the VOD play, then goes to step 2 - 5 to play a scheduled advertisement until the end of the advertisement play, and then goes to step 2 - 3 to continue the VOD play. As a parallel process, no matter what the decision result is at step 2 - 2 , the program goes to step 2 - 6 to incur a delay and goes back to step 2 - 2 to check if a new advertisement is scheduled.
[0030] The steps 2 - 2 to 2 - 6 in FIG. 2 implement the advertisement functions coupled to the VOD play function. With the software program disclosed in this invention, the advertisement commercials cannot be skipped by viewers using the fast-forward play since the advertisement function is separated from the VOD function and cannot be controlled by the client.
[0031] While considerable emphasis has been herein on the preferred embodiment illustrated and described hereinabove, it will be appreciated that other embodiments of the invention can be made and that changes can be made in the preferred embodiment without departing from the principals of the present invention. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. | An advertisement system and methods for video-on-demand (VOD) services. The invented system comprises means and steps of synchronizing and coordinating between advertisement play and VOD play so that the advertisement play will not be skipped by fast-forwarding of the VOD play to assure the viewing of advertisements by viewers. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority on U.S. Patent Application No. 61/901,452 filed on Nov. 8, 2013 in USA, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of ubiquitin analysis. In particular, the present invention relates to the method for determining ubiquitin chain length, which reveals functional units of polyubiquitin chains in cells.
SEQUENCE LISTING(S)
[0003] This application contains a sequence listing filed in electronic form as an ASCII.txt file entitled 02105066.txt, created on Oct. 31, 2014, and having a size of 5321 bytes. The content of the sequence listing is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0004] Protein ubiquitylation is an essential post-translational modification responsible for a diverse array of cellular processes, including protein degradation, protein trafficking, signal transduction, and the DNA damage response. Ubiquitylation is catalyzed by the concerted action of ubiquitin activating (E1), ubiquitin conjugating (E2), and ubiquitin ligase (E3) enzymes. Deubiquitylating (DUB) enzymes antagonize ubiquitylation by removing ubiquitin modifications from their substrates. Ubiquitin can be covalently conjugated to substrates in several ways: as single ubiquitin conjugated to a single site (monoubiquitylation) or multiple sites (multiple monoubiquitylation), or as a polymeric chain (polyubiquitylation). Ubiquitin can form various isopeptide linkages with itself via seven internal lysine (K) residues as well as its N-terminal methionine (M1). In addition to the homogeneous chains, it has been assumed that cells contain heterogeneous chains, such as forked or mixed chains that contain multiple types of linkages.
[0005] Accumulating evidence has suggested that the various functions of ubiquitylation are mediated by distinct chain topologies with eight different ubiquitin linkages, lengths, and complexities ( FIG. 1 ). Of these, the linkage types are generally thought to be a critical determinant of chain function. It is widely accepted that K48-linked chains function as targeting signals for proteasomal destruction, whereas K63-linked chains are usually involved in DNA repair and the trafficking of membrane proteins. The functions of atypical chains linked through M1, K6, K11, K27, K29, or K33 are only beginning to be understood, and the roles of mixed and branched chains are unknown. Ubiquitin binding domain (UBD)-containing proteins, many of which exhibit preferences for specific ubiquitin chain types or lengths, play key roles in decoding the signals embedded in the structure of ubiquitin chains. Previous in vitro studies have shown that tetraubiquitin is the minimal recognition signal for proteasomal degradation of folded proteins. In this regard, ubiquitin ligases such as SCF and APC can build long polyubiquitin chains processively to ensure rapid degradation of their substrates. Furthermore, Rad23 and Dsk2, extrinsic ubiquitin receptors of the proteasome, preferentially bind polyubiquitin chains with four or more ubiquitins in vitro.
[0006] To understand the biological significance of different ubiquitin chain topologies, it is essential to dissect the types of ubiquitin linkages, chain complexities, and chain lengths of endogenous ubiquitylated substrates. Recent advances in mass spectrometry and antibody engineering technologies allow to determine and quantitate ubiquitin linkages in biological complex samples. In addition, the chain complexity of mixed or branched chains can be analyzed by ubiquitin linkage quantitation. By contrast, the length of substrate-attached ubiquitin chains has been analyzed only by gel mobility shift ( FIG. 2 ). However, because most endogenous substrates have multiple ubiquitylation sites and the attached chains have intrinsically heterogeneous lengths, currently, there is no practical technique for determining the actual chain length of endogenous ubiquitylated substrates. Here a novel biochemical method for determining ubiquitin chain length is described. Using this method, the mean length of the substrate-attached polyubiquitin chains and the robustness of ubiquitin length regulation in cells were investigated.
PRIOR ART DOCUMENT
[0007] [Patent Document 1] US 2009/0220470 A1
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a method for determining ubiquitin chain length, which reveals functional units of polyubiquitin chains in cells, and a polypeptide which is used in the method.
[0009] The present inventors have conducted an intensive an extensive study in order to solve the above problems. As a result, the present inventors have found that a polypeptide comprising ubiquitin binding domains having trypsin-resistance is useful for the method for determining ubiquitin chain length, and the present invention was completed.
[0010] According to the present invention, the following aspects are provided.
[0000] (1) A polypeptide comprising ubiquitin binding domains, wherein said ubiquitin binding domains are linked to each other via a linker amino acid sequence, and wherein the ubiquitin binding domains are protected from trypsinization.
(2) A polypeptide comprising ubiquitin binding domains, wherein said ubiquitin binding domains are linked to each other via a linker amino acid sequence, and wherein the ubiquitin binding domains are trypsin-resistant.
(3) The polypeptide according to (1) or (2), wherein the polypeptide comprises at least four ubiquitin binding domains.
(4) The polypeptide according to any one of (1) to (3), wherein the polypeptide comprises eight or less ubiquitin binding domains.
(5) The polypeptide according to any one of (1) to (4), wherein the ubiquitin binding domain is selected from a group consisting of UBA, UIM, MIU, DIUM, CUE, NZF, A20 ZnF, UBP ZnF, UBZ, UEV, PFU, GLUE, GAT, Jab/MPN, UBM, Ubc, functionally equivalent variant of the aforementioned ubiquitin binding domains, and combinations thereof.
(6) The polypeptide according to any one of (1) to (5), wherein said linker amino acid sequence is a flexible linker sequence.
(7) The polypeptide according to any one of (1) to (6), wherein said linker amino acid sequence is GGGSGGG.
(8) The polypeptide according to any one of (1) to (7), wherein said polypeptide further comprises a tag amino acid sequence.
(9) The polypeptide according to (8), wherein said tag is selected from a group consisting of a detection tag, a purification tag, and combinations thereof
(10) The polypeptide according to (8) or (9), wherein the tag is a biotin tag, a polyhistidine, or a flag tag.
(11) The polypeptide according to any one of (1) to (10), wherein said ubiquitin binding domains are the same or different.
(12) The polypeptide according to any one of (1) to (11), wherein said polypeptide comprises a polypeptide sequence represented by SEQ ID No:1.
(13) The polypeptide according to any one of (1) to (11), wherein a polypeptide sequence has 95% or more homology with the polypeptide sequence represented by SEQ ID No:1.
(14) A polynucleotide comprising a polynucleotide sequence represented by SEQ ID No:2.
(15) A polynucleotide comprising a polynucleotide sequence having 95% or more homology with the polynucleotide sequence represented by SEQ ID No:2.
(16) A gene construct comprising the polynucleotide according to (14) or (15).
(17) An expression vector comprising the gene construct according to (16).
(18) The expression vector according to (17), wherein the gene construct is operatively bound to transcription, and optionally translation, control elements.
(19) The expression vector according to (18), wherein an expression of the gene construct is externally controlled.
(20) The expression vector according to (19), wherein the expression of said gene construct is externally controlled using IPTG.
(21) A method for determining ubiquitin chain length using the polypeptide according to any one of (1) to (13).
(22) The method for determining ubiquitin chain length according to (21) which comprises:
(i) preparing a mixture of an analyte and the polypeptide according to any one of (1) to (13),
(ii) digesting the mixture with a protease to form a digested mixture, and
(iii) analyzing the digested mixture.
(23) The method for determining ubiquitin chain length according to (22), wherein the protease is trypsin.
(24) The method for determining ubiquitin chain length according to (22) or (23), wherein the digested mixture is analyzed by electrophoresis.
(25) The method for determining ubiquitin chain length according to any one of (22) to
(24), wherein the digested mixture is analyzed by western blotting analysis.
(26) The method for determining ubiquitin chain length according to (25), wherein an anti-ubiquitin antibody is used in the western blotting analysis.
(27) The method for determining ubiquitin chain length according to any one of (22) to
(26), wherein the mixture further comprises a proteasome inhibitor.
(28) The method for determining ubiquitin chain length according to (27), wherein the proteasome inhibitor is MG132.
(29) A host cell comprising:
(i) the polynucleotide according to (14) or (15);
(ii) the gene construct according to (16); or
(iii) the expression vector according to any one of (17) to (20).
(30) The host cell according to (29), wherein said cell is a bacterial cell.
(31) A kit comprising the polypeptide according to any one of (1) to (13).
(32) The kit according to (31), further comprising a solid support.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 : Elements of polyubiquitin chains.
[0000] (left) The structure of ubiquitin. Amino acid residues for polyubiquitylation, seven Lys (K) residues and the 1 st Met (M1), are indicated.
(right) All the ubiquitin-chain topologies can be divided into three elements, eight different ubiquitin linkages, lengths, and complexities. All of them contribute the ubiquitin function.
[0012] FIG. 2 : Estimation of ubiquitin chain length by gel mobility on SDS-PAGE is limited. By analyzing gel mobility on SDS-PAGE analysis, the chain length can be estimated for ubiquitinated proteins with a single ubiquitin chains as in the cartoon. However, most endogenous substrates have multiple ubiquitylation sites and the attached chains have intrinsically heterogeneous lengths. Because of this reason, the SDS-PAGE analysis is not practical technique for determining the actual chain length of endogenous ubiquitylated substrates, i.e., three possible ubiquitinated substrates with four ubiquitin molecules, a single tetra-ubiquitin chain, two di-ubiquitin chains, and mono-ubiquitin and a tri-ubiquitin chain, are not distinguished by their gel mobilities. Furthermore, highly ubiquitinated substrates are detected as smear.
[0013] FIGS. 3A and 3B demonstrate one embodiment of a method for determining the chain length of substrate-attached polyubiquitin chains. Trypsinization of the polyubiquitylated substrates under non-denaturing condition results in complete digestion of substrate proteins and partial digestion of ubiquitin chains ( FIG. 3A ). In the presence of affinity probe for polyubiquitin chains, the polyubiquitin chain would be protected from trypsinization ( FIG. 3B ). For the purpose, we developed a novel affinity probe, named trypsin-resistant tandem ubiquitin binding entity (TR-TUBE).
[0014] FIG. 4 : DNA and protein sequences of TR-TUBE.
[0000] TR-TUBE contains a Cys residue (shown by an arrow) for biotinylation, a hexahistidine tag (shown by a frame) for purification, and six tandem repeats of the UBA domain (gray) for high-affinity capture of polyubiquitin chains. Mutated Ala residues within the UBA domain are indicated at 127-129, 175-177, 235-237, 313-315, 361-363, 421-423, 499-501, 547-549, 607-609, 685-687, 733-735, 793-795, 871-873, 919-921, 979-981, 1057-1059, 1105-1107 and 1165-1167.
[0015] FIGS. 5A-5C demonstrate one embodiment of the construction of TR-TUBE. Illustrations of the original TUBE construct developed by Hierpe et al ( EMBO reports 10, 1250-1258, doi:10.1038/embor.2009.192 (2009)), which contains four tandem repeats of the UBA domain of human UBQLN1 (top), and of TR-TUBE, developed in this study (bottom) ( FIG. 5A ). Expression and purification of 4× TUBE, 6× TUBE, and 6× TR-TUBE. The purified proteins were analyzed by SDS-PAGE ( FIG. 5B ). Trypsin digestion of TUBEs. The purified TUBEs (1 μg) indicated by asterisks were incubated with trypsin (200 ng) overnight at 37° C. ( FIG. 5C ).
[0016] FIG. 6 : Ub-ProT assay of free polyubiquitin chains.
[0000] K48-linked (left), K63-linked (middle), and M1-linked (right) polyubiquitin chains were subjected to the Ub-ProT assay. Ubiquitin was detected by western blotting with a monoclonal ubiquitin antibody. The numbers of ubiquitin molecules in the chains are labeled at right of each panel.
[0017] FIG. 7 : Ub-ProT assay of polyubiquitylated proteins.
[0000] Self-ubiquitylated GST-Cdc34 (Ubn-Cdc34, left), self-ubiquitylated GST-Rsp5 (Ubn-Rsp5, middle), and self-ubiquitylated MBP-Parkin (Ubn-Parkin, right) were subjected to Ub-ProT assay. Free polyubiquitin chains (K48 chain and K63 chain) were used to determine the chain lengths.
[0018] FIGS. 8A-8C demonstrate one embodiment of a Ub Pro T assay of yeast whole lysate. Ub-ProT analysis of endogenous polyubiquitylated proteins is demonstrated in FIG. 8A . Exponentially growing cells in SC medium were treated with or without 100 μM MG132 for 4 h. Polyubiquitylated proteins in the lysates were captured by TR-TUBE and subjected to trypsinization. Free polyubiquitin chains were used as a marker. Representation of ubiquitin linkages from yeast lysate and TR-TUBE-bound proteins ( FIG. 8B ). The individual ubiquitin chains in MG132-treated wild-type cells and samples pulled down with TR-TUBE were quantitated by mass spectrometry. Proportions of ubiquitin linkages are represented by pie charts (mean; n=3 biological replicates). Ub-ProT assay of di-ubiquitins. Di-ubiquitin (500 ng) linked through K6, K11, K27, K29, K33, K48, K63, or M1 was incubated with TR-TUBE (5 μg) and trypsin (50 ng) overnight at 37° C. ( FIG. 8C ). Proteins were subjected to SDS-PAGE and visualized by Oriole staining Di-ubiquitins are marked with asterisks.
[0019] FIGS. 9A-9C demonstrate length and linkage contents of substituted attached polyubiquitin chains in cells at steady state and in cells treated with a proteasome inhibitor. FIG. 9A demonstrates ubiquitin ladders of substrate-attached polyubiquitin chains. Long exposure of western blot (left) and protein staining (right) of the Ub-ProT sample in FIG. 8A . Gel regions subjected to MS quantitation are indicated by numbers between horizontal lines. The position of the ubiquitin monomer was defined as gel fraction #1. FIG. 9B demonstrates length — distributions of total ubiquitin and five major ubiquitin linkages in steady-state cells. Gel fractions in (b) were analyzed by a quantitative mass spectrometry (mean±s.e.m.; n=3 biological replicates). Relative positions of K48- and K63-linked chains are labeled at left. FIG. 9C demonstrates a comparison of ubiquitin chain lengths in MG132-treated cells.
[0020] FIG. 10 : Functional units of polyubiquitin chains in the cells.
[0000] Protein ubiquitylation is in equilibrium determined by the relative activities of E1-E2-E3 ubiquitin enzymes and antagonizing deubiquitylating enzymes. In rapidly growing cells, steady-state lengths of individual polyubiquitin chains are as follows: K6-, K29-, and K48-linked chains are long, whereas K11- and K63-linked chains are short. Note that the former linkage group might be involved in complex chains such as branched or mixed ubiquitin chains, although their actual levels are currently unknown. The ubiquitin chain topologies built on various substrates lead to diverse biological consequences via specific UBD proteins.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The inventors of the present invention have developed a new effective tool for the method for determining ubiquitin chain length by means of generating polypeptides comprising ubiquitin binding domains which possess trypsin-resistance.
[0022] In the first aspect, the present invention relates to a polypeptide comprising ubiquitin binding domains, wherein said ubiquitin binding domains are linked to each other via a linker amino acid sequence, and wherein the ubiquitin binding domains are protected from trypsinization. In other words, the present invention in the first aspect relates to a polypeptide comprising ubiquitin binding domains, wherein said ubiquitin binding domains are linked to each other via a linker amino acid sequence, and wherein the ubiquitin binding domains are trypsin-resistant.
[0023] Hereinafter, the above polypeptides are sometimes called as TR-TUBE (trypsin-resistant tandem ubiquitin binding entity).
[0024] The TR-TUBE preferably contains four to eight ubiquitin binding domains. In addition, the TR-TUBE more preferably contains five to eight ubiquitin binding domains. Furthermore, the TR-TUBE even more preferably contains six to eight ubiquitin binding domains. Moreover, the TR-TUBE most preferably contains six ubiquitin binding domains.
[0025] In a particular embodiment of the present invention, the ubiquitin binding domain is preferably selected from a group consisting of an UBA (Ubiquitin Associated domain), UIM (Ubiquitin Interacting Motif), MIU (Motif Interacting with Ubiquitin) domain, DUIM (double-sided ubiquitin-interacting motif), CUE (coupling of ubiquitin conjugation to ER degradation) domain, NZF (Np14 zinc finger), A20 ZnF (zinc finger), UBP ZnF (ubiquitin-specific processing protease zinc finger), UBZ (ubiquitin-binding zinc finger), UEV (ubiquitin-conjugating enzyme E2 variant), PFU (PLAA family ubiquitin binding), GLUE (GRAM-like ubiquitin binding in EAP45), GAT (Golgi-localized, Gamma-ear-containing, Arf-binding), Jab/MPN (Jun kinase activation domain binding/Mpr1p and Pad1p N-termini), UBM (Ubiquitin binding motif) and a Ubc (ubiquitin-conjugating enzyme), functionally equivalent variant of the aforementioned ubiquitin binding domains, and combinations thereof.
[0026] The functionally equivalent variant of the aforementioned ubiquitin binding domains preferably possesses a polypeptide sequence having 90% or more homology, and more preferably, 95% or more homology with the polypeptide sequence of UBA, UIM, MIU, DIUM, CUE, NZF, A20 ZnF, UBP ZnF, UBZ, UEV, PFU, GLUE, GAT, Jab/MPN, UBM, or Ubc.
[0027] In a particular embodiment of the present invention, said linker amino acid sequence is preferably a flexible linker sequence. In addition, said linker amino acid sequence is more preferably GGGSGGG.
[0028] Said polypeptide is able to further comprise at least one of tag amino acid sequences. Furthermore, said tag is preferably selected from a group consisting of a detection tag, a purification tag, and combinations thereof. Moreover, the tag is more preferably selected from a group consisting of a biotin tag, a polyhistidine tag, a flag tag and a combination thereof.
[0029] Said ubiquitin binding domains of said polypeptides are able to be the same or different. In addition, said polypeptides can comprise a polypeptide sequence having 90% or more homology, and more preferably, 95% or more homology with the polypeptide sequence represented by SEQ ID No:1. Furthermore, the polypeptide sequence is preferably a polypeptide sequence represented by SEQ ID No:1.
[0030] In the second aspect, the present invention relates to a polynucleotide comprising a polynucleotide sequence having 90% or more homology, and more preferably, 95% or more homology with the polynucleotide sequence represented by SEQ ID No: 2. In addition, the polynucleotide sequence is preferably a polynucleotide sequence represented by SEQ ID No: 2. Furthermore, the polynucleotide sequence can be a polynucleotide sequence encoding any one of the above polypeptides.
[0031] In the third aspect, the present invention relates to a gene construct comprising the above polynucleotides described in the second aspect of the present invention. In addition, the gene construct can be a gene construct encoding any one of the above polypeptides.
[0032] In the fourth aspect, the present invention relates to an expression vector comprising the above gene construct described in the third aspect of the present invention. Said expression vector preferably possesses the gene construct which is operatively bound to transcription, and optionally translation, control elements. In addition, said expression vector preferably contain the gene construct, expression thereof can be externally controlled. Furthermore, the expression of said gene construct is more preferably externally controlled by using IPTG.
[0033] In the fifth aspect, the present invention relates to a method for determining ubiquitin chain length using the above polypeptides (TR-TUBES). The method for determining ubiquitin chain length preferably comprises: (i) preparing a mixture of an analyte and at least one of the above polypeptides (TR-TUBES), (ii) digesting the mixture with a protease to form a digested mixture, and (iii) analyzing the digested mixture. Said protease used in the above method for determining ubiquitin chain length is preferably trypsin.
[0034] The digested mixture is preferably analyzed by electrophoresis, and the digested mixture is more preferably analyzed by western blotting analysis. In addition, an anti-ubiquitin antibody is preferably used in the western blotting analysis.
[0035] A proteasome inhibitor is preferably contained in the mixture of above (i). In addition, the proteasome inhibitor is preferably MG132.
[0036] In the sixth aspect, the present invention relates to a host cell comprising: (i) at least one of the above polynucleotides; (ii) at least one of the above gene constructs; or (iii) at least one of the above expression vectors. In addition, said host cell is preferably a bacterial cell.
[0037] In the seventh aspect, the present invention relates to a kit comprising at least one of the above polypeptides (TR-TUBES). Furthermore, the kit is able to further comprise a solid support.
EXAMPLES
[0038] The present invention will be described below in further detail using Examples. However, the present invention is not limited to the following Examples.
Materials and Methods
Yeast Strains and Media
[0039] S. cerevisiae strains used in this study are isogenic to W303 strain. Standard genetic techniques were used to manipulate yeast strains. The deletion mutant of PDR5 (YYS1325) was used to increase sensitivity to the proteasome inhibitor MG132. Yeast cells were grown in SC medium (0.67% yeast nitrogen base without amino acids, 0.5% casamino acids, 2% glucose, 10 mM potassium phosphate [pH 7.5], 400 mg/1 adenine sulfate, 10 mg/1 uracil, and 20 mg/1 tryptophan) or SC-Ura medium at 28° C.
Construction, Protein Expression, and Purification of Trypsin Resistant (TR)-TUBE
[0040] The UBA domain of human UBQLN1 (NM — 013438.4) was cloned into the vector pBlueScript KS (Agilent Technologies), and three Arg residues of the UBA domain were mutated to Ala using the QuikChange site-directed mutagenesis kit (Stratagene). The EcoRV site was also mutated for further construction. Six tandem copies of the UBA domain with a flexible linker sequence (GGGSGGG) were cloned into vector pRSET-A (Life Technologies), in which a Cys residue was introduced upstream of the hexahistidine tag for biotinylation. The protein-coding sequence of TR-TUBE is shown in FIG. 4 . TR-TUBE was expressed in E. coli Rosetta2 (DE3) with 0.1 mM IPTG for 15 h at 22° C. Cells were lysed by passage through a precooled French pressure cell (Ohtake Works) in lysis buffer (50 mM sodium phosphate, 300 mM NaCl, 10% glycerol, 1 mM Tris[2-carboxyethyl]phosphinehydrochloride, pH 7.0), and the lysate was clarified by 30-min centrifugation at 29,300×g. The supernatant was incubated with TALON resin (Clontech), and TR-TUBE was eluted with elution buffer (50 mM sodium-HEPES [pH 7.1], 100 mM NaCl, and 0.2 M imidazole). Then, TR-TUBE was biotinylated with EZ-link Maleimide-PEG2-Biotin (Thermo Scientific) according to the manufacturer's instructions, and further purified by gel filtration on Superdex 75 10/100 GL (GE Healthcare), preequilibrated with 50 mM HEPES (pH 7.5), 100 mM NaCl, and 10% glycerol. Biotinylated TR-TUBE was used throughout the study unless otherwise noted.
Preparation of Polyubiquitin Chains and Ubiquitylated Proteins
[0041] K48- and K63-linked polyubiquitin chains and di-ubiquitins were purchased from Boston Biochem. M1-linked polyubiquitin chains were prepared by a method described in The EMBO journal 25, 4877-4887, (2006) with modifications. Self-ubiquitinated GST-Cdc34 was prepared by incubating 100 μg/ml GST-Cdc34 on glutathione Sepharose beads 4B (GE Healthcare) in the presence of 33 μg/ml human His 6 -E1 (Boston Biochem), 500 μg/ml bovine ubiquitin (Sigma) in 20 mM Tris-HCl (pH 7.5), 10 mM MgCl 2 , 0.1 mM DTT, and 2 mM ATP for 15 h at 37° C., as described in Nature cell biology 4, 725-730, (2002). Self-ubiquitylation of GST-Rsp5 was carried out by incubating 50 μg/ml GST-WW-HECT on glutathione Sepharose beads 4B in the presence of 6.25 μg/ml human His 6 -E1, 50 μg/ml Ubc4, 500 μg/ml ubiquitin in 50 mM sodium-HEPES (pH 7.5), 100 mM NaCl, 10% glycerol, 10 mM MgCl 2 , 1 mM DTT, and 5 mM ATP for 15 h at 28° C. Self-ubiquitylated MBP-Parkin was prepared by incubating 20 μg/ml MBP-Parkin on Amylose resin (New England BioLabs) in the presence of 1.6 μg/ml human His 6 -E1, 100 μg/ml Ubc4, 50 μg/ml ubiquitin in 50 mM Tris-HCl (pH 8.8), 2 mM MgCl 2 , 2 mM DTT, and 4 mM ATP for 3 h at 32° C., as described in The Journal of biological chemistry 281, 3204-3209, (2006). After the reactions, the beads were washed with PBS plus 0.05% Tween 20 (PBS-T) and stored at 4° C.
SDS-PAGE and Western Blotting
[0042] Proteins were separated by SDS-PAGE on 4-12% NuPAGE Bis-Tris gels with MES buffer (Life Technologies) and visualized with Oriole fluorescent gel stain (BioRad) or Bio-Safe Coomassie Stain (BioRad). For western blotting, proteins were blotted onto PVDF membrane (GE Healthcare) using the NuPAGE immunoblotting system (Life Technologies). The membranes were probed with anti-ubiquitin monoclonal antibody (P4D1, HRP conjugated, Santa Cruz Biotechnology). Note that ubiquitin monomer was detected at ˜5 kDa in this electrophoresis system.
[0000] Ubiquitin Protection from Trypsinization (Ub-ProT) Assay for In Vitro Substrates
[0043] Because trypsin sensitivity of proteins varies with their structural properties, the amount of trypsin was titrated in each experimental setup. For free ubiquitin chains, polyubiquitin chain mixtures (500 ng), modified sequencing-grade trypsin (100 ng, Promega), and TR-TUBE (5 μg) were incubated in 20 μl of 50 mM ammonium bicarbonate (AMBC) supplemented with 0.01% Rapigest SF (Waters) overnight at 37° C. For self-ubiquitylated substrates, ubiquitin conjugates on beads (1 μg), trypsin (300-500 ng), and TR-TUBE (5 μg) were incubated in 20 μl of 50 mM AMBC plus 0.01% Rapigest SF overnight at 37° C. The reaction was quenched by addition of 3× NuPAGE LDS sample buffer.
Ub-ProT Assay for Yeast Lysates
[0044] For Ub-ProT assay of yeast extracts, 30 OD 600 units of log-phase cells were harvested and lysed with glass beads in 300 μl of lysis buffer (50 mM Tris-HCl [pH 7.5], 100 mM NaCl, 10% glycerol, 10 μM MG132, 10 mM iodoacetamide, and 1× complete protease inhibitor cocktail [Roche, EDTA-free]). After centrifugation, the supernatant (100 μg) was incubated with TR-TUBE (10 μg) for 1 h at 4° C. Next, TR-TUBE-bound polyubiquitylated proteins were incubated with Dynabeads MyOne Streptavidin C1 (1 mg, Life Technologies) for 45 min at 4° C. The beads were washed three times with PBS-T, and then incubated in 100 μl of 50 mM AMBC, 0.01% Rapigest SF, and trypsin (1.5 μg) overnight at 37° C. The inventors of the present invention found that streptavidin was not digested by trypsin under this condition; therefore, the polyubiquitin chains were still retained on the beads via the TR-TUBE/streptavidin complex after trypsinization. After the beads were washed with PBS-T, the polyubiquitin chains were selectively eluted by 30-min incubation with 1× NuPAGE LDS sample buffer. The samples were directly subjected to electrophoresis on NuPAGE gels in order to avoid aggregation of polyubiquitin chains.
Quantitation of Ubiquitin Chains by Mass Spectrometry
[0045] Ubiquitin chains were quantitated as described in Biochemical and biophysical research communications 436, 223-229, (2013). For ubiquitin quantitation of total lysate and samples pulled down with TR-TUBE shown in FIG. 1 d , proteins (10 μg) were fractionated on NuPAGE gels with a short run (3 cm). The gel region corresponding to molecular weight above 62 kDa was excised, diced into 1-mm 3 pieces, and subjected to trypsinization. For Ub-ProT samples, proteins were fractionated by NuPAGE gels with a full run (8 cm); gel lanes were cut into 12 fractions, starting at the position corresponding to ubiquitin monomer, using a grid cutter (2 mm long×7 mm wide, Gel Company); and then subjected to trypsinization. Trypsinized peptides were extracted, spiked with nine ubiquitin AQUA peptides (M1-, K6-, K11-, K27-, K29-, K33-, K48-, and K63-linkages, as well as ESTLHVLR [EST]), and then oxidized with 0.05% H 2 O 2 in 0.1% trifluoroacetic acid. A nanoflow UHPLC instrument (Easy nLC 1000, Thermo Fisher Scientific) was coupled on-line to a Q Exactive MS (Thermo Fisher Scientific) with a nanoelectrospray ion source (Thermo Fisher Scientific). To improve the peak shape of the K29-linkage, the peptide samples were directly loaded onto a C18 analytical column (Reprosil-Pur 3 μm, 75 μm id×12 cm packed-tip column, Nikkyo Technos Co. Ltd). Reversed-phase chromatography was performed using the Thermo EASY-nLC 1000 with a binary buffer system consisting of 0.1% formic acid (FA) (solvent A) and 100% acetonitrile/0.1% FA (solvent B) with a flow rate of 300 nl/min. For Ub-ProT samples, E. coli matrix (MassPREP, Waters) was added to the peptides samples (100 ng on column) to avoid nonspecific peptide adsorption. The Q Exactive MS was operated in targeted MS/MS mode, using the Xcalibur software, with time-scheduled acquisition of the nine pairs of isotopically labeled AQUA peptides/endogenous peptides in ±6 min retention-time windows. Total ubiquitin levels were calculated by EST peptide. Raw files were processed using the PinPoint software, version 1.3 (Thermo Fisher Scientific).
Example 1
A Method for Measuring Polyubiquitin Chain Length
[0046] The method of the present invention is based on the trypsin sensitivity of polyubiquitylated proteins. When polyubiquitylated proteins are subjected to trypsinization under native conditions, the substrate proteins are almost completely digested, but the polyubiquitin chains are partially digested or only cleaved at Arg74 of ubiquitin molecules, by which a signature peptide containing a di-Gly remnant of ubiquitin is produced ( FIG. 3 a ). However, in the presence of a high-affinity probe for polyubiquitin chains, substrate-attached chains are protected from trypsinization; thus, the inventors of the present invention named the method ‘ubiquitin protection from trypsinization’ (Ub-ProT) ( FIG. 3 b ). For the probe, the inventors of the present invention modified a previously reported high-affinity probe for polyubiquitin, tandem ubiquitin binding entity (TUBE) ( EMBO reports 10, 1250-1258, (2009)). The original TUBE construct consists of four repeats of the ubiquitin-associated (UBA) domain (ubiquitin binding domain) of human Rad23 or UBQLN1, connected with flexible linkers. The inventors of the present invention constructed trypsin-resistant (TR)-TUBE that consists of a biotin tag, hexahistidine tag, and six repeats of the UBQLN1 UBA domain in which the Arg residues were replaced by Ala residues ( FIGS. 4 , 5 A- 5 C).
[0047] The inventors of the present invention first tested the method using available free polyubiquitin chains of defined lengths, linked through K48, K63, and M1 of ubiquitin ( FIG. 6 ). The inventors of the present invention titrated the amount of trypsin and determined the smallest amount of trypsin necessary for complete cleavage of polyubiquitin chains. Under this condition, each polyubiquitin chain was cleaved into monomers or digested by trypsinization; however, in the presence of TR-TUBE, all ubiquitin chains were almost completely protected. Unexpectedly, TR-TUBE can protect M1 chains of up to sixteen ubiquitin molecules, suggesting that multiple molecules of TR-TUBE can bind with a single chain and thereby restrict trypsin accessibility. The inventors of the present invention next applied the method to self-ubiquitylated Cdc34, Rsp5, and Parkin, model substrates with distinct ubiquitylation patterns (K48-linked poly, K63-linked poly, and multiple mono, respectively) ( FIG. 7 ). In each case, when monitored by western blotting using an anti-ubiquitin antibody, the ubiquitylated proteins were detected as a smear and were almost completely disappeared following trypsinization. By contrast, in the presence of TR-TUBE, typical ubiquitin ladders were detected after trypsinization. Comparison with free K48-linked polyubiquitins (used as a length marker) revealed that the polyubiquitin chains that had been attached to Cdc34 contained up to ten ubiquitin molecules ( FIG. 7 , left). In the case of polyubiquitylated Rsp5, the length of attached K63-linked chains was determined to be up to octamer ( FIG. 7 , middle). By contrast, Ub-ProT assay of self-ubiquitylated Parkin revealed monoubiquitin and, to a lesser extent, short ubiquitin chains ( FIG. 7 , right). Because TR-TUBE captured almost all the ubiquitylated Parkin (data not shown), TR-TUBE can bind multiple monoubiquitylated substrates as well as polyubiquitin chains as discussed below.
[0048] To investigate the versatility of Ub-ProT, the inventors of the present invention analyzed the linkage specificity of TR-TUBE using yeast lysate. The inventors of the present invention quantitated the individual ubiquitin linkages by parallel reaction monitoring (PRM), a MS/MS quantitation method for high-resolution mass spectrometry. PRM allowed to quantitate all the ubiquitin linkages from 100 amol to 1 pmol, even in biological complex samples. Lysate prepared from MG132-treated cells was fractionated by SDS-PAGE and the gel region corresponding to high molecular weight (>62 kDa) was excised, trypsinized, spiked with isotopically labeled peptide standards, and analyzed by ubiquitin-PRM ( FIGS. 8A-8C ), As reported previously, K48- and K63-linkages were detected predominantly. Remaining linkages were also clearly detected with an absolute abundance order of K29>K11>K6>M1≅K27≅K33 ( FIG. 8 b , left). The proportions of ubiquitin linkages were similar to those reported in a recent study by other group ( Molecular & cellular proteomics: MCP 10, M111 009753, (2011)). Ubiquitylated proteins in the lysate were pulled down by TR-TUBE ( FIG. 2 a ) and analyzed in the same way. The proportions of ubiquitin-linkages among TR-TUBE-captured proteins were quite similar to those in the lysate ( FIG. 8 b , right). Because the precise amount of mixed and branched chains has not been determined in the cells, TR-TUBE may bind indirectly with atypical chains. However, Ub-ProT assays against di-ubiquitin of all eight linkage types revealed that TR-TUBE protected all chains from trypsinization ( FIG. 8 c ). These results suggested that TR-TUBE binds ubiquitylated proteins without any linkage preference.
Example 2
Steady-State Units of Polyubiquitin Chains
[0049] The inventors of the present invention next investigated the mean lengths of substrate-attached polyubiquitin chains in yeast lysate. To the knowledge of the inventors of the present invention, the actual chain lengths of polyubiquitylated proteins in vivo have not been previously determined. In this experiment, the inventors of the present invention used a drug-sensitive pdr5 mutant to determine the effect of a proteasome inhibitor, MG132. Exponentially growing cells were lysed with glass beads in the presence of MG132 and iodoacetamide in order to inhibit deubiquitylating enzymes. Ubiquitylated proteins in the lysate were captured and pulled down by TR-TUBE using the biotin tag. The patterns of ubiquitylated proteins were quite similar between lysate and TR-TUBE-captured proteins, with the exception of ubiquitin monomer, suggesting that TR-TUBE can capture all endogenous ubiquitylated proteins other than ubiquitin monomer ( FIG. 8 a , lanes 1 and 5). Upon trypsinization of the lysate, signals from ubiquitin conjugates completely disappeared ( FIG. 8 a , lanes 3 and 4). When the TR-TUBE-captured proteins were trypsinized, a ubiquitin-chain ladder was produced ( FIG. 8 a , lanes 7 and 8). A previous proteomics study has suggested that yeast tryptic peptides are, on average, 8.4 amino acids in length (Journal of proteome research 9, 1323-1329, (2010)). Thus, if the ubiquitylation sites were structurally hindered, i.e., if trypsin were unable to attack the proximal ubiquitins, the substrate-attached ubiquitin chains should converge to the individual chain sizes. It is also noted that different ubiquitin chains with three or more ubiquitins exhibited different gel mobilities ( FIG. 8 a , free chains). Comparisons with free K48-linked ubiquitin chains, used as size standards, revealed that the mean lengths of the substrate-attached ubiquitin chains were in the dimer to hexamer range.
[0050] The inventors of the present invention also quantitated the individual ubiquitin linkages in the substrate-bound ubiquitin chains of each length. Gel lanes were fractionated into 12 pieces corresponding to ubiquitin monomers and longer chains, and the fractions were subjected to Ub-PRM ( FIGS. 9A-9C ). Because the abundances of M1-, K27-, and K33-linkages are quite low (<0.17% of total linkages), the inventors of the present invention focused on the five major linkages in this experiment. As shown in FIG. 9 b , the length distributions of the five major ubiquitin linkages were quite different, but they could be divided into two groups: K6-, K29-, and K48-linkages were mainly detected in the longer chains, whereas K11- and K63-linkages were mainly detected in the shorter chains. When total ubiquitin levels were quantitated by EST peptide, nearly 50% of ubiquitin was detected as the monomer ( FIG. 9 b , total). TR-TUBE did not bind ubiquitin monomer, suggesting that a significant portion of ubiquitylated proteins exist as the multiply monoubiquitylated form, consistent with the results of a previous study ( Nature methods 8, 691-696, (2011)). Thus, at steady state, most endogenous substrates are attached to up to six ubiquitin molecules; K6, K29-, and K48-linkages are detected in longer chains, whereas K11- and K63-linked chains are mainly detected as dimers.
Example 3
Effect of Proteasome Inhibitor on Chain Length
[0051] The inventors of the present invention also analyzed proteasome inhibitor-treated cells by Ub-ProT. After treatment with 100 μM MG132 for 4 h, ubiquitylated proteins accumulated in the cells ( FIG. 8 a , lanes 1 and 2). Surprisingly, the Ub-ProT assay suggested that signal intensities of the ubiquitin ladder were increased, but the chain length was not changed ( FIG. 9 a , left). The inventors of the present invention quantitated the ubiquitin linkages from the ubiquitin ladder; compared to untreated cells, proteasome-inhibited cells accumulated all types of linkages. K6-, K29-, and K48-linked chains accumulated at high levels, but their length distributions were unchanged. Furthermore, long K11- and K63-linked chains accumulated slightly in the proteasome inhibitor-treated cells ( FIG. 9 c ). It will be of great interest to determine whether the long K11- and K63-linked chains are homogeneous. Collectively, these results suggested that most proteasome substrates in cells are attached to ubiquitin chains within a length of six ubiquitins.
CONCLUSIONS
Robustness of Ubiquitin Length Regulation
[0052] In the 1980s, it was realized that polyubiquitin chain is a protein degradation signal for the proteasome (reviewed in Annual review of biochemistry 67, 425-479, (1998) and Cell 116, S29-32, 22 p following S32 (2004)). Subsequent in vitro studies have defined that tetraubiquitin is the minimal signal for proteasomal degradation. Nowadays, eight different ubiquitin linkages have been identified in cells, and a large number of studies have focused on the generation and decoding of ubiquitin signals in regard to chain types. However, the length of ubiquitin chains, additional key element of ubiquitylation, has not been carefully examined especially in vivo. In the present application, the inventors of the present invention established the Ub-ProT method, which can reveal the chain length of endogenous ubiquitinated proteins. Using Ub-ProT, the inventors of the present invention determined the mean lengths of substrate-attached ubiquitin chains: K6-, K29-, and K48-linked chains were mainly in the tetramer to hexamer range, whereas K11- and K63-lined chains were mainly dimers ( FIG. 10 ). In the steady-state, these chain lengths might be functional units in cells. Surprisingly, the maximum lengths of the individual chains, up to hexamers, were not changed by either proteasome inhibition or ubiquitin overexpression. Because ubiquitin modifications are generally thought to exist in equilibrium between ubiquitylation and deubiquitylation, enhanced ubiquitylation might be predicted to cause chain elongation by overwhelming deubiquitylation. The robustness of the regulation of chain length might be due to specific UBD-containing proteins that bind and protect ubiquitin chains with appropriate lengths (probably in the 2-6-mer range) from deubiquitylating enzymes before they exert their functions, as proposed previously ( FEBS letters 535, 77-81 (2003), Cell 120, 73-84, (2005)). Alternatively, the ability of ubiquitylating enzymes to elongate chains may be intrinsically limited in vivo, as suggested by a previous in vitro study ( Nature 462, 615-619, (2009)). Because single attachment of ubiquitin costs one molecule of ATP, restriction of chain lengths would benefit the cell by reducing total energy consumption.
[0053] Collectively, the results of this study reveal the mean length of substrate-attached polyubiquitin chains and demonstrate the robustness of ubiquitin chain length regulation in cells. These findings suggest that ubiquitin chain length represents an additional layer in the regulation of ubiquitin-mediated cellular processes. | Protein ubiquitylation, an essential post-translational modification, regulates almost every cellular process including protein degradation, protein trafficking, signal transduction, and DNA damage response in eukaryotic cells. The diverse functions of ubiquitylation are thought to be mediated by distinct chain topologies resulting from eight different ubiquitin linkages, chain lengths, and complexities. Currently, ubiquitin linkages are generally thought to be a critical determinant of ubiquitin signaling. However, ubiquitin chain lengths, another key element of ubiquitin signaling, have not been well documented especially in vivo situation during past three decades from the discovery of ubiquitin. The reason of this was simply because no method has been available for determination of ubiquitin chain length in endogenous ubiquitylated substrates. In the present invention, a practical technique for determining the actual length of substrate-attached polyubiquitin chains from biological samples is established. Using the method, the mean length of substrate-attached polyubiquitin chains was determined and the robustness of ubiquitin chain length regulation in cells is investigated. The following is a summary of findings in this invention: 1. A method for determining ubiquitin chain length was developed and this method was named ‘ubiquitin protection from trypsinization’ (Ub-ProT). 2. Using Ub-ProT, it was determined that the mean length of substrate-attached ubiquitin chains is in the dimer to decamer range. 3. By quantitative proteomics, it was found that the mean lengths of five major types of ubiquitin chains can be divided into two groups. 4. Proteasome-inhibition did not alter the mean length of substrate-attached polyubiquitin chains, indicating that cells have a robust system for regulating ubiquitin chain length. | 6 |
This is a continuation, of application Ser. No. 100,162, filed Dec. 4, 1979 now abandoned.
BACKGROUND OF INVENTION
Due to their inadequate damping elastic structures, such as for example thin metal sheets used for vehicle bodies or machine casings, emit airborne sound of different frequencies if excited by airborne sound or by structure-borne vibrations.
Hitherto, this mainly low frequency noise, especially in the range 100 to 1000 cps has been deadened by applying damping materials. Suitable materials for this purpose are viscoelastic damping foils based on bitumen and/or filled synthetic resins, as well as bituminous felts with and without additional damping coverings. The bitumen foils which are at present mainly used in the manufacture of vehicles and which are placed on the floor inside of the vehicle must have a high weight per unit area in order to bring about an effective vibration damping. Generally, the weight is approximately 4 to 7 kg/m 2 . However, this results only in a sound loss factor of approximately 0.1 to 0.2. l In addition, such high weights are particularly disadvantageous in vehicle building.
Materials which can be applied by spraying are also known. These are the known coatings for underbody protection of motor vehicles having a synthetic resin and/or bitumen base and which solidify to give resilient coatings of low or high bending resistance. However, these materials are mainly intended to provide good corrosion protection and high abrasion resistance. Their vibration and sound damping properties are so poor that they are inadequate without the use of the abovementioned foils inside the vehicle. Thus, conventional underbody protection materials based on filled PVC plastisols provide only a loss factor of approximately 0.02 at ambient temperature and 200 cps at a coating weight of 3 kg/m 2 .
It is known that sound insulation can be improved if a sandwich-like covering is formed on the sound radiating and transmitting substrate, for example a metal sheet, in such a way that a layer of resilient material, e.g. a foam material is applied to the substrate, followed by the applying thereon a layer of a material with high bending resistance and high specific gravity. Such structures are for example known from German Auslegeschrift No. 2,064,445 and although they provide considerable improvements with regard to sound insulation, they are not suitable for vibration damping and sound absorption.
U.S. Pat. No. 3,833,404 discloses vibration damping and sound-abosorbing structures formed from two layers of which the inner layer comprises a viscoelastic mixture of elastomeric and thermoplastic polymers with a modulus of elasticity of below 1×10 10 dynes/cm 2 , while the outer layer comprises a rigid plastic material with a modulus of elasticity of above 1×10 10 dynes/cm 2 . Due to the high rigidity of the outer layer, which may be obtained by adding reinforcing fibres, the structure thus formed is similar to a conventional sandwich system in which a viscoelastic layer is positioned between two rigid materials such as metal, wood or the like.
It is the object of the present invention to provide a process of producing sound and vibration damping coatings in which process conventional materials are applied in a simple manner, i.e. more particularly by spraying, and which process yields coatings fulfilling all requirements relative to corrosion and abrasion protection and simultaneously providing good damping agent structure-borne vibrations and good sound absorption at relatively low weights per unit area.
SUMMARY OF INVENTION
It has surprisingly been found that this problem can be solved if two layers are applied, whose moduli of elasticity after gelling or curing are within a defined range and which in each case differ from each other by at least the factor 10.
The invention therefore relates to a method of producing a structure-borne vibration and sound damping and at the same time corrosion and abrasion resistant coating on a rigid substrate in which successively two coating materials with different moduli of elasticity are applied to the substrate. This method is improved in that a first coating of a viscoelastic material is sprayed onto the substrate having after gelling and/or curing a modulus of elasticity of 5×10 6 to 5×10 8 dynes/cm 2 and in that onto said first coating there is sprayed a second coating of a viscoelastic material which after gelling and/or curing has a modulus of elasticity of 5×10 7 to 5×10 9 dynes/cm 2 , the modulus of elasticity of said second outer coating being at least 10 times greater than that of said first coating.
Preferably the coating materials are selected in such a way that the modulus of elasticity of the second outer layer is 40 to 100 times greater than that of the first inner layer.
It has surprisingly been found that contrary to the "constrained layer" theories upon which U.S. Pat. No. 3,833,404 is also based, it is not necessary for obtaining good structure-borne vibration damping and sound absorption to produce a surface layer with a modulus of elasticity above 10 10 dynes/cm 2 , which poses serious practical difficulties and requires the use of special reinforced materials. It has in fact been found quite unexpectedly that high loss factors of approximately 0.1 to 0.3 within the relevant temperature range of approximately -20° to +50° C. are obtained if, in accordance with the invention, two materials are sprayed onto the substrate and are subsequently gelled, whose moduli of elasticity differ from one another by at least a power of ten. Coating weights of approximately 10 to 70, more particularly 20 to 60% of the substrate weight are sufficient to obtain these loss factors. These figures relate to measurement at 200 cps, but similar values are also obtained at other frequencies in the physiologically particularly important frequency range of approximately 20 to 1000 cps.
DETAILED DESCRIPTION OF INVENTION
Materials already known per se for corrosion and abrasion protection, such as for example those used for the underbody protection of motor vehicles are suitable for producing the coatings according to the invention. These are mainly plastisols based on polyvinyl chloride homopolymers or copolymers, e.g. with vinylidene chloride. Plastisols made from acrylic homopolymers or copolymers, such as those recently disclosed in German Auslegeschriften Nos. 2,454,235 and 2,529,732 are also very suitable. Polyamine epoxides are also usable. In order to adjust the moduli of elasticity of the materials for the two layers, plasticizers can be used in a manner known per se. The greater the plasticizing effect and the larger the quantity of plasticizer added, the greater the drop in the modulus of elasticity of a given material. The modulus of elasticity can also be reduced by converting the material into a foam material, e.g. a by adding a foaming agent which is activated during gelling. The mechanical properties, particularly the abrasion resistance, can be improved by adding fillers in a manner known per se.
Contrary to the known methods (cf e.g. U.S. Pat. No. 3,833,404) it is possible in the process according to the invention to use materials with the same chemical base, e.g. two PVC plastisols, for the two layers, provided that their moduli of elasticity differ sufficiently. Due to the complete compatibility of the materials this leads to an excellent adhesion between the layers and it is possible without difficulty to successively apply both layers by spraying and then jointly gel them by heating. The coating has the abrasion and corrosion resisting properties of a conventional underbody protective coatings made from polyvinyl chloride, but is approximately 10 times superior to the latter with regard to the sound loss factor for the same weight per unit area (a loss factor of only about 0.02 is obtained under otherwise identical conditions with conventional underbody protection materials).
It is also possible for the first inner layer to be a material with a lower abrasion resistance, for example one of the above-mentioned acrylic polymer based plastisols, having the additional advantage that as a result of their freedom from chlorine they give steel sheets a particularly effective corrosion protection. A second layer of a filled PVC plastisol with a higher modulus of elasticity and excellent abrasion resistance can then be applied to the first layer. It has also been found that the impact resistance of the coating is significantly improved compared with conventional coverings due to the softer layer underneath. The weight of the coating can be approximately 10 to 70, preferably approximately 20 to 60% of the substrate weight. The total layer thickness is normally about 1 to 20 mm, dependent on the desired coating weight, which generally varies between approximately 1 and 5 kg/m 2 , preferably between 2 and 4 kg/m 2 . The first inner layer of the coating can represent 10 to 80%, preferably 10 to 40% of the total layer thickness.
The attached drawings and the following examples will serve to further illustrate the invention.
FIG. 1 shows a cross section of a coating according to the invention on a sheet metal substrate, comprising a viscoelastic softer intermediate layer and a viscoelastic harder outer layer.
FIG. 2 is a graph showing the dependence of the loss factor on the frequency for coatings produced according to the following examples 1 and 2 of the invention.
FIG. 3 is a graph showing the dependence of the loss factor on the temperature (measured at 200 cps) for the coatings of the following examples 1 (continuous curves) and 2 (dotted-line curves). Curve 1 corresponds to the coating according to the invention, curve 2 to a coating made from the material of the softer intermediate layer and curve 3 to a coating made from the harder outer layer (with idential coating weight in each case). The superiority of the coatings according to the invention is particularly apparent.
FIG. 4 is a graph showing the dependence of the loss factor on the coating weight as a percentage of the sheet metal weight (measured in each case at 20° C. and 200 cps). The measuring points A were obtained for six coatings according to the invention. Area C corresponds to a harder PVC, area E to a softer PVC, in each case when used alone. Areas B and D were correspondingly obtained for hard and soft materials based on acrylic polymer plastisols. Here again, the superior sound absorbing and vibration damping properties of the coatings according to the invention are apparent.
EXAMPLE 1
The coating material for the first inner layer comprised 20% by weight of a methyl methacrylate/butyl methacrylate copolymer, 50% by weight of aryl alkyl sulphonate, 27% by weight of chalk (filler) and 3% by weight of azodicarbonamide (foaming agent). This composition was sprayed onto a metal sheet and for gelling and foaming heated for 30 minutes at 170° C.
A composition comprising 20% by weight of polyvinyl chloride, 7% by weight of monomeric dimethacrylate, 20% by weight of dioctyl phthalate, 10% by weight of dibutyl phthalate, 43% by weight of chalk and 0.7% by weight of butyl perbenzoate was used for the second outer layer. This layer was also heated for 30 minutes at 170° C. after spraying.
The two layers were applied in a layer thickness ratio of 1:3, the coating weight amounting to 57% of the sheet metal weight.
The modulus of elasticity of the first layer was 6×10 7 dynes/cm 2 and that of the second layer 4×10 9 dynes/cm 2 .
FIGS. 2 and 3 show the loss factors obtained with this coating as a function of the frequency and the temperature, respectively.
EXAMPLE 2
The same composition as in example 1 was used for the first inner layer.
A composition of 30% by weight of a methyl methacrylate/butyl methacrylate copolymer, 32.8% by weight of aryl alkyl sulphonate, 32% by weight of chalk, 54% by weight of naphtha and 0.2% by weight of perylene tetracarboxylic acid was used for the second outer layer. Gelling took place within 30 minutes at 170° C.
The two layers were applied in a layer thickness ratio of 1:4, the coating weight amounting to 54% of the substrate weight. The modulus of elasticity of the first layer was 6×10 7 dynes/cm 2 and that of the second layer 1×10 9 dynes/cm 2 .
FIGS. 2 and 3 show the loss factors for the coating as a function of the frequency and the temperature, respectively. | A novel method of producing a vibration damping and sound absorbing coating on a rigid substrate is provided in which method a first coating of a viscoelastic material having after gelling a modulus of elasticity of 5×10 6 to 5×10 8 dynes/cm 2 is sprayed onto the substrate whereafter there is sprayed onto said first coating a second coating of a viscoelastic material having after gelling a modulus of elasticity of 5×10 7 to 5×10 9 dynes/cm 2 , the modulus of elasticity of said second outer coating being at least 10 times greater than that of said first coating. | 1 |
FIELD OF THE INVENTION
[0001] The invention pertains to the technical field of integrated circuit (IC) design, relates to a clock generator, and in particular to a clock generator which is less susceptible to PVT factor and can generate a multiple phase non-overlapping clock signal as well as a switch-capacitor circuit applied with the clock generator.
BACKGROUND
[0002] In IC design, some circuit modules in the chip needs to use a multiple phase clock signal, especially a multiple phase non-overlapping clock signal simultaneously, wherein a time interval is set between any two clock signals so that for the clock signals in each phase, any two clock signals will not be in an “on” status simultaneously at any timing. Therefore, a time sequence relationship between the clock signals in individual phases has to be well controlled so as to ensure non-overlapping.
[0003] FIG. 1 is a schematic view of a two-phase none-overlapping clock signal, wherein “clock 1 ” indicates of one clock signal and “clock 2 ” indicates of another clock signal. In the embodiment shown in FIG. 1 , a phase difference between clock 1 and clock 2 is 180°, and the clock signals of the two phases must not be in an “on” status simultaneously at any timing. In order to ensure non-overlapping between clocks, a corresponding clock generator must ensure that a gap is kept between a trailing edge of any one of the clock signals and a rising edge of the other clock signal, which gap is referred to as a time interval between two phase clocks (i.e., the “τ” shown in FIG. 1 ).
[0004] The multiple-phase none-overlapping clock signal such as that shown in FIG. 1 has been widely used in integrated circuits. Moreover, the higher the time sequence accuracy is, the better performance the integrated circuit exhibits. Taking the two-phase none-overlapping clock signal as an example, it has been widely used in a switch-capacitor circuit. For example, in a sample and hold circuit of a AD converter, in order to achieve a sampling and amplifying function of the switch-capacitor circuit, a clock signal control is required to be provided therefore; in order to avoid a so-called “charge sharing” phenomenon in the switch-capacitor circuit and to reduce the destruct to the accuracy of information caused by charge-sharing, the switch circuit thereof generally adopts the two-phase none-overlapping clock signal shown in FIG. 1 .
[0005] FIG. 2 is a schematic view of the circuit of a conventional clock generator for generating a two-phase none-overlapping clock signal shown in FIG. 1 , wherein a phase inverter I 0 is used for inverting clocks; an input end of the NOT-AND gate N 1 is connected to a reference clock signal, the other input end is input with clock 2 signal, and the output end of the NOT-AND gate N 1 is output to a first set of phase inverters (I 11 /I 12 /I 13 ) connected in series sequentially; an input end of the NOT-AND gate N 2 is connected to an inverted clock signal (I 0 output), the other end of input with clock 1 signal, and the output end of the NOT-AND gate N 2 is output to a second set of phase inverters (I 21 /I 22 /I 23 ) connected in series sequentially. The closed-loop circuit composed of the NOT-AND gates (N 1 , N 2 ) and two sets of phase inverters (I 11 /I 12 /I 13 and I 21 /I 22 /I 23 ) can ensure a time interval τ between clock 1 and clock 2 ; the specific size of the time interval τ can be also determined by a delay (t) of the first set of phase inverters (I 11 /I 12 /I 13 ) or the second set of phase inverters (I 21 /I 22 /I 23 ).
[0006] However, in an actual integrated circuit, the clock generator generating a multiple-phase none-overlapping clock signal are easily affected by many factors such as process, voltage and/or temperature (abbreviated as PVT in the industry), and the time interval τ between the clocks of two phases will also be prone to offset with the variation of PVT. For example, when the batches of water are different, the time intervals τ may be different; when the environment temperatures are different, the time intervals τ may be different; and when the voltages of power source are different, the time intervals τ may be different. Therefore, in an existing clock generator, the time interval τ between any two phase clock signals generated thereby is not stable, and a large offset may easily occur. The larger the offset of the time interval τ is, the more easily the performance of the circuit system using the clock signal is affected. For example, in a switch-capacitor circuit, when the value of τ is shortened to a certain degree (due to a larger offset of τ), a “charge sharing” phenomenon might occur in the switch-capacitor circuit because of a delay mismatch of a buffer behind the clock generator, thus greatly reducing the performance of the switch-capacitor circuit.
SUMMARY OF THE INVENTION
[0007] The object of the invention is to reduce the offset of the time interval τ between two phase clocks of a multiple phase non-overlapping clock signal and to improve the stability of the time interval τ between two phase clocks.
[0008] In order to achieve the above object or other objects, the invention provides the following technical solutions.
[0009] According to an aspect of the invention, a clock generator is provided, comprising a non-overlapping clock signal generating module ( 31 ) for generating a multiple phase non-overlapping clock signal, and further comprising:
[0010] a ring oscillator ( 32 ) for generating a third clock signal (clock 3 ) which reflects the offset of the time interval (τ) between two phase clocks of the multiple phase non-overlapping clock signal;
[0011] a frequency detecting module ( 33 ) for detecting the frequency of a standard clock signal (clock 4 ) input by the frequency detecting module ( 33 ) and the frequency of the third clock signal (clock 3 );
[0012] a comparator module ( 34 ) for comparing the frequency of the standard clock signal (clock 4 ) and the frequency of the third clock signal (clock 3 );
[0013] a programmable biasing signal generating module ( 35 ) for adjustably outputting a biasing signal according to the comparison result output by the comparator module ( 34 );
[0014] wherein the biasing signal is fed back and input to the ring oscillator ( 32 ) so as to adjust the frequency of the third clock signal (clock 3 ) until the frequency of the third clock signal (clock 3 ) is compared as be substantially equal to the frequency of the standard clock signal (clock 4 ) in the comparator module ( 34 ); and
[0015] wherein, the biasing signal is fed back and input to the non-overlapping clock signal generating module ( 31 ) so as to reduce the offset of the time interval (τ) between two phase clocks.
[0016] In the clock generator according to an embodiment of the invention, the non-overlapping clock signal generating module ( 31 ) is disposed adjacent to the ring oscillator ( 32 ) in the chip and is manufactured in synchronization with the ring oscillator ( 32 ) in the same process.
[0017] Further, optionally, the phase inverter for generating delay used in the non-overlapping clock signal generating module ( 31 ) is the same as the phase inverter for generating delay used in the ring oscillator ( 32 ), and the layouts and structures of them are also the same.
[0018] In the clock generator according to any of the above embodiments, the delay (τ 1 ) generated by the phase inverter used in the ring oscillator ( 32 ) is n times larger than the time interval (τ) between two phase clocks generated by the phase inverter used in non-overlapping clock signal generating module ( 31 ), wherein n is an integer larger than or equal to 1.
[0019] In the clock generator according to any of the above embodiments, a plurality of phase inverters used in the non-overlapping clock signal generating module ( 31 ) can be the same, or be different.
[0020] In the clock generator according to another embodiment of the invention, the offset of the time interval (τ) between two phase clocks is caused by the fact that the multiple phase non-overlapping clock signal is influenced by the factors of process, voltage and/or temperature.
[0021] In the clock generator according to any of the above embodiments, the influence on the third clock signal (clock 3 ) by the factors of process, voltage and/or temperature is substantially equal to the influence on the multiple phase non-overlapping clock signal by the factors of process, voltage and/or temperature.
[0022] In the clock generator according to any of the above embodiments, the non-overlapping clock signal generating module ( 31 ) is a current controllable non-overlapping clock signal generating module ( 31 ), the ring oscillator ( 32 ) is a current controllable ring oscillator ( 32 ), and the biasing signal is a biasing current signal.
[0023] In the clock generator according to any of the above embodiments, the biasing current signal adjusts the magnitude of current according to the comparison result of the comparator module ( 34 ) so as to correct the frequency of the third clock signal (clock 3 ) and the time interval (τ) between two phase clocks.
[0024] In the clock generator according to any of the above embodiments, the biasing signal is biased onto all the gate circuits of the ring oscillator ( 32 ), and the biasing signal is also biased onto all the gate circuits of the non-overlapping clock signal generating module ( 31 ).
[0025] In the clock generator according to any of the above embodiments, the multiple phase non-overlapping clock signal can be a multiple phase non-overlapping clock signal of two or more than two phases.
[0026] In the clock generator according to any of the above embodiments, a reference clock signal generated by crystal oscillator is input to the non-overlapping clock signal generating module ( 31 ).
[0027] In the clock generator according to any of the above embodiments, the standard clock signal (clock 4 ) is not influenced by the factors of process, voltage and/or temperature.
[0028] In the clock generator according to any of the above embodiments, the time interval between two phase clocks of the multiple phase non-overlapping clock signal is controlled by the standard clock signal (clock 4 ).
[0029] According to another aspect of the invention, a switch-capacitor circuit is provided, comprising any of the above described clock generators, wherein the multiple phase non-overlapping clock signal output by the clock generator is applied in the switch-capacitor circuit.
[0030] In the clock generator and switch-capacitor circuit provided by the invention, a feedback circuit (i.e., a compensation circuit or compensation system) is formed by the ring oscillator, the frequency detecting module, the comparator module and the programmable biasing signal generating module; the biasing signal is fed back and the frequency of the clock signal output by the ring oscillator is adjusted to be equal to the frequency of the standard clock signal, and meanwhile, the time interval between two phase clocks of the multiple phase non-overlapping clock signal can be also corrected in real time or in a one-time manner. Therefore, the offset of the time interval τ between two phase clocks is reduced so that it is substantially immune to the influence by the factors of PVT, etc. The time interval τ between two phase clocks of the multiple phase non-overlapping clock signal output by the clock generator is stable and has a high accuracy, and the switch-capacitor circuit using the clock generator exhibits an excellent performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other objects and advantages of the invention will become completely apparent from the following detailed description with reference to the accompanying drawings, wherein identical or similar elements are denoted by identical reference signs.
[0032] FIG. 1 is a schematic view of a two-phase none-overlapping clock signal.
[0033] FIG. 2 is a schematic view of the circuit of a conventional clock generator for generating the two-phase none-overlapping clock signal shown in FIG. 1 .
[0034] FIG. 3 is a schematic structure view of the clock generator according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Some of the many possible embodiments of the invention will be described below in order to provide a basic understanding of the invention, and it is not intended to identify the crucial or decisive elements of the invention or limit the scope of protection. It is easily understood that according to the technical solutions of the invention, those skilled in the art can propose other alternative implementations without departing from the true spirit of the invention. Therefore, the following specific embodiments and drawings are merely exemplary description of the technical solutions of the invention, and should not be taken as the whole invention or as defining or limiting the technical solutions of the invention.
[0036] In the following description, in order to the make the description clear and concise, not all the many component shown in the drawings are described. Many components that enable those skilled in the art to completely carry out the invention are shown in the Drawings. For those skilled in the art, the operation of many components is familiar and obvious.
[0037] FIG. 3 is a schematic structure view of the clock generator according to an embodiment of the invention. In this embodiment, the clock generator 30 is used for generating a two-phase none-overlapping clock signal, i.e., clock signals clock 1 and clock 2 . Therefore, the clock generator 30 necessarily comprises a non-overlapping clock signal generating module 31 which can output an input reference clock signal to generate two none-overlapping clock signals, i.e., clock signals clock 1 and clock 2 . The reference clock signal can be generated by crystal oscillator, but not limited thereto. Specifically, as shown in FIG. 1 , the non-overlapping clock signal generating module 31 uses several phase inverters and NOT-AND gates, wherein the phase inverter 311 is used for inverting the reference clock signal and further inputting the inverted reference clock signal to an end of the NOT-AND gate 316 ; an input end of the NOT-AND gate 312 is connected with the reference clock signal, and the other input end is feedback input by the clock signal clock 2 . The reference clock signal and the clock signal clock 2 are processed in a NOT-AND logic by the NOT-AND gate 312 and then output to the phase inverter 311 . Further, the phase inverters 313 , 314 and 315 that are connected in series sequentially are used for generating delay, which is substantially equal to the time interval τ. Further, the phase inverter 315 outputs the clock signal clock 1 ; the clock signal clock 1 is input to another input end of the NOT-AND gate 316 in feedback, and the inverted reference clock signal and clock signal clock 1 are processed in a NOT-AND logic by the NOT-AND gate 316 and then output to the phase invert 317 . Further, the phase inverters 317 , 318 and 319 that are connected in series sequentially are used for generating delay, which is substantially equal to the time interval τ. Further, the phase inverter 319 outputs the clock signal clock 2 ; the clock signal clock 1 is feedback input to the NOT-AND gate 312 , and the clock signal clock 2 is feedback input to the NOT-AND gate 316 , thus ensuring a two phase clock time interval τ (referred to as “time interval τ” for short hereinafter) exists between clock 1 and clock 2 . Not considering the influences of such factors as PVT, the offset of the time interval τ is substantially zero, i.e., the time interval τ is a certain predetermined constant value. However, under the influence of such factors as PVT, the variation of the frequencies of clock 1 and clock 2 enables the time interval τ to change and offset relative to the predetermined constant value, i.e., an offset of the two phase clock time interval τ is generated.
[0038] In order to reduce the offset generated by the time interval τ due to an influence by the PVT, preferably, the phase inverters 313 , 314 , 315 , 317 , 318 and 319 are the same phase inverters. Not only the structures and parameters of them are identical, but also the layout and arrangement are identical, and they are disposed adjacent to each other; therefore, the delay generated by the phase inverters 313 , 314 and 315 are the same as the delay generated by the phase inverters 317 , 318 and 319 to the greatest extent possible.
[0039] With continued reference to FIG. 3 the clock generator 30 further comprises a ring oscillator 32 . Specifically, the ring oscillator 32 can be also mainly composed of NOT-AND gates and a plurality of phase inverters. The delay τ 1 generated by the plurality of phase inverters determines the frequency of the clock signal clock 3 output by the ring oscillator 32 . In this embodiment, the ring oscillator 32 is disposed adjacent to the non-overlapping clock signal generating module 31 in the chip and is manufactured in synchronization with the non-overlapping clock signal generating module 31 in the same process. The NOT-AND gates used in the ring oscillator 32 are the same as the NOT-AND gates used in the non-overlapping clock signal generating module 31 , the phase inverters used in the ring oscillator 32 are the same as the phase inverters used in the non-overlapping clock signal generating module 31 , and the structure and layout of the phase inverters in the ring oscillator 32 are also the same as those of the phase inverters in the non-overlapping clock signal generating module 31 . Therefore, the ring oscillator 32 and the non-overlapping clock signal generating module 31 can be easily made to have the same process (i.e., the same manufacture process), the same voltage (i.e., the same power source voltage) and the same temperature (i.e., the same environment temperature). The influence on the output clock signal clock 3 of the ring oscillator 32 by the PVT is substantially equal to the influence on the output clock signals clock 1 and clock 2 of the non-overlapping clock signal generating module 31 by the PVT. Therefore, the variation in the frequency caused by the influence on the clock signal clock 3 by PVT can reflect the offset of the two phase clock time interval τ between clock 1 and clock 2 . In this embodiment, the frequency of clock 3 is determined by the delay τ 1 of the plurality of phase inverters connected in series used by clock 3 . When τ 1 is equal to τ, the frequency of the clock signal clock 3 is equal to the frequencies of the clock signal clock 1 and clock 2 . Moreover, the ratio of ON/OFF of the clock signal clock 3 is also the same as the ratio of ON/OFF of the clock signal clock 1 or clock 2 . The larger the difference between the frequency of the clock signal clock 3 and the frequency of the standard signal clock 4 is, the larger the offset of the two phase clock time interval τ in the non-overlapping clock signal generating module 31 is (the t becomes larger or smaller), and vice-versa.
[0040] In other embodiments, when the clock generator 30 is applied to a high speed situation, in order to avoid a too short period of clock 3 (or to avoid a too high frequency), a multiple relationship can be formed between τ 1 and τ. That is, the number of the phase inverters used in the ring oscillator 32 is n times of the number of the phase inverters for generating the time interval τ used in the non-overlapping clock signal generating module 31 (n is an integer larger than or equal to 2, e.g., n=10). In this way, the frequency f 3 of the clock signal clock 3 is one n th of the frequency of the clock signal clock 1 or clock 2 . At this time, the influence on the ring oscillator 32 by the PVT is also consistent with the influence on the non-overlapping clock signal generating module 31 by the PVT.
[0041] With continued reference to FIG. 3 , the clock generator 30 further comprises a frequency detecting module 33 , to which the clock signal clock 3 output from the ring oscillator 32 and the standard clock signal clock 4 provided externally are input simultaneously. The frequency detecting module 33 can detect the frequency f 3 of the clock signal clock 3 , and can also detect the frequency f 4 of the standard clock signal clock 4 . The standard clock signal clock 4 has a very high accuracy, and is substantially immune to the influence from PVT. The standard clock signal clock 4 has the same frequency as the clock signal clock 1 or clock 2 generated by the non-overlapping clock signal generating module 31 when the offset of the two phase clock time interval τ is zero. Therefore, the two phase clock time interval between the two phase non-overlapping clock signals (clock 1 and clock 2 ) can be controlled by the standard clock signal clock 4 .
[0042] With continued reference to FIG. 3 , the clock generator 30 further comprises a comparator module 34 and a programmable biasing signal generating module 35 . The comparator module 34 can compare the frequency f 3 of the clock signal clock 3 with the frequency f 4 of the clock signal clock 4 . If the frequencies f 3 and f 4 are not the same, it means that the ring oscillator 32 is influenced by the PVT, and an offset of the two phase clock time interval τ between the two phase non-overlapping clock signals has occurred. The comparator module 34 can output a control signal to the programmable biasing signal generating module 35 so that the programmable biasing signal generating module 35 can adjust the height of an output biasing signal. If the frequencies f 3 and f 4 are the same, it means that the ring oscillator 32 is substantially not influenced by the PVT, and an offset of the two phase clock time interval τ between the two phase non-overlapping clock signals has not occurred. The comparator module 34 outputs another control signal to the programmable biasing signal generating module 35 so that the programmable biasing signal generating module 35 still outputs a biasing signal of the same height.
[0043] In this embodiment, the output end 351 of the programmable biasing signal generating module 35 outputs a biasing signal p 1 to the ring oscillator 32 , and the output end 352 outputs a biasing signal p 2 to the non-overlapping clock signal generating module 31 , wherein the biasing signals p 1 and p 2 are the same. In case where the non-overlapping clock signal generating module 31 is a current controllable non-overlapping clock signal generating module and the ring oscillator 32 is a current controllable ring oscillator, the biasing signals p 1 and p 2 are the same biasing current signals, and the magnitude of the current of the biasing signals p 1 and p 2 can be adjustably output according to a comparison result of the frequencies f 3 and f 4 in the comparator module 34 . Therefore, the variation in the magnitude of the output biasing current signals can further cause a change of the frequency of the ring oscillator 32 , until the frequencies f 3 and f 4 are substantially the same. Meanwhile, the biasing current signal (p 2 ) is also adjusted synchronously, and the frequencies of clock 1 and clock 2 can thus be adjusted, thus further reducing an offset of the two phase clock time interval τ. When the frequencies f 3 and f 4 are substantially the same, which means that an offset of the two phase clock time interval τ has been substantially eliminated, the accuracy of the output two phase non-overlapping clock signals (clock 1 and clock 2 ) is high, making it easier to ensure no overlapping will occur between the two clock signals (clock 1 and clock 2 ). When it is applied to a CMOS switch-capacitor circuit, a “charge sharing” phenomenon will not occur, which is highly advantageous for an accurate linearization process of an analogue signal in an AD converter.
[0044] In other embodiments where the non-overlapping clock signal generating module 31 is a voltage controllable non-overlapping clock signal generating module and the ring oscillator 32 is a voltage controllable ring oscillator, the biasing signals p 1 and p 2 can be correspondingly set as biasing voltage signals, and the magnitude of the voltage of the biasing signals p 1 and p 2 can be adjustably changed according to a comparison result, thus further correcting the frequency of the third clock signal clock 3 and the two phase clock time interval τ. Therefore, in the above embodiments, the two phase clock time interval τ can be corrected in real time (in case where the PVT changes at any time) or be corrected in a one-time manner (in case where the PVT no longer changes) so as to reduce the offset of the two phase clock time interval τ.
[0045] In an embodiment, the biasing current signal p 1 can be biased to all the gate circuits (e.g., NOT-AND gates and phase inverters) of the ring oscillator 32 , i.e., the output end 351 is coupled to all the gate circuits of the ring oscillator 32 ; the biasing current signal p 2 can be also biased to all the gate circuits (e.g., NOT-AND gates and phase inverters) of the non-overlapping clock signal generating module 31 , and output end 352 is coupled to all the gate circuits of the non-overlapping clock signal generating module 31 . The biasing current signal p 2 can be generated in a way of being the mirror of the biasing current signal p 1 . For example, if the frequency f 3 is larger than f 4 , the comparator module 34 will output a signal so that the current of the biasing current signal p 1 output by the programmable biasing signal generating module 35 will be reduced, and the current of p 2 will also be reduced. In this way, the frequency f 3 of the clock signal clock 3 will be reduced, the offset of the two phase clock time interval τ will also be reduced, and the influence by such factors as PVT will be corrected.
[0046] It will be understood that the expression “programmable” in the programmable biasing signal generating module 35 indicates a characteristic that the magnitude of the biasing signal output by the programmable biasing signal generating module 35 is adjustable.
[0047] The clock generator 30 in the embodiment shown in FIG. 3 can be applied to a switch-capacitor circuit of an AD converter and an analogue filter, for example, and the two phase non-overlapping clock signal provided by the clock generator 30 in not easily influenced by PCT conditions. The offset of the two phase clock time interval is small, and the two phase clock time interval is stable and accurate. Therefore, when a switch-capacitor circuit uses the clock generator 30 of the embodiment, a “charge sharing” phenomenon can be avoided, thus greatly improving the performance of the switch-capacitor circuit.
[0048] Although the above example have been described based on a clock generator 30 which generates a two phase non-overlapping clock signal, it is understood that on the basis of the above teaching or enlightenment, those skilled in the art can configure a clock generator which generates a multiple phase non-overlapping clock signal in which the offset of the two phase clock time interval is small. For example, if it is required to generate a multiple phase non-overlapping clock signal having three or more than three phases, the non-overlapping clock signal generating module 31 can be reconfigured equivalently so that it has the function of generating a non-overlapping clock signal having three or more than three phases. The structures and arrangements of other modules (e.g., the frequency detecting module 33 , the comparator module 34 and the programmable biasing signal generating module 35 ) do not have to be changed substantively, except for the adaptive changes made to them.
[0049] It will be understood that when a component is referred to as “connected” or “coupled” to another component, it can be connected or coupled directly to the other component, or there can be an intermediate component. Rather, when a component is referred to as “directly connected” or “directly coupled” to another component, there is no intermediate component. Moreover, the expressions “connect” or “couple” used herein can comprise wireless connecting or coupling. As used herein, the term “and/or” comprises any and all combinations of one or more relevant listed items, and can be abbreviated as “/”.
[0050] The above embodiments mainly describe the clock generator of the invention and a switch-capacitor circuit using the clock generator. While only some of the embodiments of the invention are described, those skilled in the art will understand that the invention can be carried out in many other ways without departing from the spirit and scope of the invention. Therefore, the illustrated examples and embodiments should be considered as illustrative rather than limiting. The invention may cover various modifications and substitutes without departing from the spirit and scope of the invention defined by the appended claims. | The invention provides a clock generator and a switch-capacitor circuit comprising the same, and pertains to the technical field of integrated circuit (IC) design. The clock generator comprises a non-overlapping clock signal generating module and a ring oscillator, a frequency detecting module, a comparator module and a programmable biasing signal generating module for forming a feedback circuit, wherein a biasing signal generated by the programmable biasing signal generating module is fed back and input to the ring oscillator so as to adjust the frequency of the third clock signal output by the ring oscillator, until the frequency of the third clock signal is compared as being substantially equal to the frequency of a standard clock signal in the comparator module. Moreover, the biasing signal can be fed back and input to the non-overlapping clock signal generating module so as to reduce the offset of the two phase clock time interval τ. The time interval τ between two phase clocks of the multiple phase non-overlapping clock signal output by the clock generator is stable and has a high accuracy, and the switch-capacitor circuit using the clock generator exhibits an excellent performance. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 14/700,107, filed Apr. 29, 2015, now U.S. Pat. No. 9,499,294, which ′107 application is a nonprovisional of, and claims the benefit under 35 U.S.C. §119(e) to, U.S. provisional patent application 61/985,830 filed Apr. 29, 2014, which is hereby incorporated herein by reference in its entirety. Furthermore, the disclosure of the priority provisional patent application is found in the Appendix attached hereto, which is incorporated by reference.
COPYRIGHT STATEMENT
All of the material in this patent documents is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
BACKGROUND OF THE INVENTION
The present invention generally relates to box designs, blanks for forming boxes by folding, collapsible and non-collapsible boxes formed thereby, and manufacturing methods therefor. Preferably boxes of the invention are used as disposable coolers and are formed from cardboard to which is applied a water-resistant or waterproof coating. An exemplary disposable cooler is disclosed, for example, in Costanzo U.S. Pat. No. 8,573,430. Even in view of the foregoing, it is believed that need continues to exist for improvements and variations to such box designs, blanks, and boxes. One or more aspects and features of the present invention are believed to address such need.
SUMMARY OF THE INVENTION
The present invention includes many aspects and features. Moreover, while many aspects and features relate to, and are described in, the context of disposable ice coolers, the present invention is not limited to only such coolers and applies to other types and uses of boxes, as will become apparent from the following summaries and detailed descriptions of aspects, features, and one or more embodiments of the present invention.
Accordingly, a first aspect of the invention comprises a box as shown and described herein.
Another aspect of the invention comprises an assembled box as shown and described herein.
Another aspect of the invention comprises an assembled, collapsible box as shown and described herein.
Another aspect of the invention comprises a box in the form of a blank as shown and described herein.
Another aspect of the invention comprises a method of making any of the foregoing.
Another aspect of the invention comprises a method of assembling any of the foregoing boxes.
Another aspect of the invention comprises a method of collapsing and storing any of the foregoing.
In another aspect of the invention, a box comprises a center handle for grasping and carrying of the box using a single hand, and further comprises end handles for grasping and carrying of the box by two hands.
In another aspect of the invention, a box is formed from folding a single sheet of material having fold lines therein. In this aspect, the assembled box comprises: a bottom panel defined by subpanels; a first end panel defined by subpanels; a second, opposite end panel defined by subpanels; a first side panel; a second, opposite side panel; a first corner panel defined by subpanels; a second corner panel defined by subpanels; a third corner panel defined by subpanels; a fourth corner panel defined by subpanels; a first tab-lock and counterbalancing handle panel defined by subpanels; a second tab-lock and counterbalancing handle panel defined by subpanels; a first lid panel; a second lid panel; and a center handle panel defined by subpanels.
In various possible features of this aspect, some of which may or may not be mutually exclusive: the first and the second tab-lock and counterbalancing handle panels collectively define two-ply handles on opposite ends of the box for gripping the box, which handles are provided both when the box is in the open and closed positions; the handles are equally spaced relative to a center of the box for counterbalancing torques that result from supporting the box at two spaced apart locations; the end handles are defined respectively by openings in the subpanels connected directly to—and respectively separated by a fold line from—corner subpanels; handle subpanels define a single, two-ply handle located along the center of the box when the box is in the closed position; handle subpanels define curved tabs which align and define two-ply tabs that are received within openings defined in the end handles when the box is in the closed position, thereby locking the box in the closed position; when the box is assembled and in the open or closed positions, the openings in corner subpanels are elongate and generally extend longitudinally in a direction that is orthogonal to the openings defined therein for receiving the tabs, which openings also are elongate; when the box is assembled and in the open or closed positions, the hand openings defined by the corner subpanels extend generally orthogonally to the tab openings defined by the corner subpanels; the hand openings and the tab openings defined by the corner subpanels intersect and bisect each other.
In yet an additional feature, the box is collapsible even though it is in an assembled state by folding the box along an axis bisecting the bottom panel and the opposite end panels.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more preferred embodiments of the present invention now will be described in detail with reference to the accompanying drawings.
FIG. 1 is a plan view of a box blank in an unassembled, flat condition in accordance with one or more aspects and features of the present invention.
FIG. 2 illustrates a box that has been assembled by folding the box blank of FIG. 1 , wherein the assembled box is in a closed configuration.
FIG. 3 illustrates a method of gripping and carrying the box using two handles defined on opposite ends of the box of FIG. 2 .
FIG. 4 illustrates an alternative method of gripping and carrying the box using a single handle defined at a centered location of the box of FIG. 2 .
DETAILED DESCRIPTION
As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (“Ordinary Artisan”) that the present invention has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the present invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the present invention. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the invention and may further incorporate only one or a plurality of the above-disclosed features. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.
Accordingly, while the present invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present invention, and is made merely for the purposes of providing a full and enabling disclosure of the present invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the present invention, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.
Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the present invention. Accordingly, it is intended that the scope of patent protection afforded the present invention is to be defined by the appended claims upon issuance rather than the description set forth herein.
Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein—as understood by the Ordinary Artisan based on the contextual use of such term—differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.
Regarding applicability of 35 U.S.C. §112 subsection (f), no claim element is intended to be read in accordance with this statutory provision unless the explicit phrase “means for” or “step for” is actually used in such claim element, whereupon this statutory provision is intended to apply in the interpretation of such claim element.
Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to “a picnic basket having an apple” describes “a picnic basket having at least one apple” as well as “a picnic basket having apples.” In contrast, reference to “a picnic basket having a single apple” describes “a picnic basket having only one apple.”
When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Thus, reference to “a picnic basket having cheese or crackers” describes “a picnic basket having cheese without crackers”, “a picnic basket having crackers without cheese”, and “a picnic basket having both cheese and crackers.” Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.” Thus, reference to “a picnic basket having cheese and crackers” describes “a picnic basket having cheese, wherein the picnic basket further has crackers,” as well as describes “a picnic basket having crackers, wherein the picnic basket further has cheese.”
Referring now to the drawings, a first preferred embodiment of a box in accordance with one or more aspects and features of the invention is represented by a box blank 100 shown in FIG. 1 in plan view in an unassembled, flat condition.
The blank 100 includes fold lines comprising score lines or areas of reduced thickness or weakness that facilitate folding of the blank during assembly of the box. The fold lines in the blank 100 serve to define discrete panels, including: a bottom panel defined by subpanels 102 a , 102 b ; a first end panel defined by subpanels 104 a , 104 b ; a second, opposite end panel defined by subpanels 106 a , 106 b ; a first side panel 108 ; a second, opposite side panel 110 ; a first corner panel defined by subpanels 112 a , 112 b ; a second corner panel defined by subpanels 114 a , 114 b ; a third corner panel defined by subpanels 118 a , 118 b ; a fourth corner panel defined by subpanels 116 a , 116 b ; a first tab-lock and counterbalancing handle panel defined by subpanels 120 a , 120 b ; a second tab-lock and counterbalancing handle panel defined by subpanels 122 a , 122 b ; a first lid panel 124 ; a second lid panel 126 ; and a center handle panel defined by subpanels 128 a , 128 b.
FIG. 2 illustrates a box 200 that has been assembled by folding the box blank 100 of FIG. 1 along fold lines, wherein the box 200 is in a closed configuration. The assembled box 200 preferably includes a waterproof or water-resistant coating on the interior surfaces such that the box may be used for containing ice, beverages, and food within an interior cooler space thereof.
As seen in box 200 , the first tab-lock and counterbalancing handle panel defined by subpanels 120 a , 120 b and the second tab-lock and counterbalancing handle panel defined by subpanels 122 a , 122 b collectively define two-ply handles on opposite ends of the box 200 for gripping the box 200 . These handles are provided both when the box 200 is in the open and closed positions. The handles are equally spaced relative to a center of the box for counterbalancing torques that result from supporting the box at two spaced apart locations. It will further be appreciated that these handles are defined respectively by openings in the subpanels 120 a , 120 b connected directly to—and separated by a fold line from—subpanel 112 a , and in the subpanels 122 a , 122 b connected directly to—and separated by a fold line from—subpanel 114 a.
FIG. 3 illustrates a method of gripping and carrying the box 200 using the two handles defined on opposite ends of the box 200 .
As further seen in the drawings, subpanels 120 a , 120 b define notches 130 a , 130 b that align when these subpanels are folded relative to each other to form a first handle, whereby these notches define a first recess in the first handle for receiving and retaining lid panel 126 when the box 200 is in the closed position. Similarly, subpanels 122 a , 122 b define notches 132 a , 132 b that align when these subpanels are folded relative to each other to form a second handle, whereby these notches define a second recess in the second handle for receiving and retaining lid panel 126 when the box 200 is in the closed position. These recesses operate to hold and retain the lid 126 in the closed position of the box 200 with the lid 126 being inserted into the recesses.
As further seen in the drawings, subpanels 128 a , 128 b define a single, two-ply handle located along the center of the box 200 when the box 200 is in the closed position. FIG. 4 illustrates an alternative method of gripping and carrying the box using this single handle.
Additionally, subpanels 128 a , 128 b further define curved tabs 134 a , 134 b and 136 a , 136 b which align and define two-ply tabs that are received within openings defined in the end handles when the box 200 is in the closed position, thereby locking the box 200 in the closed position. When the box 200 is assembled and in the open or closed positions, the openings in subpanels 120 a , 120 b , 122 a , 122 b are elongate and generally extend longitudinally in a direction that is orthogonal to the openings defined therein for receiving the tabs, which openings also are elongate. In other words, the hand openings preferably extend generally orthogonally to the tab openings. Moreover, the two types of openings preferably intersect each other and, more preferably, bisect each other.
It will be appreciated that the blank 100 further is designed to form, when assembled, a box that is collapsible even though it is in an assembled state by folding the box 200 along axis A shown in FIG. 1 , which axis bisects the bottom panel and the opposite end panels.
Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention.
Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | Dual handle box designs, blanks for forming boxes by folding, collapsible and non-collapsible boxes formed thereby, and manufacturing methods therefor are disclosed. Preferably each handle is located on an opposite end of the box; is two-ply; defines an elongate hand opening for receiving fingers of a hand; defines an elongate tab opening for receiving a tab of a center handle, and that intersects the hand opening; and defines a recess for receiving and retaining a lid panel of the box. Furthermore, the boxes preferably have a waterproof or water-resistant coating applied and are used as ice coolers for beverages and food items. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to steam control. More particularly, the invention relates to the control of steam distribution to a plurality of boilers, and to optimizing the performance of a steam boiler.
The technology for control of steam-generation systems has evolved by trial and error over the years, with very few scientific principles applied. Recently the use of BTU summing and oxygen-bias controls have led to increases in efficiency, along with improved burner designs and better metallurgy. However, the basic system has remained, for the most part, unchanged.
Burner management and combustion control are currently done by a system which comprises fuel-air lead-lag control, stack-oxygen measurement which biases combustion air flow, BTU summing of fuel values which is then used to ratio air-to-fuel control, and master pressure control which resets the fuel rate.
Most of the changes which have been made to boilers and fired heaters have come as a retrofit to existing equipment. This has precluded the examination of the total system in a scientific and analytical manner. When this is done, it can be seen that a reordering of priorities is desirable.
Much experimentation has been carried out in the area of burner and gun design, in order to promote atomization and mixing of fuels with combustion air to promote rapid and efficient burning of the fuel while reducing the amount of excess air required, in the quest of fuel efficiency and of reducing the size of the equipment. This work has resulted in the equipment in use today, but the equipment is quite susceptible to damage due to upset conditions or mis-operation.
The present invention provides technology which solves many of the problems discussed above.
SUMMARY OF THE INVENTION
In general, the present invention in a first aspect provides a steam-distribution control system for a plurality of boilers. The control system comprises (a) a plurality of steam sub-headers; (b) a plurality of steam-flow sensors for sensing the flow of steam through the sub-headers; (c) means for summing the total flow of steam through the sub-headers; (d) a main steam-supply header; (e) a steam-flow sensor in the main steam-supply header, for measuring the total flow of steam to the sub-headers; (f) a comparator for relating the sum of the individual steam flows through the individual sub-headers to the total steam flow measured by the steam-flow sensor; (g) a master control system for overall control of steam distribution; (h) a pressure sensor in the main steam-supply header for measuring the pressure in the main steam-supply header; (i) means for sending a first signal from the pressure sensor in the main steam-supply header to the master control system and to the comparator module, the first signal indicating the pressure in the main steam-supply header; (j) means for sending a second signal from the steam-flow sensor in the main steam-supply header to the master control system, the second signal indicating the steam flow through the main steam-supply header; (k) a summer module to provide the means for summing the total flow of steam through the steam sub-headers; (l) means for sending a third signal from each steam-flow sensor in each steam sub-header to the summer module, the third signal indicating the steam flow through each steam sub-header; (m) means for sending a fourth signal from the summer module to the comparator module, the fourth signal indicating the total steam flow through the steam sub-headers; (n) means for sending a fifth signal from the comparator module to the master control system, the fifth signal indicating the magnitudes of the total measured flow of steam through the main steam-supply header and of the summation of the steam flows through each of the steam sub-headers; and (o) means for adjusting the amount of steam production to each boiler in accordance with elements (a) through (n).
In a second aspect the invention provides a steam boiler control system. The control system comprises (a) a steam back-pressure controller which maintains a constant steam pressure in the boiler; (b) means for measuring the relative humidity of the air supply for fuel combustion; and (c) means for supplying and controlling the amount of steam to be mixed with the air supply in order to optimize the combustion process.
In a third aspect the present invention provides a method for controlling the distribution of steam production to a plurality of boilers. The method comprises the steps of (a) providing a plurality of steam sub-headers; (b) measuring the rate of flow of the steam through each of the sub-headers; (c) providing a main steam-supply header; (d) measuring the rate of flow of the steam through the main steam-supply header; (e) summing the individual rates of steam flow through the individual sub-headers; (f) comparing the sum of the individual rates of steam flow through the individual sub-headers with the measured rate of steam flow through the main steam-supply header; (g) controlling the distribution of steam production to each boiler; (h) measuring the pressure in the main steam-supply header with a pressure sensor in the main steam-supply header; (i) providing a master control system for controlling the distribution of steam production to each boiler; (j) utilizing a comparator module for comparing the sum of the rates of steam flow through the sub-headers with the rate of steam flow through the main steam-supply header; (k) sending a first signal from the pressure sensor in the main steam-supply header to the master control system and to the comparator module, the first signal indicating the pressure in the main steam-supply header; (l) utilizing a steam-flow sensor in the main steam-supply header to measure the rate of steam flow through the main steam-supply header; (m) sending a second signal from the steam-flow sensor in the main steam-supply header to the master control system, the second signal indicating the steam flow through the main steam-supply header; (n) utilizing a summer module to sum the individual rates of steam flow through the individual sub-headers; (o) utilizing a steam-flow sensor in each sub-header to measure the flow of steam through each sub-header; (p) sending a third signal from each steam-flow sensor in each steam sub-header to the summer module, the third signal indicating the steam flow through each steam sub-header; (q) sending a fourth signal from the summer module in the comparator module, the fourth signal indicating the total steam flow through the steam sub-headers; (r) sending a fifth signal from the comparator module to the master control system, the fifth signal indicating the magnitudes of the total measured flow of steam through the main steam-supply header and of the summation of the steam flows through each of the steam sub-headers; and (s) regulating the flow of steam production to each boiler in accordance with steps (a) through (r).
In a fourth aspect the present invention provides a method for optimizing the performance of a steam boiler. The method comprises the steps of (a) maintaining a constant steam pressure in the boiler; (b) measuring the relative humidity of the air supply for fuel combustion; and (c) supplying and controlling the amount of steam to be mixed with the air supply to optimize the combustion process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a steam boiler, made in accordance with the principles of the present invention.
FIG. 2 is a schematic representation of a steam-distribution control system for a plurality of boilers, made in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention controls the flows of air, fuel, and steam to a boiler or a plurality of boilers, and the flow of steam from the boiler or boilers.
More specifically, reference is made to FIG. 1, in which is shown a schematic representation of a steam boiler, made in accordance with the principles of the present invention and generally designated by the numeral 2. Incoming air passes through an air filter 4 to the inlet of a forced-draft fan 6. The air then passes through the fan 6 outlet into an air heater 8, which is heated by flue gas from the boiler 2. The air pressure in an air duct 10 is controlled by a pressure controller 12, which resets the opening of the fan 6 inlet damper. The control of the air pressure enables an air-flow sensor 14 to operate much more accurately.
A relative-humidity sensor 16 is used to correct the air-flow measurement of the air-flow sensor 14, by subtracting the contribution of the water vapor in the air from the total air flow, thereby measuring the flow of air on a dry basis. The signal from the relative-humidity sensor 16 is also used to adjust the level of the water vapor in the air to the level desired for optimum combustion by resetting a first flow controller 18 which admits steam into the air duct 10. The mixture of air and steam then enters the burner area 20 of the boiler 2. The flow of air is controlled by a first flow-control valve 22, and the flow of steam by a second flow-control valve 24.
Incoming fuel is regulated by a third flow-control valve 26, and is fed to the burner area 20, where it admixes with the optimized steam-air mixture, and burns. The above-described control of the air and water vapor promotes enhanced burning, increased flame radiation, shorter flame bursts, and more nearly complete combustion.
There is a plethora of empirical evidence indicating that the presence or absence of water vapor in burner influent has a profound effect on the quality of combustion, as well as on the ratio of of the combustion products. Indeed, when No. 2 oil is atomized with air, a yellow flame with dark spots is produced, while atomization with steam gives a fine blue flame. The difference is not due to mechanical differences in the atomization of the fuel, but to the presence of the water vapor in the flame. It is also demonstrable that a natural gas flame in a conventional heater is shorter and of better quality during periods of high humidity.
The effect of hydrogen-to-carbon ration in a fuel on the quality of a flame is readily observable. The higher the hydrogen-to-carbon ratio, the better the fuel burns. Natural gas, methane, has a very high hydrogen-to-carbon ratio compared to most other fuels, and it burns quite cleanly. Olefins, diolefins, and acetylenes produce sooty flames, even when mixed with adequate amounts of air for combustion. When steam is added to the burner constituents, the soot disappears and even these fuels burn cleanly. Preferably, the hydrogen-to-carbon ratio is adjusted by steam addition if and as needed to from about three tenths to about five tenths.
Heat transfer in a furnace is effected by radiation and convection. The incandescent gases present in a furnace firebox radiate to the walls and tubes, and then transfer the rest of the contained heat by surface conduction to cooler areas of the unit. It is known that elemental gases such as nitrogen and oxygen cannot radiate, but that binary gases such as water, carbon dioxide, and carbon monoxide radiate heat very well. In the light of these observations, it can be postulated that the higher the ratio of binary to elemental gases in a flame, the greater the radiation of heat, which will result in a more rapid reduction of the temperature of the flame.
When boilers are equipped with preheat systems, the production of oxides of nitrogen is increased. This condition is usually controlled by the recirculation of the stack gas to the burner. The motivating theory is that the carbon dioxide present in the recycled gas reduces the flame temperature and lowers the production of nitrogen oxides by shifting the equilibrium of the reaction to the left. This theory is only partially correct. The rest of the phenomenon has to do with the fact that a certain amount of radiation from the flame is necessary, and that in the absence of a necessary number of binary-gas molecules to effect the required radiation, requirement for equilibrium in the flame will cause the formation of additional binary-gas molecules. Because of the larger amount of nitrogen present, oxides of nitrogen will be formed. When binary gases such as water and carbon dioxide are introduced, the requirement for radiation is satisfied, and excessive amounts of nitrogen oxides are not generated. It is the radiative capability of the water molecules which causes the reduction of soot in flames from the burning of olefins, acetylenes, and aromatic hydrocarbons, by the heating of carbon to temperatures which are sufficiently high to permit its combustion.
The principal problem in the control of combustion air flow to a furnace is caused by the changes in relative humidity in the local climate. Water vapor in atmospheric air can vary from a very low concentration to as much as six-and-one-half percent by volume at high ambient temperatures and humidities. Because such high levels of water vapor in the combustion air introduce errors in conventional air-flow measurement, the air-flow controller is generally biased by measuring the stack oxygen content, in order to maintain the necessary amount of excess air at the burner. Because the method generally used for this purpose is the depression of the measured value of air flow, in essence "lying" to the air-flow controller, the actual air flow cannot be known.
In order to control any chemical reaction, of which combustion is a specific example, it is desirable to control all of its aspects. The focus of burner management has traditionally been to provide a given amount of excess oxygen at the burner at all times, including normal steady operation, increasing rates, and decreasing rates. Otherwise, very little attention has been given to the chemistry of the burning of fuel. When the evidence suggesting that efficiency of burning is greatly enhanced by the hydrogen-to-carbon ratio in the flame, and the higher radiation rates observed in the presence of binary gases in the flame are considered, it can be concluded that control of relative humidity in the combustion air can only enhance the efficiency of burning and heat transfer in the furnace. This can beneficially be done, in accordance with the principles of the present invention, by the addition of low-pressure steam to the combustion air, in order to control the water content at the most efficient value. This value will vary from furnace to furnace, and will also depend on the fuel which is being fired. Control of steam addition can be determined by air-flow measurement coupled with humidity measurement, in order to control the amount of steam which is to be added to the combustion air. In this way, the amount of water vapor present in the combustion air can be absolutely controlled, and the amount of oxygen present can be calculated by the control system. Oxygen measurement in the stack can then be used to verify the flow-control scheme. The water-vapor content of the combustion air can then be adjusted to obtain optimum burning conditions, producing both maximum heat transfer and low emissions of nitrogen oxides.
A firing system 28 for the boiler 2 is reset by a second flow controller 30, which receives a signal from a master control system 32. The second flow controller 30 adjusts the proportions and amounts of air and fuel to regulate and control the quantity of steam generated by the boiler 2. Conventionally, a pressure controller is used to perform this function. However, pressure control is capable of overfiring a boiler. The use of a flow controller 30 prevents the master control system 32 from ovefiring the boiler 2 during periods of unstable steam distribution.
Steam produced by the boiler 2 leaves the boiler 2 by way of a control valve 34, which is reset by a pressure controller 36 in order to maintain the steam pressure in the boiler 2 constant under all firing conditions, thereby eliminating problems of drum (not shown) level control and steaming in the boiler 2 tubes (not shown).
Reference is now made to FIG. 2, in which is shown a schematic representation of a steam-distribution control system for a plurality of boilers, made in accordance with the principles of the present invention and generally designated by the numeral 40.
Product steam from the individual boilers 2 enters a main steam supply header 42, where the steam-header pressure is measured by a pressure sensor 44, whose signal is sent to the master control system 32. A steam-flow sensor 47 measures the flow of steam passing through the main steam header 42, and whose output signal is sent to the master control system 32 and to a comparator module 48. Steam passes from the main steam header 42 and enters a plurality of steam sub-headers 50.
Each sub-header 50 is equipped with a steam-flow sensor 52, whose signal is sent to a summer module 54. The summer module 54 adds the flows through the sub-headers 50, and outputs to the comparator module 48 a signal equal to the total steam flow through the sub-headers 50. A signal from the comparator module 48 is sent to the master control system 32, indicating the magnitudes of the total measured flow of steam through the main steam sub-header 42 and of the summation of the steam flow through each of the sub-headers 50.
From each of the boilers 2 in the steam supply system a signal 64 is sent to the master control system 32, indicating the status of a given boiler 2, as to whether the boiler 2 is producing steam or is off-line. From the master control system 32 a flow signal 66 is sent to each master control system 32 flow controller 30, which raises or lowers the production of steam demand for each boiler 2 as required. In order to regulate the boilers 2 to properly and efficiently meet the demand of the steam-distribution control system 40, the master control system 32 considers the pressure sensor 44 signal, the flow sensor 47 signal, and the comparator module 48 signal. A logic scheme in the master control system 32 raises or lowers the output signals 66 as needed, based on the status inputs from the summer module 54 signal as well as on a signal input 18 from a human operator (not shown).
Because the sum of the steam flows in the sub-headers 50 is constantly being compared by the comparator module 48 to the steam flow through the main steam header 42 and the flow sensor 47, the master control system 32 is able to anticipate an increase or decrease in steam demand, and in response thereto make flow corrections in a timely manner before steam-system conditions are disturbed. | Apparati and methods for controlling the distribution of steam to a number of boilers, and for optimizing the performance of a steam boiler. The distribution of steam to the boilers is controlled by a master control system in communication with the boilers, steam subheaders, steam-flow sensors, a comparator module, a summer module, a main steam-supply header, and a pressure sensor in the main steam-supply header. The performance of an individual boiler is optimized by (a) maintaining a constant steam pressure in the boiler, (b) measuring the relative humidity of the air supply for fuel combustion, and (c) supplying and controlling the amount of steam to be mixed with the air supply to optimize the combustion process. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 08/166,487, filed Dec. 13, 1993.
TECHNICAL FIELD
This invention relates to a process for reducing the level of residual monomer in an N-vinyl pyrrolidone containing polymerization reaction product.
BACKGROUND OF THE INVENTION
Processes for the polymerization of vinyl pyrrolidone polymers, with or without other ethylenic monomers copolymerizable therewith, at elevated temperature in the presence of free radical polymerization initiators are known. The resulting polymers have wide commercial acceptance because of their low toxicity and solubility in both organic solvents and water.
One of the problems associated with the batch polymerization of vinyl pyrrolidone containing polymers is in the reduction of residual monomer contained in the polymerization reaction product at the end of the normal polymerization. Residual monomer is unacceptable from an environmental point of view. It also represents an economic loss, since there is substantial cost in removing the monomer. Some of the conventional techniques for removing residual monomer have been through physical processes, e.g., steam or inert gas stripping or additional polymerization through subsequent heat treatments. These processes tend to extend the batch polymerization causing long reaction times as well as leading to product discoloration and changes in product molecular weight distribution and viscosity.
Representative patents illustrating approaches to the removal of residual monomer content in polymerization reaction products are as follows:
U.S. Pat. No. 4,053,696 disclose a process for the manufacture of vinyl pyrrolidone polymers practically free from residual monomer and impurities via a continuous polymerization technique. Polymerization is carried in an organic solvent in the presence of free radical polymerization initiators. These initiators are introduced ab initio, i.e., introduced with the initial charge of reactants or introduced at various points of the reaction.
U.S. Pat. No. 3,459,720 discloses an improved process for the polymerization of N-vinyl lactams in the presence of azo catalysts and hydrogen peroxide. Disclosed in the background portion of the patent are two methods for the polymerization of N-vinyl pyrrolidone. One method utilizes a peroxide catalyst and the other uses an azobis(isobutyronitrile) catalyst. The patentees point out that the peroxide catalysts result in products inferior in terms of color stability, odor and viscosity, while the azo catalysts yield products of superior quality, but often have a high molecular weight, too high for many purposes. The improved batch process for the polymerization of N-vinyl pyrrolidone is carried out by polymerizing the monomer in the presence of an azo catalyst and controlling the molecular weight by addition of hydroperoxide. The azo catalyst and hydroperoxide are advantageously added at the start of the polymerization to avoid any need for supervision.
U.S. Pat. No. 4,520,180 discloses a process for the polymerization of N-vinyl pyrrolidone using t-butylperoxypivalate, preferably in a solvent consisting essentially of water, isopropanol, and secondary butyl alcohol. In the polymerization process, N-vinyl pyrrolidone is continuously added to a kettle containing solvent, an initial charge of N-vinyl pyrrolidone and t-butylperoxypivalate catalyst.
U.S. Pat. No. 4,205,161 discloses a process for reducing the residual level of vinyl chloride monomer and vinyl chloride monomer in polymers and copolymers. The process comprises post-polymerizing the polymerization reaction product until there is a decrease in the autogenous pressure, then releasing the pressure, cooling the copolymer to a temperature of from 10° to 40° C. and introducing a redox catalyst to effect final polymerization.
U.S. Pat. No. 4,529,753 discloses a process for reducing the residual monomer level in emulsion polymerization reaction products. Residual acrylonitrile is reduced in a latex by adding stoichiometric amounts of amine, by adding additional catalysts and comonomer, steam or inert gas stripping or passing a latex through an apparatus that reduces pressure. A process described in the '753 patent utilizes temperature and pressure conditions at which the vapor pressure of water in ambient environment is less than the vapor pressure water in the emulsion and then utilizes a free radical generator to polymerize residual monomer in the emulsion.
U.S. Pat. No. 4,241,203 discloses a process for reducing the monomer content in acrylonitrile containing copolymers by heating the polymerization product to a temperature slightly exceeding 130° C. for a time sufficient to permit polymerization of the residual monomer.
SUMMARY OF THE INVENTION
This invention relates to an improved process for the batch polymerization, neat, of a monomer system comprising N-vinyl pyrrolidone monomer utilizing an oil soluble, thermally activated, free radical initiator. The improvement for reducing the monomer level from about 1 to 2% by weight of the polymerization product to a level below about 0.2 and preferably below about 0.1% by weight of the polymerization reaction product comprises continuously adding an oil soluble azo type free radical generating catalyst to the polymerization reaction product and establishing and maintaining the polymerization reaction product containing residual monomer at a temperature and for a time sufficient to effect substantial polymerization of the residual monomer. Typically the oil soluble, azo type free radical generating catalyst is azobis(isobutyronitrile).
Several advantages are achieved. They include: an ability to achieve low residual monomer with small catalyst additives, an ability to achieve low monomer levels at enhanced rates leading to short post-polymerization schedules, an ability to reduce monomer level without imparting undesirable color and an ability to obtain low monomer concentrations in the polymerization reaction product with reduced catalyst, reduced catalyst levels resulting in cost savings and reduced levels of possibly toxic by-product formation.
DETAILED DESCRIPTION OF THE INVENTION
Batch polymerization of N-vinyl pyrrolidone and vinyl monomers incorporating N-vinyl pyrrolidone monomer are known. These monomer systems comprise N-vinyl pyrrolidone to produce an N-vinyl pyrrolidone homopolymer or other vinyl monomers copolymerizable with N-vinyl pyrrolidone to product a copolymer containing N-vinyl pyrrolidone. The N-vinyl pyrrolidone content in the resulting polymers typically will range from 60 to 100% by weight with about 0 to 40% by weight of another vinyl monomer based on the resulting polymer. Examples of vinyl monomers commonly copolymerized with N-vinyl pyrrolidone include N-vinyl caprolactam, N-vinyl piperidone, vinyl esters, e.g., vinylacetate and vinylpropionate, C 1-4 alkyl esters of acrylic and methacrylic acid, e.g., methylacrylate and methyl methacrylate, C 1-4 esters of maleic and fumaric acid, e.g., dibutylmaleate; vinyl chloride, acrylonitrile, and others commonly used to form N-vinyl pyrrolidone containing copolymers.
The N-vinyl pyrrolidone polymers are prepared by batch polymerization, neat, wherein essentially all of the monomers are introduced to a stirred autoclave under conditions sufficient for effecting polymerization. No solvent or carrier is required. The catalysts commonly used in effecting polymerization are the oil soluble azo type catalysts represented by the formula:
N.tbd.C--R.sub.1 --N═N--R.sub.2 --C.tbd.N
wherein R 1 and R 2 are C 4 to C10 aliphatic and cycloaliphatic radicals. These azo type free radical generating catalysts include azobis(isobutyronitrile); azobis(dimethylvaleronitrile); azobis(methylbutyronitrile); azobis(ethylbutyronitrile); azobis(phenylpropionitrile); azobis(cyclohexylpropionitrile); azobis(cycloheptylpropionitrile), and the like. These azo type compounds are widely utilized in the art as free radical initiators and are effective for polymerization of N-vinyl pyrrolidone monomer containing systems. Temperatures for effecting polymerization range from about 100° to 130° C. and pressures range from about subatmospheric to above atmospheric; atmospheric pressure being preferred. Reaction times to produce an N-vinyl pyrrolidone polymer range from about 1 to 2 hours, resulting in a polymerization reaction product containing generally in the range from 1 to 2% residual monomer based on the weight of the polymerization reaction product.
Post polymerization of the residual monomer in the polymerization reaction product is accomplished by continuously adding the above described oil soluble, thermally activated azo type free radical initiators to the polymerization reaction product. The concentration of oil soluble, thermally activated azo type free radical initiator typically added to the polymerization reaction product ranges from about 0.15 to 2% and preferably from about 0.3 to 0.6% to reduce the free monomer content to a level below about 0.2% and preferably below about 0.1% by weight of the polymerization reaction product. Higher levels are not necessary and lead to enhanced by-product production. The continuous addition of the oil soluble, thermally activated free radical initiator not only is effective for reducing the free monomer content in the reaction product to acceptably low levels, there is substantially no change with respect to color or substantial change with respect to molecular weight or viscosity, and, yet, the polymerization can be accomplished in a much shorter time than when the free radical initiator is added incrementally as opposed to being added ab initio even at higher initiator levels.
The following examples are provided to illustrate various embodiments of the invention and are not intended to restrict the scope thereof.
EXAMPLE 1
Post Polymerization of N-Vinyl Pyrrolidone/Dibutylmaleate Graft Polymer using Azobis(isobutyronitrile)
An N-vinyl pyrrolidone (NVP)/dibutylmaleate polymerization reaction product is prepared by a conventional batch polymerization technique wherein the N-vinyl pyrrolidone and dibutylmaleate are charged to an autoclave containing a polyglycol reactant (which also serves as a solvent) and equipped with agitation and means for heating and cooling the reactants during polymerization. The polymerization is initiated with 1% of azobis(isobutyronitrile) based on the weight of the reactor contents. The contents are heated, under agitation, and polymerization is effected over a period of about 2 hours in which a polymerization reaction product containing from about 1 to 2 weight percent residual monomer is produced. Azobis(isobutyronitrile) is added to the polymerization reaction product to reduce residual monomers. Table 1 sets forth results for different charges of azobis(isobutyronitrile). In Run 1, 0.3 wt % of azobis(isobutyronitrile) is added ab initio, i.e., introduced initially to the polymerization reaction product. In Run 2, 0.3 wt % of azobis(isobutyronitrile) was added in two separate charges of 0.15 wt %. In Run 3, 0.3 wt % of azobis(isobutyronitrile) was added in three separate charges of 0.1 wt %. Residual vinyl monomer content is recorded as a function of time and is set forth in Table 1.
Table 2 sets forth results comparing the addition of a single 0.6% charge of azobis(isobutyronitrile) based upon the weight of the N-vinyl pyrrolidone polymerization reaction product (Run 4) vis-a-vis two charges of 0.6% azobis(isobutyronitrile) which were introduced on a continuous basis based upon the weight of the N-vinyl pyrrolidone polymerization reaction product over the 120 minute time frame (Runs 5 and 6). The percent residual N-vinyl pyrrolidone monomer is recorded as a function of time in minutes and the results are set forth.
TABLE 1______________________________________PELLET CHARGES RUN 1 RUN 2 RUN 3 One 0.3% Two 0.15% Three 0.1%TIME CHARGE CHARGES CHARGESMinutes % NVP % NVP % NVP______________________________________0 1.0* 1.0* .90*15 .36 .51 .4630 .22 .45 .42*45 .26 .36 .3560 .23 .26* --75 .22 .15 .1990 .22 .11 .14*105 .22 .10 .12120 .22 .09 .11______________________________________ *Time at which charge is introduced
TABLE 2______________________________________SLURRY CHARGES RUN 4 RUN 5 RUN 6 One 0.6% 0.6% 0.6%TIME CHARGE CONTINUOUS CONTINUOUSMinutes % NVP % NVP % NVP______________________________________0 1.1* 1.1 1.115 .45 .43 --30 .33 .32 .3245 .29 .21 --60 .28 .17 .1675 .23 .14 --90 .24 .12 .11105 .25 -- --120 .25 .06 .08______________________________________ *Time at which charge is introduced
Table 1 shows that the addition of azobis(isobutyronitrile) in a single charge (Run 1) is ineffective for reducing residual N-vinyl pyrrolidone monomer in the N-vinyl pyrrolidone polymerization reaction product. Greater reductions are achieved when the azobis(isobutyronitrile) is introduced in increments (Runs 2 and 3). The monomers were reduced to a level of about 0.1%.
The results in Table 2 show that the continuous addition of azobis(isobutyronitrile) (Runs 5 and 6) is much more effective at catalyzing the polymerization of the residual monomer, then when the catalyst is added ab initio (Run 4). The addition of 0.6% azobis(isobutyronitrile) in a single charge, ab initio, gave results similar to those shown with a single 0.3% charge (Run 1, Table 1). Table 2 also shows that extremely low levels of residual monomer are achieved in about 60 to 90 minutes when the azobis(isobutyronitrile) is added continuously (Runs 5 and 6), thus showing an excellent rate of reduction of residual vinyl monomer in the polymerization product. The post treated product had a good color, no viscosity increase or change in molecular weight distribution.
EXAMPLE 2
Post Polymerization N-Vinyl Pyrrolidone/Dibutylmaleate Graft Polymer using t-Butylperoxybenzoate
An N-vinyl pyrrolidone/dibutylmaleate graft copolymer is prepared as in Example 1. The post-treatment processes consist of adding a continuous charge of t-butylperoxybenzoate (tBPB) as the oil soluble, thermally activated free radical initiator. Table 3 sets forth results wherein the t-butylperoxybenzoate is added at a rate of 1 wt % of the polymerization reaction product per hour. Table 4 sets forth results when the t-butylperoxybenzoate is added at a rate of 2 wt %, based upon the polymerization reaction product, per hour. Residual monomer versus time is set forth.
TABLE 3______________________________________1 wt % of t-butylperoxybenzoate/hr.TIME (min) % WT NVP REMAINING______________________________________0 0.8115 0.7645 0.7175 0.65______________________________________
TABLE 4______________________________________2 wt % of t-butylperoxybenzoate/hr.TIME (MIN) % WT NVP REMAINING______________________________________0 0.6530 0.4960 0.2875 0.1890 0.12120 0.07______________________________________
As can be seen from the results presented in Tables 3 and 4, the t-butylperoxybenzoate is inefficient as an oil soluble, thermally activated free radical initiator for the reduction of NVP in the polymerization reaction product. The amount of tBPB is 1.5% (1%/hour for 1.5 hours) in Table 3 and 4% (2%/hour for 2 hours}in Table 4. The amounts are extreme as compared to the azobis(isobutyronitrile) catalyst introduced on a continuous basis. | This invention relates to an improved process for the batch polymerization, neat, of a monomer system comprising N-vinyl pyrrolidone monomer utilizing an oil soluble,-thermally activated, free radical initiator. The improvement for reducing the monomer level from about 1 to 2% by weight of the polymerization product to a level below about 0.2 and preferably below about 0.1% by weight of the polymerization reaction product comprises continuously adding an oil soluble azo type free radical generating catalyst to the polymerization reaction product and establishing and maintaining the polymerization reaction product containing residual monomer at a temperature and for a time sufficient to effect substantial polymerization of the residual monomer. Typically the oil soluble, azo type free radical generating catalyst is azobis(isobutyronitrile). | 2 |
BACKGROUND OF THE INVENTION
I. Technical Field
The present invention relates to a thermostat apparatus which automatically controls a temperature of a coolant mainly cooling the engine of an automobile.
II. Description of the Related Art
A conventional thermostat apparatus 20 , as shown in FIG. 7 , has a housing body 16 including a radiator coupling port 2 to let a low-temperature coolant A, cooled by a radiator or the like, flow into a housing body interior 19 , a bypass port 3 to let a high-temperature coolant B, heated by the engine, flow into the housing body interior 19 , and an engine coupling port 4 to feed out a coolant C, which is a mixture of the coolants flowing through the radiator coupling port 2 and the bypass port 3 , to the engine.
The thermostat apparatus 20 also includes a temperature sensitive movable part 8 or a thermally expanding element which moves according to a liquid temperature in the housing body interior 19 , a piston shaft 7 which has one end retained in the temperature sensitive movable part 8 and slides in response to thermal expansion or contraction of the thermal extension body, a piston shaft support 6 provided on a radiator coupling port 2 side to support the other end of the piston shaft 7 , a main valve 9 which moves together with the temperature sensitive movable part 8 to control the flow-in amount of the low-temperature coolant A into the housing body interior 19 through the radiator coupling port 2 , a frame 10 supported by a housing cover 1 , a main spring 11 which is provided between the main valve 9 and the frame 10 in a compressed state and urges the main valve 9 toward the radiator coupling port 2 , a bypass shaft 12 provided in a direction toward the bypass port 3 from the temperature sensitive movable part 8 , a bypass valve 13 which is provided at the bypass shaft 12 and controls the flow-in amount of the high-temperature coolant B into the housing body interior 19 through the bypass port 3 , and a bypass spring 14 which is provided between the bypass valve 13 and the temperature sensitive movable part 8 in a compressed state and urges the bypass valve 13 toward the bypass port 3 .
When the liquid temperature around the temperature sensitive movable part 8 rises, the thermal extension body sealed in a cup 15 is thermally expanded to push the piston shaft 7 . This causes an opening movement of the main valve 9 together with the temperature sensitive movable part 8 against the load of the main spring 11 , increasing the flow-in amount of the low-temperature coolant A, and causes a closing movement of the bypass valve 13 , reducing the flow-in amount of the high-temperature coolant B.
When the liquid temperature around the temperature sensitive movable part 8 falls, contraction of the thermal extension body occurs, so that the urging force of the main spring 11 pushes back the piston shaft 7 , causing the closing movement of the main valve 9 to decrease the flow-in amount of the low-temperature coolant A from the radiator, and increasing the flow-in amount of the high-temperature coolant B.
Through such an operation, the conventional thermostat apparatus 20 detects mainly the liquid temperature of the coolant C or a mixture of the high-temperature coolant B and the low-temperature coolant A from the radiator, controls it, and feeds the coolant C to the engine.
Thermostat apparatuses which have similar configurations and perform similar operations or techniques are disclosed in Japanese Unexamined Utility Model Publication No. Hei 2-5672, Japanese Unexamined Utility Model Publication No. Hei 6-37524, Japanese Unexamined Patent Publication No. Hei 10-19160, Japanese Patent Publication No. Sho 47-16584 and Japanese Unexamined Utility Model Publication No. Sho 61-175534 are proposed.
Japanese Unexamined Utility Model Publication No. Sho 61-175534 discloses the structure such that a coolant guiding cylinder is attached to the foregoing so-called bottom bypass type thermostat so that the coolant from the bypass is guided to the periphery of the temperature sensitive movable part.
SUMMARY OF THE INVENTION
The foregoing conventional thermostat apparatuses have the following drawbacks.
(1) In the housing body interior 19 , the bypass port 3 and a deflector 18 are spaced apart from the temperature sensitive movable part 8 , and the bypass valve 13 blocks the flow of the high-temperature coolant before the temperature sensitive movable part 8 , making it difficult for the high-temperature coolant B to reach the temperature sensitive movable part 8 . Therefore, the low-temperature coolant A and the high-temperature coolant B cannot be mixed efficiently at the temperature sensitive movable part 8 , making it difficult for the temperature sensitive movable part 8 to detect the temperature of the coolant C. This results in a drawback such that the liquid temperature of the coolant C cooling the engine becomes unstable, and the range of the temperature control in response to a change or the like in engine load becomes great.
Further, when the coolant returning from the circuit for the cabin heater flows into the housing body interior 19 , mixing with a higher efficiency cannot be carried out, so that the above drawback is amplified.
Furthermore, the performance of detecting the high-temperature coolant B is poor, so that there is a large possibility of overshooting when the temperature of the entire cooling system rises.
Since the coolant temperature has an upper limit, the normal control liquid temperature should be controlled to a relatively low temperature beforehand, causing a reduction in the combustion efficiency of the engine, and a reduction in fuel consumption originating from increases in the friction loss of the engine and thermal loss.
An increase in the temperature control range of the coolant C in response to a change in engine load brings about the characteristic of the conventional thermostat apparatus as shown in FIG. 8 , making the thermal expansion and contraction of the engine greater. If such happens frequently, it would lead to shorter life originating from an increased engine stress, impairing of the engine performance at the time the temperature falls and due to a temperature difference, etc.
(2) Conventionally, at the time the high-temperature coolant B is blocked so that all the high-temperature coolant B is allowed to flow to the radiator, the bypass valve 13 is pressed against the bypass port 3 by the bypass spring 14 . However, the load of the bypass spring 14 becomes a load on the temperature sensitive movable part 8 . As the load on the temperature sensitive movable part 8 becomes greater, the life of the temperature sensitive movable part 8 inevitably becomes shorter. As the pressure on the thermal extension body becomes higher, the melting point of the thermal extension body rises, so that a high coolant temperature is needed to make the degree of opening of the main valve 9 larger. That is, when the temperature of the coolant C rises, requiring a greater degree of opening of the main valve 9 , the degree of opening of the main valve 9 cannot be secured as apparent from the characteristic of the conventional thermostat apparatus as shown in FIG. 9 . (3) At the time of closing the bypass port 3 , the bypass port 3 is blocked rapidly, bringing about a problem that temperature hunting occurs immediately after the bypass port 3 is closed, making the temperature of the coolant C instable. (4) The bypass valve 13 in the conventional thermostat apparatus is structured so as to be closed when its flat disk surface abuts on the entire surface of the bypass port 3 . The distance between the bypass valve 13 and the bypass port 3 when the main valve 9 is closed is determined by the following factors: a: the area of the flow passage of the bypass port 3 for the high-temperature coolant B at the time of closing the main valve 9 is secured, b: the turns of the bypass spring 14 do not touch one another when the temperature sensitive movable part 8 is moved further as the temperature of the coolant C becomes higher after closing the bypass valve 13 , and c: the bypass valve 13 and the temperature sensitive movable part 8 do not contact each other.
That is, it is necessary to set a large distance between the bypass valve 13 and the bypass port 3 when the main valve 9 is closed.
This requires a complex structure like the deflector 18 in order to guide the high-temperature coolant B toward the temperature sensitive movable part 8 as much as possible.
Even the “coolant guiding cylinder” disclosed in Japanese Unexamined Utility Model Publication No. Sho 61-175534 causes the high-temperature coolant B to be ejected into the “coolant guiding cylinder” larger in diameter than the flow-in passage for the high-temperature coolant B, provided at the bypass port having a relatively small diameter, from the flow-in passage, so that the high-temperature coolant B flowing in is scattered before contacting the temperature sensitive movable part, thus impairing the temperature and flow rate of the high-temperature coolant B.
Further, the high-temperature coolant B flowing in the “coolant guiding cylinder” is blocked by the bypass valve before the temperature sensitive movable part, and is further scattered to be considerably mixed with the low-temperature coolant A and the coolant C (mixture) turbulently flowing around, so that the original temperature is no longer kept.
When the failure of keeping the original temperature occurs until the high-temperature coolant B reaches the periphery of the temperature sensitive movable part, which causes the foregoing problem, the performance of the temperature sensitive movable part to detect the temperature of the high-temperature coolant B is impaired, bringing about a problem such that there is a large possibility of overshooting when the temperature of the entire cooling system rises. In addition, how the “failure of keeping the original temperature” occurs is not stable depending on the number of rotations of a coolant pump which operates according to the operational state of the engine, so that the liquid temperature control lacks stability.
When the flow rate of the coolant at the top surface of the temperature sensitive movable part is fast, the temperature of the coolant is quickly transmitted to the temperature sensitive movable part. The high-temperature coolant B that has flowed into the “coolant guiding cylinder” loses the original flow rate until it reaches the periphery of the temperature sensitive movable part, so that the performance of the temperature sensitive movable part to detect the temperature of the high-temperature coolant B in good response is impaired accordingly, bringing about the problem such that there is a large possibility of overshooting when the temperature of the entire cooling system rises. Further, the response to a change in the temperature of the coolant caused by a change in the operational state of the engine is impaired, so that the liquid temperature control lacks stability.
As described above, even the “coolant guiding cylinder” does not allow the temperature and flow rate of the high-temperature coolant B to be maintained until the high-temperature coolant B reaches the periphery of temperature sensitive movable part, disabling a sufficient improvement of the temperature detection of the temperature sensitive movable part in response to an abrupt change in the temperature of the coolant, so that the temperature of the coolant cannot be controlled with high accuracy.
The present invention has been made in consideration of the foregoing problems of the conventional thermostat apparatus, and aims at providing a thermostat apparatus capable of accurately controlling the temperature of the coolant. Accordingly, it is an object of the invention to provide a thermostat apparatus which contributes to improving the combustion efficiency of an engine, reducing the friction loss of the engine, and reducing the thermal loss, thereby contributing to reduction in fuel consumption.
To solve the problems, a thermostat apparatus to which the present invention is adapted is characterized in that a conduit for bypassing a high-temperature coolant heated by the engine to the thermostat apparatus is structured so as to extend until the conduit covers all of or a part of the temperature sensitive movable part and to form a high-temperature coolant conduit having an inside diameter commensurate with an outside diameter of the temperature sensitive movable part in such a way as to cause the high-temperature coolant flowing the conduit to directly contact a periphery (bottom surface/side surface) of the temperature sensitive movable part without impairing a temperature and a flow rate of the high-temperature coolant, and then let the high-temperature coolant flow out of an ejection opening.
The present invention with the foregoing structure has the following advantages.
The structure of the high-temperature coolant conduit forms a state where the high-temperature coolant B dominates the area where the temperature sensitive movable part is disposed, thus bringing about advantages to be described below.
According to the present invention, the movement of the temperature sensitive movable part can be controlled mostly by the temperature of the high-temperature coolant alone. It is possible to sufficiently enhance the temperature dominant ratio of the high-temperature coolant to the temperature sensitive movable part and realize the state where the movable state of the temperature sensitive movable part can be controlled upon influence of the temperature of the high-temperature coolant.
Even when the coolant returning from the circuit for the cabin heater flows into the housing body interior (space into which the high-temperature coolant is ejected from the ejection opening of the high-temperature coolant conduit; the same is applied hereunder), the high-temperature coolant conduit and the high-temperature coolant B which has passed the high-temperature coolant conduit guard the coolant from the circuit for the cabin heater, thus making it possible to keep the temperature dominant ratio of the high-temperature coolant to the temperature sensitive movable part.
The “temperature dominant ratio of the high-temperature coolant to the temperature sensitive movable part” is defined by a coefficient a expressed by the following equation. (detecting temperature of temperature sensitive movable part)=a×(high-temperature coolant)+b×(low-temperature coolant)
Even when the coolant returning from the circuit for the cabin heater using the heat of the coolant is returned into the housing body interior, the above equation is basically established.
While the conventional thermostat is an apparatus of mainly detecting the liquid temperature of the coolant C which is a liquid mixture, therefore, the thermostat according to the present invention is transformed to an apparatus which mainly and sufficiently detects the liquid temperature of the coolant at the outlet of the engine (high-temperature coolant B), and supplies the coolant C to the engine in such a way as to keep the liquid temperature of the high-temperature coolant B constant.
Because the transformation is achieved without changing the apparatus positional relationship of the thermostat apparatus in the cooling system, the thermostat apparatus can be realized without significantly modifying the design of the cooling system configured by using the widely prevailing conventional thermostat apparatus.
In general, the maximum temperature of the coolant in the cooling system has a limit and the coolant temperature is set and controlled so as not to exceed the limit. In the cooling system to be installed in an automobile or the like, a portion where the coolant becomes hottest is the outlet of the engine. In the conventional thermostat apparatus, the temperature of the coolant to be supplied to the engine is controlled to a low temperature and supplied thereto beforehand so that the temperature at the outlet of the engine (high-temperature coolant temperature) does not exceed the allowable limit in various operational states. According to the present invention, however, the engine outlet temperature is directly detected and controlled with the foregoing advantages, making it possible to set the coolant temperature as high as the allowable limit. As the coolant temperature at the engine outlet is stably kept at the portion near the high-temperature side allowable limit while increasing or decreasing the temperature of the coolant to be supplied to the engine as needed, the average water temperature in the engine can be set higher than that allowed by the prior art.
This contributes to improving the combustion efficiency of the engine, reducing the friction loss of the engine, reducing the thermal loss, etc., resulting in achievement of reduced fuel consumption of the engine. It is also possible to contribute to improving the performance of the cabin heater or the like.
The foregoing advantages allow the temperature of the high-temperature coolant to be detected stably, and can thus overcome the problem that the temperature of the coolant cooling the engine becomes instable and realize stable control of the coolant temperature around the high-temperature coolant. This can suppress thermal expansion or contraction originating from a change in the temperature of the coolant of the engine, thus achieving reduction of stress on the engine.
Those advantages can be provided specifically by the coolant temperature characteristic during automobile driving, as shown in FIG. 8 , obtained by the present invention.
Data shown in FIG. 8 is the progress of the engine outlet temperature (high-temperature coolant temperature) recorded when the test was conducted in the same drive mode in cases of installing the conventional thermostat apparatus described referring to FIG. 7 and the thermostat apparatus according to the present invention in the same automobile while the other conditions are set to be identical.
For an exemplified description, for an automobile which behaves as shown in FIG. 8 , a coolant temperature T° C. (e.g., 97° C.) at the engine outlet in the cooling system is an ideal value for the coolant temperature at which the engine operates at the highest efficiency and lowest fuel consumption. That is, it is ideal that the engine operates at the constant engine outlet coolant temperature of 97° C.
In the conventional thermostat apparatus, the coolant temperature at the engine outlet considerably varies at a temperature difference between T max ° C. (e.g., 100° C.) and T 2 ° C. (e.g., 88° C.) because mainly the state of mixture of the low-temperature coolant and the high-temperature coolant is instable and changes mainly in synchronization with the load state of the engine and then in accordance with a change in the flow state of the coolant in the housing body interior, so that the coolant temperature around the temperature sensitive movable part which is detected by the temperature sensitive movable part is instable.
According to the thermostat apparatus of the present invention, the coolant temperature at the engine outlet stably transitions at a temperature difference between T max ° C. (e.g., 100° C.) and T 1 ° C. (e.g., 95° C.).
The coolant temperature at the engine outlet (high-temperature coolant temperature) is considered as an index indicative of the necessary degree of cooling of the engine, and direct detection of the engine outlet temperature is direct recognition of the necessary amount of cooling of the engine by the thermostat apparatus, enabling an improvement on the response that has been difficult for the conventional thermostat apparatus which mainly detects the temperature of a liquid mixture.
Paying attention to the positional relationship between the high-temperature coolant conduit and the temperature sensitive movable part, in the aspect where the temperature of the high-temperature coolant rises, the piston shaft protracts, so that the temperature sensitive movable part enters the high-temperature coolant conduit, increasing the “temperature dominant ratio of the high-temperature coolant to the temperature sensitive movable part”, quickening the response of the operation (opening operation of the main valve) in the direction of demonstrating the cooling performance needed by the engine outlet temperature, whereas in the aspect where the temperature of the high-temperature coolant falls, the piston shaft is pushed back, so that the temperature sensitive movable part moves outside from inside the high-temperature coolant conduit, decreasing the “temperature dominant ratio of the high-temperature coolant to the temperature sensitive movable part”, quickening the response of the operation (closing operation of the main valve) in the direction of suppressing the cooling performance needed by the engine outlet temperature. The above mechanically improves the response of the temperature sensitive movable part to the high-temperature coolant B.
Even in case of reducing the amount of the high-temperature coolant flowing in the bypass circuit, the sensitivity to the temperature of the high-temperature coolant is high so that the performance of the present invention can be demonstrated sufficiently.
The advantages described above make it unnecessary to take the complex structure of the deflector 18 as discussed in the problem (4) of the conventional thermostat apparatus.
Because the main valve 9 of the conventional thermostat apparatus is characterized in that it starts opening while tilting in a direction defined by the end position of the main spring 11 , the characteristic in the cooling system differs depending on the end position of the main spring. By way of contrast, because the high-temperature coolant conduit sufficiently guards the action of the low-temperature coolant flowing in from the main valve on the temperature sensitive movable part, the characteristic of the thermostat apparatus of the present invention in the cooling system is hardly influenced by the end position of the main spring. The subject matter recited in at least one embodiment of the present invention can suppress the inclination of the main valve itself.
The provision of the high-temperature coolant conduit can add a function of “restricting the passage for the high-temperature coolant”, bringing about an effect of eliminating the need for the bypass spring 14 of the conventional thermostat apparatus which presses the bypass valve 13 against the bypass port 3 , and providing single urging means for urging the main valve toward the low-temperature coolant port.
Disposing the single urging means outside the high-temperature coolant conduit makes it possible to create a state where no urging means is present in the area between the high-temperature coolant conduit 42 and the temperature sensing portion of the temperature sensitive movable part.
Further, “providing single urging means” brings about an effect of reducing the load applied when the piston shaft is pushed into the temperature sensitive movable part to the urging force of only single urging means.
FIG. 9 shows the effect of reducing the urging force in the form of the characteristics of the “coolant temperature vs. degree of opening of the main valve” of the conventional thermostat apparatus and the thermostat apparatus according to the present invention in comparison with each other.
That is, since the conventional thermostat apparatus closes the bypass port with the bypass valve, and then applies double urging forces provided by the main spring and the bypass spring, the pressure acting on the thermal extension body in the temperature sensitive movable part becomes higher, raising the melting point of the thermal extension body, so that setting a large degree of opening of the main valve requires a higher coolant temperature, causing a change in the degree of opening of the main valve with respect to the temperature of the coolant having a transition point. By way of contrast, since the thermostat apparatus according to the present invention uses a single urging force, so that a change in the degree of opening of the main valve with respect to the coolant temperature is smooth, achieving more accurate control of the coolant temperature. In addition, a large degree of opening of the main valve can be taken at a relatively low coolant temperature, so that when the coolant temperature becomes high, the cooling performance of the radiator can be demonstrated sufficiently, thus preventing the overshooting of the coolant temperature.
The reduction in urging force reduces the load applied to the temperature sensitive movable part, thereby realizing an elongated life thereof.
As the load applied to the temperature sensitive movable part can be reduced, a smaller temperature sensitive movable part can be used, so that making the temperature sensitive movable part compact makes the response (response to a change in the temperature of the coolant) higher, making it possible to ensure more stable control of the temperature of the coolant and miniaturization-oriented cost reduction.
According to the subject matter recited in one embodiment of the present invention, the coaxial structure comprising a piston shaft, temperature sensitive movable part and extension shaft takes a two-point support structure supporting at a piston shaft support and a support guide part spaced apart from the piston shaft support, and does not guide the side surface of the temperature sensing portion of the temperature sensitive movable part, but guides the extension shaft with the support guide part. This makes it possible to set the clearance between the extension shaft and the support guide part smaller, bringing about an effect that the fluctuation range of the temperature sensitive movable part caused by the vibration of the engine, pulsation of the coolant and the driving vibration can be made smaller.
This makes the movements of the temperature sensitive movable part and the main valve smoother and reduces stress to achieve longer life of the thermostat apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
A thermostat apparatus adaptable at the time of controlling the coolant temperature of the engine of an automobile, as the best mode of carrying out the present invention, will be elaborated below with reference to the accompanying drawings, in which:
FIG. 1 is a first embodiment of the present invention and an example where a projection is provided;
FIG. 2 is a second embodiment of the present invention;
FIG. 3 is a third embodiment of the present invention;
FIG. 4 is an example of a small-diameter portion according to the present invention;
FIG. 5 is an example of a deflector according to the present invention;
FIG. 6 is an embodiment of an outlet control according to the present invention;
FIG. 7 is a configurational example of the conventional thermostat apparatus;
FIG. 8 is a relationship among outlet temperatures in individual loaded operation modes; and
FIG. 9 is a relationship of the degree of opening of the main valve with respect to coolant temperature.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the configuration of a thermostat apparatus 300 as a first embodiment of the present invention.
The thermostat apparatus 300 is included in a so-called inlet control type in which a low-temperature coolant A cooled at a radiator 52 and a high-temperature coolant B supplied via a bypass 53 from an engine 51 flow into the thermostat apparatus 300 , and the temperature of a coolant C which is let to flow into the engine 51 is controlled by controlling the ratio of the mixture thereof.
That is, the control system includes a bypass port 33 to which the high-temperature coolant B having passed the engine 51 is supplied via the bypass 53 , and a radiator coupling port 31 to which the low-temperature coolant A that is a part of the high-temperature coolant B having passed the engine 51 and cooled at the radiator 52 is supplied from the radiator 52 , and the low-temperature coolant A and the high-temperature coolant B are mixed in a housing body interior 32 to produce the coolant C. The produced coolant C is supplied to the engine 51 via the engine coupling port 30 .
The feature of the thermostat apparatus 300 lies in that a state where the movable state of the temperature sensitive movable part can be realized only by mostly the temperature of the high-temperature coolant, so that the thermostat apparatus 300 can operate to make the temperature of the high-temperature coolant B flowing out from the engine 51 constant.
A cabin heater 101 is provided on a halfway between the bypass 53 and the radiator 52 .
In executing this control, the thermostat apparatus 300 further has a housing body 48 and a housing cover 47 attached thereto to form its casing. The housing body 48 has an internal shape corresponding to the bypass port 33 and the engine coupling port 30 . The housing cover 47 also has an internal shape corresponding to the radiator coupling port 31 . The housing body 48 and the housing cover 47 are each made of aluminum (die-cast), plastics or the like.
The thermostat apparatus 300 includes a temperature sensitive movable part 39 , a piston shaft 34 having one end retained in the temperature sensitive movable part 39 , a piston shaft support 35 which is provided on the radiator coupling port 31 side and supports the other end of the piston shaft 34 , a main valve 36 integrally attached to the temperature sensitive movable part 39 , a spring 41 which urges the main valve 36 toward the radiator coupling port 31 , and a high-temperature coolant conduit 42 projecting toward the housing body interior 32 from the bypass port 33 and coupled toward the housing body interior 32 from the bypass port 33 via an ejection opening 46 , and further has an extension shaft 43 extending from the temperature sensitive movable part 39 toward the bypass port 33 , and a support guide part 44 formed in the high-temperature coolant conduit 42 to support and guide the extension shaft 43 .
The material for the high-temperature coolant conduit 42 is, for example, a resin, which is not restrictive. The upper end of the high-temperature coolant conduit 42 is positioned above the lower end of the temperature sensitive movable part 39 , as shown in FIG. 1 . As a result, the lower end of the temperature sensitive movable part 39 enters the high-temperature coolant conduit 42 . The “above” here is equivalent to the position of the radiator coupling port 31 side, while the “under” is equivalent to the position of the bypass port 33 side. The same is applied in the following description.
The inside diameter of the high-temperature coolant conduit 42 is set wider than the outside diameter of the temperature sensitive movable part 39 . Consequently, at the time the distal end of the temperature sensitive movable part 39 is inserted into a tube constituting the high-temperature coolant conduit 42 , it is inserted in a so-called loosely insertable state with some spatial margin provided between the inner wall of the high-temperature coolant conduit 42 and the outer wall of the temperature sensitive movable part 39 .
It is to be noted that the spring 41 is fitted over the outer surface of the high-temperature coolant conduit 42 . A frame 59 is further embedded in the high-temperature coolant conduit 42 , and has one end fixed to the housing cover 47 . The structure of the frame 59 may be omitted.
The support guide part 44 has its outer periphery formed on the inner wall of the high-temperature coolant conduit 42 . The support guide part 44 has unillustrated holes formed therethrough at upper and lower surfaces, so that through the unillustrated holes, the high-temperature coolant B flows from the bypass port 33 toward the ejection opening 46 and flows out to the housing body interior 32 .
The operation of the thermostat apparatus 300 with the foregoing configuration will be described next. When a hot high-temperature coolant B heated by the engine 51 is supplied to the bypass port 33 , the high-temperature coolant B is fed to the high-temperature coolant conduit 42 . The high-temperature coolant conduit 42 can cause the fed high-temperature coolant B to directly contact the periphery of the temperature sensitive movable part 39 . The temperature sensitive movable part 39 is loosely fitted in the high-temperature coolant conduit 42 beforehand, with a predetermined clearance previously formed between the temperature sensitive movable part 39 and the high-temperature coolant conduit 42 . The high-temperature coolant B flows out to the housing body interior 32 through the clearance formed between the temperature sensitive movable part 39 and the high-temperature coolant conduit 42 . This can allow the high-temperature coolant B to directly contact the periphery (bottom surface/side surface) of the temperature sensitive movable part 39 without impairing the temperature and flow rate thereof, thereby transmitting heat. Accordingly, the temperature sensitive movable part 39 can detect the temperature of the high-temperature coolant B with a high efficiency, so that the temperature sensitive movable part 39 can be moved according to the temperature of the high-temperature coolant B.
The high-temperature coolant B which has flowed out into the housing body interior 32 from the ejection opening 46 first flows so as to surround the temperature sensitive movable part 39 . This can form a state where the high-temperature coolant B dominates the area where the temperature sensitive movable part 39 is disposed.
As the main valve 36 is urged toward the radiator coupling port 31 by the spring 41 , the radiator coupling port 31 and the housing body interior 32 are blocked from each other when the temperature sensitive movable part 39 is not driven. When a high-temperature coolant B with a predetermined temperature or higher is supplied into high-temperature coolant conduit 42 , on the other hand, the temperature sensitive movable part 39 is driven toward the bypass port 33 , so that the main valve 36 is opened against the load of the spring 41 , making it possible to increase the flow-in amount of the low-temperature coolant A to the housing body interior 32 from the radiator coupling port 31 . As a result, the flow-in amount of the low-temperature coolant A to the housing body interior 32 from the radiator coupling port 31 can be controlled according to the temperature of the high-temperature coolant B.
The thermostat apparatus 300 to which the present invention is adapted may be configured so that the temperature sensitive movable part 39 is inserted and guided into a support guide part 62 inside the high-temperature coolant conduit 42 as in a second embodiment shown in FIG. 2 . With regard to those components and members in FIG. 2 and subsequent drawings, which are similar to the corresponding components and members in FIG. 1 , same reference numerals are given to omit their descriptions below.
The support guide part 62 is formed by bending, press-working, etc. of a steel member, and is configured so as to be able to support and guide the side surface of the temperature sensitive movable part 39 disposed in an insertable manner. The support guide part 62 may be integrated with the aforementioned auxiliary fitting 59 , or may be spaced apart therefrom. Multiple holes not shown are provided in the support guide part 62 . The high-temperature coolant B passes through the unillustrated holes.
The thermostat apparatus 300 to which the present invention is adapted may be adapted to a third embodiment shown in FIG. 3 .
In the embodiment shown in FIG. 3 , the high-temperature coolant conduit 42 is formed by a combination of a high-temperature coolant inlet passage of the housing body 48 and the support guide part 62 , the ejection opening 46 is formed in the support guide part 62 , and the temperature sensitive movable part 39 is supported and guided to the support guide part 62 .
The support guide part 62 is provided with a plurality of unillustrated holes=ejection openings 46 , so that the high-temperature coolant B supplied from the bypass port 33 directly contacts the periphery (bottom surface/side surface) of the temperature sensitive movable part 39 , thereby transmitting heat, and then flows into the housing body interior 32 through the ejection openings 46 . This can realize a simple and compact structure while keeping the function of the high-temperature coolant conduit.
The thermostat apparatus 300 to which the present invention is adapted may have a projection 40 formed on the outer surface of the temperature sensitive movable part 39 and corresponding in shape to the clearance between the temperature sensitive movable part 39 and the high-temperature coolant conduit 42 as shown in, for example, FIG. 1 . When a hot high-temperature coolant B is supplied, the temperature sensitive movable part 39 is driven toward the bypass port 33 as shown in FIG. 1( b ), and the projection 40 is likewise shifted toward the bypass port 33 accordingly. Consequently, the clearance formed between the temperature sensitive movable part 39 and the high-temperature coolant conduit 42 can be narrowed by the projection 40 , making it possible to narrow the passage for the high-temperature coolant B to the housing body interior 32 . As a result, the flow amount of the high-temperature coolant B from the bypass port 33 to the housing body interior 32 can be reduced. Therefore, the ratio of the mixture of the high-temperature coolant B from the engine 51 and the low-temperature coolant A from the radiator 52 can also be controlled by the provision of the projection 40 . When the temperature of the high-temperature coolant B is high, a larger amount of the high-temperature coolant B can be supplied to the radiator 52 to maximize the cooling performance, which can be realized by a simple structure.
The thermostat apparatus 300 to which the present invention is adapted may have a small-diameter portion 61 narrowed inward and formed on the inner wall of the high-temperature coolant conduit 42 as shown in, for example, FIG. 4 . Accordingly, the clearance between the temperature sensitive movable part 39 and the high-temperature coolant conduit 42 can be freely restricted according to the driving of the temperature sensitive movable part 39 .
As a result, the flow amount of the high-temperature coolant B to the housing body interior 32 from the bypass port 33 can be reduced, so that a larger amount of the high-temperature coolant B can be supplied to the radiator 52 to maximize the cooling performance. The ratio of the mixture of the high-temperature coolant B from the engine 51 and the low-temperature coolant A from the radiator 52 can also be controlled by the small-diameter portion 61 .
Furthermore, the flow rate of the high-temperature coolant B can be made not to be impaired significantly by narrowing the flowing clearance of the high-temperature coolant B around the temperature sensitive movable part 39 while suppressing the flow-in amount of the high-temperature coolant B to the housing body interior 32 from the bypass port 33 . This can more reliably keep the state where the high-temperature coolant B dominates the area where the temperature sensitive movable part 39 is disposed, even with the flow amount of the high-temperature coolant B in the high-temperature coolant conduit 42 being suppressed.
Because the small-diameter portion 61 can be formed in various forms, such as a tapered form, a recessed and curved form, and a projecting and curved form, it is possible to tune the flow-in amount of the high-temperature coolant B in such a way as to adequately and gradually restrict the flow-in amount thereof at the time the flow passage for the high-temperature coolant B is restricted by the ingress of the temperature sensitive movable part 39 . When the flow passage for the high-temperature coolant B is restricted or when the bypass port 33 and the housing body interior 32 are completely blocked, the thermostat apparatus does not cause temperature hunting of the coolant and can achieve stable coolant temperature control as compared with the conventional thermostat apparatus.
The thermostat apparatus 300 to which the present invention is adapted may be adapted to a mode as shown in FIG. 5 , for example.
The mode shown in FIG. 5 further has a deflector 70 extending from the main valve 36 . The deflector 70 is disposed in such a way as to surround the temperature sensitive movable part 39 from a position spaced apart from the outer periphery of the temperature sensitive movable part 39 . Although the deflector 70 is disposed outside the spring 41 in FIG. 5 , which is not restrictive, the deflector 70 can be provided inside the spring 41 . The provision of the deflector 70 can allow the high-temperature coolant B, led along the inner wall of the high-temperature coolant conduit 42 , to directly contact the periphery of the temperature sensitive movable part 39 more reliably. The presence of the deflector 70 can guard the low-temperature coolant A so that the low-temperature coolant A does not contact the temperature sensitive movable part 39 carelessly.
The structure may be modified in such a way that when the temperature sensitive movable part 39 is driven, the flow of the high-temperature coolant B out of the housing body interior is restricted by the positional relationship between the lower end portion of the deflector 70 and the upper end portion of the high-temperature coolant conduit 42 . Consequently, the flow amount of the high-temperature coolant B to the housing body interior 32 from the bypass port 33 can be reduced. Therefore, the ratio of the mixture of the high-temperature coolant B from the engine 51 and the low-temperature coolant A from the radiator 52 can also be controlled by the provision of the deflector 70 . When the temperature of the high-temperature coolant B is high, a larger amount of the high-temperature coolant B can be supplied to the radiator 52 to maximize the cooling performance.
A thermostat apparatus 400 to which the present invention is adapted is not limited to a case where the foregoing control is executed, but may be adapted in executing control at the outlet.
FIG. 6 shows the configuration of the thermostat apparatus 400 adapted in executing the outlet control. The thermostat apparatus 400 has an engine coupling port 72 for letting a high-temperature coolant heated in the engine 51 flow inside, a bypass port 73 to return the coolant to the engine 51 , and a radiator coupling port 71 to feed out the coolant to the radiator. With regard to those components and members in the thermostat apparatus 400 shown in FIG. 6 , which are similar to the corresponding components and members in FIG. 1 , same reference numerals are given to omit their descriptions below.
The thermostat apparatus 400 shown in FIG. 6 further has a bypass valve 74 attached to the extension shaft 43 . The formation of the bypass valve 74 can allow the flow passage to the bypass port 73 to be closed by the bypass valve 74 according to the driving of the temperature sensitive movable part 39 as shown in FIG. 6( b ). This makes it possible to control the flow amount.
The high-temperature coolant conduit 42 is structured in a cylinder shape with the height adjusted to such an extent that the temperature sensitive movable part 39 is exposed to the high-temperature coolant flowing from the engine coupling port 72 , regardless of the drive state of the temperature sensitive movable part 39 . Therefore, the high-temperature coolant supplied from the engine coupling port 72 directly contacts the temperature sensitive movable part 39 to transmit heat, and the temperature sensitive movable part 39 can be driven upward or downward freely based on mainly the temperature of the high-temperature coolant. | An apparatus includes a movable temperature sensing member capable of sensing mainly the temperature of high-temperature coolant flowing in from a high-temperature coolant port and driving toward the side of the high-temperature coolant port in dependence upon the sensed temperature; a main valve fitted integrally to the movable temperature sensing member and constructed so as to render a low-temperature coolant port and a mixing compartment openable in conformity to the driving of the movable temperature sensing member toward the side of the high-temperature coolant port, thereby controlling the inflow rate of low-temperature coolant from the low-temperature coolant port to the mixing compartment; and a high-temperature coolant inducing part communicating with the high-temperature coolant port and adapted to regulate the flow of high-temperature coolant from the high-temperature coolant port toward the surround of the movable temperature sensing member and effect outflow thereof to the mixing compartment. | 5 |
CROSS REFERENCE
[0001] This application is a divisional of U.S. Ser. No. 12/608,489 filed Oct. 29, 2009 which claims priority from U.S. provisional application Ser. No. 61/111,499 filed Nov. 5, 2008, herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The task of epigenomic mapping is inherently more complex than genome sequencing since the epigenome is much more variable than the genome. While an individual only has one genome, one's epigenome varies in time and space with age, tissue type, exposure to environmental factors, and shows aberrations in diseases especially in cancer. With methylated CpG's only accounting for ˜2-6% of the genome (18), large scale shotgun sequencing efforts will require some form of purification of short CpG methylated sequences. Many current enrichment technologies fall short of the dynamic range necessary to capture minute changes in CpG methylation that can have large repercussions in gene expression.
[0003] In the mammalian genome, 60-80% of relatively infrequent (1 per 100 bp on average) CpG dinucleotides are methylated at the carbon 5 position (1). In contrast, dense clusters of unmethylated CpG sequences (˜1 per 10 bp) are found at the transcription start sites of genes (2). In certain circumstances, these CpG islands are heavily methylated with the concomitant silencing of the promoter and the silencing of gene activity (3). These modifications are considered to be important for development (4), genomic imprinting (5), and X chromosome inactivation through gene silencing (6, 7). Aberrant DNA methylation of CpG islands has been frequently observed in cancer cells (8).
[0004] Many techniques exist for the enrichment of heavily methylated CpG islands from genomic DNA. One protocol relies on methylation-sensitive restriction endonucleases such as HpaII (CCGG) and HhaI (GCGC) followed by PCR identification, Southern Blot analysis or microarray profiling (9). Another approach utilizes the ability of an immobilized methyl-CpG-binding domain (MBD) of the MeCP2 protein to selectively bind to methylated double-stranded DNA sequences. Restriction endonuclease-digested genomic DNA is loaded onto the affinity column and methylated-CpG island-enriched fractions are eluted by a linear gradient of sodium chloride. PCR, microarray, DNA sequencing and Southern hybridization techniques are used to detect specific sequences in these fractions (10). These techniques are limited due to the specific cleavage moiety of the restriction enzyme and therefore will not completely reflect all combinations of bases flanking the methylated CpG dinucleotide.
[0005] There are several additional methods for analysis of methylation patterns. In the bisulfite method, single-stranded DNA (ssDNA) is exposed to a deamination reagent (bisulfite) that converts unmethylated cytosines to uracils while methylated cytosines remain relatively intact (11). After cleanup, the resultant treated DNA of interest must be PCR amplified (converting the uracils to thymines) and analyzed by a myriad of techniques that can distinguish between methylated and unmethylated DNA. If the PCR products are cloned and sequenced, alignment analysis of the untreated and treated nucleotide sequences can reveal the in vivo methylation status of the amplified region. The PCR products can also be analyzed by combined bisulfite-restriction analysis (COBRA assay) and methylation-specific PCR (MSP) (12, 13).
[0006] Recently, direct shotgun ultra-high-throughput sequencing of bisulfite-converted DNA using the Illumina 1G Genome Analyzer and Solexa sequencing technology have yielded insights of the methylation state of the small (˜120 Mbp) genome of the mustard plant Arabidopsis (14). This new technology allowed the exact identification and quantification of 5-methylcytosines at the single-nucleotide level in genes. Although highly specific and reasonably sensitive, it required at least 20-fold coverage to theoretically cover all potential methylated cytosines. Currently, no method exists to enrich bisulfite-converted CpG methylated DNA, which by the nature of the deamination reaction, is single-stranded, from total genomic DNA.
SUMMARY
[0007] Methods and compositions are described herein that include the embodiments listed below.
[0008] In one embodiment, an isolated first polypeptide is provided that includes an amino acid sequence having at least 90% homology or identity with SEQ ID NO:3 and is capable of binding single-stranded methylated polynucleotides. The first polypeptide may be fused to a second polypeptide and may be immobilized on a solid substrate by means of the second polypeptide if the second polypeptide is a substrate-binding domain such as maltose-binding domain (MBP). A property of the isolated first polypeptide may include an ability to bind a methylated CpG in a single-stranded polynucleotide.
[0009] Examples of the first polypeptide are human UHRFI, and mouse NP95 SRA. Either of these polypeptides may be used in series or in parallel with a methyl-binding domain (MBD), which binds double-stranded methylated DNA and thus recovery of methylated DNA may be enhanced. For example, the sample may be applied to a MBD column, eluted, denatured and then applied to an SRA column. Additionally, one aliquot of a sample may be applied to an MBD column and one aliquot of sample applied to an SRA column.
[0010] The above-described polypeptides either alone or as a fusion protein, either in solution or immobilized on a substrate, may be used for differentially binding a single-stranded methylated polynucleotide to a solid substrate, for example at a CpG site in a low salt solution.
[0011] In an embodiment of the invention, a method is provided for enriching for CpG methylated single-stranded polynucleotides from a mixture containing methylated and unmethylated polynucleotides.
[0012] This method includes: binding the mixture to the first polypeptide described above; eluting the unmethylated polynucleotide from the isolated polypeptide in a solution containing a low concentration of a salt; and eluting the methylated polynucleotide from the isolated polypeptide in a solution containing a high concentration of a salt.
[0013] The eluted methylated polynucleotide can then be sequenced and the methylation site analyzed.
[0014] In embodiments of the invention, a low concentration of the salt is less than 0.4 M salt and a high concentration of the salt is 0.4 M-0.6 M salt. The salt may be, for example, sodium chloride.
[0015] In an embodiment of the invention, a method is provided which can be applied to determining the existence of pre-cancerous cells. The method includes: (a) comparing the methylation pattern for selected polynucleotide sequences in both pre-identified transformed eukaryotic cells and non-transformed eukaryotic cells by differential binding of methylated polynucleotides to the first polypeptide of claim 1 ; (b) determining the presence of abnormal methylation patterns associated with alteration of tumor suppressor function; and (c) utilizing the abnormal methylation patterns as a diagnostic tool for determining whether any eukaryotic cells in a sample are transformed. (In this context “transformed” is intended to mean converted to a pre-cancerous state where the cell is immortalized.)
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1A-1C show a GST-SRA-domain resin with bound and eluted methylated, and unmethylated dsDNA at low NaCl; and eluted methylated ssDNA at high NaCl.
[0017] FIG. 1A is a chromatogram profile at A280 of human chromatin DNA spiked with a small amount of FAM-labeled methylated (M) and unmethylated (U) CpG-containing oligonucleotides. Both the unmethylated and methylated oligos co-eluted with the bulk of the chromatin DNA between 0.2 M and 0.3 M NaCl.
[0018] FIG. 1B shows a gel containing individual column fractions in each lane. At higher NaCl, a faint band (*) on the gel was observed corresponding to single-stranded methylated DNA.
[0019] FIG. 1C shows a side-by-side comparison of the methylated and unmethylated oligos confirming that the band (*) corresponded to methylated CpG-containing ssDNA.
[0020] FIGS. 2A-2B show a DNA preparation with significantly altered elution characteristics of the GST-SRA-domain column.
[0021] FIG. 2A is a comparison of chromatogram profiles at A280 of 100 μg of MseI-digested HeLa DNA spiked with 3 μg of MseI digested M.SssI-labeled 3 H-Adomet HeLa DNA. The DNA composition was heated to 98° C. for one minute and quickly chilled prior to loading onto the column. A large portion of the 3 H-labeled DNA eluted off the column at 0.15 M NaCl, however, three distinct peaks that eluted at 0.3 M, 0.35 M and 0.4 M NaCl were observed with a small peak of 3 H-labeled DNA co-eluted with the 0.4 M NaCl peak. The gel shows the content of each fraction.
[0022] FIG. 2B shows the same DNA load preparation, which was sonicated for 1 minute followed by heating of the sample to 98° C. for 1 minute, chilled, and loaded onto the column. Three peaks were observed at 0.35 M, 0.4 M and 0.45 M NaCl with the bulk of the 3 H-labeled DNA co-eluted with the 0.4 M and 0.45 M peaks, respectively. The gel shows the content of each fraction.
[0023] FIG. 3 shows a flowchart of the procedures used to enrich single-stranded methylated CpG-containing DNA. Total genomic DNA was sonicated to 50-150 base fragments. The sample was heated to 98° C., chilled and loaded onto the GST-SRA-domain column (or magnetic beads), or bisulfite-converted (which made the sample single-stranded and converted all non-methyl cytosines to uracils) prior to loading. The column/beads were washed with buffer containing 0.3 M NaCl, which eluted the active gene fraction. Methylated CpG-containing DNA remained on the column matrix and can be eluted with 0.5 M NaCl or alternatively equilibrated with low NaCl buffer prior to the addition of the “fourN” cloning/sequencing primer (SEQ ID NO:1). The sample was heated to 98° C., chilled to 4° C., and then slowly raised to 37° C. Sequenase was introduced into the reaction, allowed to extend the ssDNA fragments, heated and chilled, with more Sequenase added to label the other end of the DNA fragment. The defined-ends DNA was further amplified by a complementary PCR primer without the random nucleotides, purified and digested with BamH1, purified and cloned into a sequencing vector.
[0024] FIGS. 4A-4D show a simplified step salt gradient of GST-SRA-domain column yielded reproducible elution profiles.
[0025] FIGS. 4A-4B show a comparison of two chromatogram profiles at A280 of 100 μg of sonicated, heated HeLa genomic DNA FIG. 4A or 200 μg initial concentration of sonicated, bisulfite-converted genomic DNA FIG. 4B . The 0.3 M and 0.5 M fractions were characterized by qRT-PCR or cloned and sequenced.
[0026] FIG. 4C shows the bisulfite-converted fractions which were labeled and extended with a random “fourN” oligonucleotide, and PCR amplified. Ethidium-stained 20% TBE polyacrylamide gel analysis of the PCR products before (−) and after (+) BamH1 treatment showed the size distribution of fragments from the two peaks.
[0027] FIG. 4D shows GST-SRA-domain coupled magnetic beads only retained methylated (M) ssDNA lambda DNA after extensive washing with 0.3M NaCl as assayed on an ethidium-stained 20% TBE polyacrylamide gel.
[0028] FIG. 5 shows active and inactive gene enrichment from GST-SRA-domain column. Active genes showed at least a 2-fold enrichment over input DNA in the 0.3 M peak. Single copy inactive genes showed a direct correlation of the fold enrichment and CpG occupancy in the 0.5 M peak. As the copy number increased, satellite and line elements showed an inverse correlation between CpG occupancy and enrichment.
[0029] FIG. 6 shows a cartoon of the UHRFI gene illustrating the location of the different domains in the protein. The inset shows an amino acid alignment of the SRA domains from mouse and human (SEQ ID NOS:2 and 3, respectively), revealing that the sequences are 90% identical.
[0030] FIG. 7 shows the DNA sequences of mouse and human (SEQ ID NOS:4 and 5, respectively).
[0031] FIG. 8 shows how SRA domain can be used in sequencing platforms (e.g. Helicos sequence platform) to detect methylated CpG DNA. 1. Methylated ssDNA (SEQ ID NO:6) annealed to polyT on a slide. 2. Methylated cytosine detected by fluorescence labeled NP95 SRA domain and 3. SRA is washed off. DNA is sequenced. Within the flow cells, billions of single molecules of ssDNA are captured on a solid surface. These captured strands serve as templates for the sequencing-by-synthesis process. Prior to the addition of polymerase and one fluorescently labeled nucleotide (C, G, A or T), the cell is flooded with MBP-SRA domain protein, which binds specifically to methylated CpG sequences. The cell is washed with a 100 mM NaCl wash buffer, and fluorescently labeled Anti-MBP antibody couples to the MBP-NP95 SRA domain/methylated CpG DNA complexes. After a wash step, which removes free Anti-MBP antibody, the cell is imaged and the positions of the methylated CpG-containing DNA strands are recorded. A high wash step (500 mM NaCl) removes the Antibody-MBP-NP95 SRA domain and the sequencing process continues with a polymerase catalyzing the sequence-specific incorporation of fluorescent nucleotides into nascent complementary strands on all the templates. Multiple cycles result in complementary strands greater than 25 bases in length synthesized on billions of templates, providing a sequence read on the methylated CpG templates.
[0032] FIG. 9 shows a flowchart of the procedure used to compare a commercially available methylated CpG DNA enrichment system (e.g. Invitrogen) with MBP-NP95 SRA domain. Total HeLa genomic DNA was sonicated to 50-150 base fragments. Half of the sample was heated to 95° C. for 5 minutes and chilled on ice. The other half of the sample was not heated. To 1 μg of unheated sample, 1 μg of biotinylated (bt) MBD and buffer were added. Similarly, to 1 μg of heated DNA, 1 μg of MBP-NP95 SRA domain and buffer were added. Both samples were incubated at room temperature for 20 minutes. To the bt-MBD sample 100 μl (1 mg) of Streptavidin Magnetic Beads was added. To the MBP-NP95 SRA domain sample 100 μl (1 mg) of Anti-MBP Magnetic Beads was added. The samples were then incubated overnight at 4° C. with rotation. The bound complexes were then washed 3× with 100 mM NaCl, 1% Triton, 0.1% Tween buffer, with magnetic separation and aspiration of buffer and 1× with TE buffer containing 0.1% Tween. Finally, a small quantity of water was added to the aspirated samples, and the enriched methylated DNA complexes were eluted from the magnetic beads by heat. The complexes were then assayed by qPCR using primer sets to known active and inactive genes in HeLa DNA.
[0033] FIG. 10 shows the number of fold enrichment values of known methylated (inactive) and unmethylated (active) genes comparing a commercially available methyl CpG enrichment system (e.g. Invitrogen) with MBP-NP95 SRA domain protein. Both techniques resulted in similar enrichment of the inactive genes rDNA and MYOD, with no enrichment of the active gene RPL30.
DETAILED DESCRIPTION OF EMBODIMENTS
[0034] UHRFI is a ubiquitin-like protein that improves fidelity of maintenance of methylation and has a histone methyltransferase function. It contains multiple domains (see FIG. 6 ). Two adjacent domains in the protein are named SET and RING and together are called the SRA domain. The SRA domain has a sequence shown in FIG. 7 . The SRA domain is capable of binding methylated CpG in a salt-dependent manner. In an embodiment of the invention, the SRA is immobilized on a matrix and can be used to bind methylated and unmethylated ssDNA or bisulfite-converted genomic DNA at low salt conditions (for example 0.15 M NaCl). The unmethylated DNA can be eluted from the SRA protein in conditions of increased salt concentration such as 0.3 M NaCl while methylated DNA can be eluted at 0.5 M NaCl.
[0035] Human UHRFI is an example of a family of DNA-binding proteins that are associated with regulating gene expression via methylation. Other examples include DNMTI and mouse NP95 SRA. This family of related proteins are shown here to be effective in differentiating methylated from unmethylated DNA.
[0036] These proteins can be produced in high yield and are relatively stable, which makes them suitable for attaching to solid substrates such as agarose resin or carbohydrate-coated beads or magnetic beads (NEB) without loss of binding activity. The immobilized protein can easily be integrated in a high-throughput bisufite sequencing setup. With just one wash step, mild elution characteristics, sensitivity and accuracy are enhanced. Thus, the reusable matrix provides valuable information on the methylome, providing insights into aging and disease.
[0037] There are a variety of approaches by which the SRA-like proteins can be immobilized on a matrix. The matrix may include beads, 96 well plastic dishes, columns or any other support material. Where beads are selected, these can be magnetic, colored and/or coated with a carbohydrate or other ligand suitable for binding the SRA. To facilitate binding of the SRA-like proteins to a matrix, the SRA-like protein can be synthesized as a fusion protein by standard molecular biology techniques in prokaryotic or eukaryotic host cells. For example, the SRA-like proteins may be synthesized as SRA-chitin-binding domain for binding chitin or SRA-MBP for binding to amylose. Examples of suitable fusion proteins are provided for example in U.S. Pat. No. 5,643,758.
[0038] Other examples of fusion proteins include SRA-AGT or SRA-ACT proteins (using the SNAP-tag® or CLIP-tag™ technology provided commercially by New England Biolabs). These fusion proteins can be labeled as required for detection of purification of polynucleotides for example by using fluorescent labels after covalent binding of the ACT/AGT in the fusion protein to labeled substrates such as benzyl guanine or benzyl cytosine, leaving available the SRA to bind methylated DNA in vitro or in vivo.
[0039] The SRA may also be bound to a matrix or solid substrate such as beads, columns, glass, plastic or polymer surfaces, etc. Binding can be achieved by any ligand/ligand-binding molecule system including antibody/antigens or biotin/strepavidin, chitin-binding domain, maltose-binding domain, etc. SRA-like proteins may be synthesized as intein fusions to facilitate certain separation methods (U.S. Pat. Nos. 5,496,714 and 5,834,247).
[0040] In an embodiment of the invention, a binding preference for methylated single-stranded polynucleotides by SRA-like proteins was demonstrated. This property can be exploited for detection, purification and analysis of the polynucleotides using immobilized SRA bound to the matrix. The methylated polynucleotides can then be sequenced to identify the location of the methylated CpG. In another embodiment, a double stranded polynucleotide can be bound to SRA where methylation if present can be detected on one strand or the other.
[0041] Mammalian UHRF1 SRA domains (such as human UHRF1 or murine NP95) can be used to augment high-throughput sequencing methodologies, for example, True Single Molecule Sequencing (tSMS)™ technology (Helicos Biosciences) by binding and identifying single-stranded methylated CpG-containing DNA prior to a series of nucleotide additions and detection cycles that will then determine the sequence of each fragment ( FIG. 8 ). By integrating the UHFR1-SRA domain into this instrumentation setup, additional epigenetic information can be layered on top of rapid and inexpensive resequencing of genomes to facilitate the understanding of methylation states in complex organisms.
[0042] The mammalian UHRF1 SRA domains can be displaced from the polynucleotide by adding cations that neutralize the charge on the DNA and thereby release the electrovalently bound protein. In embodiments of the invention, the protein binding to the polynucleotide is disrupted using NaCl. However, the use of this salt is not intended to be limiting. Moreover, it was found that protein binds to polynucleotide at methylated CpGs more tightly so that a high salt concentration was required to release CpG methylated polynucleotides and a low salt concentration was required to release CpG unmethylated polynucleotides. In an embodiment of the invention, the low salt concentration was 0.3 M NaCl whereas the high salt concentration was 0.5 M NaCl. Table 1 provides the results of a two-step salt gradient.
[0043] Table 1 shows a sequence analysis of the two NaCl peaks from the GST-SRA-domain column. Greater than 10-fold enrichment of methylated CpG-containing DNA was observed. 19/30 reads with an average size of 63 bases in the high (0.5 M) NaCl fraction contained at least one methylated CpG. 44/1900 bases were methylated CpG or 2.32% of the total. 3/22 reads with an average size of 105 bases in the low salt 0.3M peak contained methylated CpG. 5/2327 bisulfite-converted bases were identified as methylated CpG or 0.215% of the total.
[0044] All references cited herein, as well as U.S. provisional application Ser. No. 61/111,499 filed Nov. 5, 2008 and U.S. Ser. No. 12/608,489 filed Oct. 29, 2009 are incorporated by reference.
EXAMPLES
Example 1
SRA-Domain Protein Purification and the Covalent Coupling of the Protein to Solid-State Matrixes
[0045] The SRA domain (386-618) was amplified from full-length human UHRF1 cDNA synthesized using total RNA from HeLa cells. The product was cloned into pENTR-TEV (GST Tag Invitrogen) and recombined into pDEST15 (Invitrogen, Carlsbad, Calif.) to create the GST fusion. The construct was propagated in T7 Express E. coli (NEB) to an OD 590 of 0.5 at 37° C. and induced with 0.1 mM IPTG overnight at 16° C. Cells were spun, broken open by French press, spun again and the supernatant layered over a 10 ml Glutathione Separose High Performance column (GE Healthcare). After a 10-column wash, the protein was eluted with a 10 mM L-Glutathione (Sigma) solution. The yield was 12 mg total of purified SRA-domain from 8 liters shake flasks.
GST-SRA Column
[0046] 9 μls of 1.2 mg/ml (10.8 mg total) of previously purified and dialyzed GST-SRA-domain protein in 10 mM Tris pH. 7.5, 1 mM EDTA and 0.2 M NaCl was layered onto a 4.5 ml Glutathione Sepharose matrix equilibrated with the above buffer. Of the 10.8 mg load, 7.83 mg remained bound to the column. The resin was washed with 10 column volumes of the above buffer, then cycled twice with the above buffer supplemented with 1 M NaCl before final equilibration at 0.05 M NaCl. Sequences of the methylated oligonucleotides were FAM-GTAGG5GGTGCTACA5GGTTCCTGAAGTG top strand (SEQ ID NO:7), FAM-CACTTCAGGAAC5GTGTAGCAC5GCCTAC bottom strand with 5=5 methyl cytosine. Sequences of the unmethylated oligonucleotides were GTCACTGAAGCGGGAAGGGACTGGCTGCTCCCGGGCGAAGTGCCGGGG CAGGATCT-FAM top strand (SEQ ID NO:8), AGATCCTGCCCCGGCACTTCGCCCGGGAGCAGCCAGTCCCTTCCCGCTT CAGTGAC-FAM bottom strand.
[0000] qPCR Analysis of NaCl Fractions from GST-SRA-Column
[0047] DNA from the high and low salt fractions were characterized by real-time PCR on a Bio-Rad MyiQ iCycler using Bio-Rad iQ SYBR Green Supermix and the following primer sets: hsALDOA TCCTGGCAAGATAAGGAGTTGAC forward (SEQ ID NO:9), ACACACGATAGCCCTAGCAGTTC reverse (SEQ ID NO:10), hsSERPINA GGCTCAAGCTGGCATTCCT forward (SEQ ID NO:11), GGCTTAATCACGCACTGAGCTTA reverse (SEQ ID NO:12), hsRPL30 CAAGGCAAAGCGAAATTGGT forward (SEQ ID NO:13), GCCCGTTCAGTCTCTTCGATT reverse (SEQ ID NO:14), hsRASSF1 TCATCTGGGGCGTCGTG forward (SEQ ID NO:15), CGTTCGTGTCCCGCTCC reverse (SEQ ID NO:16), hsMYO-D CCGCCTGAGCAAAGTAAATGA forward (SEQ ID NO:17), GGCAACCGCTGGTTTGG reverse (SEQ ID NO:18), hsMYT1 TGAAACCTTGGGTGTCGTTGGGAA forward (SEQ ID NO:19), TTGCGGGCCATTGTTCCATGATGA reverse (SEQ ID NO:20), rDNA CGTACTTTATCGGGGAAATAGGAGAAGTACG forward (SEQ ID NO:21), GTGCTTAGAGAGGCCGAGAGGA reverse (SEQ ID NO:22), hsSAT ATCGAATGGAAATGAAAGGAGTCA forward (SEQ ID NO:23), GACCATTGGATGATTGCAGTCA reverse (SEQ ID NO:24), LINE CGGAGGCCGAATAGGAACAGCTCCG forward (SEQ ID NO:25), GAAATGCAGAAATCACCCGTCTT reverse (SEQ ID NO:26). Cycle program was as follows: cycle 1: (1×) 95° C., 5 minutes, cycle 2 (40×) step 1: 95° C. 10 seconds, step 2: 61° C. 30 seconds, step 3 72° C. 30 seconds.
[0000] Cloning and Sequencing of NaCl DNA Fragments from GST-SRA-Column
[0048] Eluted and de-salted DNA fragments were cloned into BamH1 cut and alkaline phosphatase (CIP) treated LITMUS 28i cloning vector using the “fourN” procedure (17) with the exception of the sequence of the oligonucleotide: GTTTCCCAGTCAGGATCCNNNN (SEQ ID NO:1) and PCR primer GTTTCCCAGTCAGGATCC (SEQ ID NO:27). PCR products were purified using Qiagen columns cut with BamH1, purified again, ligated to the vector and cloned as stated.
Results
GST-SRA-domain of Human UHFR1 Coupled to a Solid Matrix Enriched Single-Stranded Methylated CpG-Containing DNA
[0049] To determine the preference of the SRA-domain for unmethylated, fully methylated or hemi-methylated double-stranded or ssDNA in a solid state matrix, the following experiment was performed. 7.83 milligrams of purified GST-SRA domain was bound to a 4.5 ml GST column. 1.68 milligrams of MNase digested chromatin (˜150-1000 bp) from human Jurkat cells spiked with 1 μg each of fluorescein (FAM)-labeled double-stranded methylated CpG oligonucleotide and unmethylated CpG oligonucleotide of different sizes were layered onto the column in buffer A (10 mM Tris pH. 7.5, 1 mM EDTA, 0.05 M NaCl). After a 10 volume column wash with buffer A, the column was developed with a 100 ml NaCl gradient to 1 M and the fractions were assayed by gel electrophoresis ( FIGS. 1A-1C ). Both the methylated and unmethylated DNA oligos co-eluted with the bulk of the chromatin DNA between 0.2 M and 0.3 M NaCl. Interestingly, a faint fluorescent band that was smaller than the two annealed oligos was eluted off the column at ˜0.4 M NaCl. It was speculated that this band might contain unannealed methylated ssDNA.
[0050] To further investigate the binding preferences of the SRA-domain resin for ssDNA, 100 μg of MseI-digested HeLa DNA spiked with 3 μg of MseI-digested M.SssI-labeled 3 H-Adomet HeLa DNA was applied to the above equilibrated GST-SRA domain column. After column wash in buffer A, a 30 ml step gradient from 0.1 M to 0.6 M NaCl was initiated and fractions collected. The double stranded DNA and the 3 H-labeled fully methylated double-stranded DNA eluted off the column in the first two fractions at 0.15 M NaCl. Next, another DNA preparation of the same composition was heated to 98° C. for 1 minute and quickly chilled on ice for 5 minutes prior to loading on the equilibrated column. The above step gradient was used to elute the DNA and the fractions were analyzed as before. A large portion of the 3 H-labeled DNA eluted off the column at 0.15 M NaCl; however, three distinct peaks that eluted at 0.3 M, 0.35 M and 0.4 M NaCl were observed with a small peak of 3 H-labeled DNA co-eluted with the 0.4 M NaCl peak. Finally, a third DNA load preparation was sonicated for 1 minute followed by heating of the sample to 98° C. for 1 minute, chilled, and loaded onto the column. Three peaks were observed at 0.35 M, 0.4 M and 0.45 M NaCl with the bulk of the 3 H-labeled DNA co-eluted with the 0.4 M and 0.45 M peaks, respectively ( FIGS. 2A and 2B ). It was concluded that sonication plus heating of the sample fully fractionated the genomic DNA into a single-stranded form that facilitated binding of the DNA to the resin and greatly improved the resolving power of the matrix to discriminate between unmethylated and fully methylated CpG DNA.
Simplified Elution Profile Enriched Active and Inactive Genes
[0051] A new DNA preparation containing 100 μg of sonicated, heated HeLa genomic DNA was layered onto the above equilibrated column in buffer A. To simplify the elution protocol, a 0.15 M wash step and a 0.3 M and 0.5 M elution steps were employed. Fractions containing the 0.3 M and 0.5 M peaks were collected, desalted and concentrated using a Qiagen miniprep column ( FIG. 3 flow chart and FIGS. 4A-4D ). The products from the salt fractions were characterized by qPCR on a BioRad iCycler using primers to known active and inactive genes in HeLa cells ( FIG. 5 ). The actively transcribed genes Aldolase A (ALDOA), serpin peptidase inhibitor (SERPINA) and 60S ribosomal protein L30 (RPL30) showed a consistent two-fold enrichment in the 0.3 M peak over input DNA. The high salt peak, presumably containing the inactive gene fraction, revealed little or no enhancement of these genes.
[0052] Six known repressed areas of the HeLa genome were interrogated in a similar fashion. Single-copy genes RAS association domain family protein 1 (RASSF1), myogenic differentiation 1 (MYO-D), and myelin transcription factor 1 (MYT1) as well as tandem repetitive ribosomal DNA (rDNA) showed a direct correlation of fold enrichment and CpG occupancy in the 0.5 M peak. Highly repetitive satellite DNA (hsSAT) showed less enrichment in the high salt peak. In spite of high CpG content, long interspersed nuclear (LINE) elements that are transcribed by RNA polymerase II into mRNA (16) showed little difference between the low and high salt fractions, suggesting that the SRA-domain column may accurately reflect the extent of methylation of these sequences in the genome.
[0000] Random Sequencing of Cloned Fragments Derived from NaCl Eluted Fractions
[0053] Sodium bisulfite conversion of genomic DNA, while highly degrading as a consequence of the reaction, can yield very high-resolution information about the methylation state of a given segment of DNA. As the SRA-domain resin favored fragmented ssDNA, it was ideally suited to bind and resolve bisulfite-converted DNA. To explore the characteristics of the SRA-domain column when bisulfite DNA is applied, 200 μg of HeLa genomic DNA converted by the Epitect Bisulfite Kit (Qiagen) was applied to the equilibrated column, washed and eluted as before. As in previous runs, two peaks were observed at the 0.3 M and 0.5 M NaCl step elutions. Fractions were collected, concentrated and de-salted by Qiagen columns. Cloning of the fragments was accomplished using a modification of the “fourN” procedure (17) in which a small oligonucleotide containing four random bases followed by a BamHI restriction site were annealed to the fragments at both ends and extended with Sequenase. Primers complementary to known sequences introduced during the random priming reaction were added and a PCR reaction amplified the products. After cleavage with BamHI restriction enzyme, the DNA was cloned into a BamHI linearized Litmus 28i vector and plated on AMP/IPTG/XGAL plates ( FIG. 3 flow chart).
[0054] The DNA from 100 white colonies of the 0.5 M peak and 50 colonies of the 0.3 M peak were submitted for sequencing. Of those 100 reads from the 0.5 M peak, 30 were deemed suitable for analysis by the following criteria: 1) Contained viable sequences that could be identified by NCBI BlastN as human; 2) Showed evidence of non-methyl cytosine conversion (C to T or G to A, depending on orientation); and 3) unconverted C that was followed by G or unconverted G followed by C, again depending on forward or reverse sequencing orientation. Out of these 30 reads (Table 1) with an average size of 63 bases, 19 contained at least one methylated CpG. Of the 1900 bases sequenced, 44 were methylated CpG or 2.32% of the total. Amazingly, out of the 19 methylated CpG sequences, 10 mapped to known CpG methylation sites: nuclear receptor subfamily 4 (19), Fanconi anemia (20), von Willebrand factor (21), coagulation factor XIII and transglutaminase (22), chromodomain protein Y-like (23), spectrin repeat (24), HECTD1 (25), zinc finger and BTB domain containing 46 (26), and pumilio (27). Out of 22 reads with an average size of 105 bases in the low salt 0.3M peak, 3 contained methylated CpG. Of these 2327 bisulfite-converted bases, 5 were identified as methylated CpG or 0.215% of the total. Although limited in scope, these data showed a better than 10-fold enrichment of methylated CpG from the high NaCl peak versus the low NaCl peak. Additional sequencing efforts will be required to fully determine the potential fold enrichment by the SRA-domain resin as compared to random sequencing of genomic DNA or to CpG methylated DNA that was augmented by other means such as an MBD column.
GST-SRA-Domain Protein Covalently Coupled to Magnetic Beads Showed Similar Binding and Elution Characteristics
[0055] An alternative to column chromatography, GST-SRA-domain protein covalently coupled to a nonporous paramagnetic particle was tested for its suitability as a high-throughput purification matrix for methylated CpG sequences. To compare the binding characteristics of the GST-SRA-domain magnetic beads, 5 μg of sonicated unmethylated lambda DNA or 5 μg of sonicated fully enzymatically methylated (M.SssI) lambda DNA was added to a 50 μl of a 50% slurry of 10 mg/ml SRA-domain magnetic beads in 150 mM NaCl, 0.1% Tween 20, 10 mM Tris pH 7.5, and 1 mM EDTA and allowed to mix end over end for 30 minutes at room temperature. The tubes were placed on a magnetic separation rack and the supernatant was aspirated. The samples were washed and magnetically separated three times by the above buffer supplemented with 150 mM NaCl. The beads were then loaded directly on a 20% native TBE acrylamide gel for analysis. Similarly, sonicated methylated and unmethylated lambda DNA samples were heated to 98° C. and chilled prior to binding on the magnetic beads, followed by washes as stated above. Based on the ethidium stained DNA gel, it was determined that only the methylated heated lambda DNA remained on the beads after the 0.3 M NaCl washes ( FIGS. 4A-4D ). Additional work is needed to characterize the DNA fragments that remain bound to the beads by direct linker addition and DNA sequencing.
Example 2
Common Properties Shared by Sra Domains from Different Sources
[0056] MBP-NP95 SRA-domain fusion protein effectively enriched single-stranded methylated CpG DNA using a small amount of input DNA. This was demonstrated as described below.
[0057] The SRA domain of mouse NP95, which is 90% identical to human UHRF1, bound and enriched fragmented methylated ssDNA using 1 μg of input DNA. In addition, mouse NP95 SRA domain purified methylated CpG-containing DNA by 20-25 fold from 1 μg of fractionated ssDNA, and was comparable to methyl binding domain in yield and sensitivity.
[0058] An alternative to column chromatography, a MBP-NP95 SRA-domain fusion protein in conjunction with Anti-MBP monoclonal antibody coupled to a paramagnetic bead was tested for its suitability as a high-throughput purification matrix for methylated CpG sequences. To compare the binding and elution characteristics of the NP95 SRA-domain with a commercially available methylated CpG enrichment system employing biotinylated MBD (MethylMiner™
[0059] Methylated DNA Enrichment Kit from Invitrogen), 1 μg of sonicated, heated HeLa DNA (NP95 SRA) and 1 μg of sonicated HeLa DNA (MBD) was added to 1 μg of MBP-NP95 SRA (15 μl) or 1 μg of biotinylated MBD (2 μl), in a 200 μl total reaction mix containing 20 μl 10×NEBuffer 4 (50 mM potassium acetate, 20 mM Tris-acetate, 10 mM magnesium acetate, 1 mM dithiothreitol pH 7.9) and 2 μl 100 μg/ml BSA was incubated for 30 minutes at room temperature. To the MBP-NP95 SRA reactions, 100 μl (1 mg) of Anti-MBP magnetic beads (NEB) was added. To the MBD reactions, 100 μl (˜1 mg) of streptavidin magnetic beads (Invitrogen) was added. Both reactions were allowed to mix end over end overnight at 4° C. The tubes were placed on a magnetic separation rack and the supernatant was aspirated. The samples were washed and magnetically separated 3× by 15 ml of wash buffer (20 mM Tris-HCl pH 7.5, 100 mM NaCl, 1 mM EDTA, 1% Triton X-100, 0.1% Tween 20) followed by a final 15 ml wash in low salt buffer (20 mM Tris-HCL, 1 mM EDTA, 0.1% Tween 20 (see FIG. 9 ). 140 μl of water was added to the bead complexes and the DNA samples were heated to 98° C. to liberate the enriched methylated DNA. The products from this heat step were characterized by qPCR on a BioRad iCycler using primers to known active and inactive genes in HeLa cells. The actively transcribed gene ribosomal protein L30 (RPL30) showed no enrichment in the MPB-NP95 SRA samples or the bt-MBD samples. The methylated genes myogenic differentiation 1 (MYO-D), and tandem repetitive ribosomal DNA (rDNA) showed a 20-25 fold enrichment in MPB-NP95 SRA samples, and is comparable to the enrichment values in the bt-MBD samples ( FIG. 8 ). Additional work is needed to characterize the DNA fragments that remain bound to the beads by direct linker addition and DNA sequencing.
[0000]
TABLE 1
High Salt 0.5 M (enriched) peak, no CpG
1 1-33 .5
TGTGGGGTTGTTGTTTTGAGAGGGTTTTTTTTTGGGGTTTTTATTAATGATG (SEQ ID NO: 79)
6-33 .5
AAACATTGGGAATATAGTATTTATTTTTGGTGATTATGTGTTTAGTTAAGTATTAGAGGATATTTTTA
(SEQ ID NO: 28)
7-33 .5
AATTTTTGTAGTTTTAGTAGAGATGGAGTTTTATTATGTTGGTTAGGTTGG (SEQ ID NO: 29)
8-33 .5
GAAACAGGAGAATTTTTTGAATTTGGGTGGTAGAGG (SEQ ID NO: 30)
9-33 .5
AGAAAATATGGTTTGTTAATGAATGATAGGTTAATTTTAGTATGTTGGTTATTTTAATATTTTGTTATTAGT
TGGTTTGG (SEQ ID NO: 31)
H19-33 .5
CAGGTATAGTGGTAAGAATTTGTAGTTTTAGTTATTTGGGAGGTTGAGTTAGGA (SEQ ID NO: 32)
H76-33 .5
AAACTTTTGGTTGGGGGTGGTGGTTTATGTTTGTAATTTTAGTATTTTGGGAGGTCAAGGTGAGTGGAT
(SEQ ID NO: 33)
H2-33 .5
AGGTAGTTTTATTTTGGGTTTTAGGGAATAGGAGGGAATTAGAAGGA (SEQ ID NO: 34)
H5-33 .5
CAGTATTTTGGGAGGTTAAGGTAGGTGGATTATGAGGTTAGGAGATTGAGA (SEQ ID NO: 35)
H21-33 .5
GATGGATTGTTTGAGTTTAGGAGTTTGAGATTAG (SEQ ID NO: 36)
H24-33 .5
TGAGTTTAGTTTAAGTTGATTGGGTAGGTAAATGTTTGTTATGAATTTGGAAGTGAGAGA (SEQ ID NO: 37)
High Salt 0.5 M (enriched) peak, CpG
3-33 .5
725439 bp at 3′ side: nuclear receptor subfamily 4, group A, member 2
isoform a
CAGGTGTTGAGTGGTGAGGGATGTGTAAATAAGTAAGTGTGGGGTT GTTATTG TATAGTTAGGTATAT
TGGTTGTTGTGGGGTGGGGTAGGTAATTTAAGTATTAGTATGGGTATTGGTTTTTTGTGAGGC
(SEQ ID NO: 38)
4-33 .5
Fanconi anemia, complementation group M
ACAAAAATTAGTTAGGTATAGTGGTATGTATTTGTAGTTTTAGTTAAT GGATCCTGA (SEQ ID NO: 39)
5-33 .5
GENE ID: 10692 RRH | retinal pigment epithelium-derived rhodopsin homolog
GAATGGCAAGTATTGGATTATTTA GT TGGTTGTGGAT ATA (SEQ ID NO: 40)
10-33 .5
transglutaminase 2 isoform b
AGTTTGTA GTGAAGTTTAGGTTTTATTGTGGATA GTTGAAATAGAAGAGTGATGGG (SEQ ID NO: 41)
H6-33 .5
31781 bp at 5′ side: von Willebrand factor preproprotein
46059 bp at 3′ side: CD9 antigen
TGAA GGAGG GAGTTTGTAGTGAGTTAAGAT TTATTGTATTTTAG (SEQ ID NO: 42)
H7-33 .5
ref|NW_001838799.1|H52_WGA192_36
GGAAA AATGAAATTAT AATGGAAT AATGGTGTTAT AA GA (SEQ ID NO: 43)
H12-33 .5
coagulation factor XIII A1 subunit precursor
GATAGGAGGGGTTGTTATGAAG (SEQ ID NO: 44)
H15-33 .5
545337 bp at 5′ side: EGF-like repeats and discoidin I-like
domains-containing
TAGTTAATTATATGTGTT TTATTTGTGTATGTGG (SEQ ID NO: 45)
H45-33 .5
114563 bp at 5′ side: similar to hCG2036843
ATGAAAGTGTTTTGGGGATGGATGGGGGATATGGTTGTATAATGTGG GA (SEQ ID NO: 46)
H55-33 .5
B-cell novel protein 1 isoform a
AGAAT TTTGAGTTTAGGAGTTTAAGATTAGTTTGGGTAATATAGTGAGATTTTGTTGTTA AAAATAAA
TAAAAAATTAGTTAGGTGTGGTGGTGTATGTTTGTGGT (SEQ ID NO: 47)
H64-33 .5
17408 bp at 5′ side: musashi 2 isoform b
TGTTTGTTGAGTGTA TNTNNNGTATTTGTGTTGGGTGTATGTGGATGTGTGNGNTGAG (SEQ ID NO: 48)
H74-33 .5
Homo sapiens HECT domain containing 1 (HECTD1), mRNA
AGTTTGAAGTTTTTATAGAAGAAGGTTATGATTTATTTT GTAGGAAGTTTTGAAGAG
(SEQ ID NO: 49)
H15a-33 .5
62438 bp at 5′ side: D-amino acid oxidase activator
AGGAAAGTTGGAAGGATGAGGATAA TAGTGTTTTGTTGAAGAAGGAAGAGANNNNGGATTAAATTGAAAT
TGATTGGGTTTYTAAAATGGATGGGAT (SEQ ID NO: 50)
H27-33 .5
unc-51-like kinase 4
AGTTTGATTTTAGATTGTTGTGTTAGTAATGAG AGG (SEQ ID NO: 51)
H30-33 .5
spectrin repeat containing, nuclear envelope 2 isoform 1
TTATTTTTATAAAAATAAAAAAATTAGTTGGGTGTAGTGG TATGTTTGTNGTTTTAGT (SEQ ID NO: 52)
H H31-33 .5
256834 bp at 5′ side: alpha 1 type IV collagen preproprotein
AA ATAAAGAAAATAAAAGGAGTGAGGGAGGATAGATGGG (SEQ ID NO: 53)
H35-33 .5
pumilio 1 isoform 1
ATTAGTTAGG TGGGGGTGGGTGTTTGTAGTTTTAGTTATTTAGGAGGTTGAGGTAGGA (SEQ ID NO: 54)
H7a-33 .5
zinc finger and BTB domain containing 46
AAGGTGGGGGTTGGGGGGNTNGTTTTTT GGNTGTTGT GNGGAGGAG TTTTAGAGTTTA G T
AGTTTTATT T GNATTTAGGTGGA TTGAT GGGGAGAGAATTGAGTAT GGATC
(SEQ ID NO: 55)
H9-33 .5
259088 BP AT 3′ SIDE: CHROMODOMAIN PROTEIN, Y-LIKE 2
AGAGTAGAGAGATGATTAAATTTATGTTAATTTTATTATTTTGGTTTTGAGGTTGTTGTRYAAGTTTTTTAG
AATGTGAGT GGTATTGTTTTTGAGGTTAA TTATTTGGTTTG TTT (SEQ ID NO: 56)
Low Salt 0.3 M(control) peak, CpG
13-33 .3
GGGAGGTAGTGATGAGAGTAATAGATAGGGTTTAGGTGTTTGTGTATGATATGTTTG (SEQ ID NO: 57)
L9-33 .3
GATGTTATTAAATAATTAGATTATTTGTATT AATTGGGTAAGTAGTATAAAGGANAANGATATTATTAAA
TAATTAGACTATTTGTATT AATTGGGTAAGTAGTACAAAGGAGAAGTGGGGNAA (SEQ ID NO: 58)
3-2-33 .3
19744 bp at 3′ side: Myc-binding protein-associated protein
TTTGTAGAAGGATGTGAGAGGAGAAGTGAG GTTTTATAGGTATGATGTTAGTTATAAGGGGTTGGTGAGT
TGATGTGGGAGGATTATTTGGTTTAGGAGTTTAAGGTTG GTGAGT (SEQ ID NO: 59)
L-17.33
dihydrouridine synthase 3-like
TGAGGGTTGGGTTTAGGATAGAGTATAGAGAGGGAGATTTAGTTAGGAGTTTTTTTAAGGTATATAGTTTTT
GATTTTTAGGTAGTTAGAATAGGAA TGGATATAGTTGGTATTTAATAGA TATATTAGATGGATAGATT
TGTTATTGA (SEQ ID NO: 60)
Low Salt 0.3 M(control) peak, no CpG
3-5-33 .3
TAGTAGTATGATGTTAGTTTTTTTTAAATTATAGATTCAATAAAATTCAGTTAAAATTTTATTAGTTTTATT
TATTTATTGATTTAGTAGAGATGGATATAGTACTGT (SEQ ID NO: 61)
3-6-33 .3
GTGTTAT TATTGGGGTTATTTGTGTAATTAATATGTGTTATTTAGTTTTAGGGTGTATGTTTATTGTTTT
AATTATGATGGAGGTGTAGTTTGGAGATTTTGTGTTAGGAGATTAGTAGAGTTTGGGGTTTTAAGGGGATTT
TTTGTGGGGGAGAGGGATAGTTGTGTAGTAGAGTGATAATGAAGGTTTTTGATTTAATGTGTAGTTTTTAGG
TTATGTGT (SEQ ID NO: 62)
3-8-33 .3
TTTGGGAGGTTGAGGTGGGTAGATTATGATGTTAAGAGATTGAGATTAT (SEQ ID NO: 63)
L1-33 .3
GATGAAAGGTTAAAAATTGAGATAGAAGATGTGATTTGGAAGGTTATAAGAGAAGTTGGATAAAGTTAAATAAGGA
AAGGAATTTAGAAAAAAGTGTTTAATGTTGTAGAAGG (SEQ ID NO: 64)
L1-19 .3
CTATTCTTCCCATTCTCAACATAACTCTAACCTTCCTTCATCCTCACACCCAACAATCATTCACTCATTTATCTA
(SEQ ID NO: 65)
L-1.33
GATAAAGTTGTGNGTAGGGATTTTTGGTAGAGGGAATAGAAAGATGGAGGTGTTGAGGTAGGAGTGATGGGTAGGTTTG
AAGAGTAGAGTTTAGTGTAGTGAGGGGGTTATTAGTAAGGG (SEQ ID NO: 66)
L-11.33
ATATTTTATGGAGGAGTAATTTTTAGAGTATATGAATTGGTTTTATGGAGGAAGATTGTTATTTATAGGTTGGTGTAAG
TGATGGTAGTAGTGGTTTGTC (SEQ ID NO: 67)
L-12.33
AGAAGATAAGGAGAAGATAATTATTNTTTTGGTAGAGGTAATTGATTTGATTATTAGGA (SEQ ID NO: 68)
L-15.33
ATGTGTATTTAAAGTAAGGTTATGAGATTTTGGATTGTTTTTTGTTTAGGATGATATGTG (SEQ ID NO: 69)
L-16.33
AAGTAAAATAATTTTGTTTTTATTTATTTTANAGGATTGTT (SEQ ID NO: 70)
L-18.33
AAAATTTTAAGATTAGGTAAAAATATTGTGTAAAGTGAGAGGGATGTGATGGTTAAAAAGTGATTTAAGATT
TTTGTAATTTTTAGTTATAATTTAAGA (SEQ ID NO: 71)
L-2.33
GAGATAATAGTGAGTATGATATTTTTTGTTTTTTTTATTATGTGTTAAGTATTGTTTAGGGATTAAGTGGGG
TTGTGTTTATTGTAGATGTTGTAGGTATGGAGTTAGTA (SEQ ID NO: 72)
L-20.33
ATGTATTTAGTTGTTTATTGAATATTATTTTAATATTGTATTATGAATATTGTTATGTTATGGATTTTAGGT
TTTATTAGATTGGTATTAGTATCATTTAGGAATATTTTATGATGTGTGTTGATAAATTTTTAAGATAAATGA
ATTTGAGATATGTGTGAGTATTTTATAAAATAAATTTTGTTGGA (SEQ ID NO: 73)
L-23.33
ATGGTTTGTTTGTTTTTGTGGAAAATGGTATGAAGATTGGGTTTGTATTGAATTTG (SEQ ID NO: 74)
L-24.33
TGTAGTTTTAGTTATTTAGGAGGTTGAGATATGAGAATTATTTGAATTTGGGGGGGGAAGGTTGTAGTGA
(SEQ ID NO: 75)
L-27.33
TGAGAAGGGGGTAGTGGGGATGGTTTTGTGGGTTTATGTTGTTTTTGATTTTAGAAAATAAAGTTTTTTGTA
GGAAGTAGGTGGGAAGTAATTTGTTGATAAGTGTAAAGATTTGGGAATTATATTAAGGGGTAAATGGAGGAN
AGGTGTTGGTGTTAANGAGGTAGACNTATGGGAGTTNGGTTTTAGGAANGGNNGTGGNTAGAAAGG
((SEQ ID NO: 76)
L-28.33
GGTAGGTAGATTATTTGAGGTTAGGAGTTTAAG (SEQ ID NO: 77)
L-4.33
ATATTTTTTTATTGAAGAATGTAGTTTTTTAAAATTAAAATGTATTTTTAAAATTTATTTATTATTTTTT--
GAGATAAGGTTTTGTTTTGTTGTTTAAGTTAGAGTATAGTATGTGATTATAGTTTATTGTAGTTTTGAATTT
TTGGGTTTAAG (SEQ ID NO: 78)
[0060] Table 1 above shows the results of sequence analysis of the two NaCl peaks from the SRA-domain column showed a better than 10-fold enrichment of methylated CpG DNA. Out of 30 reads with an average size of 63 bases in the high (0.5 M) NaCl fraction, 19 contained at least one methylated CpG. Of the 1900 bases sequenced, 44 were methylated CpG or 2.32% of the total. Out of 22 reads with an average size of 105 bases in the low salt 0.3M peak, 3 contained methylated CpG. Of these 2327 bisulfite-converted bases, 5 were identified as methylated CpG or 0.215% of the total.
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2. Bird, A P (2002) DNA methylation patterns and epigenetic memory. Genes Dev 16: 6-21.
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4. Illingworth R, Kerr A, DeSousa D, Jorgensen H, Ellis P, et al. (2008) A novel CpG island set identifies tissue-specific methylation at developmental gene loci. PloS Biol 6(1): e22.
5. Reik W (2007) Stability and flexibility of epigenetic gene regulation in mammalian development. Nature 447: 425-432.
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7. Sado T, Fenner M H, Tan S S, Tam P, Shioda T, et al. (2000) X inactivation in the mouse embryo deficient for Dnmt1: distinct effect of hypomethylation on imprinted and random X inactivation. Dev Biol 225: 294-303.
8. Ueki T, Walter K, Skinner H, Jaffee E, et al. (2002) Aberrant CpG island methylation in cancer cell lines arises in the primary cancers from which they were derived. Oncogene 21(13): 2114-2117.
9. Das R, Dimitrova N, Xuan Z, Rollins R, et al. (2006) Computational prediction of methylation status in human genomic sequences. PNAS 103 (28): 10713-10716.
10. Hendrich B, Bird A (1998) Identification and Characterization of a Family of Mammalian Methyl-CpG Binding Proteins. Mol Cell Biol. 18(11): 6538-6547.
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18. Song L, James S R, Kazim L, Karpf A (2005) Specific Method for the Determination of Genomic DNA Methylation by Liquid Chromatography-Electrospray Ionization Tandem Mass Spectrometry. Anal. Chem., 77 (2): 504-510.
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25. Carrasco D, Tonon G, Huang Y, Zhang Y, Sinha R, Feng B, Stewart J, Zhan F, Khatry D, Protopopova, M. (2003) High-resolution genomic profiles define distinct clinico-pathogenetic subgroups of multiple myeloma patients. Cancer Cell, 9(4): 313-325.
26. Filion G J P, Zhenilo S, Salozhin S, Yamada D, Prokhortchouk E, Pierre-Defossez P A. (2006) A Family of Human Zinc Finger Proteins That Bind Methylated DNA and Repress Transcription Mol Cell Biol. 26(1): 169-181.
27. Li Z X, Ma X, Wang Z H. (2006) A differentially methylated region of the DAZ1 gene in spermatic and somatic cells. Asian Journal of Andrology. 8(1): 61-67. | Compositions and methods are provided for facilitating the enrichment of single-stranded DNA containing methylated CpG in a mixture containing methylated and unmethylated DNA. The compositions relate to methylation-binding protein domains that selectively bind to methylated single strand DNA. In embodiments of the invention, the methylated DNA is eluted in 0.4M-0.6M NaCl while the unmethylated single strand DNA is eluted in less than 0.4M salt. The ability to readily enrich for methylated DNA permits high throughput sequencing of the methylated DNA and identification of abnormal methylation patterns associated with disease. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
Applicants' copending application, Ser. No. 043,812, filed concurrently herewith, and assigned to the assignee hereof.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel thermosetting polymers comprising imide functions, and, more especially, to the copolymerization products of a bis-imide with a (meth)acrylic acid amide.
2. Description of the Prior Art
It is known to this art that heat resistant polyimide resins may be obtained by simple heating of the bis-imides of unsaturated carboxylic acids. Shaped articles molded from such resins, however, are fragile because of their high degree of cross-linking. The reduction of the cross-linking density by means of an addition reaction between the bis-imide and a diamine [see U.S. Pat. No. 3,562,223 and French Pat. No. 1,555,564] or a polyamine-monoamine mixture [see U.S. Pat. No. 3,669,930] has been suggested. These molded shaped articles have been found useful in applications requiring high temperature strength. Nonetheless, in numerous applications which do not require a high thermal index, the difficulty in processing these resins is a pronounced obstacle to their use and development.
SUMMARY OF THE INVENTION
It is the major object of the present invention to provide novel polymers comprising imide groups which are more easily processed than related polymers known to the art. The polymers of the present invention are processed without solvents, by simple hot casting, and, after hardening or curing, yield products having superior mechanical properties. Prior to hardening, the polymers of the present invention are in the form of fluid resins of low viscosity at moderate temperatures, and are thus easily processed. For this reason, they are particularly suitable for molding by simple hot casting and by impregnation techniques. Polymers of the present invention may be used after cooling and grinding, in the form of powders which are remarkably well suited for compression molding, and may be used in association with fibrous or power fillers. The polymers may also be used for the preparation of coatings, for adhesive bonding, in laminated materials which may have a skeleton of mineral, vegetable or synthetic fibers, and for cellular materials or foams, following incorporation of a pore-forming agent therein. Further, the polymers of the present invention may also be used as an impregnating varnish and as an enamel, both without solvent.
The polymers of the present invention are prepared by copolymerization between:
[i] a bis maleimide of the structural formula: ##STR2## wherein A is a divalent radical, preferably selected from the group comprising phenylene and radicals of the structural formula: ##STR3## wherein T is a divalent radical, preferably selected from the group comprising --CH 2 --, --C(CH 3 ) 2 --, --O-- and --SO 2 --; and
[ii] a (meth)acrylic acid amide comonomer copolymerizable therewith.
DETAILED DESCRIPTION OF THE INVENTION
The bis-maleimides of structural formula (I) are known to the art. Same may be prepared by the methods disclosed in U.S. Pat. No. 3,018,290 and British Patent Specification No. 1,137,592 which are hereby expressly incorporated by reference and relied upon. The following are representative examples of such bis-maleimides:
N,N'-metaphenylene bis-maleimide,
N,N',4,4'-diphenylether bis-maleimide,
N,N',4,4'-diphenyl-2,2-propyl bis-maleimide,
N,N,4,4'-diphenylsulfone bis-maleimide, and
N,N',4,4'-diphenylmethane bis-maleimide.
The latter bis-maleimide is preferentially utilized in consonance with the present invention: obviously, mixtures of the aforementioned bis-maleimides may also be utilized consistent herewith.
A mixture comprising a bis-maleimide of structural formula (I) and a mono-imide, wherein the number of imide groups of the mono-imide is up to 30% of the total number of imide groups in the mixture, may also be used in the present invention.
The (meth)acrylic acid imides [ii] which are copolymerized according to the invention preferably include acrylamide, methacrylamide, and admixtures thereof.
The conditions of polymerization which yield the polymers of the present invention may vary over wide limits. The ratio r is equal to the number of imide groups divided by the number of moles of (meth)acrylic acid amide, and may vary from 0.25 to 8. The polymers of particular interest are those wherein the proportions of the starting material monomers are such that the ratio r is equal to at least 1, and preferably ranges from 1.6 to 3.5.
The reaction temperature too may vary over wide limits, as a function of the nature and of the proportions of the reactants. However, typically the temperature ranges from 90° to 250° C.
The polymers of the present invention can be prepared via bulk polymerization whereby the mixture of the (meth)acrylic acid amide [ii] and the bis-maleimide [i] is heated until a homogeneous liquid results. To obtain a homogeneous liquid composition it is typically not necessary to exceed a temperature of 160° C. Prior to heating the mixture of the reactants, it is advantageous to effect preliminary homogenization. It may be possible to first melt one of the two reactants and then mix the melt with the other reactant.
The polymers of the present invention may also be prepared by heating a mixture of the reactants in an inert organic diluent which is liquid over at least part of the temperature range of the reaction. Suitable as diluents are the polar organic solvents N-methylpyrrolidone, dimethylformamide, dimethylacetamide, N-methylcaprolactam, diethylformamide, N-acetylpyrrolidone, and the cresols. Also suitable as diluents are the various hydrocarbons, chlorinated hydrocarbons, linear or cyclic ethers and nitriles.
Solutions or suspensions of the polymers of the invention may be utilized for a wealth of applications. It is also possible to isolate or separate the polymers of the present invention from any such solution or suspension. For example, the polymers may be isolated by precipitation by means of an organic reagent which is miscible with the solvent used. Advantageously, hydrocarbon solvents are employed which have boiling points not substantially in excess of 120° C. However, in the majority of cases it is not necessary to add such diluents because the initial mixtures are sufficiently fluid at moderate temperatures.
The polymers of the present invention may be prepared in the presence of a free-radical inhibitor, such as phenothiazine or any one of those noted at Encyclopedia of Polymer Science and Technology, Vo. 7, pages 644 to 662, which is hereby incorporated by reference.
The polymers of the present invention may be hardened or cured [thermoset] polymers, which are insoluble in conventional solvents and which do not exhibit appreciable softening below the temperature at which softening begins. However, the polymers may also be prepared in the form of prepolymers which are indeed soluble in polar organic solvents and which have a softening point at a temperature below 250° C. These prepolymers may be prepared in bulk by heating the mixture of reactants until a homogeneous or viscous product is obtained, typically at a temperature of from 50° to 180° C. The preparation of these prepolymers may also be carried out in suspension, or in solution, in an organic diluent which is a liquid over at least part of the temperature range of from 50° to 180° C., and preferably the reaction is carried out in a polar organic solvent.
In a second stage, whereby the polymer is obtained from the prepolymer, the resins may be hardened or cured by heating to a temperature up to the order of 300° C., and usually from 150° to 250° C. Optionally, such heating may be preceded by addition of a free-radical initiator to the reaction mix, such as a peroxide, e.g., dicumyl peroxide, di-t-butyl peroxide, t-butyl perbenzoate, azobisisobutyronitrile, or by addition of an anionic polymerization catalyst, e.g., diazobicyclooctane. As another option, an additional shaping operation may be performed upon the reaction mass during the hardening thereof. This shaping operation may be conducted under pressure in excess of atmospheric, or under vacuum. These operations may also be carried out consecutively.
The polymers of the present invention may also comprise an aromatic compound having from 2 to 4 benzene rings, which does not sublime at temperatures less than 250° C. under atmospheric pressure and which has a boiling point in excess of 250° C. The addition of such aromatic compounds is of particular interest in connection with the aforenoted prepolymers, because same typically contribute to a reduction in softening point. Suitable aromatic compounds are described in U.S. Pat. No. 3,679,639, and French Pat. No. 2,046,025, which is hereby incorporated by reference.
The polymers of the present invention may be modified by the addition, prior to hardening, of a monomer M other than an imide which comprises at least one polymerizable ##STR4## group. Such polymerizable group may be of the vinyl, maleic, allylic or arcylic type. These monomers may contain several ##STR5## groups, provided, however, that the double bonds are not conjugated. In a single monomer, the polymerizable groups may be of the same type or they may be different types. Both a monomer of the given formula or a mixture of such copolymerizable monomers may be used. Suitable monomers are disclosed in U.S. Pat. No. 4,035,345 and French Pat. No. 2,094,607, hereby expressly incorporated by reference.
The monomer(s) M may be added to the prepolymer or same may be introduced into the mixture of the reactants at any time during the preparation of the polymer. The amount of monomer added is selected such that said monomer constitutes at most 50%, and preferably from 5 to 40%, of the weight of either the prepolymer or the mixture of reagents. The hardening of the reaction mixture modified by the monomer, and of the prepolymer modified by the monomer, is carried out under the reaction conditions specified hereinabove for the unmodified polymerization recipe, and for the unmodified prepolymer, respectively.
The polymers of the present invention may also be modified by the addition, prior to hardening, of an unsaturated polyester. Suitable unsaturated polyesters are described in U.S. Pat. No. 3,772,939 and French Pat. No. 2,102,818. The mode of introduction and the amounts of the unsaturated polyester, together with the mode of hardening the polymer modified by the unsaturated polyester are the same as those mentioned hereinabove with reference to addition of the monomer M comprising a polymerizable site of olefinic unsaturation.
In order to further illustrate the present invention and the advantages thereof, the following specific examples are given, it being understood that same are intended only as illustrative and in nowise limitative.
EXAMPLE 1
80 grams of N,N',4,4'-diphenylmethane bis-maleimide and 20 grams acrylamide were introduced into a reactor which was provided with means for agitation and placed in a bath that was thermostatically maintained at 150° C. The mixture was melted under agitation until a clear, homogeneous, translucent liquid is obtained. The air dissolved in the liquid was eliminated by subjecting the contents of the reactor to a reduced pressure of 200 mm of mercury for 2 minutes. The resulting, degassed liquid mixture was cast into a mold (127×75×4 mm) which had been preheated to temperature of 150° C. The mold was of parallelepipedic shape. The mold was maintained for 6 hours at a temperature of 150° C., then for 2 hours at a temperature of 200° C., and, finally, for 24 hours at a temperature of 250° C. The properties of the object thus obtained are set out in Table 1, below.
EXAMPLE 2
In a second experiment, the preparation as described in Example 1 was repeated, except that a mixture of 85 grams of N,N',4,4'-diphenylmethane bis-maleimide and 15 grams of acrylamide were used. The properties of the shaped article thus obtained are reported in Table 1, below.
EXAMPLE 3
In a third experiment, the preparation as described in Example 1 was repeated, except that a mixture of 80 grams of N,N',4,4'-diphenylmethane bis-maleimide and 10 grams of acrylamide were used. The properties of the shaped article thus obtained are reported in Table 1, below.
TABLE I______________________________________ Example Example ExampleProperties 1 2 3______________________________________Initial Flexural Bending Strength(in kg/mm.sup.2):at 25° C. 11.55 10.50 10.60at 200° C. 3.40 7.10 1.20Flexural Bending Strength after1000 hours at 200° C.(in kg/mm.sup.2):at 25° C. 11.0 8.95 9.80at 200° C. 5.15Flexural Bending Strength after1000 hours at 250° C.(in kg/mm.sup.2):at 25° C. 9.5 5.5 9.10at 200° C. 2.70Initial FlexuralModulus (in kg/mm.sup.2):at 25° C. 340 292 302at 200° C. 174 264 112Flexural Modulus after1000 hours at 200° C.(in kg/mm.sup.2):at 25° C. 276 330 352at 200° C. 302Flexural Modulus after1000 hours at 250° C.(in kg/mm.sup.2):at 25° C. 297 280 312at 200° C. 225Impact Strength 0.65 0.85 0.35(in j/cm.sup.3)(according to PTstandard 51-017)Gelling Time at 150° C. 32 41 54(in minutes)L.O.I. Index (according 33 34 34to ASTM Standard D1621-64)______________________________________
EXAMPLE 4
The following were intimately admixed under gradual heating to 115° C.:
(1) 50 g of N,N'-diphenylmethane bis-maleimide,
(2) 50 g of acrylamide, and
(3) 5 g of azodicarbonamide as a blowing agent, and 1 g of a surface-active agent of the polyalkylene glycol laurate type, marketed under the trademark "Cepretrol J".
19 g of the product obtained after homogenation were placed into a receptacle consisting of a steel frame having the dimensions, 75×75×30 mm, wraped in aluminium foil which was folded up along the exterior walls of the frame. The entire assembly was placed between two chromium-plated brass plates and the mold thus formed was in turn placed between the two platens of a press, these platens having been preheated to 200° C.
The platens were brought into contact with the brass plates without applying pressure, and the entire apparatus was thus maintained for 20 minutes to allow the foam to expand.
The cellular material thus obtained, having a density of 0.12 was baked for an additional 24 hours at 250° C.
The compressive strength (10 percent compression) of a 5×5 cm sample, measured according to standard specification ASTM D 1621-64 (traverse speed: 2.5 mm/min.) was 5 kg/cm2.
While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims. | Novel imido copolymers are prepared by copolymerizing:
[i] a bis-maleimide of the structural formula: ##STR1## with [ii] a (meth)acrylic acid amide.
The subject copolymers are applicable to the production of a variety of useful shaped articles, coatings, laminates, foams, and the like. | 2 |
BACKGROUND OF THE INVENTION
1. Description of the Prior Art
Perforating guns have long been employed to achieve the perforation of a well casing and an adjacent production formation. Originally, such perforating guns were lowered into the casing to the desired location on a wire line and then electrically activated to effect their discharge. More recently, perforating guns have been conveyed on the bottom of a tool string having an uninterrupted bore through which a detonating bar could be dropped to effect the firing of the gun, or in which a fluid pressure could be developed to effect a fluid pressure actuated detonation of a perforating gun. The tubing conveyed perforating gun has the advantage that other operations, such as chemical treatment, washing and/or gravel packing of the perforations and the production screen, can be accomplished with a single trip of the tool string into the well. See for example U.S. Pat. No. 3,987,854 (Callihan, et al).
It has been previously suggested in the prior art that production tubing be utilized as the tool string on which the perforating gun is inserted in the well. In such case, it often becomes desirable to disconnect the perforating gun after the perforating operation has been performed so that the subsequent movements of the tool string to effect the positioning of the screen adjacent to the perforations and to effect the chemical treatment, washing and/or gravel packing of the perforations may be conveniently accomplished without requiring the movement of the additional weight of the discharged perforating gun. It is therefore desirable to provide an economical, yet reliable apparatus for effecting the release of the perforating gun from the tool string.
The release of a tubing conveyed perforating gun has heretofore been disclosed in the prior art. See for example U.S. Pat. No. 3,706,344 (Vann) and U.S. Pat. No. 4,040,482 (Vann) and earlier references. Such prior art references, however, contemplate the severance of a perforating gun from the tool string by a tubing cutter or a wire line operated latch releasing mechanism. Obviously, the employment of a tubing cutter or any wire line disconnecting device necessitates the introduction of substantial delay due solely to the operation of separating the perforating gun from the tool string.
SUMMARY OF THE INVENTION
This invention provides a releasable coupling device for a perforating gun which is run into the well on a tubular work string or production string which may include one or more tools, such as packers, screens, washers, perforation treatment apparatus, gravel packers or the like. The releasable coupling comprises a first tubular assemblage which is threadably secured to the top of the housing containing the perforating gun. A second tubular assembly is threadably connected to the bottom of the tubular tool string. The two tubular assemblies have nestable sleeve portions which are normally held in secured relationship by a plurality of peripherally spaced, radially shiftable locking elements.
The locking elements are held in their securing position with respect to the two nested sleeves by a retaining sleeve which in turn forms part of an annular piston. The upper portion of the annular piston projects into an annular fluid pressure chamber maintained at surface ambient pressure. The lower portion of the annular piston projects into an annular fluid pressure chamber which is connected by fluid conduits to the interior of the perforating gun housing so that the high pressure blast of gas which is normally created within the perforating gun housing upon discharge of the perforating gun is directed into engagement with the lower end of the annular piston. This produces an upward movement of the piston sufficient to bring an annular recess into alignment with the radially shiftable locking elements which are then cammed into such recess by the inherent weight of the perforating gun suspended therefrom and moved radially inwardly to disconnect the nested sleeves, thus permitting the second tubular assembly and the tubular tool string to be moved upwardly relative to the perforating gun, or conversely, to permit the first tubular assembly and the discharged perforating gun to slide downwardly out of engagement with the tubular tool string to lodge in the bottom of the well.
It is thus assured that when the perforating gun is discharged, the releasable coupling will be automatically actuated to effect the disconnection of the two tubular assemblies due to the gas pressure force developed by the discharge. Such gas pressure force may be conveniently directed to the actuating piston by positioning the hammer and the explosive primer within the lower portion of the bore of the second tubular assembly and providing an annular communicating chamber between the explosive primer and the lower annular fluid pressure chamber. If, for any reason, the gas pressure developed by the discharge of the perforating gun is inadequate to effect the shifting of the actuating piston to effect the release of the coupling mechanism, the fluid pressure existing in the well at the location of the perforating gun will flow through the newly created openings in the gun housing and into the lower annular fluid pressure chamber to operate against the lower portion of the annular actuating piston and thus assure the release of the radially shiftable locking elements.
Accordingly, the disconnection of the tubing string conveyed perforating gun from the tool string occurs automatically immediately following the discharge of the perforating gun, thus eliminating the necessity for any wire line or other operations for effecting the disconnection of the perforating gun.
Further objects and advantages of the invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B collectively constitute a vertical quarter-sectional view of a perforating gun coupling mechanism embodying this invention, with components thereof shown in the coupled or connected position.
FIG. 2 is a view similar to FIG. 1A but showing the shifting of the actuating piston to a position permitting the latching elements to shift radially inwardly to release the two components of the coupling mechanism.
FIG. 3 is a vertical quarter-sectional view showing the axial separation of the two disconnected components of the coupling mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to FIGS. 1A and 1B, there is shown a releasable coupling mechanism 10 embodying this invention. Such mechanism comprises an upper tubular assembly 11 having internal threads 12a for sealably connecting to the bottom end of a tubular tool string. Such tool string may include a packer and one or more other well treatment or well completion devices, such as a screen, perforation washer, perforation treatment apparatus, and/or a gravel packing apparatus.
Releasable coupling 10 further comprises a lower tubular assembly 20 which terminates in external threads 21a to which may be sealably secured the housing 1 of a conventional perforating gun. The two tubular assemblies 11 and 20 are normally interconnected by a plurality of peripherally spaced, radially shiftable latching lugs 30. In the connected position shown in FIG. 1A, the latching lugs 30 are shown in their radially outermost position wherein downwardly facing, inclined shoulders 30a on the lugs 30 are in abutting engagement with an upwardly facing inclined shoulder 13a provided on the bottom portion of a latching sleeve 13 which is threadably secured at its upper end by threads 13b to the bottom end of a sub 12 which forms the other component of the upper tubular assembly 11.
Starting from the bottom and proceeding upwardly, the lower tubular assembly 20 comprises a connecting nipple 21 which is externally threaded at 21a for sealably mounting thereto the housing 1 of a conventional perforating gun. O-rings 1a seal the threads 21a. A typical gun which may be employed is that shown in co-pending application, Ser. No. 366,267, filed May 7, 1982. Nipple 21 has a constricted axial bore 21b which is normally traversed by a length of Primacord P which transmits energy from a detonatable primer 25 contained in the upper portion of the lower tubular assembly 20 down to the plurality of horizontally and vertically spaced shaped charges (not shown) that are conventionally provided in the perforating gun housing 1.
An inner body sleeve 22 is secured by internal threads 22a to the top portion of nipple 21 and the threaded joint is sealed by O-rings 22b. Inner body sleeve 22 is contoured to surround the upper end of nipple 21 and is provided with an axial bore 22c extending therethrough. The bore 22c is counterbored at 22d to provide an open bottom chamber for mounting of primer 25. A second counterbore 22e is provided above counterbore 22d to mount a conventional firing head 26 by threads 22f. Firing head 26 includes a conventional hammer 27 which is mounted for axial movement upon receipt of a downwardly directed impact blow. Any such blow imparted to hammer 27 detonates the primer 25 and in turn ignites the Primacord P.
Since there is an unobstructed axial passage from the location of the firing head 26 up through the bore of the upper tubular assembly 12, those skilled in the art will recognize that any type of firing mechanism, such as an electrically actuated mechanism, could be employed merely by connecting an appropriate electric wire line to the firing head 26, with the electric wire line passing through the unobstructed bore of the coupling 10 and through the tubing string to the surface of the well. Preferably, however, a conventional detonating bar (not shown) is dropped through the bore of the connected tool string to impact upon hammer 27 to effect the ignition of primer 26 and the subsequent ignition of the charges in the perforating gun. To aid in the direction of the detonating bar, an axially upwardly extending guide sleeve 28 is provided which is threadably secured at its lower end by threads 28a to a nipple portion 22g of the inner body sleeve 22. O-rings 28b seal the threaded connection 28a. Guide sleeve 28 has an internal bore 28b contoured to direct the detonating bar to centrally impact on hammer 27.
An outer body sleeve 32 is threadably secured by internal threads 32a to the lower portions of the inner body sleeve 22. Threads 32a are of larger diameter than threads 28a. The outer body sleeve 32 extends upwardly beyond the upper end of the guide sleeve 28 where it projects inwardly and is sealingly engaged with such upper end by O-rings 32c. The annular space 33 between the inner body sleeve 22 and the outer body sleeve 32 is divided into an upper portion 33a constituting a closed fluid pressure chamber, and a lower portion 33b constituting an open bottom fluid pressure chamber, by an annular piston 35 which is sealably engaged with the inner wall 32d of the outer body sleeve 32 by O-rings 35a and 35b, and with the upper end of the exterior cylindrical wall 28c of the guide sleeve 28 and is sealingly engaged with such upper end by O-ring 32c. It will therefore be apparent that the upper annular fluid pressure chamber 33a is maintained at the surface ambient pressure as the tool string is inserted into the well. Fluid pressure chamber 33a is preferably filled with air or an inert gas so that upward movement of the piston 35 can occur, provided a suitable pressure differential exists across the upper and lower surfaces of piston 35.
The lower annular fluid pressure chamber 33b is in fluid communication with a plurality of peripherally spaced vertical fluid passages 22h which are formed in the inner body sleeve 22. These passages in turn communicate with an annular chamber 36 defined between a radial wall 22j formed on the inner body member 22 and the extreme upper end face 21c of the nipple 21. The lower annular pressure chamber 33b is therefore in fluid communication with the restricted bore 21b containing the Primacord P and hence is in fluid communication with the interior of the perforating gun housing 1 and thus will receive the high pressure gases generated within such housing as a result of the discharge of the shaped charges contained in the perforating gun housing.
As shown in FIG. 1A, the outer surface 35d of the annular piston 35 is in abutting relationship with the interior surfaces of the latching lug elements 30 and hence maintains a coupling or connection between the upper tubular assembly 11 and the lower tubular assembly 20 so long as the piston 35 remains in the illustrated position. Whenever a fluid pressure differential is built up across the top and bottom ends of the annular piston 35, and in particular, a higher fluid pressure is exerted on the bottom end of the annular piston 35 than on the top end, the piston 35 will be shifted upwardly, compressing the ambient pressure compressible gas contained in the upper enclosed annular fluid pressure chamber 33a. Such upward movement of piston 35 will bring an annular recess 35e on its periphery into alignment with the peripherally spaced latching elements 30, thus permitting such latching elements to be cammed inwardly by cooperating inclined surfaces 30a and 13a to release the latching engagement between the cooperating latching surfaces 30a and 13a, as illustrated in FIG. 2. Since the latching lugs 30 constitute the only physical connection between the upper tubular assembly 11 and the lower tubular assembly 20, the coupling 10 is effectively disconnected and the perforating gun may be axially separated from the tubular work string as illustrated in FIG. 3.
Latching lugs 30 are mounted in peripherally spaced slots 32f provided in outer body sleeve 32. In order to prevent the latching lugs 30 from falling into the well bore when released from the latching sleeve 13, a locking lug holding sleeve 38 is provided which is secured to the upper external portion of the internal body sleeve 22 by a plurality of radially disposed bolts 38a. Retaining sleeve 38 extends downwardly and overlies a notch 30b provided in each of the locking elements 30, thus preventing such locking elements from falling out of the assemblage when the tubular assemblages are separated, as illustrated in FIG. 3. Additionally, in order to prevent the premature movement of the piston 35, a plurality of shear pins 35d are mounted between the piston 35 and the upper body sleeve 32 to maintain the piston in the coupled position illustrated in FIG. 1 until sufficient fluid pressure force is exerted on the piston to shear the shear pins 35d and permit piston 35 to move upwardly.
In the event that the perforating gun does not generate sufficient fluid pressure force to cause the piston 35 to shear the shear pins 35d and move upwardly to release the radially shiftable locking lugs 30, it will be apparent that the lower annular fluid pressure chamber 33b will be promptly filled with well fluids resulting from flow through the perforations and into the interior of the perforating gun housing. Such well fluid pressures are normally substantially in excess of the surface ambient pressure existing in the upper annular fluid pressure chamber 33a, and hence will exert an upward force on the piston 35 to effect the shearing of the shear pins 35d and the movement of piston 35 to the latching lug releasing position illustrated in FIG. 2.
Accordingly, if firing of any portion of the charges contained in the perforating gun is accomplished, it will be readily apparent to those skilled in the art that the annular piston 35 will be actuated to release the radially shiftable locking lugs and effect the disconnection of the upper tubular assembly 11 and the lower tubular assembly 20, thus disconnecting the perforating gun from the tubular tool string as illustrated in FIG. 3. Such action is automatic and requires no time or effort on the part of the operator, thus permitting the completion of the well to be accomplished more rapidly.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | A method and apparatus for releasing a subterranean well perforating gun from a tubular string after firing of the subterranean well perforating gun. The apparatus comprises two telescopically inter-related tubular assemblies which are interconnected for axial co-movement solely by a plurality of radially shiftable latching elements. Such latching elements are normally maintained in a locked position by an annular piston. One end of the annular piston is exposed to gas at surface ambient pressure and the other end is exposed to the gas pressure generated in the perforating gun by its discharge and subsequently to the well fluid pressures produced by flow of well fluids through the perforations. The movement of the annular piston under such fluid pressure forces permits the locking elements to be cammed radially inwardly and release the connection between the tubular tool string and the perforating gun without any action on the part of the operator. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an oil pan for an internal combustion engine. Specifically, the present invention relates to an oil pan which is easily manufactured and which exhibits low noise emmission characteristics.
2. Description of the Prior Art
Various designs have been proposed for oil pans of internal combustion engines. Generally, the oil pan is positioned at a lower side of a cylinder block of an internal combustion engine and is of a comparatively deep relief for receiving accumulated lubricating oil from the engine block which is pumped throughout the engine under pressure by an oil pump. Such oil pans are generally made by pressing of a thin metal plate. Consequently, when engine vibration is applied thereto a relatively loud noise may be caused by the vibration of the oil pan.
To address this problem, Japanese Utility Model application 54-25941 disclose an oil pan for an internal combustion engine having a two-ply construction. The disclosed oil pan includes an outer layer and an inner layer with a given gap therebetween, the inner layer being formed with a plurality of holes therethrough. Lubricating oil is allowed to flow between the inner and outer layers and the holes provided in the inner layer are effective to reduce vibration applied to the oil pan.
However, according to the above construction, since the inner layer must be formed with the plurality of holes and must be fixedly supported by the outer layer, manufacturing of the oil pan becomes complex and costs are raised significantly due to the number of parts and required processing. Further, since the oil flows between the outer and inner layer through the plurality of holes of the inner layer, oil flow caused by oil pan vibration is impeded and energy loss may be incurred. Also, the limits in constructing the oil pan limits the gap between the inner and outer layers, etc., and it is thus difficult to obtain sufficient noise reduction.
Thus it has been required to provide an oil pan for an internal combustion engine in which sufficient vibration reduction and noise emmission reduction can be obtained with simple, low cost construction.
SUMMARY OF THE INVENTION
It is therefore a principal object of the present invention to overcome the drawbacks of the prior art.
It is a further object of the present invention to provide an oil pan for an internal combustion engine in which sufficient vibration reduction and noise emmission reduction can be obtained with simple, low cost construction.
In order to accomplish the aforementioned and other objects, an oil pan for an internal combustion engine is provided, comprising an outer pan attached to a lower side of the engine block, and an inner pan disposed within the outer pan so as to float freely in a fluid contained in the outer pan.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a cross-sectional view of a first embodiment of an oil pan according to the invention;
FIG. 2 is a lateral view of the oil pan of the first embodiment, taken along line II--II of FIG. 1;
FIG. 3 is an exploded perspective view of the oil pan of the first embodiment;
FIG. 4 is a graph comparing noise emmission levels of the oil pan of the invention and of a conventional oil pan;
FIG. 5 is a perpsective view of a major portion of an oil pan according to a second preferred embodiment of the invention;
FIG. 6 is a perspective view of an oil pan according to a third embodiment of the invention;
FIG. 7 is a perspective view of an oil pan according to a fourth embodiment of the invention;
FIG. 8 is a perspective view of an oil pan according to a fifth embodiment of the invention;
FIG. 9 is a cross-sectional lateral view of a bead portion of an inner pan according to a sixth preferred embodiment;
FIG. 10 shows a reinforced portion of an oil pan according to a seventh embodiment of the invention;
FIG. 11 is a perspective view of an inner pan according to an eighth embodiment of the invention;
FIG. 12 is a perspective view of an inner pan according to an ninth embodiment of the invention;
FIG. 13 is a perspective view of an inner pan according to an tenth embodiment of the invention; and
FIG. 14 is a lateral cross-sectional view showing the disposition of resilient members between the baffle plate and the inner pan according to an eleventh embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIGS. 1-3, a first preferred embodiment of an oil pan 1 according to the invention will be described hereinbelow in detail.
As may be seen in FIG. 1, the oil pan 1 comprises a deep portion 1a and a shallow portion 1b respectively having flat bottoms. At an upper peripheral portion of the oil pan 1, a flange 2 is formed at which the oil pan 1 is attached to the lower side of an engine cylinder block (not shown).
Inside the oil pan 1, an inner pan 3 formed of pressed steel plate is accommodated. Like the oil pan 1, the inner pan 3 is comprised of a deep portion 3a and a shallow portion 3b such that the shape of the inner pan 3 follows the contours of the inner surface of the oil pan 1. As seen in FIGS. 1 and 2 the inner pan 3 sits in the oil pan 1 such that a space 4 is provided between the inner pan 3 and the oil pan 1. Referring to FIG. 2, the space 4 extends to both bottom and side portions of the oil pan 1 and the inner pan 3. When oil accumulates in the oil pan 1, some oil will be held in the inner pan 3 while some of the oil flows freely in the space 4. It will be noted that the positioning of the inner pan 8 relative the oil pan 1 is not fixedly established.
It will further be noted that a bottom contour of said oil pan may include convex portions for defining said space 4 between said oil pan 1 and said inner pan 3.
Referring to FIGS. 1--3 a baffle plate 5 is fixed at an upper side of the oil pan 1, in a position over the inner pan 3, so as to prevent splashing of oil accumulated in the oil pan 1. The baffle plate also serves to limit movement of the inner pan 8. The baffle plate is formed with a plurality of elongate openings 8 to allow oil to flow downward from the engine interior to the oil pan 1. According to the present embodiment, the baffle plate includes openings 8A and 8B which are parallel to and proximate edge portions of the baffle plate 5 such that, when oil runs down from engine interior components, such as a conrod 6 or crankshaft 7 (FIG. 1), oil is introduced into the space 4 between the inner pan 3 and the oil pan 1.
As best seen in FIG. 2, a drain cock 9 is provided on a front side portion of the deep portion 1a of the oil pan 1. Corresponding to the positioning of the drain cock 9, a drain opening 10 is provided in the inner pan 3 to allow oil to be drained completely from both the inner pan 3 and the oil pan 1. A suction pipe 12 having a strainer 11 attached to an end thereof extends downwardly into the deep portion 3a of the inner pan 3. The suction pipe 12 is associated with an oil pump (not shown) of the engine (not shown) for supplying lubricating oil from the oil pan 1 to the engine components. The suction pipe introduced to the inner pan 3 through a cut-out 13 provided in the baffle plate 5.
When vibration is applied to the oil structure from the engine block (not shown), the dimension of the space 4 between the oil pan 1 and the inner pan 3 varies slightly causing oil in the space to move. Thus, vibrational energy transmitted to the oil pan 1 is absorbed by the motion of oil in the space 4. According to this, a wide range of vibration transmission to the oil pan 1 can be controlled. Further to this, owing to the inertia of the inner pan 3 disposed in the oil pan 1, when oil pressure is high, even greater energy reduction may be obtained. Referring to FIG. 4 it may be seen that, in noise level tests for the present invention as compared with a conventional oil pan, the noise level of resonant vibrations resulting from vibration applied to the oil pan 1 of the invention is significantly lower than that of the conventional oil pan over a substantially wide frequency range. Further, due to the viscosity of oil contained in the space 4, even if a very large vibration is applied to the oil pan structure, the inner pan 3 cannot be displaced in a manner so as to strike the oil pan 1 or the baffle plate 5 with damaging force.
Further, according to the above described construction, since the inner pan 3 need not be fixed in position relative the oil pan 1, manufacturing is simplified and assembly steps such as welding or the like, are not necessary and costs may be reduced. In addition, control of the volume of oil in the space 4 is extremely simple and the inertia of the inner pan 3 serves to keep the thickness of the space 4 to a minimum. Thus, be determining a weight of the inner pan 3 to be high, vibration suppression characteristics also become high.
Also, since the opening 10 of the inner pan 3 is provided in a location corresponding to the drain cock 9 of the oil pan 1, draining of oil from the engine for performing oil changes or maintenance may be accomplished smoothly.
Referring now to FIG. 5, a second preferred embodiment of an inner pan structure according to the invention will be described hereinbelow in detail.
As may be seen in the drawing, the inner pan 3 of the second embodiment includes a deep portion 3a and a shallow portion 3b, similar to the previous embodiment. However, according to the present embodiment, the side walls of the deep portion 3a are relatively lower than the side walls of the oil pan 1 and the shallow portion 3b has no side walls. According to this construction, costs are reduced and assembly further simplified while all the same advantages taught in the previous embodiment may be obtained.
FIG. 6 shows a third embodiment of the invention. The inner pan 3 of the third embodiment is in a cup shape consisting of a deep portion 3a defined by four side walls and a bottom wall. According to this, the inner pan 3 is provided in the deep portion 1a of the oil pan 1. According to this, the same advantages as the previous embodiments are available and cost and weight may be further reduced.
Referring now to FIG. 7, a fourth embodiment of an inner pan 3 according to the invention is shown. According to this embodiment, the inner pan 3 comprises a U-shaped plate such that the bottom of the inner pan 3 is defined between front and rear walls 3c, 3c while no side walls are provided. The inner pan 3 may be formed of a metal plate via bending processing or the like. According to this construction, noise suppression is obtained and filling and draining of oil to and from the oil pan 1 is optimally facilitated. Also the simple structure reduces manufacturing costs and reduces radiant heat of oil in the inner pan 3. Resilient members 14, 14 are provided at both sides of the inner pan 3 such that when the inner pan 3 is subjected to side to side (arrow direction if FIG. 7) movement, noise is not produced by contact between the sides of the inner pan 3 and the inner walls of the oil pan 1.
In FIG. 8, a fifth embodiment of the inner pan 3 of the invention is shown. According to this embodiment, the inner pan 3 consists only of a rectangular plate disposed in the bottom of the deep portion 1a of the oil pan 1. The resilient member 14 is provided completely around the peripheral edge of the inner pan 3 to prevent noise resulting from contact between the inner pan 3 and the oil pan 1.
According to the above described embodiments, the lower side of the inner pan 3 is of a flat construction. Referring to the sixth embodiment shown in FIG. 9, it may be seen that, alternatively, projecting portions, or beads 15 may be formed on the lower side of the inner pan 3 for maintaining a certain minimum width of the space 4 for allowing oil to flow therein even when oil levels are low, or to further facilitate draining of oil from the oil pan 1.
FIG. 10 shows a seventh embodiment according to the invention. According to this, reinforcing members 16 are provided between the oil pan 1 and the inner pan 3 and thus a relatively wide bead 17 is formed for accomodating the reinforcing portions. The space between the inner pan 3 and the oil pan 1 not occupied by the reinforcing members 16 or the bead 17 thus act as the space 4 for allowing oil to flow between the inner pan 3 and the oil pan 1, in other respects the present embodiment functions similarly to the above-described sixth embodiment.
Hereinbelow, with reference to FIGS. 11-14, additional embodiments of the invention, relating to the side wall structure of the inner pan 3 will be described in detail.
Referring now to FIG. 11, an eighth embodiment of an inner pan 3 according to the invention is shown. According to this embodiment, the inner pan 3 includes a deep portion 8a, and a shallow portion 3b similar to the first embodiment. Side walls 21, 21, 21 are provided for the deep portion 3a and side walls 22, 22, 22 are provided for the shallow portion 3b. Since no corner portions are formed between the side walls 21, 21 or 22, 22, the inner pan 3 may be pressed from a flat piece of metal plate and manufacturing is simplified. An additional feature of the present embodiment is a bead 23 that is formed around a circumferential section of each of the side walls 21, 21 . . . 22, 22 . . . In addition, a bead 23 is formed laterally along a section 24 of the bottom of the inner pan 3 which connects the deep portion 3a with the shallow portion 3b. According to provision of the bead 23, and the lack of corner portions, in an instance, for example, when the oil pan 1 collides with a curbstone or other obstacle, when the inner pan 3 is knocked up against the lower side of the baffle plate, the relatively fragile bead 23 will allow the associated wall section (21, 22, 24) to deform such that strong impact is not transmitted to the baffle plate 5. In addition, according to this construction, under no circumstances will the baffle plate or the inner pan interfere with operation of the con rods 6 or other engine components.
FIG. 12 shows a ninth embodiment of the invention, according to this embodiment, the inner pan 3 is of the same construction as in the above-described eighth embodiment with the additional feature of corner portions 24 being attached by welding at the four extreme corners of the inner pan 3. According to this, additional rigidity and weight is obtained, though the wall portions remain deformable in case of impact.
Referring now to FIG. 13, an inner pan 3 according to the tenth embodiment of the invention is shown. The inner pan 3 of the present embodiment is similar in structure to that of the first embodiment shown in FIG. 3. However, according to the present embodiment, at corner portions of the inner pan 3 as well as at the boundaries of the deep portion 3a and the shallow portion 3b, vertical slits 26 are formed. In addition, horizontal slits 25 are formed at an upper side of each side wall portion between, but not meeting, the vertical slits 26. According to this construction, similar advantages as those described in connection with the eighth and ninth embodiments may be obtained.
Finally, referring to FIG. 14, an eleventh embodiment of an inner pan according to the invention is shown. According to this embodiment, a resilient member 27 is provided at an upper peripheral edge of the inner pan 3 such that the resilient member 27 is interposed between the baffle plate 5 and the inner pan 3. In the figure, an inner pan 3 including the circumferential bead 23 is shown, though the present stucture may be implemented with any of the above-described embodiments. According to this, noise resulting from contact between the upper side of the inner pan 3 and the lower side of the baffle plate 5 is prevented and.
Thus, according to the invention, noise emission caused by engine vibrations applied to an engine oil pan may be significantly reduced at low cost and with simple structure. These advantages may be reliably obtained according to any of the embodiments described herein.
While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modification to the shown embodiments which can be embodied without departing from the principle of the invention as set forth in the appended claims. | An oil pan for an internal combustion engine includes an outer shell made of metal plate an includes on at least a bottom surface of the outer shell and inner pan separate from the outer shell. The bottom of the oil pan includes a deep portion and a shallow portion and a baffle plate is disposed over the inner pan. The inner pan settles on the inner surface of the outer shell amidst the oil contained in the oil pan, thereby forming a layer of oil between the outer shell and the inner pan. Thus, oil flow is not impeded and vibration of the oil pan is significantly reduced. In addition, wall portions of the inner pan are made to be deformable so as not to cause strong impact to other portions of the oil pan structure or to engine components. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 61/719,765, entitled “Production String Activated Wellbore Sealing Apparatus and Method for Sealing a Wellbore Using a Production String”, filed Oct. 29, 2012, and hereby incorporates the same provisional application by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure is related to the field of wellbore sealing apparatuses, in particular, wellbore sealing apparatuses that can be connected in-line with a production string.
BACKGROUND
[0003] Various wellbore sealing apparatuses are used in producing oil wells to provide a seal between the outside of tubing inserted into the wellbore and the inside of the casing, liner or wall of the wellbore. Providing a seal between the outside of the tubing and the inside of the wellbore is necessary in order to isolate different zones within the wellbore to facilitate various tasks. The wellbore sealing apparatuses used for this purpose are commonly known as packers. Production packers remain in wells while they are producing oil while service packers are used with work strings and are temporarily in wells for various well maintenance tasks, including cement squeezing, acidizing, fracturing and well testing.
[0004] Many packers are not removable once they are put in place. A packer of this kind must be milled out of the wellbore when the user no longer wishes to use them. This is a time-consuming and expensive process, and the packer is destroyed as a result.
[0005] More complex packers that use mechanical and hydraulic systems to engage and disengage can be removed more easily and reused. However, these packers cannot be operated using a production string. Instead, they require the use of additional equipment, specifically service rigs hooked up to a work string. To get the work string into the wellbore the production string must first be removed. When the work is completed, the work string is removed and the production string placed back in the well. This complicated process is time consuming and costly.
[0006] Work strings can be used to deposit fluids into a wellbore when performing various maintenance tasks. Sand and other debris can collect at the sites of the perforations in a formation during production, which slows the rate of oil production and can cause wear on the production pumps. When the rate of production slows to a particular level, the well is cleaned. Typically this type of maintenance is performed using a work string which allows fluid to be pushed into the wellbore to clean the sand and other debris away from the perforations. Along with being forced into the formation through the perforation, thereby pushing the sand and debris from the openings, the fluid fills the space between the casing and the work string tubing. The amount of fluid required is typically greater than can be transported in standard tank trucks, therefore more than one trip has to be made. The majority of the fluid must be removed before the work string is removed and the production string put back in place. Whether or not sufficient sand and debris has been removed during the maintenance process can only be determined after the production string is replaced in the wellbore. Therefore, only one cleaning cycle can occur every day.
[0007] It is therefore desirable to provide a wellbore sealing apparatus that overcomes the shortcomings of the prior art.
SUMMARY
[0008] A wellbore sealing apparatus which is positioned along production string tubing is provided. This sealing apparatus combines an outer sleeve, an inner mandrel telescopically received within the outer sleeve, a sealing element that expands when compressed, an actuator interaction assembly and top and bottom seal pushers. The sealing element is disposed on the inner mandrel with the top seal pusher uphole and the bottom seal pusher downhole. The actuator interaction assembly has a means to couple to an actuator and is positioned downhole, but in-line with the inner mandrel. The inner mandrel includes a pin or peg extending outwardly and interacts with a slot in the outer sleeve to limit rotation of the inner mandrel. When the actuator couples to the actuator interaction assembly, the inner mandrel is pushed upwardly to be telescopically received into the outer sleeve. This movement also causes the top and bottom seal pushers to be brought closer together and exert opposing pressure on the sealing element such that the sealing element compresses and expands to form a seal with the wellbore casing.
[0009] In one aspect of the invention, the actuator interaction assembly contains one or more slots in the assembly body that allow an actuator having one or more connectors to couple to the actuator interaction assembly by sliding the one or more connectors into the one or more slots. Alternatively the slots may be on the actuator and the connectors may be on the assembly body. In one aspect of the invention the slots are J-shaped.
[0010] In a further aspect of the invention, the actuator interaction assembly may also include at least one gap between the first and section sections of the assembly body to allow connectors in the actuator to pass through the actuation interaction assembly. Alternatively, there may be at least one by-pass gap extending longitudinally along the length of the actuator to allow it to pass by connectors in the actuator interaction assembly.
[0011] The actuator interaction assembly can further comprise a top assembly sleeve, an assembly body having first and second sections, and a bottom assembly sleeve. The top and bottom assembly sleeves can comprise an assembly body enclosure for housing the first and second sections of the assembly body. The first and second sections of the assembly body can also each include a slot and/or a connector. The first and second sections of the assembly body can be oriented such that slots or connectors, or a combination thereof, can connect or couple to the actuator.
[0012] In one aspect of the invention the length and location of the peg slot on the outer sleeve and the location of the at least one peg on the inner mandrel can be such that the inner mandrel is unable to extend out of the outer sleeve to a position where substances in the well could enter the central conduit running through the inside of the wellbore sealing apparatus through the at least one peg slot.
[0013] In some embodiments, the wellbore sealing apparatus can further comprise a seal piston. The seal piston can attach to the top of the inner mandrel and the seal piston and the inner mandrel can be inserted into the bottom of the outer sleeve. The inner mandrel can slide back and forth within the outer sleeve while the seal piston acts to prevent substances from leaking into a central conduit running through the inside of the wellbore sealing apparatus by forming a seal between the inside of the outer sleeve and the outside of the seal piston. In some embodiments, the seal between the inside of the outer sleeve and the outside of the seal piston can be airtight.
[0014] The seal piston can further comprise a piston body, a seal and a cap. The piston body can comprise a threaded cap insert, a seal holder and a first collar. The cap can comprise a threaded midsection. The seal can be put over the piston body around the seal holder and the threaded midsection of the cap can be threaded onto the threaded cap insert of the piston body to secure the seal in place.
[0015] In another aspect of the invention the sealing apparatus also includes a biasing means, disposed on the inner mandrel between the outer sleeve and the top seal pusher. The biasing means can assist in disengaging the wellbore sealing apparatus by pushing the inner mandrel out of the outer sleeve when the actuator stops pushing the inner mandrel into the outer sleeve.
[0016] The wellbore sealing apparatus can further comprise a spring pusher connected to the bottom end of the outer sleeve. The main body of the spring pusher can comprise a spring slot, with the spring slot oriented such the top end of the spring fits into the spring slot.
[0017] An actuator positioned on a production rod string is also provided. The actuator has a coupling or connecting means that allows it to couple to an actuator interaction assembly when the production rod string is pulled upwardly. The coupling or connecting means can be connectors or slots, or a combination thereof. The actuator may also comprise a by-pass gap that allows it to pass by the connectors positioned on the actuator interaction assembly.
[0018] A method for sealing a wellbore using a production string is also provided. A sealing apparatus having a sealing element and an actuator interaction assembly is positioned along the production string tubing and an actuator positioned along the production rod string. The actuator is coupled or connected to the actuator interaction assembly of the sealing apparatus, and then the sealing element is compressed and expands to form a seal between the sealing apparatus and the wellbore casing.
[0019] The actuator interaction assembly may include slots and/or connectors which interact with corresponding connectors and/or slots on the actuator. This interaction allows the actuator to couple or connect to the sealing apparatus.
[0020] In one aspect of the invention, the slots are J-shaped and are oriented in such a way that when placed adjacent to one or more connectors, when the actuator is rotated and/or lifted the connectors slide into the slots.
[0021] In one aspect of the invention the method further comprises disengaging the sealing apparatus by lowering and uncoupling the actuator from the sealing assembly. The production string rod can push down on the actuator and the actuator interaction assembly, thereby pulling the inner mandrel out of the outer sleeve and contracting the sealing element to disengage the wellbore sealing apparatus. The actuator can be removed from the actuator interaction assembly by positioning and rotating the actuator so that the connectors slide out of the slots.
[0022] Since the sealing apparatus is positioned along the production string tubing and the actuator is positioned along the production rod string, there is no need to use a work string or to remove the production string from the wellbore when is it desirable to seal the well to perform maintenance tasks. It also means that it may be possible to provide multiple stimulations per day. In addition, the use of a seating element means that less volume of fluid may be required to perform any necessary treatment and may also improve the degree of success of the treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a partial cross-section side view depicting one embodiment of a production string activated wellbore sealing apparatus.
[0024] FIG. 2 is a partial cross-section side view depicting an embodiment of a top connector of the production string activated wellbore sealing apparatus of FIG. 1 .
[0025] FIG. 3 is a cross-section side view depicting an embodiment of an outer sleeve of the production string activated wellbore sealing apparatus of FIG. 1 .
[0026] FIG. 4 is a partial cross-section side view depicting an embodiment of a spring pusher of the production string activated wellbore sealing apparatus of FIG. 1 .
[0027] FIG. 5 is a partial cross-section side view depicting components of an embodiment of a seal piston of the production string activated wellbore sealing apparatus of FIG. 1 .
[0028] FIG. 6 is a partial cross-section side view depicting an embodiment of an inner mandrel of the production string activated wellbore sealing apparatus of FIG. 1 .
[0029] FIG. 7 is a side view depicting an embodiment of a top seal pusher of the production string activated wellbore sealing apparatus of FIG. 1 .
[0030] FIG. 8A is a side view depicting an embodiment of a bottom seal pusher of the production string activated wellbore sealing apparatus of FIG. 1 .
[0031] FIG. 8B is a top view depicting the bottom seal pusher of FIG. 8A .
[0032] FIG. 9A is a side view depicting an embodiment of a peg of the production string activated wellbore sealing apparatus of FIG. 1 .
[0033] FIG. 9B is a top view depicting the peg of FIG. 9A .
[0034] FIG. 10 is a cross-section side view depicting an embodiment of a top assembly sleeve of the production string activated wellbore sealing apparatus of FIG. 1 .
[0035] FIG. 11A is a top elevation view depicting an embodiment of the assembly body of the production string activated wellbore sealing apparatus of FIG. 1 .
[0036] FIG. 11B is a side elevation view depicting the assembly body of FIG. 11A .
[0037] FIG. 12 is a cross-section side view depicting an embodiment of a bottom assembly sleeve of the production string activated wellbore sealing apparatus of FIG. 1 .
[0038] FIG. 13A is a partial cross-section side view depicting the production string activated wellbore sealing apparatus of FIG. 1 disengaged within a well along with an actuator attached to the end of a production rod string.
[0039] FIG. 13B is a partial cross-section side view depicting the production string activated wellbore sealing apparatus of FIG. 1 engaged within a well along using an actuator attached to the end of a production rod string.
[0040] FIG. 14A is a side view depicting an embodiment of the actuator of FIGS. 13A and 13B .
[0041] FIG. 14B is a top view depicting the actuator of FIG. 14A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] A production string is comprised of two main components, the production string tubing and the production rod string. The bottom end of the production string is open to allow for fluid to enter into the inner portion of the tubing. The fluid is pulled into the tubing and pushed upwardly by a pump located at the bottom end of the production string. The pump is comprised of a rotor and stator. The rotor is attached to the end of the production rod string, which travels the inner length of the tubing. When it is desirable to deposit fluid into the formation, the production rod string is pulled upward and the rotor is disengaged from the stator so that the fluid can move past the rotor and out the openings at the bottom end of the production string.
[0043] The production string activated wellbore sealing apparatus is positioned along the production string tubing, and the actuator is positioned along the production rod string.
[0044] Referring to FIG. 1 , a preferred embodiment of a production string activated wellbore sealing apparatus is shown. In this embodiment the production string activated wellbore sealing apparatus 10 comprises top connector 20 , outer sleeve 30 , spring pusher 40 , seal piston 100 , inner mandrel 90 , spring 50 , top seal pusher 60 , sealing element 70 , bottom seal pusher 80 and actuator interaction assembly 140 .
[0045] Referring to FIG. 2 , an embodiment of top connector 20 is shown. The top connector 20 can comprise main body 21 , threaded production string tubing insert 27 , collar 22 , threaded outer sleeve insert 23 , central conduit 25 and widened opening 26 .
[0046] Referring to FIG. 3 , an embodiment of outer sleeve 30 is shown. The outer sleeve 30 can comprise main body 31 , peg slot 32 , first inner threaded opening 36 , second inner threaded opening 37 and central conduit 35 .
[0047] Referring to FIG. 4 , in some embodiments, a spring pusher 40 can be used. The spring pusher 40 can comprise main body 41 , spring slot 42 , threaded outer sleeve insert 43 and mandrel passage 45 .
[0048] Referring to FIG. 5 , an embodiment of the seal piston 100 is shown. The seal piston 100 comprises cap 101 and piston 110 . Cap 101 can comprise inner threaded midsection 102 , widened opening 103 , central conduit 105 , seal holder opening 106 , seal end 107 and chamfered end 108 . Piston 110 can comprise threaded cap insert 111 , seal holder 112 , first collar 113 , central conduit 115 , midsection 116 , second collar 117 , threaded mandrel insert 118 and seal 120 . The seal 120 fits over the top of piston 110 at seal holder 112 . The inner threaded midsection 102 of cap 101 screws onto the threaded cap insert 111 of piston 110 so that seal holder opening 106 of cap 101 fits around the seal holder 112 of piston 110 and the threaded insert 111 of piston 110 contacts the edge of the central conduit 105 of cap 101 such that the seal 120 can be held in place between the first collar 113 of piston 110 and the seal end 107 of cap 101 . The central conduit 115 of piston 110 and the central conduit 105 of cap 101 form one continuous passageway through the center of the seal piston 100 .
[0049] Referring to FIG. 6 , an embodiment of inner mandrel 90 is shown. The inner mandrel 90 comprises main body 91 , threaded peg passage 92 , collar 93 , central conduit 95 , threaded channel assembly insert 96 and inner threaded opening 97 .
[0050] Referring to FIG. 7 , an embodiment of top seal pusher 60 is shown. The top seal pusher 60 can comprise seal end 61 , chamfered end 62 , spring slot 63 and mandrel passage 65 .
[0051] Referring to FIGS. 8A and 8B , an embodiment of bottom seal pusher 80 is shown. The bottom seal pusher 80 can comprise seal end 81 , chamfered end 82 and mandrel passage 85 .
[0052] Referring to FIGS. 9A and 9B , an embodiment of peg 130 is shown. The peg 130 can comprise threaded section 131 , head 132 and wrench slot 133 .
[0053] Referring to FIGS. 1 , 10 , 11 A, 11 B and 12 , an embodiment of the actuator interaction assembly 140 is shown. The actuator interaction assembly comprises a top assembly sleeve 150 , an assembly body 158 , having a first section 160 and a second section 170 , and a bottom assembly sleeve 180 . The top assembly sleeve 150 can comprise inner mandrel end 151 , widened opening 152 , inner threaded opening 153 , assembly body enclosure 155 and chamfered end 156 . The first section of the assembly body 160 can comprise a first slot 161 having slot opening 162 , angled portion 163 , vertical portion 164 and slot end 165 . The second section of the assembly body 170 can comprise s second slot 171 having slot opening 172 , angled portion 173 , vertical portion 174 and slot end 175 . The bottom assembly sleeve 180 can comprise chamfered end 181 , enclosure section 182 , threaded end 183 and assembly body enclosure 185 .
[0054] The curvature of the assembly body 158 corresponds to the curvature of the inside of assembly body enclosures 155 and 185 of top assembly sleeve 150 and bottom assembly sleeve 180 . Chamfered end 156 of top assembly sleeve 150 can be welded to chamfered end 181 of bottom assembly sleeve 180 . The assembly body 158 can be welded to the walls of the cavity formed by assembly body enclosures 155 and 185 , and oriented such that the vertical portion 164 and the slot end 165 of the first slot 161 are aligned directly with the vertical portion 174 and the slot end 175 of the second slot 171 . The angled portion 163 and the slot opening 162 of first section of the assembly body 160 are oriented in a substantially opposite direction to the angled portion 173 and the slot opening 172 of second section of the assembly body 170 . The two gaps between the first and second sections of the assembly body 160 and 170 are oriented opposite one another at the midpoint between the vertical portions 164 and 174 and slot ends 165 and 175 . The central conduit 145 of the actuator interaction assembly 140 is formed by the space in the center of the top assembly sleeve 150 and bottom assembly sleeve 180 , terminating with bottom opening 190 .
[0055] The production string activated wellbore sealing apparatus is positioned within the length of a production string tubing, with the top connector 20 being attached to the production string tubing uphole of the apparatus and the bottom opening 190 being attached to the production string tubing downhole of the apparatus. The apparatus is hollow such that it has a passageway along its entire length that allows fluid communication between the uphole and downhole sections of production string tubing.
[0056] Referring to FIGS. 1 through 4 , the threaded outer sleeve insert 23 of top connector 23 can screw into first inner threaded opening 36 of outer sleeve 30 such that collar 22 of top connector 20 rests against the edge of main body 31 of outer sleeve 30 .
[0057] When a spring 50 is present, the threaded outer sleeve insert 43 of spring pusher 40 screws into the second inner threaded opening 37 of outer sleeve 30 and the main body 41 of spring pusher 40 can rest against the main body 31 of the outer sleeve 30 . The central conduit 25 of top collar 20 and central conduit 35 of outer sleeve 30 therefore form a continuous passageway. Although a spring 50 is shown in the figures, other biasing means may be placed between the sealing element 70 and the outer sleeve 30 . An apparatus without a spring or other biasing means is also contemplated.
[0058] Referring to FIGS. 1 , 5 and 6 , to form a continuous passageway, the threaded mandrel insert 118 of seal piston 100 can screw into the inner threaded opening 97 of the inner mandrel 90 such that the second collar 117 of seal piston 110 can rest against the main body 91 of inner mandrel 90 and central conduit 115 of piston 110 .
[0059] Referring to FIGS. 1 and 4 through 7 , the seal piston 100 and main body 91 of inner mandrel 90 can be inserted into outer sleeve 30 and spring pusher 40 through mandrel passage 45 of spring pusher 40 . The outer diameter of the main body 91 of the inner mandrel 90 and the inner diameters of mandrel passage 45 of the spring pusher 40 and the main body 31 of outer sleeve 30 can be such that the main body 91 of inner mandrel 90 is telescopically received by the mandrel passage 45 of spring pusher 40 and main body 31 of outer sleeve 30 . Seal 120 of seal piston 100 fits snugly against the inside of main body 31 of outer sleeve 30 so that a continuous passageway is formed by central conduit 95 of inner mandrel 90 , central conduit 115 of piston 110 of seal piston 100 , central conduit 105 of cap 101 of seal piston 100 , central conduit 35 of outer sleeve 30 . In addition, the central conduit 25 of top collar 20 is isolated from the narrow annulus formed between the outside of main body 91 of the inner mandrel 90 and the inside of main body 31 of the outer sleeve 30 . The position and dimensions of the seal piston 100 are such that any fluid or material that may be traveling through the hollow center of the apparatus 10 is not able to escape through the peg slot 32 of the outer sleeve 30 and enter into the space between the outer sleeve 32 and the well casing 2 .
[0060] It is desirable to keep the production string tubing, actuator interaction assembly 140 and inner mandrel 90 from rotating within the well casing 2 . The preferred method to minimize rotation is shown in FIGS. 1 , 3 , 4 , 6 , 9 A and 9 B. The threaded peg passage 92 of the inner mandrel 90 aligns with peg slot 32 of outer sleeve 30 so that outer threaded section 131 of peg 130 can screw into the threaded peg passage 92 of inner mandrel 90 . The outer diameter of the head 132 of peg 130 corresponds with the width of the peg slot 32 of the outer sleeve 30 such that there is minimal rotation by the inner mandrel 90 with respect to the outer sleeve 30 , while allowing the head 132 of peg 130 can slide back and forth within peg slot 32 of the outer sleeve 30 as the main body 91 of the inner mandrel 90 is retracted into and extended out of the mandrel passage 45 of spring pusher 40 . The length of the peg slot 32 and its location on outer sleeve 30 as well as the location of the threaded peg passage 92 of the inner mandrel 90 can be such that the seal 120 of seal piston 100 will always remain completely above the peg slot 32 so that debris cannot enter the central conduit 35 of outer sleeve 30 through peg slot 32 . Limiting the rotation of the inner mandrel 90 also limits the rotation of the actuator interaction assembly 140 and the downhole production string tubing. While the figures show the use of a circular peg and an elongated peg slot, it is contemplated that the peg and peg slot may have an alternate shape, for example square or tapered, and an L-shape or a T-shape, respectively.
[0061] Referring to FIGS. 1 , 4 and 6 through 8 B, the bottom seal pusher 80 , sealing element 70 and top seal pusher 60 are disposed on the main body 91 of inner mandrel 90 . The inner diameters of the mandrel passage 85 of bottom seal pusher 80 , sealing element 70 and mandrel passage 65 of top seal pusher 60 may all correspond to the outer diameter of main body 91 of inner mandrel 90 . The top seal pusher 60 is positioned uphole of the sealing element 70 and downhole of the outer sleeve 30 , while the bottom seal pusher 80 is positioned downhole of the sealing element 70 and uphole of the actuator interaction assembly 140 . When in the sealing or engaged position, described below, the top seal pusher 60 produces a downward force on the sealing element 70 and the bottom seal pusher 80 produces an upwards force on the sealing element 70 , thereby causing the sealing element 70 to be compressed. The top seal pusher may be contiguous with the outer sleeve 30 , the sealing element 70 , both or neither when the sealing apparatus is in the disengaged position. Similarly, the bottom seal pusher may be contiguous with the actuator interaction assembly 140 , the sealing element 70 , both or neither when the sealing apparatus is in the disengaged position.
[0062] In the preferred embodiment, chamfered end 82 of the bottom seal pusher 80 rests against collar 93 of the inner mandrel 90 . The sealing element 70 is positioned between seal end 81 of bottom seal pusher 80 and seal end 61 of top seal pusher 60 .
[0063] When present, the spring 50 is disposed on the main body 91 of the inner mandrel 90 and may have an inner diameter that corresponds to the outer diameter of the main body 91 of the inner mandrel 90 . The bottom of the spring 50 can rest in the spring slot 63 of the top seal pusher 60 and top of spring 50 can rest in spring slot 42 of spring pusher 40 .
[0064] Referring to FIGS. 1 , 6 and 10 , the threaded assembly insert 96 of inner mandrel 90 can screw into the inner threaded opening 153 of the top assembly sleeve 150 of actuator interaction assembly 140 such that collar 93 of inner mandrel 90 can rest within widened opening 152 of top assembly sleeve 150 .
[0065] The wellbore sealing apparatus 10 interacts with an actuator 200 . The actuator 200 is positioned along the production rod string, which runs longitudinally through the internal passageway of the production string tubing.
[0066] In one embodiment, as shown in FIGS. 14A and 14B , the actuator 200 has connectors 202 which interact with the slots in the assembly body 158 . Alternatively, the slots can be located in the actuator 200 and the connectors can be located in the assembly body 158 .
[0067] In use, the wellbore sealing apparatus 10 is placed at a certain point along the production string and lowered into the well 1 . Similarly, the actuator 200 is placed at a certain point along the production rod string 3 and lowered into the well 1 . The sealing apparatus is engaged or disengaged using actuator 200 , through the movement of the production rod string 3 .
[0068] When the well is producing oil the sealing apparatus 10 is in its disengaged state, meaning the sealing element 70 is relaxed and not contacting the well casing 2 . To move the apparatus into its sealed or engaged position, the production rod string 3 is pulled upwardly so that the actuator 200 couples to the actuator interaction assembly. This coupling results in the upward movement of the inner mandrel 90 telescopically into the outer sleeve 30 , thereby causing the top seal pusher 60 and bottom seal pusher 80 to exert opposing forces on the sealing element 70 . This pressure results in the sealing element 70 compressing vertically and extending horizontally thereby creating a seal with the well casing 2 .
[0069] In the preferred embodiment the coupling of the actuator 200 and the actuator interaction assembly 140 occurs as a result of the alignment of the slots and connectors on the assembly body 158 and actuator 200 , respectively. In an alternate embodiment, the slots may be found on the actuator 200 and the connectors on the assembly body 158 . While the figures show the preferred use of round connectors and J-shaped slots, it is contemplated that other shapes of connectors and slots can be used to couple the actuator 200 and the actuator interaction assembly 140 .
[0070] In order to engage the apparatus of the preferred embodiment, the connectors 202 on the actuator 200 should first align vertically with the first and second slot openings 162 and 172 of the assembly body 158 . Next, the production rod string 3 is rotated such that connectors 202 enter slots 161 and 171 . The production rod string continues to be rotated and raised until connectors 202 contact slot ends 165 and 175 . Once this coupling has occurred, the production rod string 3 can pull up on actuator 200 and thus actuator interaction assembly 140 , causing the top and bottom seal pushers to move towards each other and exert opposing forces on the sealing element 7 . These opposing forces compress the sealing element vertically, while expanding it horizontally. When a spring 50 , or other biasing means, is present, it can assist in the compressing of the sealing element 70 by placing additional force on the top or bottom seal pushers or both. At the same time, the inner mandrel 90 and seal piston 100 to slide up into the outer sleeve 30 .
[0071] The apparatus is fully engaged when sealing element 70 forms an airtight seal against well casing 2 of well 1 , isolating the upper well section 4 from the lower well section 5 .
[0072] With the lower section of the well being sealed off from the upper section of the well, fluid or other material may be injected into the well.
[0073] After the maintenance is completed, the sealing apparatus can be disengaged using the production rod string 3 . The actuator 200 is lowered and allows the force of gravity to act on the actuator interaction assembly 140 and inner mandrel 90 . The pressure on the sealing element 70 from the top and bottom seal pushers is relaxed, which allows sealing element 70 to expand vertically and retract horizontally, removing the seal between sealing element 70 and well casing 2 of well 1 . When present, the force of the spring 50 , or other biasing means, can also assist in sliding the inner mandrel 90 and seal piston 100 out of outer sleeve 30 .
[0074] Once the sealing apparatus is disengaged the well can quickly begin producing again. If the maintenance process did not adequately fix the production problem, the sealing apparatus can be re-engaged and subsequent maintenance can begin. Therefore, multiple stimulation of the well may occur in one day.
[0075] In the preferred embodiment, the production rod string 3 can raise and lower the actuator 200 past the actuator interaction assembly 140 by rotating the actuator 200 so that connectors 200 are oriented to pass through the gaps between first assembly body 160 and second assembly body 170 . This allows the rotor and/or actuator 200 to be removed and serviced without have to remove the production string tubing. Alternatively, where the connectors are on the assembly body, the gaps are located in the actuator.
[0076] In some embodiments there is a widened opening 26 of top connector 20 to prevent attachments on the end of production rod string 3 from getting caught on the threaded outer sleeve insert 23 of the top connector 20 as the production rod string 3 is being raised. Similarly, the widened opening 103 of cap 101 of seal piston 100 can prevent attachments on the end of production rod string 3 from getting caught on the cap 101 of seal piston 100 as production rod string 3 is being lowered.
[0077] Although a few embodiments have been shown and described, it wilt be appreciated by those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent or functionality. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow. | A wellbore sealing apparatus positioned along production string tubing is provided to allow for sealing of a wellbore without needing to use a work string. The sealing apparatus includes an outer sleeve, an inner mandrel telescopically received within the outer sleeve, a sealing element positioned on the inner mandrel, an actuator interaction assembly and top and bottom seal pushers. An actuator positioned along the production rod string is also provided. The wellbore sealing apparatus has a sealed or engaged position and a disengaged position. To seal the wellbore, the actuator is pulled upwardly via the production rod string and couples to the actuator interaction assembly of the sealing apparatus. The continued upward movement of the actuator results in the inner mandrel moving further into the outer sleeve and the top and bottom pushers exerting opposing forces on the sealing element. The sealing element compresses and expands to seal the wellbore. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to an electric conference system and a control method thereof and, more particularly, to an electric conference system using a large-screen display.
BACKGROUND OF THE INVENTION
[0002] An electric conference system using a large-screen display has been proposed, in which a terminal and a host computer (PC) are connected through a serial cable or the like, and presentation is done by controlling the host PC by the terminal. Only one terminal is connected, and no special procedures are necessary for connection between the terminal and the host PC.
[0003] In recent years, however, environments which allow to simultaneously connect a plurality of terminals to a host PC by wireless LAN using IEEE802.11b or Bluetooth™ are becoming popular. For this reason, even a portable terminal such as a PDA (Personal Digital Assistants) or cellular phone can easily be connected to a host PC by using radio communication.
[0004] Japanese Patent Laid-Open No. 2001-175602 proposes a technique for generating a password and connecting a device to another device after visually confirming the password. However, this technique can cope with only one-to-one connection but not with connection between a plurality of devices.
[0005] In the above-described electric conference system, presentation in an environment with a plurality of portable terminals connected is not taken into consideration.
SUMMARY OF THE INVENTION
[0006] According to an aspect of the present invention, there is disclosed a host computer for an electric conference system, which stores a member ID to specify a terminal, generates a password, displays the generated password on a display and makes the password open to participants of a conference, authenticates the terminal on the basis of a member ID and a password, which are contained in a connection request received from the terminal, and processes a command received from the terminal on the basis of the authentication result.
[0007] According to the electric conference system having such a host computer, connection from a terminal of the electric conference system is facilitated. The electric conference system can be operated from the terminal. In addition, password management by the participants of the conference can be made easy and safe.
[0008] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram showing the arrangement of an electric conference system;
[0010] FIG. 2 is a block diagram for explaining the function of the electric conference system;
[0011] FIG. 3 is a block diagram showing the arrangement of a host PC;
[0012] FIG. 4 is a block diagram showing the arrangement of a remote PC;
[0013] FIG. 5 is a view for explaining the connection procedures to the host PC and the operation procedures of the host PC by the remote PC;
[0014] FIG. 6 is a view showing the operation of the host PC by the remote PC after connection;
[0015] FIG. 7 is a flowchart showing the outline of processing by the remote PC and host PC;
[0016] FIG. 8 is a flowchart showing details of processing by the host PC; and
[0017] FIG. 9 is a flowchart showing details of processing by the remote PC.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] An electric conference system according to an embodiment of the present invention will be described below in detail with reference to the accompanying drawings.
[0019] FIG. 1 is a block diagram showing the arrangement of the electric conference system according to the embodiment.
[0020] Remote PCs 101 are portable terminals such as pocket PCs, palmtop PCs, or notebook PCs, i.e., computer devices which participants carry to a conference hall. The participants of the conference can connect the terminals to a host PC 104 and control it.
[0021] A wireless network interface (I/F) 103 is a radio communication apparatus for a wireless LAN 102 such as IEEE802.11a/b/g or Bluetooth™ and is used to connect each host PC 104 to the remote PC 101 . The host PC 104 is a computer which controls the electric conference system. The host PC 104 executes a program which controls connection authentication for terminals, execution of commands for, e.g., drawing on a display 105 , and the flow of the entire electric conference system.
[0022] The display 105 is a large-screen display for the electric conference system. The display 105 has a display screen which is so large that all participants of the conference can simultaneously see it. A LAN 106 is a wire network which is used for connection to the main system.
[0023] FIG. 2 is a block diagram for explaining the function of the electric conference system.
[0024] The remote PC 101 transmits a connection request or a drawing command to the host PC 104 . In requesting connection, the remote PC 101 transmits a member ID & password 202 .
[0025] The host PC 104 causes a comparison function 203 to compare the received member ID & password 202 with a member ID list 205 registered in a memory in advance and a generated common password 209 and determines whether connection is possible. The authentication result is recorded by a member ID list updating function 204 .
[0026] The host PC 104 displays the temporarily issued common password 209 on the display 105 by a host PC processing function 208 to notify the participants of the conference of the password. The member ID list 205 stores the ID list of members who can participate in the conference. A connection enabled/disabled state can also be recorded in correspondence with each member ID.
[0027] The remote PC 101 can transmit a remote operation command 206 containing a drawing command or the like together with the member ID. Upon receiving the remote operation command 206 , the host PC 104 causes a remote command filter 207 to compare the member ID attached to the command with the record in the member ID list 205 to determine whether the command is received from an already authenticated terminal. A command which is received from an already authenticated terminal is sent to the host PC processing function 208 .
[0028] The host PC processing function 208 covers the whole processing by the host PC 104 . In this embodiment, the host PC processing function 208 mainly executes display of the common password 209 and processing and display of a drawing command received from a terminal.
[0029] With the above arrangement, the temporary common password 209 generated by the host PC 104 is displayed on the large-screen display 105 so that all the participants of the conference are notified of the password. Each participant sends a connection request by using his/her member ID and the common password 209 . Accordingly, the participant can control the host PC 104 and display on the large-screen display 105 from the remote PC 101 of his/her own. A plurality of participants can simultaneously be connected to the host PC 104 , as a matter of course.
[0030] FIG. 3 is a block diagram showing the arrangement of the host PC 104 .
[0031] A CPU 301 controls the entire host PC 104 in accordance with programs stored in a program memory 302 and disk 304 by using a work memory 303 as a work area. The CPU 301 executes generation of the common password 209 , terminal authentication processing, and the host PC processing function 208 including execution of a drawing command. The program memory 302 or disk 304 stores an operating system (OS), various kinds of application programs containing the series of processing procedures of the electric conference system, and various data of documents, photos, and sound.
[0032] A keyboard/mouse 305 includes a keyboard and a mouse to operate the host PC 104 . A display 306 is used to operate the host PC 104 and can commonly be used as the large-screen display 105 . A LAN I/F 308 is a cable network interface to be connected to the main system.
[0033] The above components and wireless network I/F 103 are connected to each other through a system bus 309 .
[0034] FIG. 4 is a block diagram showing the arrangement of the remote PC 101 .
[0035] A CPU 401 controls the entire remote PC 101 in accordance with programs stored in storage media such as a program memory 402 and a memory card 404 by using a work memory 403 as a work area. The CPU 401 executes processing such as issue of a connection request or drawing command. The program memory 402 or memory card 404 stores an operating system (OS), various kinds of application programs containing the series of processing procedures of the terminal function, and various data of documents, photos, and sound.
[0036] A touch pad 405 is used to operate the remote PC 101 by a pen operation or the like. A display 406 is integrated with the touch pad 405 and used to operate the remote PC 101 . A result of pen operation is directly displayed on the display 406 . A wireless network I/F 407 is a structure to execute radio communication with the host PC 104 . A wireless network card can also be used, as a matter of course.
[0037] The above components are connected to each other through a system bus 409
[0038] The connection procedures to the host PC 104 and the operation procedures of the host PC 104 by the remote PC 101 will be described next.
[0039] When the host PC 104 displays the host name and password on the display 105 , like a window 502 shown in FIG. 5 , the user (the participant of the conference) of the remote PC 101 operates it to input the host name, member ID, and password, like a window 501 , and presses the “connect” button. In this case, since the member ID “Member-ID1” is registered in a member column 503 of the member ID list 205 , a status 504 corresponding to this member is updated to “OK” which represents that the member is already authenticated. “NG” in the status 504 represents an unconnected member or a member who has failed in connection.
[0040] In, e.g., a Windows environment, the host PC 104 can be specified by the host name. If the host name cannot be used as the means for specifying the host PC 104 , the host PC 104 can be specified by inputting, e.g., a TCP/IP address or URL. In this embodiment, the host name is used assuming use of a Windows environment.
[0041] FIG. 6 is a view showing the operation of the host PC 104 by the remote PC 101 after connection. In this example, the drawing operation on the remote PC 101 is directly reflected on display on the large-screen display 105 connected to the host PC 104 .
[0042] FIG. 7 is a flowchart showing the outline of processing by the remote PC 101 and host PC 104 .
[0043] When the electric conference system is activated, the host PC 104 generates the common password 209 (S 201 ) and displays the host name and password on the display 105 (S 202 ). When the user inputs the host name, member ID, and password, the remote PC 101 sends a connection request to the host PC 104 (S 101 ) and determines whether connection is permitted (S 102 ).
[0044] The host PC 104 determines whether the member ID contained in the received connection request is present in the member ID list 205 (S 203 ) and also determines whether the password contained in the connection request coincides with the common password 209 (S 204 ). If the member ID and password coincide, the host PC 104 updates the member ID list 205 (changes the status of the member to “OK”) (S 205 ) and gives a permission for connection to the remote PC 101 which has issued the connection request (S 206 ).
[0045] The remote PC 101 granted connection permission remote-operates the host PC 104 and issues a command including a drawing command (S 103 ). Upon receiving the command, the host PC 104 checks the status in the member ID list 205 corresponding to the member ID attached to the command (S 207 ). If the status is “OK”, the host PC 104 executes the received command and returns an end notification to the remote PC 101 (S 208 ). Upon receiving the end notification, the remote PC 101 further executes the remote operation (S 105 ).
[0046] If the member ID contained in the connection request does not coincide, the host PC 104 denies connection (S 211 ). If the password contained in the connection request does not coincide, the host PC 104 changes the status for the member ID in the member ID list 205 to “NG” (S 210 ) and denies connection (S 211 ). If the status corresponding to the member ID contained in the command is “NG”, the host PC 104 denies the remote operation (S 209 ). Upon receiving the connection denial or remote operation denial, the remote PC 101 displays on the display 406 a message representing that connection or remote operation has failed (S 106 ). The user who is notified of the failure repeats the connection request or remote operation as needed.
[0047] FIG. 8 is a flowchart showing details of processing by the host PC 104 .
[0048] First, the common password 209 is generated (S 801 ). The generated common password 209 and host name are displayed on the display 105 (S 802 ). In automatic password generation, generally, a password having about four digits is generated by using a random number.
[0049] Next, it is determined whether data is received from the remote PC 101 (S 803 ). If YES in step S 803 , it is determined whether the data is a connection request (S 804 ). If NO in step S 803 , the processing advances to step S 816 .
[0050] If YES in step S 804 , it is determined whether the member ID contained in the connection request is present in the member ID list 205 (S 805 ). If NO in step S 805 , “connection denial” is returned (S 810 ). If YES in step S 805 , it is determined whether the password contained in the connection request coincides with the common password 209 (S 806 ). If YES in step S 806 , the status of the member ID is set to “OK” (S 807 ), and “connection permission” is returned (S 808 ). If NO in step S 806 , the status of the member ID is set to “NG” (S 809 ), and “connection denial” is returned (S 810 ).
[0051] If data other than a connection request is received, it is determined whether the command is processible (S 811 ). If NO in step S 811 , the command is discarded, and the processing returns to step S 803 . If YES in step S 811 , it is determined on the basis of the corresponding status whether the member ID represents a member who is being connected (S 812 ). More specifically, when the corresponding status is “NG”, “remote operation denial” is returned (S 815 ). When the corresponding status is “OK”, the command is executed (S 813 ), and “operation end” is returned (S 814 ).
[0052] Subsequently, an operation from the keyboard/mouse 305 of the host PC 104 is received (S 816 ). It is determined whether a normal command is input (S 817 ). If YES in step S 817 , the command is executed (S 819 ), and the processing returns to step S 803 . If NO in step S 817 , it is determined whether the command is an end command (S 818 ). If YES in step S 818 , the processing by the host PC 104 is ended. Otherwise, the processing returns to step S 803 . If the keyboard/mouse 305 is not operated for a predetermined time, the processing returns to step S 803 .
[0053] FIG. 9 is a flowchart showing details of processing by the remote PC 101 .
[0054] First, the user inputs the host name representing the address of the host PC 104 , the member ID, and the password (S 901 to S 903 ). As the member ID, an ID registered in the host PC 104 in advance must be input. If an unregistered member ID is input, connection is denied. The password is the common password 209 which is temporarily generated and displayed on the large-screen display 105 .
[0055] Next, the remote PC 101 transmits a connection request to the host PC 104 (S 904 ), waits for a response from the host PC 104 (S 905 ), and determines whether the response is connection permission (S 906 ). If the response is connection denial, the processing advances to step S 911 .
[0056] If the response from the host PC 104 is connection permission, the command is received (S 907 ). The input command is determined (S 908 ). If it is an end command, the processing by the remote PC 101 is ended. Otherwise, the input command is transmitted to the host PC 104 (S 909 ). It is determined whether the response from the host PC 104 is an operation end notification (S 910 ). If YES in step S 910 , the processing returns to step S 907 to repeat the series of command input and transmission.
[0057] When connection denial or remote operation denial is returned from the host PC 104 , a message representing it is displayed on the display 406 (S 911 ) to notify the user that connection or remote operation has failed. It is determined whether an instruction that requests connection is input again (S 912 ). If YES in step S 912 , the processing returns to step S 901 . Otherwise, the processing by the remote PC 101 is ended.
[0058] As described above, display on the host PC and large-screen display, which form the electric conference system, can be operated by using a portable terminal or the like. A plurality of terminals can also simultaneously be connected, as a matter of course. At this time, when the member ID registered in the host PC in advance and the common password which is made open to the public at the site of a conference are used, illicit access to the electric conference system can be prevented, and each participant need not manage the password. Hence, even when a participant forgets the password, he/she can access the electric conference system. In addition, the leakage of password can also be prevented.
[0059] Even a computer which is connected to the host PC of the electric conference system through the LAN cannot know the password without participating in the conference. Hence, unnecessary connection of a non-participant through a network such as a LAN can be prevented.
[0060] In place of the member ID, the MAC (Media Access Control) address of the wireless network I/F 407 of the remote PC 101 may be used. In this case, the MAC address of each remote PC 101 used by a participant of the conference is registered in the member ID list 205 of the host PC 104 in advance. When the MAC address is used, each user (participant) of the remote PC 101 need not manage the member ID.
[0061] When a participant name field is added to the member ID list 205 , and a participant name corresponding to a member ID is registered, information (name) representing the participant who is operating display on the large-screen display 105 can also be displayed.
[heading-0062] <Other Embodiments>
[0063] Note that the present invention can be applied to an apparatus comprising a single device or to system constituted by a plurality of devices.
[0064] Furthermore, the invention can be implemented by supplying a software program, which implements the functions of the foregoing embodiments, directly or indirectly to a system or apparatus, reading the supplied program code with a computer of the system or apparatus,. and then executing the program code. In this case, so long as the system or apparatus has the functions of the program, the mode of implementation need not rely upon a program.
[0065] Accordingly, since the functions of the present invention are implemented by computer, the program code installed in the computer also implements the present invention. In other words, the claims of the present invention also cover a computer program for the purpose of implementing the functions of the present invention.
[0066] In this case, so long as the system or apparatus has the functions of the program, the program may be executed in any form, such as an object code, a program executed by an interpreter, or scrip data supplied to an operating system.
[0067] Example of storage media that can be used for supplying the program are a floppy disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a CD-RW, a magnetic tape, a non-volatile type memory card, a ROM, and a DVD (DVD-ROM and a DVD-R).
[0068] As for the method of supplying the program, a client computer can be connected to a website on the Internet using a browser of the client computer, and the computer program of the present invention or an automatically-installable compressed file of the program can be downloaded to a recording medium such as a hard disk. Further, the program of the present invention can be supplied by dividing the program code constituting the program into a plurality of files and downloading the files from different websites. In other words, a WWW (World Wide Web) server that downloads, to multiple users, the program files that implement the functions of the present invention by computer is also covered by the claims of the present invention.
[0069] It is also possible to encrypt and store the program of the present invention on a storage medium such as a CD-ROM, distribute the storage medium to users, allow users who meet certain requirements to download decryption key information from a website via the Internet, and allow these users to decrypt the encrypted program by using the key information, whereby the program is installed in the user computer.
[0070] Besides the cases where the aforementioned functions according to the embodiments are implemented by executing the read program by computer, an operating system or the like running on the computer may perform all or a part of the actual processing so that the functions of the foregoing embodiments can be implemented by this processing.
[0071] Furthermore, after the program read from the storage medium is written to a function expansion board inserted into the computer or to a memory provided in a function expansion unit connected to the computer, a CPU or the like mounted on the function expansion board or function expansion unit performs all or a part of the actual processing so that the functions of the foregoing embodiments can be implemented by this processing.
[0072] 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. | In an electric conference system using a large-screen display, presentation in an environment with a plurality of portable terminals connected is not taken into consideration. To do this, a host computer for an electric conference system is arranged to store a member ID to specify a terminal, generate a password, display the generated password on a large-screen display and make the password open to participants of a conference, authenticate the terminal on the basis of a member ID and a password, which are contained in a connection request received from the terminal, and process a command received from the terminal on the basis of the authentication result. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/438,894 filed on Feb. 2, 2011 titled “METHOD AND SYSTEM FOR AN INTERACTIVE GAME ON A MOBILE DEVICE” which is incorporated herein by reference in its entirety for all that is taught and disclosed therein.
BACKGROUND
This application relates to interactive games played on electronic devices having touch screen user interfaces.
SUMMARY
This Summary is provided to introduce in a simplified form a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
The present system allows a player or user to play a “handclapping” game on a device with a touch screen interface (mobile phone, tablet, computer, laptop, or other such device with a touch screen interface) with a 3D model or a 2D model of an animal, a person, or any other character. The player must successfully mimic the moves of the 3D or 2D model/character, which in one embodiment shown in the figures is a 3D image of a giraffe, to progress in the game. Specifically the player must match his moves by touching the screen with his finger or fingers with the moves made by the giraffe, which is also touching its hooves to specific areas of the screen.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a screen capture from a mobile device displaying a level picker screen in an embodiment.
FIG. 2 shows a screen capture from a mobile device displaying a game play screen in an embodiment.
FIGS. 3A-3Q show screen captures from a mobile device displaying seventeen active moves in an embodiment.
FIGS. 4A-4D show screen captures from a mobile device displaying four passive moves in an embodiment.
DETAILED DESCRIPTION
The invention may be implemented as a computer process, a computing system or as an article of manufacture such as a computer program product. The computer program product may be a computer storage medium readable by a computer system and encoding a computer program of instructions for executing a computer process. The computer program product may also be a propagated signal on a carrier readable by a computing system and encoding a computer program of instructions for executing a computer process.
With the computing environment in mind, embodiments of the present invention are described with reference to logical operations being performed to implement processes embodying various embodiments of the present invention. These logical operations are implemented (1) as a sequence of computer implemented steps or program modules running on a computing system and/or (2) as interconnected machine logic circuits or circuit modules within the computing system. The implementation is a matter of choice dependent on the performance requirements of the computing system implementing the invention. Accordingly, the logical operations making up the embodiments of the present invention described herein are referred to variously as operations, structural devices, acts or modules. It will be recognized by one skilled in the art that these operations, structural devices, acts and modules may be implemented in software, in firmware, in special purpose digital logic, and any combination thereof without deviating from the spirit and scope of the present invention as recited within the claims attached hereto.
Referring to the Figures, like reference numerals and names refer to structurally and/or functionally similar elements thereof, and if objects depicted in the figures that are covered by another object, as well as the tag line for the element number thereto, may be shown in dashed lines.
Game Play
FIG. 1 shows a screen capture from a mobile device displaying a level picker screen. Referring now to FIG. 1 , the game is divided into multiple levels, where each level has its own choreography of “handclapping” moves that the giraffe is making. When starting the game, the player must first choose the level on the level picker screen by touching the level's icon with his finger. The level picker screen contains a list of levels arranged in a grid. There are 16 levels on the first screen, with additional screens of 16 levels available by swiping the screen to the left. The programming for the game may be accomplished with any of the programming languages and software developer kits commonly utilized for applications designed to be downloaded as applications on smart phones, such as the Apple iPhone® and Android® phones, as well as other devices.
FIG. 2 shows a screen capture from a mobile device displaying a game play screen. Referring now to FIG. 2 , in the beginning of the game only the first level is unlocked and accessible for game play. This is indicated by the fact that the first level's icon is different from all other level icons. The first level icon has a number (1) and three empty stars below, indicating that the level is unlocked but has not been completed at any speed. Levels 2 and 3 are also shown unlocked in FIG. 2 . The other levels are locked, a fact that is indicated by a lock icon. When the player presses/touches the unlocked first level, the game play screen ( FIG. 2 ) opens and the giraffe starts its choreography of moves. Each level of the game has three speeds: slow, medium, and high. When beginning a new level, the choreography of moves and the music speed are the lowest, i.e., slow.
The giraffe plays the “handclapping” game with its hooves by virtually touching the screen with one or more hooves, while the player must touch the screen from the user interface side with his finger or fingers at the exact same time and in the same area of the screen, providing touch screen input from the player. The area the player should touch is indicated by a circle around the giraffe's hoof/hooves as shown in FIG. 2 .
The player touches the screen only on areas that the giraffe is touching with its hooves. When a touch is made by the giraffe, that area of the screen is marked by a white translucent circle with a pink edge. The player must touch the screen with his finger or fingers during that time. If the player is successful, the white translucent circle with the pink edge changes color to green, thereby indicating success. If the player touches that area too soon, the area changes color to a red circle. If the player touches the area too late or not at all, the area also changes color to a red circle. If the player misses the circle area that the giraffe is touching by its hoof or hooves, the entire game play screen flashes with red color.
The choreography of moves for a particular level is accompanied by music, where some beats indicate moves/touches that are made by the giraffe. In this way the music helps the player to intuitively anticipate moves before they are actually made.
There is also a progress bar in the top center part of the game play screen as shown in FIG. 2 . The progress bar is divided into three equal parts, one for slow speed, one for medium speed and one for high speed. The progress bar is empty in the beginning, if that level has not been completed at any speed or if the player replays a completed level on low speed. As the music and choreography progress with time, the progress bar gets filled with green color as long as all the moves are successfully made. If the player makes a mistake or doesn't touch the screen at all, the progress bar switches color to red and gets filled with red color until the music and the choreography stop.
When the progress bar becomes red, indicating that the level will not be successfully completed, a pulsating restart button appears in the top right part of the screen right next to the progress bar. A stop or cancel button appears in the top left part of the screen right next to the progress bar. If the player presses the restart button, the level starts again at the same speed. If the player presses the stop or cancel button, the game ends.
When a particular choreography of moves ends, the music also stops. If the player has successfully touched the right parts of the screen at the right time, he/she has completed the level.
If the player successfully completes the level at the lowest speed, a screen appears (not shown) where three baby giraffes give him a one star rating. After that, the screen changes from the game play screen ( FIG. 2 ) to the level picker screen ( FIG. 1 ). The level that was just completed now has a one star rating, indicated by one yellow star and two empty stars in the level's icon. The next available level is unlocked, a fact that is indicated by an animation (not shown), the locked level icon turns around and becomes an unlocked level icon with no rating (three empty stars).
If the player fails the level, a screen appears (not shown) where the giraffe is sad indicating that the player was not successful. Two buttons are available on this screen, the replay button in the top right of the screen and the back button in the top left of the screen (not shown). The restart button restarts the level at the same speed. The back button switches the game play screen ( FIG. 2 ) to the level picker screen ( FIG. 1 ).
The player can start the level at medium speed only if the slow speed was successfully completed. Similarly, the player can only start the level at high speed if the medium speed was completed.
To start the level at medium or high speed the player must press the level icon. A menu (speed menu) appears with three choices: one star for slow speed, two stars for medium speed and three stars for high speed (not shown). If the player presses one star, the game play screen appears and the level begins at low speed. If the player presses two stars the level begins at medium speed and if the player presses three stars, the level begins at high speed.
If only the slow speed was completed for a level, the speed menu of that level has two active choices: slow and medium (one and two stars), the third choice is visible but not active, a fact which is indicated by three empty stars. The active choices are one yellow colored star and two yellow colored stars for slow and medium speed, respectively. If slow and medium speed were completed for a level, the speed menu has three active choices, and the player can therefore choose to play that level at any speed.
Possible Moves of the Giraffe
The giraffe can make twenty-one possible moves in the game. Seventeen moves are referred to as active moves: the giraffe touches the screen with one or more hooves, and the user is supposed to mimic those moves by touching the touch screen. FIGS. 3A-3Q are screen captures from a mobile device displaying these active moves which require the player to touch the touch screen in response. Some moves are referred to as passive moves: the giraffe touches its hooves together but does not touch the screen, and in response the user is not supposed to touch the touch screen. See FIGS. 4A-4D are screen captures from a mobile device displaying these passive moves require the player to not touch the touch screen.
Active Moves
Left Hand: the giraffe touches the screen with the hoof on its left hand. See FIG. 3A .
Left Hand Middle: the giraffe touches the center of the screen with the hoof on its left hand. See FIG. 3B .
Right Hand: the giraffe touches the screen with the hoof on its right hand. See FIG. 3C .
Right Hand Middle: the giraffe touches the center of the screen with the hoof on its right hand. See FIG. 3D .
Left Foot: the giraffe touches the screen with the hoof on its left foot. See FIG. 3E .
Right Foot: the giraffe touches the screen with the hoof on its right foot. See FIG. 3F .
Both Hands: the giraffe touches the screen with the hooves of both hands. See FIG. 3G .
Both Feet: the giraffe touches the screen with the hooves of both feet. See FIG. 3H .
Left Hand And Left Foot: the giraffe touches the screen with the hooves of its left hand and its left foot. See FIG. 3I .
Left Hand And Right Foot: the giraffe touches the screen with the hooves of its left hand and its right foot. See FIG. 3J .
Right Hand And Right Foot: the giraffe touches the screen with the hooves of its right hand and its right foot. See FIG. 3K .
Right Hand And Left Foot: the giraffe touches the screen with the hooves of its right hand and its left foot. See FIG. 3I .
Both Hands And Left Foot: the giraffe touches the screen with the hooves of its both hands and its left foot. See FIG. 3M .
Both Hands And Right Foot: the giraffe touches the screen with the hooves of its both hands and its right foot. See FIG. 3N .
Both Feet And Left Hand: the giraffe touches the screen with the hooves of its both feet and its left hand. See FIG. 3O .
Both Feet And Right Hand: the giraffe touches the screen with the hooves of its both feet and its right hand. See FIG. 3P .
Both Hands And Both Feet: the giraffe touches the screen with the hooves of both its hands and both its feet. See FIG. 3Q .
Passive Moves
Both Hands Together: the giraffe touches the hooves of both its hands together. See FIG. 4A .
Both Feet Together: the giraffe touches the hooves of both its feet together. See FIG. 4B .
Left Hand And Right Foot Together: the giraffe touches the hooves of its left hand and its right foot together. See FIG. 4C .
Right Hand And Left Foot Together: the giraffe touches the hooves of its right hand and its left foot together. See FIG. 4D .
Although the subject matter has been described in language specific to structural features and/or 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. It will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications will suggest themselves without departing from the scope of the disclosed subject matter. | An interactive game allows a player to play a “handclapping” game on a device with a touch screen interface (mobile phone, tablet or other such device) with a 3D model or a 2D model of an animal, a person, or any other character. The player must successfully mimic the moves of the 3D or 2D model/character to progress in the game. Specifically the player must match his moves by touching the screen with his finger or fingers with the moves made by the animal, a person, or any other character, which is also touching its appendages to specific areas of the touch screen. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2015-244466, filed on Dec. 15, 2015, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The embodiments discussed herein are related to a computer-readable recording medium, a mobile terminal device, and an article management method.
BACKGROUND
[0003] In recent years, articles are sometimes managed by mounting a wireless tag, such as Bluetooth (registered trademark) or the like, that can perform wireless communication on each of the articles and by using wireless communication between the wireless tags and a mobile terminal device. Specifically, it is conceivable that by, for example, the mobile terminal device receiving identification information on the articles from the corresponding wireless tags, the mobile terminal device identifies the articles near the mobile terminal device or estimates the distance between the mobile terminal device and the articles on the basis of the radio wave intensity at the time of the reception of the identification information.
[0004] Recently, wireless tags with a built-in acceleration sensor are also developed and technologies related to Internet of Things (IoT) in which wireless tags are mounted on various kinds of articles and the articles are connected to the Internet are actively studied. By using IoT, articles can be managed or controlled from a remote place.
[0005] Patent Document 1: Japanese Laid-open Patent Publication No. 2004-334439
[0006] Patent Document 2: Japanese Laid-open Patent Publication No. 2005-56177
[0007] Patent Document 3: Japanese Laid-open Patent Publication No. 2007-256180
[0008] The management of the articles by using each of the wireless tags is also useful when managing personal belongings. For example, a wireless tag is mounted on each of the articles that are daily used by a user and, when the user uses these articles, the position of the articles can be searched by a mobile terminal device, such as a smart phone, held by the user.
[0009] However, if the number of articles on each of which a wireless tag is mounted is increased, there is a problem in that management of the personal belongings of the user becomes complicated. Namely, with the development of reducing the size and manufacturing costs, it is conceivable that a wireless tag is mounted on each of the large number of articles held by persons. Consequently, for example, if the positions of articles present around the mobile terminal device are searched, the positions of the large number of articles are searched and thus it takes time to specify the position of the desired article from the position list of these articles.
[0010] Furthermore, for example, if a list of articles on each of which a wireless tags is mounted is output, pieces of identification information on the large number of articles are disorderly listed and thus it is difficult to efficiently manage the articles. In this way, if a wireless tag is mounted on each of the large number of articles, the usability of the wireless tags is not able to be sufficiently used and management of the article becomes complicated.
SUMMARY
[0011] According to an aspect of an embodiment, a non-transitory computer-readable recording medium stores therein an article management program. The article management program causes a computer to execute a process including: receiving, from a plurality of articles each including a sensor that detects a movement state of each of the articles, a sensor signal that includes therein identification information on an article and a sensor value of the sensor; and displaying, based on the received sensor signal, display information that indicates in a comparable way a change in the sensor value related to each of the plurality of the articles and the identification information on each of the articles.
[0012] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0013] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a schematic diagram illustrating an example of an article management system according to a first embodiment;
[0015] FIG. 2 is a block diagram illustrating the configuration of a mobile terminal device according to the first embodiment;
[0016] FIG. 3 is a block diagram illustrating the function of a processor according to the first embodiment;
[0017] FIG. 4 is a schematic diagram illustrating a specific example of a target list;
[0018] FIG. 5 is a schematic diagram illustrating a specific example of a group list;
[0019] FIG. 6 is a block diagram illustrating the function of a similarity determination unit according to the first embodiment;
[0020] FIG. 7 is a flowchart illustrating an article management process according to the first embodiment;
[0021] FIG. 8 is a schematic diagram illustrating a specific example of display information;
[0022] FIG. 9 is a block diagram illustrating the function of a similarity determination unit according to a second embodiment;
[0023] FIG. 10 is a flowchart illustrating an article management process according to the second embodiment;
[0024] FIG. 11 is a block diagram illustrating the function of a similarity determination unit according to a third embodiment;
[0025] FIG. 12 is a flowchart illustrating an article management process according to the third embodiment;
[0026] FIG. 13 is a block diagram illustrating the function of a processor according to a fourth embodiment;
[0027] FIG. 14 is a flowchart illustrating an alert notification process according to the fourth embodiment;
[0028] FIG. 15 is a block diagram illustrating the function of a processor according to a fifth embodiment; and
[0029] FIG. 16 is a flowchart illustrating an article management process according to the fifth embodiment.
DESCRIPTION OF EMBODIMENTS
[0030] Preferred embodiments of the present invention will be explained with reference to accompanying drawings. The present invention is not limited to the embodiments.
[a] First Embodiment
[0031] FIG. 1 is a schematic diagram illustrating an example of an article management system according to a first embodiment. In the article management system illustrated in FIG. 1 , the articles, such as a bag 10 and a wallet 20 , are managed by a mobile terminal device 100 . Namely, a wireless tag 30 is mounted on each of the articles, such as the bag 10 and the wallet 20 .
[0032] Each of the wireless tags 30 includes, for example, a three-axis acceleration sensor and a wireless interface that can perform wireless communication using Bluetooth Low Energy (BLE). Then, each of the wireless tags 30 temporarily accumulates sensor values of a three-axis acceleration sensor in order to record the speed or the direction of the movement of the articles. Then, each of the wireless tags 30 periodically sends, from a wireless interface, a sensor signal that includes therein both the identification information on each of the articles and the accumulated sensor values.
[0033] The mobile terminal device 100 receives the sensor signal sent from each of the wireless tags 30 and manages the articles, such as the bag 10 , the wallet 20 , and the like. At this time, the mobile terminal device 100 determines, on the basis of the sensor values included in the sensor signal, a movement state that indicates whether each of the articles is moving or stands still and groups the articles that have similar movement states. In this way, by grouping the articles using the movement states, the mobile terminal device 100 efficiently manages the articles on each of which the wireless tag 30 is mounted. The management of the articles performed by the mobile terminal device 100 will be described in detail later.
[0034] FIG. 2 is a block diagram illustrating the configuration of the mobile terminal device 100 according to the first embodiment. The mobile terminal device 100 illustrated in FIG. 2 includes a wireless communication unit 110 , a processor 120 , a memory 130 , an input interface (hereinafter, simply referred to as an “input I/F”) 140 , and a display 150 .
[0035] The wireless communication unit 110 performs wireless communication using, for example, BLE and receives a sensor signal sent from the wireless tag 30 that is mounted on each of the articles. Then, the wireless communication unit 110 outputs the received sensor signal to the processor 120 .
[0036] The processor 120 includes, for example, a central processing unit (CPU), a field programmable gate array (FPGA), a digital signal processor (DSP), or the like and performs the overall control of the entirety of the mobile terminal device 100 . Namely, the processor 120 performs various kinds of processes by using the memory 130 . Specifically, the processor 120 determines, on the basis of the sensor values included in the sensor signal, the movement state of each of the article and groups the articles that have similar movement states. The function of the processor 120 will be described in detail later.
[0037] The memory 130 includes, for example, a random access memory (RAM), a read only memory (ROM), or the like and stores therein various kinds of information at the time of process performed by the processor 120 .
[0038] The input I/F 140 includes, for example, a touch panel, a physical key, a microphone, or the like and accepts an operation input performed by a user. Then, the input I/F 140 notifies the processor 120 of the accepted operation input.
[0039] The display 150 includes, for example, a liquid crystal panel, or the like and displays display information that is output from the processor 120 . The display 150 may also be arranged to be overlapped with a touch panel that is included in the input I/F 140 .
[0040] FIG. 3 is a block diagram illustrating the function of the processor 120 according to the first embodiment. The processor 120 illustrated in FIG. 3 includes a sensor signal acquiring unit 121 , a target list checking unit 122 , a similarity determination unit 123 , a display information creating unit 124 , and a group list creating unit 125 .
[0041] The sensor signal acquiring unit 121 acquires a sensor signal received by the wireless communication unit 110 . The sensor signal acquired by the sensor signal acquiring unit 121 is a signal that is periodically sent from the wireless tag 30 that is mounted on each of the articles and that includes therein both the identification information on the corresponding article and the sensor values of the three-axis acceleration sensor. The sensor signal acquiring unit 121 acquires the sensor signals sent from all of the articles that are present in the communication zone of the communication with the mobile terminal device 100 .
[0042] The target list checking unit 122 checks the identification information included in the sensor signal against the target list stored in the memory 130 . Namely, the target list checking unit 122 acquires, from the memory 130 , the target list indicating the list of the target articles that are managed by the mobile terminal device 100 and determines whether the article of the transmission source of the sensor signal corresponds to the management target. The target list acquired by the target list checking unit 122 from the memory 130 stores therein, for example, as illustrated in FIG. 4 , identification information on all of the articles targeted for the management. This target list may be created by a user registering, in the mobile terminal device 100 , for example, the identification information on the articles that are registered in the corresponding wireless tag 30 . In the target list illustrated in FIG. 4 , as the identification information on the articles, the names of the articles, for example, a “bag A”, a “bag B”, a “wallet”, or the like are stored.
[0043] If the result of checking the identification information included in the sensor signal against the identification information included in the target list indicates that the identification information included in the sensor signal is included in the target list, the target list checking unit 122 notifies the similarity determination unit 123 of the identification information and the sensor values.
[0044] The similarity determination unit 123 compares the sensor values of the articles targeted for the management and determines whether the movement states of the articles are similar. Namely, the similarity determination unit 123 decides, on the basis of the sensor values notified from the target list checking unit 122 , the movement states each of which indicates whether the article is moving or standing still and determines whether the movement states of the articles are similar. At this time, the similarity determination unit 123 accumulates a predetermined number of sensor signals that are periodically sent from each of the articles and calculates the likelihood of the movement of each of the articles (hereinafter, referred to as the “movement likelihood”) from the sensor value for each article. Then, if a difference of the movement likelihood between the articles is less than a predetermined threshold, the similarity determination unit 123 determines that both of these articles are moving. In contrast, if a difference of the movement likelihood between the articles is equal to or greater than a predetermined threshold, the similarity determination unit 123 determines that both of these articles are not moving. In this way, the similarity determination unit 123 determines that the articles whose movement states are similar are the articles in the same group and determines that the articles whose movement states are not similar are the articles that are not in the same group. Furthermore, the similarity determination unit 123 will be described in detail later.
[0045] The display information creating unit 124 creates, on the basis of the determination result obtained by the similarity determination unit 123 , the display information to be displayed on the display 150 . Specifically, the display information creating unit 124 graphs the sensor values related to, for example, each of the articles and creates display information in which graphs of the articles whose movement states are similar are adjacently arranged. Namely, the display information creating unit 124 creates display information in which graphs of the sensor values related to both the articles that are determined to be moved are arranged together with the identification information. Then, the display information creating unit 124 outputs the created display information to the display 150 and displays the information on the display 150 .
[0046] The group list creating unit 125 creates, on the basis of the determination result obtained by the similarity determination unit 123 , a group list that indicates the group of the articles. Specifically, the group list creating unit 125 creates, for each article, the group list that indicates the list of the articles whose movement state are similar to the subject article. Accordingly, the group list creating unit 125 creates, for example, as illustrated in FIG. 5 , regarding each of the articles, the group list that indicates the list of articles that were determined to have been moved together. In the example illustrated in FIG. 5 , the group list of a “bag A” stores therein identification information, such as a “wallet”, a “folding umbrella”, a “commutation pass”, and the like and the group list of a “bag B” stores therein identification information, such as a “water bottle”, a “jersey”, a “soccer ball”, and the like. Because the group list is the list in which the articles in the same group are enumerated for each article, the identification information on the article belonging to the same group is included in the counterpart group list. For example, in the example illustrated in FIG. 5 , because the “wallet” is included in the group list of the “bag A”, the “bag A” is included in the group list of the “wallet”.
[0047] Furthermore, after the display information created by the display information creating unit 124 is displayed on the display 150 , the group list creating unit 125 may also change the group list in accordance with the operation input that is performed by a user and that is accepted by the input I/F 140 . Namely, because the display information that indicates the movement state of each of the articles is displayed on the display 150 , the user may also decide the articles in the same group from the movement state of or the identification information on each of the articles and performs the operation input that groups the articles. Then, the group list creating unit 125 creates a group list in accordance with the operation input performed by the user, in addition to the determination result obtained by the similarity determination unit 123 .
[0048] Because the group lists created in this way are the lists of the articles that are simultaneously carried by the user, by managing the articles using the group lists, it is possible to output a carry item list of the user depending on the situation. Furthermore, for example, if the position of a single article is searched, it is possible to simultaneously search for the position of each of the articles that are in the same group as the searching article and it is possible to search the position of all of the articles that are simultaneously carried by the user.
[0049] FIG. 6 is a block diagram illustrating the function of the similarity determination unit 123 according to the first embodiment. The similarity determination unit 123 illustrated in FIG. 6 includes an average value calculating unit 161 , a movement likelihood calculating unit 162 , a difference calculating unit 163 , and a threshold comparing unit 164 .
[0050] The average value calculating unit 161 calculates the average value of the sensor values obtained, within a predetermined time period, from the sensor signal for each article. At this time, if the sensor signal includes the sensor values of, for example, a three-axis acceleration sensor, the average value calculating unit 161 uses the sum of the square of the sensor values of the three-axis acceleration sensor as the sensor values and calculates, for each article, the average value of these sensor values.
[0051] The movement likelihood calculating unit 162 calculates the movement likelihood for each article on the basis of both the instantaneous value of the sensor value for each article and the average value calculated by the average value calculating unit 161 . Specifically, the movement likelihood calculating unit 162 calculates, for each article, the total sum of the differences between each of the instantaneous values of the sensor values and the average value as the movement likelihood. If an article moves, because the sensor value of the wireless tag 30 mounted on the subject article varies, the movement likelihood that is the total sum of the differences between the instantaneous values of the sensor values and the average values becomes large. Accordingly, the value of the movement likelihood becomes greater as the article moves more frequently.
[0052] The difference calculating unit 163 calculates a difference between the movement likelihood for each article. Because the movement likelihood is the value that designates the movement state indicating whether the article has been moved, the values of the movement likelihood of the articles that are simultaneously move and have similar movement states tend to be similar and the difference of the movement likelihood is decreased.
[0053] The threshold comparing unit 164 compares the difference calculated by the difference calculating unit 163 with the predetermined threshold. Then, the threshold comparing unit 164 decides that the articles in which the difference of the movement likelihood is less than the predetermined threshold were moving together and determines that the movement states of these articles are similar. In contrast, the threshold comparing unit 164 decides that the articles in which the difference of the movement likelihood is equal to or greater than the predetermined threshold were not moving together and determines that the movement states of these articles are not similar. The threshold comparing unit 164 outputs the determination result to the display information creating unit 124 and the group list creating unit 125 .
[0054] In the following, an article management process performed by the mobile terminal device 100 configured as described above will be described with reference to the flowchart illustrated in FIG. 7 . In this article management process, the articles that are mainly and simultaneously carried by a user are grouped and group lists are created.
[0055] The sensor signal that includes therein both the identification information on the article and the accumulated sensor values of the three-axis acceleration sensor is periodically sent from the wireless tag 30 mounted on the article. Then, the sensor signal sent from the wireless tag 30 mounted on the article that is positioned within the communication zone of the mobile terminal device 100 is received by the wireless communication unit 110 (Step S 101 ). The received sensor signal is acquired by the sensor signal acquiring unit 121 in the processor 120 . Then, the identification information included in the sensor signal is checked against the identification information on the target list by the target list checking unit 122 (Step S 102 ).
[0056] If the result of checking against the target list indicates that the identification information included in the sensor signal is not included in the target list (No at Step S 102 ), the article of the transmission source of this sensor signal is the article or the like that is not, for example, the personal belongings of the user; therefore, the article is ignored as the out of the management target. In contrast, if the identification information included in the sensor signal is included in the target list (Yes at Step S 102 ), the average value of the sensor values is calculated for each article by the average value calculating unit 161 in the similarity determination unit 123 (Step S 103 ). Namely, the average value is calculated for each article by the average value calculating unit 161 from the sensor values measured by the three-axis acceleration sensor of the wireless tag 30 within a predetermined time period.
[0057] Then, the movement likelihood for each article is calculated by the movement likelihood calculating unit 162 (Step S 104 ). Specifically, the total sum of the difference between a plurality of the instantaneous values and the average values of the sensor values is calculated for each article. If an article is moving, because the difference between the instantaneous values and the average value of the sensor values tends to be great, the movement likelihood becomes greater as the article is moving.
[0058] If the movement likelihood is calculated for each article, the difference between the movement likelihood is calculated for each article by the difference calculating unit 163 (Step S 105 ). If the movement states of the articles are similar, because the values of the movement likelihood are close to each other, the difference of the movement likelihood between both the articles that are moving together is decreased. Thus, the difference of the movement likelihood is compared with the predetermined threshold by the threshold comparing unit 164 (Step S 106 ).
[0059] If the comparison result indicates that the difference of the movement likelihood is less than the predetermined threshold (Yes Step S 106 ), the threshold comparing unit 164 decides that both the articles having the movement likelihood are moving together and belong to the same group (Step S 107 ). Furthermore, if the difference of the movement likelihood is equal to or greater than the predetermined threshold (No at Step S 106 ), the threshold comparing unit 164 decides that both the articles having the movement likelihood are not moving together and belong to different groups (Step S 108 ). The determination of the similarity of the movement states of the articles performed in this way is performed for each of the combinations of two articles and the determination result related to each of the combinations is output to the display information creating unit 124 and the group list creating unit 125 .
[0060] Then, the display information on the basis of the determination result of the similarity is created by the display information creating unit 124 (Step S 109 ). Specifically, the sensor values of each of the articles are graphed by the display information creating unit 124 and the display information in which the graphs of articles that are in the same group and whose movement states are similar are adjacently arranged together with the identification information on the articles. Namely, for example, as illustrated in FIG. 8 , the display information in which the graphs of the sensor values for each article are arranged in accordance with the similarity of the movement states. In the example illustrated in FIG. 8 , because the movement state of the “bag A” is similar to the movement state of the “wallet”, a graph 171 and a graph 172 of these articles are adjacently arranged together with the identification information on each of the articles. In contrast, because the movement state of the “water bottle” is not similar to the movement states of the “bag A” and the “wallet”, a graph 173 corresponding to the identification information on the “water bottle” is arranged at the position that is different from the graph 171 and the graph 172 .
[0061] The display information illustrated in FIG. 8 is an example and the graph does not always need to be included in the display information. For example, instead of the graphs, sensor values related to each of the articles may also be arranged in the tabular format or identification information on the articles may also be enumerated and arranged for each group in which the movement states are similar.
[0062] A description will be given here by referring back to FIG. 7 . The display information created by the display information creating unit 124 is output to the display 150 and displayed (Step S 110 ). Because the display information is displayed on the display 150 , a user can visually confirm the group of the articles that have the similar movement states. Consequently, the user can input, to the input I/F 140 , the combination or the like of the articles desired to be added to the same group regardless of, for example, the movement state.
[0063] In contrast, if the determination result of the similarity of the movement states of the articles is output to the group list creating unit 125 , a group list is created by the group list creating unit 125 (Step S 111 ). Specifically, a group list in which the identification information on the articles that have the similar movement states is enumerated for each article. At this time, if an operation input to the input I/F 140 is performed by the user who visually confirms the display information, the group list is changed in accordance with the operation input performed by the user. Namely, in addition to the articles that have the similar movement states, a group list in which the article specified by the user belongs to the same group is created.
[0064] Consequently, the group list in which the articles that are mainly and simultaneously carried by the user and that are in the same group is created for each article and the articles that are simultaneously carried by the user can be collectively managed. Consequently, for example, it is possible to output the list of the articles that are simultaneously carried by the user depending on the situation, such as commutation or a business trip, or it is also possible to simultaneously search the position of the articles that are simultaneously carried by the user when searching the position of a single article.
[0065] As described above, according to the embodiment, the movement likelihood of each of the articles is obtained from the sensor values that are collected from the wireless tag mounted on each of the articles is obtained and the articles in which the difference of the movement likelihood is small and the movement states are similar are grouped in the same group. Consequently, the articles that are simultaneously carried by the user can be collectively managed in the same group and the articles on each of which the wireless tag is mounted can be efficiently managed.
[b] Second Embodiment
[0066] The characteristic of a second embodiment is that a movement period in which, in transition of the sensor values, an article is assumed to be moving is detected and it is determined whether the movement states of the articles are similar on the basis of the frequency analysis of each of the waveforms of the sensor values in the movement period.
[0067] The configuration of a mobile terminal device according to the second embodiment is the same as that of the mobile terminal device 100 ( FIGS. 2 and 3 ) according to the first embodiment; therefore, descriptions thereof will be omitted. In the second embodiment, the function of the similarity determination unit 123 is different from that described in the first embodiment.
[0068] FIG. 9 is a block diagram illustrating the function of the similarity determination unit 123 according to a second embodiment. The similarity determination unit 123 illustrated in FIG. 9 includes a movement period detecting unit 201 , a frequency analyzing unit 202 , and a spectrum comparing unit 203 .
[0069] The movement period detecting unit 201 detects, in transition of a plurality of the sensor values obtained from a plurality of the sensor signals for each article, a movement period in which the article is assumed to be moving. Specifically, the movement period detecting unit 201 detects, as the movement period, the section in which the sensor values are equal to or greater than the predetermined threshold. At this time, if the sensor signal includes the sensor values of, for example, the three-axis acceleration sensor, the movement period detecting unit 201 uses the sum of the square of the sensor values of the three-axis acceleration sensor as the sensor values and detects the movement period by comparing this sensor values with the predetermined threshold.
[0070] The frequency analyzing unit 202 performs the frequency analysis on the waveform of the sensor value in the movement period detected by the movement period detecting unit 201 . Specifically, by performing Fourier transformation on the waveform of, for example, sensor value, the frequency analyzing unit 202 obtains, for each article, the spectrum of the waveform of the sensor value.
[0071] The spectrum comparing unit 203 compares the spectrum for each article obtained by the frequency analyzing unit 202 . Then, if the spectrum distribution for each article satisfies a predetermined similarity criterion, the spectrum comparing unit 203 determines that the movement states of these articles are similar. In contrast, if the spectrum distribution for each article does not satisfy a predetermined similarity criterion, the spectrum comparing unit 203 determines that the movement states of these articles are not similar. The spectrum comparing unit 203 outputs the determination result to the display information creating unit 124 and the group list creating unit 125 .
[0072] In the following, an article management process performed by the mobile terminal device 100 configured as described above will be described with reference to the flowchart illustrated in FIG. 10 . In FIG. 10 , components having the same configuration as those illustrated in FIG. 7 are assigned the same reference numerals and descriptions thereof in detail will be omitted.
[0073] The sensor signal sent from the wireless tag 30 mounted on the article that is positioned in the communication zone of the mobile terminal device 100 is received by the wireless communication unit 110 (Step S 101 ). Then, the identification information included in the sensor signal is checked against the identification information in the target list by the target list checking unit 122 in the processor 120 (Step S 102 ).
[0074] If the result of checking against the target list indicates that the identification information included in the sensor signal is not included in the target list (No at Step S 102 ), the article of the transmission source of this sensor signal is the article or the like that is not, for example, the personal belongings of the user; therefore, the article is ignored as the out of the management target. In contrast, if the identification information included in the sensor signal is included in the target list (Yes at Step S 102 ), the movement period in transition of the sensor value for each article is detected by the movement period detecting unit 201 in the similarity determination unit 123 (Step S 201 ). Namely, the section in which the sensor value is equal to or greater than the predetermined threshold is detected as the movement period by the movement period detecting unit 201 .
[0075] Then, the frequency analysis is performed, by the frequency analyzing unit 202 for each article, on the waveform of the sensor value in the movement period (Step S 202 ). This frequency analysis is performed to obtain the spectrum of the waveform of the sensor value by using, for example, Fourier transformation; however, another method may also be used as long as an analysis method that can obtain the characteristic in the movement period for each article.
[0076] If the spectrum is obtained for each article by the frequency analysis, the spectrum comparing unit 203 determines whether the spectrum of each of the articles satisfies the predetermined similarity criterion (Step S 203 ). If the determination result indicates that the spectrum for each article satisfies the predetermined similarity criterion (Yes at Step S 203 ), the spectrum comparing unit 203 decides that the articles associated with these spectra are moving together and belongs to the same group (Step S 107 ). Furthermore, if the spectrum for each article does not satisfy the predetermined similarity criterion (No at Step S 203 ), the spectrum comparing unit 203 decides that the articles associated with these corresponding spectra are not move together and belong to different groups (Step S 108 ). The determination of the similarity of the movement states of the articles performed in this way is performed for each of the combinations of two articles and the determination result related to each of the combinations is output to the display information creating unit 124 and the group list creating unit 125 .
[0077] Then, the display information on the basis of the determination result of the similarity is created by the display information creating unit 124 (Step S 109 ). The display information created by the display information creating unit 124 is output to the display 150 and displayed (Step S 110 ). Because the display information is displayed on the display 150 , a user can visually confirm the group of the articles that have the similar movement states. Consequently, the user can input, to the input I/F 140 , the combination or the like of the articles desired to be added to the same group regardless of, for example, the movement state.
[0078] In contrast, if the determination result of the group of the similarity of the movement states of the articles is output to the group list creating unit 125 , a group list is created by the group list creating unit 125 (Step S 111 ). At this time, if an operation input to the input I/F 140 is performed by the user who visually confirms the display information, the group list is changed in accordance with the operation input performed by the user.
[0079] As described above, according to the embodiment, the movement period of each of the articles is detected from the sensor values that are collected from the wireless tag mounted on each of the articles and articles in which the spectra of the waveforms of the sensor values in the movement period are similar are grouped in the same group. Consequently, the articles that are simultaneously carried by the user can be collectively managed in the same group and the articles on each of which the wireless tag is mounted can be efficiently managed. Furthermore, it is possible to determine the similarity of the movement states of the articles with high accuracy by using the spectra of the waveforms of the sensors in the movement period.
[c] Third Embodiment
[0080] The characteristic of a third embodiment is that a movement period in which, in transition of the sensor values, an article is assumed to be moving is detected and it is determined whether the movement states of the articles are similar to the articles in accordance with whether the starting point and the end point of the movement period of the articles are within a predetermined range.
[0081] The configuration of a mobile terminal device according to the third embodiment is the same as that of the mobile terminal device 100 ( FIGS. 2 and 3 ) according to the first and the second embodiments; therefore, descriptions thereof will be omitted. In the third embodiment, the function of the similarity determination unit 123 is different from that described in the first and the second embodiments.
[0082] FIG. 11 is a block diagram illustrating the function of the similarity determination unit 123 according to a third embodiment. In FIG. 11 , components having the same configuration as those illustrated in FIG. 9 are assigned the same reference numerals and descriptions thereof will be omitted. The similarity determination unit 123 illustrated in FIG. 11 includes a starting point/end point comparing unit 301 instead of the frequency analyzing unit 202 and the spectrum comparing unit 203 in the similarity determination unit 123 illustrated in FIG. 9 .
[0083] The starting point/end point comparing unit 301 compares the starting point and the end point of the movement period for each article detected by the movement period detecting unit 201 . Specifically, the starting point/end point comparing unit 301 compares the positions of the starting point of the movement period for each article and compares the positions of the end point of the movement period for each article. Then, if the starting point of the movement period for each article is within the predetermined range from each of the point and the end point is within the predetermined range from each of the point, the starting point/end point comparing unit 301 determines that the movement states of these articles are similar. In contrast, if at least one of the starting point and the end point of the movement period for each article is not within the predetermined range regarding the articles, the starting point/end point comparing unit 301 determines that the movement states of these articles are not similar. The starting point/end point comparing unit 301 outputs the determination result to the display information creating unit 124 and the group list creating unit 125 .
[0084] In the following, an article management process performed by the mobile terminal device 100 configured as described above will be described with reference to the flowchart illustrated in FIG. 12 . In FIG. 12 , components having the same configuration as those illustrated in FIGS. 7 and 10 are assigned the same reference numerals and descriptions thereof in detail will be omitted.
[0085] The sensor signal sent from the wireless tag 30 mounted on the article that is positioned in the communication zone of the mobile terminal device 100 is received by the wireless communication unit 110 (Step S 101 ). Then, the identification information included in the sensor signal is checked against the identification information in the target list by the target list checking unit 122 in the processor 120 (Step S 102 ).
[0086] If the result of checking against the target list indicates that the identification information included in the sensor signal is not included in the target list (No at Step S 102 ), the article of the transmission source of this sensor signal is the article or the like that is not, for example, the personal belongings of the user; therefore, the article is ignored as the out of the management target. In contrast, if the identification information included in the sensor signal is included in the target list (Yes at Step S 102 ), the movement period in transition of the sensor value for each article is detected by the movement period detecting unit 201 in the similarity determination unit 123 (Step S 201 ).
[0087] Then, the positions of the starting point and the end point of the movement period for each article are compared by the starting point/end point comparing unit 301 (Step S 301 ). Specifically, the starting point/end point comparing unit 301 determines whether the starting points of the movement periods of the two articles are within the predetermined range and determines whether the end point of the movement periods of these articles are within the predetermined range. Furthermore, if a plurality of movement periods is detected for each of the articles, the starting points and the end points of all of the movement periods are compared by the starting point/end point comparing unit 301 .
[0088] If the determination result described above indicates that the starting point and the end point of the movement period for each article are within the predetermined range from each of the points (Yes at Step S 301 ), the starting point/end point comparing unit 301 decides that the articles of this combination are moving together and belong in the same group (Step S 107 ). Furthermore, if at least one of the starting point and the end point of the movement period for each article is not within the predetermined range from each of the points (No at Step S 301 ), the starting point/end point comparing unit 301 decides that the articles of this combination are not moving together and belong to different groups (Step S 108 ). The determination of the similarity of the movement states of the articles performed in this way is performed for each of the combinations of two articles and the determination result related to each of the combinations is output to the display information creating unit 124 and the group list creating unit 125 .
[0089] Then, display information is created on the basis of the determination result of the similarity by the display information creating unit 124 (Step S 109 ). The display information created by the display information creating unit 124 is output to the display 150 and is displayed (Step S 110 ). Because the display information is displayed on the display 150 , a user can visually confirm the group of the articles that have the similar movement states. Consequently, the user can input, to the input I/F 140 , the combination or the like of the articles desired to be added to the same group regardless of, for example, the movement state.
[0090] In contrast, if the determination result of the group of the similarity of the movement states of the articles is output to the group list creating unit 125 , a group list is created by the group list creating unit 125 (Step S 111 ). At this time, if an operation input to the input I/F 140 is performed by the user who visually confirms the display information, the group list is changed in accordance with the operation input performed by the user.
[0091] As described above, according to the embodiment, the movement period of each of the articles is detected from the sensor values that are collected from the wireless tag mounted on each of the articles and articles in each of which the starting point of the movement period of the article is within the predetermined range and the end point of the movement period of the article is within the predetermined range are grouped in the same group. Consequently, the articles that are simultaneously carried by the user can be collectively managed in the same group and the articles on each of which the wireless tag is mounted can be efficiently managed. Furthermore, the similarity of the movement state of each of the articles can be determined by using an easy process of comparing the position of the starting point and the end point of the movement period.
[d] Fourth Embodiment
[0092] The characteristic of a fourth embodiment is that, after the group list has been created, whether or not a change is present in a group is monitored and an alert is notified if a change is present.
[0093] The configuration of a mobile terminal device according to a fourth embodiment is the same as that of the mobile terminal device 100 ( FIG. 2 ) according to the first embodiment; therefore, descriptions thereof will be omitted. In the fourth embodiment, the function of the processor 120 is different from that described in the first embodiment.
[0094] FIG. 13 is a block diagram illustrating the function of the processor 120 according to a fourth embodiment. In FIG. 13 , components having the same configuration as those illustrated in FIG. 3 are assigned the same reference numerals and descriptions thereof will be omitted. The processor 120 illustrated in FIG. 13 has the configuration in which a group monitoring unit 401 and an alert notification unit 402 are added to the processor 120 illustrated in FIG. 3 .
[0095] The group monitoring unit 401 refers to the group list that is created by the group list creating unit 125 and that is stored in the memory 130 and monitors whether the articles indicated in the group list is continuously grouped. Specifically, if a sensor signal of a single article is acquired by the sensor signal acquiring unit 121 , the group monitoring unit 401 monitors whether the sensor signals are received within predetermined time from all of the articles that belong to the same group to which the subject article belongs. Then, if the sensor signals from all of the articles in the same group are not received within the predetermined time, the group monitoring unit 401 notifies the alert notification unit 402 of this status.
[0096] Furthermore, regarding a plurality of articles belonging to the same group, if the similarity determination of the movement state is performed by the similarity determination unit 123 , the group monitoring unit 401 monitors whether the movement states of these articles are similar. Then, if the movement states of the articles in the same group are not similar, the group monitoring unit 401 notifies the alert notification unit 402 of this status.
[0097] In accordance with the notification from the group monitoring unit 401 , the alert notification unit 402 notifies of an alert that warns that a change is present in a group of the already created group list. Specifically, if sensor signals are received only from some articles belonging to the same group or the movement states of the articles belonging to the same group are not similar, the alert notification unit 402 allows, for example, the display 150 to display a warning message. Furthermore, in addition to allowing the display 150 to display the warning message, the alert notification unit 402 may also notify of an alert by allowing, for example, a speaker to output a warning tone or allowing a light emitting diode (LED) to be flashed in a predetermined pattern.
[0098] In the following, an alert notification process performed by the mobile terminal device configured as described above will be described with reference to the flowchart illustrated in FIG. 14 . The alert notification process described below is performed after, for example, the group lists have been created by the article management process in the first to the third embodiments described above.
[0099] After having created the group lists, the sensor signal that includes therein the identification information on the article and the sensor values of the three-axis acceleration sensor is periodically sent from the wireless tag 30 mounted on each of the articles. Then, the sensor signal sent from the wireless tag 30 that is mounted on each of the articles and that is positioned in the communication zone of the mobile terminal device 100 is received by the wireless communication unit 110 (Step S 401 ). The received sensor signal is acquired by the sensor signal acquiring unit 121 in the processor 120 .
[0100] At this time, if the article of the transmission source of the sensor signal is moving with the article belonging to the same group, the sensor signal in which the article belonging to the same group is the transmission source is expected to be received within the predetermined time. Thus, the group monitoring unit 401 determines whether the sensor signal from the article belonging to the same group as that to which the article of the transmission source of the sensor signal belongs is acquired by the sensor signal acquiring unit 121 within the predetermined time (Step S 402 ).
[0101] Consequently, if the article whose sensor signal is not received within the predetermined time is present (Yes at Step S 402 ), it is conceivable that this article is outside the communication zone of the mobile terminal device and is positioned at the location that is different from the position of the article whose sensor signal is received. Thus, an alert indicating that the sensor signal output from the article belonging to the same group as the article of the reception source of the sensor signal is notified by the alert notification unit 402 (Step S 403 ). Namely, for example, a warning message indicating that a change is present in the group is displayed on the display 150 or a warning tone is output from a speaker.
[0102] In contrast, if the sensor signals are received from all of the articles belonging to the same group within the predetermined time (No at Step S 402 ), similarly to the first to the third embodiments, the similarity of the movement state of each of the articles is determined by the similarity determination unit 123 (Step S 404 ). Then, the group monitoring unit 401 determines whether the movement states of all of the articles belonging to the same group are similar (Step S 405 ).
[0103] If the result indicates that the article whose movement state is not similar is present in the same group (Yes at Step S 405 ), it is conceivable that this article is not moving with the other articles belonging to the same group. Consequently, an alert indicating that the article whose movement state is not similar is present in the group is notified by the alert notification unit 402 (Step S 406 ). Namely, for example, a warning message indicating that a change is present in the group is displayed on the display 150 or a warning tone is output from a speaker.
[0104] In contrast, if the movement states of all of the articles belonging to the same group are similar (No at Step S 405 ), because no change is present in the already created group lists, the process is completed without notifying of an alert.
[0105] In this way, when the sensor signal from the article is received after the group lists have been created, if the sensor signal from the article belonging to the same group as the subject article is not received or if the movement states of the articles belonging to the same group as the subject article are not similar, an alert is notified. Consequently, the user can be aware that the articles belonging to the same group are not moving together and can prevent the article, for example, that is to be simultaneously carried from being left behind. Furthermore, if an alert is notified, a group list may also be again created by the group list creating unit 125 or the group list may also be changed in accordance with the operation input of the user performed via the input I/F 140 .
[0106] As described above, according to the embodiment, after the group lists have been created, whether or not the articles in each of the groups are moving together is monitored and, if there is the article that is not moving together, an alert is notified. Consequently, the user can be aware that the articles belonging to the same group are not moving together and can prevent the article, for example, that is to be simultaneously carried from being left behind.
[0107] Furthermore, in the fourth embodiment, the levels that are used to associate the pieces of the identification information stored in the group list may also be stored and the presence or absence of the alert or the intensity may also be changed in accordance with the associated levels. Specifically, if the level that is used to associate the identification information on, for example, the article or information on the type is input by a user, a group list in which the pieces of the identification information on the articles are associated in accordance with the input information is created.
[0108] Then, in this group list, for example, the levels that indicate strength and weakness of the association between the pieces of the identification information on the articles are stored. At this time, creating the group list is performed by the group list creating unit 125 and, if the information that indicates the level or the type of the association of the identification information is received by the input I/F 140 , this information may also additionally be stored in the group list. Then, whether or not the articles in each of the groups are continuously moving together is monitored, if there is the article that is not moving together, the intensity of the alert is changed in accordance with the associated level. Namely, for example, if the articles that are strongly associated with each other are not moving together, a strong alert may be notified by using a sound and a display and, if the articles that are weakly associated with each other are not moving together, a weak alert may also be notified by using only a display.
[e] Fifth Embodiment
[0109] The characteristic of a second embodiment is that a group list is created by a category, such as the weather, the date, or the like.
[0110] The configuration of a mobile terminal device according to the fifth embodiment is the same as that of the mobile terminal device 100 ( FIG. 2 ) according to the first embodiment; therefore, descriptions thereof will be omitted. In the fifth embodiment, the function of the processor 120 is different from that described in the first embodiment.
[0111] FIG. 15 is a block diagram illustrating the function of the processor 120 according to a fifth embodiment. In FIG. 15 , components having the same configuration as those illustrated in FIG. 3 are assigned the same reference numerals and descriptions thereof will be omitted. The processor 120 illustrated in FIG. 15 has the configuration in which a weather information acquiring unit 501 is added to the processor 120 illustrated in FIG. 3 and the group list creating unit 125 is changed to a group list creating unit 502 .
[0112] The weather information acquiring unit 501 acquires, by connecting to a predetermined server via, for example, the Internet, the current weather information on the current location. Furthermore, the weather information acquiring unit 501 may also share the weather information acquired by another application stored in the mobile terminal device or may also acquire the weather information from, for example, a predetermined sensor. As the weather information, for example, information indicating the type of the weather, such as sunny, cloudy, rainy, or the like, is acquired. This weather information indicates the type of the weather at the time when the movement state of the article is in the movement state indicated by the sensor value that is included in the sensor signal.
[0113] The group list creating unit 502 creates, on the basis of the determination result obtained by the similarity determination unit 123 , a group list that indicates a group of the articles for each category indicated by the weather information. Specifically, the group list creating unit 502 associates, for each article, with the type of the current weather, the group list that indicates the list of the articles that have the movement state similar to that of the subject article. Accordingly, if, for example, the type of the current weather is “sunny”, the group list creating unit 502 sets the group list that indicates the list of the articles that are determined to be moved together as the group list used for the category of “sunny”.
[0114] Furthermore, after the display information created by the display information creating unit 124 is displayed on the display 150 , the group list creating unit 502 may also change the group list in accordance with the operation input that is performed by the user and that is received by the input I/F 140 . Furthermore, in addition to the weather information, the group list creating unit 502 may also classify the category by using, for example, the date, a day of the week, or the like and create a group list used for each category. Thus, the group list creating unit 502 may also create a group list for each category, such as, for example, a “weekday”, a “holiday”, or the like or may also create a group list for each complex category, such as, for example, a “sunny holiday” or the like.
[0115] In the following, an article management process performed by the mobile terminal device configured as described above will be described with reference to the flowchart illustrated in FIG. 16 . In FIG. 16 , components having the same configuration as those illustrated in FIG. 7 are assigned the same reference numerals and descriptions thereof in detail will be omitted.
[0116] In the embodiment, the current weather information on the current location is acquired by the weather information acquiring unit 501 (Step S 501 ). The weather information may also be acquired from a predetermined server via, for example, the Internet or may also be acquired from a predetermined sensor included in the mobile terminal device.
[0117] In contrast, the sensor signal the sensor signal sent from the wireless tag 30 that is mounted on each of the articles and that is positioned in the communication zone of the mobile terminal device 100 is received by the wireless communication unit 110 (Step S 101 ). Then, the identification information included in the sensor signal is checked against the identification information in the target list by the target list checking unit 122 in the processor 120 (Step S 102 ).
[0118] If the result of checking against the target list indicates that the identification information included in the sensor signal is not included in the target list (No at Step S 102 ), the article of the transmission source of this sensor signal is the article or the like that is not, for example, the personal belongings of the user; therefore, the article is ignored as the out of the management target. In contrast, if the identification information included in the sensor signal is included in the target list (Yes at Step S 102 ), similarly to the first to the third embodiments, it is determined, on the basis of the sensor value for each article, whether the movement states of the respective articles are similar (Step S 502 ). Namely, if a difference of the movement likelihood for each article is less than the predetermined threshold, it is determined that the movement states of these articles are similar or, if the spectra of the waveforms of the sensor values in the movement periods for each of the articles are similar, it is determined that the movement states of these articles are similar.
[0119] Then, display information on the basis of the determination result of the similarity is created by the display information creating unit 124 (Step S 109 ). The display information created by the display information creating unit 124 is output to the display 150 and displayed (Step S 110 ). Because the display information is displayed on the display 150 , a user can visually confirm the group of the articles that have the similar movement states. Consequently, the user can input, to the input I/F 140 , the combination or the like of the articles desired to be added to the same group regardless of, for example, the movement state.
[0120] In contrast, if the determination result of the similarity of the movement states of the articles is output to the group list creating unit 502 , a group list categorized by the weather is created by the group list creating unit 502 (Step S 503 ). Specifically, on the basis of the weather information acquired by the weather information acquiring unit 501 , the group list of the articles is associated with the current weather at the current location. Furthermore, the group list may also be associated with the category that is in accordance with, other than the weather, the date or a day of the week. Furthermore, for example, the category that is in accordance with the schedule of a user may also be associated with the group list. Namely, if schedule information on the user is acquired from a predetermined application or the like and if, for example, the current schedule of the user is a “business trip”, the group list may also be associated with the category of the “business trip”.
[0121] When creating such a group list, if an operation input is input to the input I/F 140 by the user who visually confirms the display information, the group list is changed in accordance with the operation input performed by the user. Namely, due to the operation performed by the user, the article belonging to the group list is changed or the group list is associated with the category, such as the weather, or the like.
[0122] As described above, according to the embodiment, the current weather information on the current location is acquired and the group list of the articles that have similar movement states is associated for each category, such as the weather, or the like. Consequently, the articles that are simultaneously carried by the user can be collectively managed, for each category, in the same group and the articles on each of which the wireless tag is mounted can be efficiently managed.
[0123] Furthermore, the fourth and the fifth embodiments described above can be implemented in combination. Namely, it is monitored whether all of the articles belonging to the group list associated with the current weather at the current location are continuously moving together and, if there is the article that is not moving together, it is also possible to notify of, for example, an alert. Consequently, it is possible to prevent the article that is to be simultaneously carried for each category, such as the weather, the date, or the like, from being left behind.
[0124] Furthermore, in each of the embodiments described above, the wireless tag 30 includes the three-axis acceleration sensor; however, the wireless tag 30 may also include another sensor as long as the sensor can detect the movement state indicating whether the article is moving or standing still. An example of such a sensor includes a gyro sensor, a geomagnetic sensor, or the like. Furthermore, the wireless tag 30 may also include, as a sensor that detects a movement of the article, a global positioning system (GPS) receiving apparatus, or the like.
[0125] Similarly, the wireless tag 30 may also include a wireless interface that is different from the BLE. Namely, the wireless tag 30 may also include a wireless interface that can perform near field wireless communication, such as infrared communication, Wi-Fi Direct (registered trademark), or the like.
[0126] Furthermore, the article management process and the alert notification process described in each of the embodiments described above may also be described as a program that can be executed by a computer. In this case, the program may also be stored in a computer readable recording medium and installed in the computer. Examples of the computer readable recording medium include a portable recording medium, such as a CD-ROM, a DVD disk, a USB memory, and the like or a semiconductor memory, such as a flash memory and the like.
[0127] According to an aspect of an embodiment of the article management program, the mobile terminal device, and the article management method, an advantage is provided in that it is efficiently manage articles on each of which a wireless tag is mounted.
[0128] All examples and conditional language recited herein are intended for pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention. | An article management program causes a computer to execute a process including: receiving, from a plurality of articles each including a sensor that detects a movement state of each of the articles, a sensor signal that includes therein identification information on an article and a sensor value of the sensor; and displaying, based on the received sensor signal, display information that indicates in a comparable way a change in the sensor value related to each of the plurality of the articles and the identification information on each of the articles. | 6 |
Development of this invention was funded by Rome Air Development Center of the U.S. Air Force under Contract No. F-30602-82-C-0069
FIELD OF THE INVENTION
The invention pertains to thermionic cathodes of a sintered, porous tungsten matrix impregnated with molten barium aluminate.
PRIOR ART
The basic impregnated cathode is described in U.S. Pat. No. 2,700,000 issued Jan. 18, 1955 to R. Levi. A porous body is formed by pressing tungsten powder, sintering to form a solid porous body, impregnating the pores with a liquid such as molten copper, converting the liquid to a solid as by freezing the copper, machining the impregnated cathode body to desired shape, removing the impregnant as by evaporation or chemical solution, and impregnating the body with barium aluminate. The aluminate is used instead of simple barium oxide because it can be infused in a molten state.
A further improvement is described in U.S. Pat. No. 3,373,307 issued Nov. 12, 1964. This is a thin layer of a platinum-group metal such as osmium, iridium, rhenium, ruthenium on the emitting surface. This results in a lowered work function which permits higher emission and/or lower temperature operation. This improvement was of limited life, later found to be due to the diffusion of the activating metal to alloy with the tungsten substrate, and to sputtering it away by bombardment with positive ions formed by collisions of the accelerated emission electrons with residual gas in the electron-discharge device.
U.S. Pat. No. 4,165,473 issued Aug. 21, 1979 to Louis R. Falce and assigned to the assignee of the present invention, discloses a cathode in which particles of iridium or the like are dispersed among the tungsten particles of the matrix. During sintering the iridium partially alloys with the tungsten. This dispersed cathode solved the problem of surface sputtering. It has been found, however, that the sintering is a very delicate process. If the time and temperature are enough to get a lot of alloying, the emission is often poor. If the sintering is held to a minimum, the emission is initially good, but interdiffusion of iridium and tungsten occurs at operating temperature to form unreactive alloy. This in turn causes the barium supply to the surface to fall off with a resultant decay in emission. Also, shrinkage of the cathode button can take place with the distortion of the emitting surface, which impacts adversely on the electron optics of the gun.
This structure has two basic disadvantages: The platinum-group metals are not as active as pure tungsten in reducing barium oxide to form the metallic barium which diffuses to the surface and activates the emission. Also, these metals are very expensive and to incorporate them in the bulk of the cathode greatly increases the cost.
Proposals have been made to incorporate platinum-group metals only in a surface layer of the body. These have had problems with fabrication. The body shrinks during sintering so the final geometry is distorted and machining down to an affordable amount of activating metal is barely possible.
Other prior art described in U.S. Pat. No. 4,675,570 issued Jun. 23, 1987 to Michael C. Green is to include, in an iridium-alloy matrix, islands of pure tungsten, large enough to resist alloying, to provide increased reducing of barium oxide. The rest of the matrix remains a relatively poor reducing medium, while the islands provide the barium supply.
Throughout this specification, a preferred embodiment of the invention is described. The materials described are only representative of the true scope, which encompasses other similar materials. The word "tungsten" shall be used to include other moderately active refractory metals and alloys, such as molybdenum. The word "osmium" includes other metals of the group consisting of osmium, platinum, iridium, rhenium and ruthenium. The word "barium" includes other alkaline earths and mixtures, such as calcium and strontium.
SUMMARY OF THE INVENTION
An object of the invention is to provide an impregnated cathode of improved emission and life.
Another object is to provide a cathode of low cost.
A further object is to provide a cathode with reproducible characteristics.
These objects have been realized by a cathode whose metallic framework comprises three different layers: an emitting surface layer containing a large percentage of osmium, an underlying buffer layer containing a comparable percentage of osmium, and a substrate of pure tungsten.
A process for producing this structure cheaply and reliably comprises removing the processing impregnant from the tungsten matrix to the depth of the buffer layer, depositing osmium in the buffer layer, removing the rest of the processing impregnant and impregnating the entire body with barium aluminate, and depositing an osmium-rich emitting layer on the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic axial cross-section of the 3-layer cathode.
FIGS. 2-4 are a series of schematic sections illustrating steps in the production process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can best be understood by combining the description of the complete structure with the process of making it, because they are intimately interrelated.
The main body of the cathode is a substrate 10 made by the process well-known in the art. Tungsten particles 12 (FIG. 1) are compacted into a porous mass by isostatic pressing.
I have found it preferable to have particles 12 all about the same size, which may be done by selective settling or sieving. This gives greater porosity for diffusing barium to the cathode surface through the larger pore spaces and also more volume of impregnant for a greater supply of impregnating oxide. A range of 2:1 or less in particle size is beneficial.
The mass is fired in hydrogen at a high temperature to sinter particles 12 together to form a rigid matrix billet with interconnecting pores 14. The matrix shrinks during sintering. The billet is too brittle to be machinable. The pores 14 are infiltrated with molten copper which is frozen to form a machinable body. Alternatively, the process impregnant may be a liquid organic monomer which is heated to polymerize into a solid body. For the inventive cathode process, I have found that the copper impregnant is preferable.
The billet is then machined to the shape of the final cathode body 10 (FIG. 1). In the prior art, the process impregnant was removed by firing or etching and the entire cathode was then impregnated with molten barium aluminate.
In my inventive cathode, substrate 10 is preferably of pure tungsten to provide adequate reduction of barium oxide. A buffer layer 16 (FIG. 2) is formed next to the emitting surface 18. Buffer layer 16 is preferably between 0.01 and 0.1 mm thick to provide low enough resistance to diffusion of barium from substrate 10 to activate the emitting surface. Buffer layer 16 is preferably formed from the body matrix by chemical processing. The process impregnant is removed from the pores 14 by chemical etching or dissolving to the required depth. For copper impregnant dilute nitric acid is satisfactory. In this way the thickness of buffer layer 16 is controlled and made uniform over the cathode emitting surface, regardless of its shape, which is usually concave to produce a convergent beam.
In a preferred embodiment, pores 20 in buffer layer 16 are made larger than pores 14 in substrate 10 (FIG. 2) to provide space for the infiltration of the addition of platinum group metal without blocking the pores, which would impede the diffusion of barium to the emitting surface. This is done by a chemical etchant which selectively dissolves the tungsten and not the process impregnant. Murakami's etch may be used.
The buffer layer 16 is composed of a tungsten-osmium alloy. The active metal may be deposited in the pores from a volatile compound such as osmium tetroxide. A reducing agent such as paraformaldehyde may be previously deposited in the buffer-layer pores to reduce the volatile oxide to an active metal deposit. During subsequent high-temperature firing, the active metal alloys with the tungsten particles.. The purpose of the osmium-rich alloy is to retard the diffusion of osmium away from the surface emitting layer. I have found that osmium diffuses readily into pure tungsten. However, the osmium in the alloy retards the in-diffusion of more osmium from the emissive surface layer.
After buffer layer 16 is formed, the remaining process impregnant is removed from substrate pores 14 by chemical solution or high-temperature vaporization.
The entire cathode body is then impregnated with molten barium aluminate 22, which provides the emission-activating barium and barium oxide (FIG. 3).
The final cathode layer is a thin surface layer 24 (FIG. 4) composed of an alloy of about 50% osmium and tungsten. I have found that this composition provides optimum emission, but alloys in the range between 40% and 60% osmium are good, and over 22% are still satisfactory. Surface layer 24 is preferably produced by atomic deposition, as by sputtering the pre-mixed alloy. The thickness of surface layer 24 should be thick enough to resist depletion during operating life by gas sputtering and any residual diffusion loss of osmium. A thickness of about one micron is desirable. Between 0.1 and 10 microns provides good performance for emission and life. The maximum thickness is limited by the dense layer becoming impervious to the diffusion of barium from the impregnant to the emitting surface.
The above-described cathode and process of manufacture are illustrative of a preferred embodiment and not intended to be limiting. Considerable differences of dimensions and materials are possible to meet a range of requirements such as operating life, emission density, and vacuum conditions in the completed electron discharge device. The scope of the invention is to be limited only by the following claims and their legal equivalents. | An impregnated cathode comprising three layers: a very thin emitting surface layer of metal such as an alloy of tungsten with a high fraction of an activating metal of the platinum group to provide low workfunction; an underlying, thin buffer layer of porous tungsten alloyed with a fraction of activating metal, to retard diffusion loss of activating metal from the emitting layer; and a substrate of porous tungsten impregnated with barium aluminate. | 8 |
BACKGROUND OF THE INVENTION
U.S. Pat. No. 6,126,291 granted to the same inventors of this application disclosed an umbrella having detachable illuminative grip ( 100 ), which however has the following drawbacks:
1. When the illuminative grip ( 100 ) is removed from the inner grip portion ( 202 ) of the shaft ( 201 ), the inner grip portion ( 202 ) will become a “slim bar” and will be inconveniently held or grasped by the umbrella user.
2. The lamp means includes a bulb ( 41 ) mounted in the grip ( 100 ), with the bulb consuming much electric energy for illumination, requiring larger volume and also being vulnerable and easily damaged.
3. No flashing mechanism is provided in the lamp means ( 4 ) to thereby reduce its safety warning effect.
The present inventor has found the drawbacks of the conventional illuminating umbrella, and invented the present umbrella grip having cassette LED illuminating unit detachably mounted therein.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an illuminating umbrella grip including a cassette LED illuminating unit detachably mounted in a holder formed on the umbrella grip, with the LED illuminating unit operatively depressed for a constant or flashing illumination; and upon withdrawal of the LED illuminating unit from the umbrella grip, it may be operated to produce illuminating warning signal for safety purpose, or it may be replaced with a fresh LED unit as fully powered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration showing an opened umbrella of the present invention, which can be automatically opened or closed.
FIG. 2 is a sectional drawing of the cassette LED illuminating unit of the present invention.
FIG. 3 is a bottom view of the cassette LED illuminating unit.
FIG. 4 is a sectional drawing of the holder adapted for engaging the LED illuminating unit.
FIG. 5 shows the LED illuminating unit of the present invention when normally turned off.
FIG. 6 shows the LED illuminating unit of the present invention when turned on.
FIG. 7 shows the circuit diagram of the LED illuminating unit driven with a flasher in accordance with the present invention.
FIG. 8 shows an opened umbrella of the present invention as held in a manually operated umbrella.
FIG. 9 is sectional drawing of the present invention having the parts enlarged from the umbrella of FIG. 8 .
DETAILED DESCRIPTION
As shown in FIGS. 1 ˜ 6 , the present invention discloses an illuminating umbrella grip 210 comprising a cassette LED (Light-Emitting Diode) illuminating unit 100 detachably mounted in a holder 200 formed on the umbrella grip 210 , especially formed on a lower portion of the umbrella grip 210 .
The umbrella of the present invention includes a central shaft 220 consisting of a plurality of tubes telescopically engageable with one another and a rib assembly 300 for securing an umbrella cloth on the rib assembly 300 pivotally secured to the shaft 220 .
The umbrella as shown in FIG. 1 is an automatically opened or closed umbrella with multiple folds, but it may also be modified to be a manually operated umbrella as shown in FIG. 8 or a single-fold umbrella, not limited in the present invention.
The holder 200 may be formed on or fixed to the grip 210 by screws or by adhesive bonding, integral forming, or by any other joining methods, not limited in the present invention.
The holder 200 is preferably formed on or secured to a bottom portion of the umbrella grip 210 to allow the LED illuminating unit 100 to be easily switched on or off through a bottom opening of the grip.
The cassette LED illuminating unit 100 includes: a housing 1 , a LED (light emitting diode) 2 mounted in the housing 1 for projecting light forwardly through a front opening 14 formed in the housing 1 , at least a battery (including button cells) 3 stored in the housing 1 and electrically connected to the LED 2 through a switch 4 slidably or movably formed on or in the housing 1 for switching on the LED 2 for illumination or for turning off the LED 2 .
The housing 1 includes a bottom cover 1 a combined with an upper cover 1 b by screws or by other joining methods to define a battery chamber 10 in between the upper and bottom covers 1 b, 1 a for storing the battery 3 (e.g. one or two button cells) in the battery chamber 10 .
The housing 1 further includes a ring portion 15 formed on a rear portion of the housing 1 to be fastened by a string 16 for a convenient pulling of the housing 1 to be snugly engaged with a cavity 201 formed in the holder 200 as shown in FIGS. 1 and 4 for smoothly mounting the LED illuminating unit 100 in the holder 200 of the umbrella grip 210 . The string 16 is also provided for carrying the umbrella of the present invention.
The housing 1 is preferably made of transparent materials, and is preferably formed as thin disk shape to be slidably inserted into or withdrawn from the holder 200 formed or fixed in the umbrella grip 210 .
The LED 2 includes a first pin 21 adjacent to the upper cover 1 b of the housing and contacting a first electrode or the positive electrode 31 of the battery 3 , and a second pin 22 adjacent to the bottom cover 1 a of the housing 1 and electrically connected with a second electrode or the negative electrode 32 of the battery 3 through the switch 4 slidably or movably formed on the bottom cover 1 a.
The switch 4 includes: a sliding plate 41 slidably held in a shallow chamber 11 formed in the bottom cover 1 a ; a collar 42 protruding inwardly from the sliding plate 41 and slidably engaging with the second pin 22 of the LED 2 , with the collar 42 made of electrically insulative material and being normally resiliently biased by the second pin 22 of LED to be separated from the second electrode 32 of the battery to normally switch off the power supply from the battery 3 to the LED 2 through the second pin 22 (FIG. 5 ); and a push button 43 protruding outwardly or downwardly from the sliding plate 41 to be slidably guided by a slot 12 longitudinally notched through the bottom cover 1 a allowing a sliding or depression movement of the push button 43 of the switch 4 ; whereby upon contacting of the second pin 22 of LED 2 , as driven by the push button 43 moving in the bottom cover 1 a, with the second electrode 32 of the battery 3 , the LED 2 will be powered by the battery 3 for its illumination.
The switch 4 has the collar 42 resiliently biased downwardly or outwardly by the second pin 22 of LED 2 to be normally separated from the second electrode 32 of the battery 3 to normally switch off the power supply from the battery 3 to the LED 2 ; whereby upon an inward or upward depression (D) of the push button 43 , the second pin 22 of LED 2 will be urged inwardly or upwardly to contact the second electrode 32 of the battery 3 to close a power supply circuit between the battery 3 and the LED 2 to illuminate the LED 2 as dotted line shown in FIG. 5; while releasing the depression of the push button 43 , the second pin 22 will resiliently restore the collar 42 and the switch 4 downwardly to switch off the LED 2 ; whereby upon alternative depression or releasing of the push button, the LED will be switched on or off alternatively for a manual flashing operation.
The switch 4 has the sliding plate 42 slidably held in the shallow chamber 11 recessed in the bottom cover 1 a having at least a protuberance 13 protruding inwardly or upwardly towards the battery 3 ; whereby upon a rearward sliding movement of the switch 4 by pushing the button 43 rearwardly, the sliding plate 42 will be simultaneously thrusted rearwardly to be gradually biased by the protuberance 13 as shown in FIG. 6 to inwardly or upwardly bend the second pin 22 , as held on the collar 42 formed on the sliding plate 41 , to be contacted with the second electrode 32 of the battery 3 to power and illuminate the LED 2 .
As shown in FIG. 4, the holder 200 includes: a cavity 201 formed in a hollow portion in the holder 200 for embedding the cassette LED illuminating unit 100 in the cavity 201 , a front hole 202 having a width generally equal to a width of the LED illuminating unit 100 for inserting the LED illuminating unit 100 therethrough, a rear hole 203 formed in a rear portion of the holder 200 for passing the string 16 of the housing 1 of the LED illuminating unit through the rear hole 203 , a bottom hole 204 formed in a bottom portion of the holder 200 to reveal the push button 43 of the switch 4 of the LED illuminating unit 100 for an operation of the push button 43 through the bottom hole 204 , a resilient hook member 205 resiliently formed on an upper portion of the holder 200 for resiliently urging the LED illuminating unit 100 downwardly to engage a protrusion 17 formed on a bottom portion of the LED illuminating unit 100 with a stopping portion 206 formed on a front portion of the holder 200 for stopping a forward releasing of the LED illuminating unit 100 from the holder 200 (FIG. 4 and FIG. 9 ); whereby upon inward or upward depression of the protrusion 17 to disengage from the stopping portion 206 , the LED illuminating unit 100 will be removed from the holder.
As shown in FIG. 7, a flasher (Fl.) 5 is connected in series in an illumination circuit including the LED 2 , the switch 4 and the battery 3 , whereby upon actuation of the switch 4 to start the flasher 5 , the LED 2 will be blinked automatically as driven by the flasher 5 .
For embedding or inserting the LED illuminating unit 100 in the holder 200 integrally formed on the umbrella grip 210 as shown in FIGS. 8, 9 , a manually-operated umbrella will be implemented with the illuminating device, i.e., the LED 2 , for a safe illumination purpose.
The present invention is superior to a conventional illuminating umbrella with the following advantages:
1. The illuminating device is a LED with miniature volume, light weight, and convenient operation and maintenance.
2. The LED illuminating unit 100 can be conveniently detachably withdrawn from the holder 200 on the umbrella grip 210 for a convenient maintenance, e.g., for replacing a new unit 100 and for serving as a miniature portable device for a convenient lighting or optical safety warning or signaling purpose.
3. Since the LED unit 100 is a small unit and even after being removed from the grip 210 , the umbrella grip 210 can still be ergonomically grasped.
4. Either manual or automatic flashing mechanism is provided for a flashing illumination for better warning effect.
The present invention may be modified without departing from the spirit and scope of this invention. | An illuminating umbrella grip includes a cassette LED illuminating unit detachably mounted in a holder formed on the umbrella grip, with the LED illuminating unit operatively depressed for a constant or flashing illumination; and upon withdrawal of the LED illuminating unit from the umbrella grip, it may be operated to produce illuminating warning signal for safety purpose, or it may be replaced with a fresh LED unit as fully powered. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) to provisional application Ser. No. 61/787,007, filed Mar. 15, 2013.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to achieving increased power conversion efficiency from the use of thermoelectric metamaterials, and more particularly to such metamaterials that can be formed or assembled in specific geometric configurations that are optimized for certain applications.
[0006] 2. Description of Related Art
[0007] Approximately 60% of energy produced in the United States is wasted in the form of heat. Industrial applications, automobiles and commercial/residential heating systems all generate an enormous amount of unused waste heat. Thermoelectric (TE) materials have the ability to convert heat into electricity by utilizing the Seebeck effect, where a voltage difference proportional to a temperature difference is produced when two dissimilar materials are joined together and their junctions held at different temperatures.
[0008] The phenomenon also works in reverse where a temperature difference is developed when a voltage is applied (Peltier effect). With respect to generating an output voltage, thermoelectric conversion efficiency is expressed through the dimensionless figure of merit ZT where increasing values of ZT equate to higher power conversion efficiencies. For isotropic materials, ZT=σS 2 T/x where Z is the figure of merit, T is temperature, σ is electrical conductivity, S is the Seebeck coefficient and x is the thermal conductivity. The power factor PF is another important thermoelectric parameter and is expressed as PF=σS 2 . It is immediately obvious that a large power factor and small thermal conductivity will result in higher power generation efficiencies.
[0009] Research efforts often engage the power factor PF=σS 2 initially, which, is optimized as a function of carrier concentration through doping. Further enhancements to ZT may be attained by reducing the thermal conductivity, however TE materials facilitate heat flow through both lattice and electronic contributions to the total thermal conductivity. Starkly demonstrating the coupled transport issue, σ is usually proportional to the electronic thermal conductivity through the Wiedemann-Franz relationship.
[0010] Therefore, reductions in the electronic thermal conductivity are accompanied by proportional reductions in σ thus negating ZT enhancements. Some efforts have focused on material fabrication techniques that result in preferential lattice phonon scattering compared to electrons. This reduces the lattice contribution to thermal conductivity which is a step in the right direction because in most TE materials, phonons are the predominant heat conduction mechanism. Fundamentally, this is a form of microscopic heat conduction management, which has the potential to dramatically increase ZT. While modern thermoelectric energy conversion devices operate at a ZT of about 0.75-1.5, the ZT must be raised to approximately 4 or greater to effectively compete with other power generation methods.
[0011] This invention utilizes a new method to precisely control the flow of heat in a thermoelectric material resulting in tunable effective thermal conductivity x eff properties. The method involves geometrical configurations that result in a bulk material that exhibits properties unlike any found in naturally occurring materials, i.e., a metamaterial. The host material Seebeck coefficient and electrical conductivity remain unchanged. The metamaterial configuration enables x eff to be selectively lowered or raised while maintaining a constant PF that is unperturbed from the host material. When x eff is lowered, the thermoelectric metamaterial exhibits high energy conversion efficiency through engineered control over the thermal transport properties. Further tuning of the transport properties result in a large figure of merit for cooling or heating applications. Consequently, the figure of merit and power generation efficiency may be substantially increased by selectively tuning the transport properties via geometrical design configurations.
[0012] The deliberate control of energetic fields and currents to produce specific selective material properties is characteristic of artificial materials or metamaterials. Metamaterials incorporate artificially combined components and should be distinguished from the widely used alloy-based processing of TE materials. Alloying entails diffusion and reaction processes that result in thermodynamically governed phases. Metamaterials are typically multi-component materials whose constituents retain their original composition and structure but may be patterned in a periodic manner. Despite the breadth of research on metamaterials (e.g., photonics, phononics, etc.), limited applications of artificial TE materials have surfaced in the literature. Several reports on the fabrication and characterization of tilted multilayer structures intended to create a transverse Seebeck response have been published, however, the research intent of these groups focused upon measurements rather than transport property manipulation. The relevant component of their work lies in the fact that they created anisotropic thermoelectric effects from carefully designed macroscopic layered structures, thus emulating crystalline materials that naturally exhibit anisotropic thermoelectric coefficients. There have also been reports on general heat flux manipulation through geometry-centric configurations, however, there have been no reports on utilizing metamaterial-based thermal management techniques to enhance the figure of merit, Z. Considering an artificial TE material subjected to a temperature difference, the induced thermal transport behavior resulting from carefully arranged materials may be contrary to expectations and more importantly, manipulated and controlled for a specific purpose.
SUMMARY OF THE INVENTION
[0013] Therefore, in a preferred embodiment, a thermoelectric metamaterial is provided, comprising a plurality of component materials selected from the group consisting of dielectrics, semiconductors, semimetals, and metals; and wherein the plurality of component materials are placed into contact with one another and arranged in a selected geometrical configuration adapted to achieve a thermal conductivity of the metamaterial that is different from the thermal conductivity of each of the component materials.
[0014] The component materials are arranged such that the figure of merit of the metamaterial and the power conversion efficiency of the metamaterial are increased relative to the figure of merit and power conversion efficiency of each of the component materials.
[0015] In a more preferred embodiment, one of the component materials includes nanoparticles of another component material.
[0016] In a further embodiment, the geometric configuration of the component materials is rearranged to affect a change in the thermoelectrical properties of the metamaterial.
[0017] The component materials are placed into contact with one another by mechanical pressure, adhesives, or welding.
[0018] Optionally, the component materials have surfaces which are coated with another component material.
[0019] In another embodiment, the thermoelectrical properties of the metamaterial are adjusted to suit a desired application by changing one or more of the following attributes: (a) one of the component materials, (b) the geometric configuration of the component materials, (c) the volume of one or more of the component materials, (d) the absence of a component material at a selected location within the metamaterial, and (e) the manner of contact between the component materials.
[0020] The above and other objects and features of the present invention will become apparent from the drawings, the description given herein, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements.
[0022] FIG. 1 depicts a schematic diagram of a possible thermoelectric (TE) material having a particular geometric configuration.
[0023] FIG. 2 depicts a finite element result of the heat flux vector direction for the TE material of FIG. 1 .
[0024] FIG. 3 depicts a finite element result of the electrical current vector direction for the TE material of FIG. 1 .
[0025] FIG. 4 depicts a graph showing tower conversion efficiency as a function of load resistance for a sample material and a control material.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Before the subject invention is further described, it is to be understood that the invention is not limited to the particular embodiments of the invention described below, as variations of the particular embodiments may be made and still fall within the scope of the appended claims. It is also to be understood that the terminology employed is for the purpose of describing particular embodiments, and is not intended to be limiting. Instead, the scope of the present invention will be established by the appended claims.
[0027] In this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs.
[0028] Referring now to FIG. 1 , one example of a thermoelectric metamaterial configuration 1 is depicted. This configuration is only one of many possible geometrical designs. The light-colored component 2 represents the monocontinuous thermoelectric host material and the dark-colored component 3 represents the dielectric material. The geometrical design is aimed at separating the electrical and thermal currents in order to independently tune x. A direct method to accomplish such decoupling is to fabricate a two-component monocontinuous composite constructed in layered form. As depicted in FIG. 1 , the monocontinuous TE host material 2 provides an uninterrupted electrical current path while an electrical insulator or dielectric (DE) material 3 layered between the TE host material 2 provides a thermally conductive path only. This configuration exploits diffusive heat flow between the TE and DE materials that is selective by blocking charge transfer yet allowing thermal current flow. By selecting a DE material with the appropriate thermal conductivity and geometrical dimensions, thermal currents develop a tensorial form and rotate at an angle θ with respect to the electrical current. From a thermal management perspective, the thermal conductance of the local TE-DE region must be larger than adjacent regions resulting in heat current diversion from the TE into the DE. Consequently, heat flows from a material with both lattice and electronic contributions (TE) into a material with lattice participation only (DE). This field-induced anisotropy places thermal resistances in series when the hot and cold sources are arranged as shown in FIG. 1 .
[0029] Series thermal resistances are analyzed through summation thus leading to a total thermal resistance that may be precisely tuned and alternatively expressed by an effective thermal conductivity x eff . By selecting DE materials with a smaller thermal conductivity than the TE, the metamaterial structure exhibits an effective thermal conductivity x eff lower than the TE material alone. Equally important, the PF remains unchanged due to energetic neutrality of the DE with respect to electrical and thermoelectrical transport. As a result, the TE metamaterial behaves as a single material from an electrical and thermoelectrical standpoint yet responds thermally as a two-component composite.
[0030] With respect to FIG. 2 , finite element computational results are shown for the heat flux vector direction in the TE metamaterial of FIG. 1 . In this specific example, the top of the metamaterial 1 is at 301 K while the bottom is at 300 K. The field induced anisotropy results in thermal currents directed downward rather than flowing along the thermoelectric material length. Guiding the thermal current through the low thermal conductivity dielectric layers degrades the overall thermal conductivity resulting in precise engineered control over x eff . FIG. 2 also confirms that the thermal gradient 4 is approximately uniform across the material width which indicates a heat flux traveling through alternating TE-DE layers in a nearly constant manner, rather than down the length of the TE. The isotherms show little deviation when compared with the Bi 2 Te 3 control sample isotherms despite the presence of DE layers that exhibit a fraction of the thermal conductivity of Bi 2 Te 3 . Analogous to electromagnetic cloaking, the TE acts as the “cloaked” material, barely perturbing the heat flux moving in the y-direction. As a result of geometrical design, the heat flux is being guided through thermal resistances in series, resulting in a lower effective thermal conductivity when the DE material thermal conductivity is less than the host TE thermal conductivity.
[0031] With respect to FIG. 3 , finite element computational results are shown for the electrical current vector direction in the TE metamaterial of FIG. 1 . The top of the metamaterial 1 is at 0.2 millivolt while the bottom is at 0 volts. The electrical current 5 travels down the length of the monocontinuous thermoelectric material only. The dielectric material has no effect on the electrical and thermoelectrical behavior thus leaving these transport properties unchanged. The result is a complete decoupling of the electrical conductivity, Seebeck coefficient and Peltier coefficient from the effective thermal conductivity of the metamaterial.
[0032] In FIG. 4 , power conversion efficiency is shown as a function of load resistance for a Bi 2 Te 3 (bismuth telluride) control material and a Bi 2 Te 3 metamaterial configured identical to FIG. 1 . The metamaterial incorporated a thermoset polymer (DP190-Gray, 3M Co.) as the dielectric material and the effective thermal conductivity x eff was measured at 0.318 W/m-K. Theoretical predictions and finite element computations of x eff resulted in 0.310 W/m-K and 0.319 W/m-K respectively. Consequently, manipulation and control of x eff has been validated experimentally and shows good agreement with theory. The control sample thermal conductivity was measured at 1.62 W/m-K. The Seebeck coefficient and electrical resistivity measurements showed no difference between the control sample and the metamaterial. Throughout the range of measurements, the metamaterial efficiency remained about five times (5×) greater than the control sample. This is due entirely to the decreased x eff which is approximately one fifth (⅕) of the control sample thermal conductivity. Due to the thermal conductivity appearing in the denominator of the efficiency equation, experimental results show excellent agreement with theoretical predictions.
[0033] Based on the foregoing descriptions, it can be seen that if an electrical conductor is interfaced with a dielectric material and submitted to a temperature gradient, a heat current will be transported by phonons and electrons within the conductor and phonons only for the dielectric (phonons representing the crystal lattice contribution to heat flow). As a result, the dielectric participates in heat conduction only, but does not take part or contribute to electrical conduction or thermoelectric effects. FIG. 2 shows computational results confirming this phenomenon. The thermal current is represented by the vector arrows in FIG. 2 and clearly follows a downward pattern that results in heat flow through alternating thermoelectric and dielectric layers. If a low thermal conductivity dielectric is selectively placed in a predetermined pattern (for example, FIGS. 1 and 2 ), thermally in series with the conductor, the overall effective thermal conductance may be substantially lowered.
[0034] Using transformation media techniques, computational analysis and theoretical predictions, the conductor and dielectric may be geometrically configured into a metamaterial where the material temperature gradient closely resembles that of any other typical temperature gradient of a regular material placed between hot and cold sources. FIG. 3 shows computational results for electrical current flow. The electrical current is represented by the vector arrows of FIG. 3 and confirms that electrical current flows through the thermoelectric material only. As a result, electrical conductivity and thermoelectric effects of the monocontinuous host material remain unchanged. Therefore, the power factor PF remains unchanged. The result is a thermoelectric metamaterial that behaves electrically and thermoelectrically like a single material, yet thermally as a classical composite with greatly reduced thermal conductivity. The reduced thermal conductivity results in a lower rate of heat flow into the metamaterial. Power conversion efficiency η is expressed as η=P out /Q n where P out is the useable output power of the thermoelectric material and Q in is the heat input to the thermoelectric material.
[0035] Subsequently, the ability to lower results in lower heat input Q in thus raising the efficiency η substantially. FIG. 4 shows experimental results of efficiency measurements on an unaltered bismuth telluride control sample and a bismuth telluride metamaterial. The experimental results agree well with theoretical predictions. While the TE metamaterial used in this initial study was configured as shown in FIG. 1 , it should be made clear that there are many different geometrical configurations that may be used to manipulate thermal, electrical and thermoelectrical properties. Therefore, while the 5-fold increase in efficiency is extremely high, there is the distinct likelihood that further research will reveal other metamaterial configurations that exhibit much higher increases in efficiency.
[0036] There are two main design parameters for thermoelectric metamaterials, namely geometrical configuration and materials selection. With respect to the geometrical configuration, the shape, volume and material constituents may be fashioned in any number of ways. The manipulation of thermal currents may be intelligently guided by changing the way a material is geometrically configured within a second host material. Specific applications and optimization goals would determine the final overall geometry. The materials selected would include multiple materials combined to form the overall thermoelectric metamaterial. These materials could be dielectrics, semiconductors, semimetals and metals. Combinations of these materials may be joined or interfaced to achieve the desired thermal or electrical current control. There may also be intentional voids which contain no solid material. Each individual material may also be modified to achieve the desired performance. For example, micro or nanoparticles may be mixed, dispersed, interfaced with or combined through solid state chemistry with a primary material. Micro or nanoparticles may also form their own individual material component in the metamaterial. Surface coatings may also be used on some or all constituent materials. These coatings may be electrically conductive or non-electrically conductive. Magnetic materials may also be used in the form of a constituent material, micro/nanomaterial or coating. The materials that make up the final metamaterial may be joined by numerous methods such as epoxy, solder, welding, compression or tension devices or other means.
[0037] Thermoelectric materials display the advantage of reverse operation. For example, instead of applying a temperature difference to generate electricity, one may apply electrical power to the thermoelectric to generate hot and cold surfaces. This phenomenon is known as Peltier cooling or heating. Peltier cooling and heating devices are used mainly in specialty applications because their conversion efficiency is typically lower than conventional vapor-compression cooling or heating systems. The metamaterial concept explained in this specification applies equally well to the Peltier cooler or heater. The corresponding figure of merit (Z) will climb substantially as a result of thermal conductivity tuning offered by metamaterials.
[0038] All references cited in this specification are herein incorporated by reference as though each reference was specifically and individually indicated to be incorporated by reference. The citation of any reference is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such reference by virtue of prior invention.
[0039] 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 methods differing from the type described above. 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 set forth in the appended claims. The foregoing embodiments are presented by way of example only, and the scope of the present invention is to be limited only by the following claims. | A thermoelectric metamaterial is provided, comprising a plurality of component materials selected from the group consisting of dielectrics, semiconductors, semimetals, and metals. The component materials are placed into contact with one another and arranged in a selected geometrical configuration adapted to achieve a thermal conductivity of the metamaterial that is different from the thermal conductivity of each of the component materials. Specifically, the component materials are arranged to affect an increase in the figure of merit and power conversion efficiency of the metamaterial. The thermoelectrical properties of the metamaterial may be adjusted to suit a desired application by changing one or more attributes, including: (a) one of the component materials, (b) the geometric configuration of the component materials, (c) the volume of one or more of the component materials, (d) the absence of a component material at a selected location within the metamaterial, and (e) the manner of contact between the component materials. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a wheel lighting system and more particularly to a disk and light assembly which is attachable to the lugs of a vehicle wheel.
2. Description of the Prior Art
Novelty vehicle lighting items have become very popular because of their ability to enhance the appearance of vehicles. In the past, lights were attached to vehicles only for purposes of visibility enhancement and safety. But now, lights are also used on vehicles for convenience and aesthetic purposes. For example, lights are now used as door lights, interior mirror lights, reading lights, etc.
It has long been a desire to illuminate the wheels of vehicles to enhance their aesthetic appeal, yet to date, a simple and reliable lighting apparatus has not been developed. There has been a desire for a wheel lighting apparatus wherein a plurality of lights could be positioned behind the wheel of a vehicle in such a manner that the lights would receive their power from the nonrotating vehicle, but still while the wheel rotated. A desirable feature of such a system would allow the vehicle owner to orient the lights as he chooses, i.e., to customize the placement of the lights to accommodate the particular type of wheel used on the vehicle.
Styer et al., U.S. Pat. No. 1,643,593, discloses a wheel mounted light which rotates with the wheel. Styer's device also includes a ring, which when used in conjunction with a brush, allows for the transfer of electrical current from the nonrotating vehicle to the rotating light.
Bradway, U.S. Pat. No. 3,113,727, discloses another wheel illumination device in which lights are electrically connected to the automobile power source by means of wires connected to a complicated lug bolt and spring tensioned brush system.
Hinricks U.S. Pat. No. 4,381,537, discloses a wheel illumination device which is not attached directly to the wheel and so no system for transferring electricl current from the nonrotating automobile power source to the rotating wheel is disclosed.
None of these prior art references discloses a ring system which completely incorporates all the structure required to transfer electrical current from a nonrotating vehicle power source to a rotating wheel light.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide an electrical lighting system for vehicle wheels which is usable on nearly any type of wheel. It is also an object of the invention to provide such a system which may be readily mounted on and dismounted from vehicles and vehicle wheels.
It is a further object of the invention to provide such a system which is constructed to minimize the chance of dirt or grit from reaching and damaging system parts.
The above and other objects of the invention are realized in a specific illustrative embodiment of a disk assembly and light assembly for use on a vehicle wheel having a hub and lug bolt system of wheel attachment. The disk assembly includes a mounting plate for mounting to the wheel hub, where the plate has mounting holes capable of matching with any lug bolt vehicle hub design. The assembly also includes a brush ring and a face ring which rotate relative to each other when the wheel is rotated relative to the vehicle. The disk assembly further includes an insulator to which the mounting plate, face ring and brush ring are assembled and which provides electrical separation of the face ring and brush ring from the mounting plate by being positioned therebetween, and a connector plate, which is attached to the mounting plate and provides means for connection of the light assemblies thereto. The insulator prevents the brush and face rings from electrically shorting with the mounting plate or any other part of the vehicle.
The light assembly includes a light bulb and bracket arrangement having a colored lens and a reflector plate. The light assembly further includes a lens stem which attaches the light to the connector plate of the disk assembly at any position around the disk perimeter. The lens stem is bendable so as to allow positioning of the light to illuminate the openings in any wheel design. The light is electrically connected on its positive side to the face ring of the disk and on its negative side to the mounting plate via the light reflector and the lens stem.
Any number of light assemblies may be used to obtain the desired illumination of the wheel. The mounting plate of the disk can be attached to any common type of vehicle wheel including four or five lug bolt designs as well as disk or drum braking systems.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a partially cut away, exploded, perspective view of the disk assembly of the wheel lighting system of the present invention showing how it would be mounted on a wheel and hub;
FIG. 2 is a front view of the disk assembly and an attached light assembly of the invention;
FIG. 3 is a rear view of the disk assembly and attached light assembly;
FIG. 4 is a cross-sectional view of the lighting system of FIG. 2 taken along lines 4--4;
FIG. 5 is a side, exploded, view of the light system oriented for mounting on an automobile brake drum; and
FIG. 6 is a side view of the disk portion of the invention mounted to a disk brake system.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows one illustrative embodiment of the present invention oriented for attachment between a wheel 11 and a hub 12 of a conventional vehicle. The two major parts of the vehicle wheel lighting apparatus include a disk assembly 10 and light assemblies 20. The disk assembly 10 attaches to the vehicle hub 12, and allows electrical current to pass from the stationary (nonrotating) vehicle, to the rotating assembly. Any number of light assemblies 20 can thereafter be attached to the disk assembly 10 at any location which will create the desired illumination of the wheel.
Moving now to a more complete description of the disk assembly 10, FIG. 2 shows the face of the disk assembly 10 which is located adjacent the wheel 11 when attached. The disk assembly is a combination of several ring shaped elements including a face ring 25, a brush ring 30, a buffer ring 38, an insulator 19, a mounting plate 15, and a connector plate 31.
The insulator 19 of the disk assembly 10 has two main functions. First, it electrically separates the face ring 25 and brush ring 30, from the mounting plate 15 and connector plate 31. Secondly, it provides the necessary surfaces to which all other elements of the disk assembly are mounted.
The mounting plate 15 is used to attach the disk assembly to the hub of a vehicle. It contains holes 14 which are arranged in a circular pattern such that they can match up with and allow to pass through, any standard arrangement such as a four or five lug bolt type vehicle hub.
The electrically conductive face ring 25 has its interior surface in rotatable electrical contact with an adjacent surface of electrically conductive brush ring 30. Face ring 25 contains tabs 49 which are spaced completely around its exterior surface to allow electrical attachment of the light terminal wire 40 in a manner which will later be described. Brush ring 30 also includes axle bracket loops 43 which allow an axle bracket 44 to be attached thereto in order to prevent its rotation relative to the vehicle. Axle bracket 44 is attachable to the axle bracket loops 43 by means of ties 45 or the like. Axle bracket loops 43 are also used to attach a source of electrical current such as wire 46 to the brush ring 30. Wire 46 is threadedly attached to the loop 43 thus electrically connecting the brush ring 30 to the vehicle's electrical power source (not shown). Since the brush ring 30 is in continuous rotatable electrical contact with face ring 25, electrical current can pass to face ring 25 even when the face ring 25 is rotating relative to the brush ring 30.
Light assembly 20 comprises a bulb 35, a set of brackets 41 and 42, a lens 23, a reflector 33, and a lens stem 17. As previously stated, the light assembly 20 is secured against movement relative to the disk assembly 10 by means of the lens stem 17.
The reflector 33 is attached to the lens 23 and bracket 41 at one of its ends by means of a rivet or the like. The opposite end of reflector 33 is generally circular and located behind the bulb 35 such that it will reflect light through the lens 23. This circular end of the reflector 33 contains tabs 34 which can be fastened by cutting portions of the reflector in a generally semi-circular pattern and then bending the semi-circular portion away from the surrounding material.
Lens stem 17 is a long, thin, bendable, and electrically conductive strip of material which contains holes 47 at one end for attachment with the reflector 33 of the light assembly 20, and connector tab 51 at its other end for attachment with the connector plate 31 of disk assembly 10.
The lens stem 17 is attached to the reflector 33 by means of reflector tabs 34 being inserted through stem slots 47. Then the tab 51 of the lens stem 17 is attached to the connector plate 31. When thus positioned, tab 51 is in contact with electrically conductive mounting plate 15. When the mounting plate 15 is attached to the lug bolts 13 of the vehicle, an electrical path is created which electrically grounds the negative side of light assembly 20.
The light assembly 20 attaches to the face ring 25 by means of terminal wire 40. The terminal wire 40 has a snap fit end 22 which snaps to the bracket 42, and a terminal loop end 52 which loops over face ring tab 49. When thus assembled, electrical current can pass from the face ring 25 to the light bulb 35 through the terminal wire 40.
It should be noted here that ridge 27 of the insulator ring 19, insulates the mounting plate 15 from the electrically conductive rings 25 and 30 to prevent the current supplied to the brush ring 30 from shorting across to the mounting plate 15 and disabling the light assembly 20.
FIG. 3 shows the reverse side of the disk assembly 10 which attaches adjacent the hub 12 of the vehicle. As best seen in FIG. 3, the insulator also has a radially extending portion 29, notch portion 54 and a mounting extension 28. Mounting extension 28 and notch portion 54 of insulator ring 19, are shown to securely hold the mounting plate 15 and the face ring 25 respectively by means of rivets 26 or the like.
Further, as best shown in FIGS. 2 and 4, mounting plate 15 also is attached to the stem connector plate 31 by rivets 26 in a like manner. Although the stem connection plate 31 is rigidly riveted to the mounting plate 15, there is sufficient spacing to allow for a plurality of the connector tabs 51 of lens stem 17 to be forced in between their adjacent surfaces at various locations around the disk. Stem connector plate tabs 53 are located such that they extend through openings 54 in the lens stem 17 to hold it in place and prevent its removal. Ridge 27 of insulator 19 abutts with mounting plate ridge 24 and prevents the mounting plate from any electrical contact with the remainder of the disk assembly 10.
Electrically conductive face ring 25 is attached to the notch portion 54 of the insulator 19 in such a manner as to create a toroidal-shaped brush track 32 in which electrically conductive brush ring 30 can rest as the remainder of the disk assembly 10 rotates with the wheel 11. Brush ring 30 comprises a contacting portion 36 and retaining portion 37. Contacting portion 36 electrically joins with the interior surface of the face ring 25 such that electrical current can pass from the brush ring contacting portion 36 to the face ring 25, even when it is rotating relative to the brush ring 30. To insure continuous contact between the brush ring 30 and the face ring 25, yet prevent excessive friction, noise and wear, a buffer ring 38 is located in the brush track 32 between the radially extending portion 29 of the insulator 19, and the brush ring 30. The buffer ring 38 freely "floats" in the brush track 32 and is prevented from misorientating itself during rotation by the brush ring retaining portion 37. The buffer ring 38 prevents excessive friction and noise by preventing the brush ring from contacting the insulator 19 at the bottom of the brush track 32.
FIG. 6 shows a modification of the invention when it is desired to attach it to a vehicle wheel which uses a disk type braking system. Instead of using the ties 45 to attach the axle bracket loop 43 to the axle bracket 44, a tie 45 is used to attach an axle bracket loop 43 to any nonrotating portion of the brake calliper assembly 39. In this type of installation, the axle bracket 44 need not be used.
As explained above, any number of light assemblies 20 may be connected about the disk assembly 10 to effect the desired lighting of the vehicle wheel 11. Reflector 33 is connected to the ground side of the light bulb 35 through bulb bracket 41. The bulb bracket 42, connected to the positive or hot side of the bulb 35, comprises electrical terminal 21 which is connectable with the snap fit end 22 of the terminal wire 40. The opposite end of terminal wire 40 comprises terminal loop 52 which can be attached to any one of the face ring tabs 49. With the terminal wire thus connected, electrical current can pass from the face ring 25 to the light bulb 35.
The light assembly further comprises a lens 23 which can be of any desired shape or color, and which covers the bulb 35 on the wheel side when installed between the wheel 11 and hub 12.
The insulator 19 can be made of any rigid nonconductive material such as fiberglass or nylon. The buffer ring 38 can be made of any wear resistant material such as nylon, teflon or fiberglass. The brush ring 30, face ring 25 and mounting ring 15 can be made of any electrically conductive material such as stainless steel.
To install the lighting system on a vehicle, the disk assembly 10 is placed onto the hub 12 by inserting the lug bolts 13 through mounting holes 14 in the mounting plate 15. The axle bracket 44 is attached to the axle bracket loops 43 on the brush ring 30 by means of ties 45. The axle bracket 44 is then secured to the vehicle axle 50 by means of a larger tie 48.
If the lighting system is to be attached to a vehicle wheel having disk brakes as shown in FIG. 6, the axle bracket is not used. Istead the axle bracket loop 43 of the brush ring 30 is attached to a fixed portion of the calliper assembly 39 by means of a tie 45. Either method fixes the brush ring 30 to the vehicle body in a nonrotating manner. The source of electrical current from the vehicle, represented as wire 46, is then also attached to one of the axle bracket loops 43. A desired number of lens stems 17 are attached to the stem connector plate 31 by pushing the connector tabs 51 between the stem connection plate 31 and the mounting plate 15 such that the connector tabs 51 are forced into electrical contact with the mounting plate 15 as best shown in FIG. 4. Stem connector tab 53 is bent over the lens stem 17 to prevent its removal once in place.
Next, the reflector tabs 34 are inserted through the desired slots 47 in the lens stem 17 and secured by clamping the tabs against the back of the lens stem. The terminal wire 40 is then snap-fitted to the electrical terminal 21 and the terminal loop 52 of the terminal wire 40 is placed over the face ring tab 49 and secured by clamping the tab securely around the terminal loop 52.
The wheel 11 is then inserted over the lug bolts 13 and the light assemblies 20 are adjusted so as to direct their light through the openings 18 in the wheel in the desired manner. Then, the wheel 11 is finally secured in place by means of lug nuts 16.
It is to be understood that the above-described embodiments and the description of installation are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative embodiments may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and embodiments. | The invention relates to a lighting system for vehicle wheels and comprises a disk assembly which facilitates the electrical attachment of a rotating light with a stationary electrical power source of a vehicle. Further, the invention includes a mounting system for mounting a disk to the lugs of the vehicle on the inside of the wheel. The disk comprises first and second coaxially mounted electrically conductive rings which remain in continuous electrical contact when rotated relative to each other. The mounting system includes an electrically conductive portion and an insulator portion which electrically separates the mounting assembly from the first and second rings; the electrically conductive portion of the mounting means being used to electrically ground the rotating lights. | 1 |
FIELD
The subject matter herein generally relates to detecting systems and methods for detecting products, and particularly to a system and method for detecting shapes, sizes, and/or positions of products.
BACKGROUND
On an assembly line, products need to be checked regularly for constancy, shapes, sizes and/or positions. Typically, the checking procedure is done manually by workmen using simple tools.
BRIEF DESCRIPTION OF THE DRAWINGS
Implementations of the present technology will now be described, by way of example only, with reference to the attached figures.
FIG. 1 is a structural diagram of an embodiment of a detecting system.
FIG. 2 is a structural diagram of the feeding module of FIG. 1 .
FIG. 3 is a structural diagram of the detecting module of FIG. 1 .
FIG. 4 is a structural diagram of the discharging module of FIG. 1 .
FIG. 5 is a structural diagram of the conveying module of FIG. 1 .
FIG. 6 is a flow diagram of a process for an operation method of the detecting system for products.
DETAILED DESCRIPTION
It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the present disclosure.
Several definitions that apply throughout this disclosure will now be presented.
The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. The term “comprising”, when utilized, means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in the so-described combination, group, series, and the like.
The present disclosure is described in relation to a detecting system and an operation method of the detecting system for products.
FIG. 1 illustrates a structural diagram of a detecting system. The detecting system 100 can include a feeding module 10 , a detecting module 20 , a discharging module 30 ; a conveying module 40 , a data processing module 50 , and a control module 60 . The feeding module 10 can be configured to supply the detecting system 100 with a plurality of products 200 . The detecting module 20 can be configured to detect shapes, sizes and/or positions of the products 200 . The discharging module 30 can be configured to remove the finished products 200 from the detecting system 100 . The conveying module 40 can be configured to transport the products 200 from the feeding module 10 to the detecting module 20 , or from the detecting module 20 to the discharging module 30 .
The data processing module 50 can be electrically connected to the detecting module 20 . The data processing module 50 can collect data information measured by the detecting module 20 , and determine whether the products 200 are qualified or not according to the data information. The data processing module 50 can include a display configured to show a diagram of product 200 numbers and quality information corresponding to the product 200 numbers. A workman can achieve the quality information of products 200 by looking at the display. In at least one embodiment, an alarm (not shown) can be electrically connected to the data processing module 50 , when the data processing module 50 picks up an unqualified product 200 , the alarm sounds, warning the workman of the unqualified product 200 .
The feeding module 10 , the detecting module 20 , the discharging module 30 , the conveying module 40 , and the data processing module 50 can be electrically connected to, and controlled by the control module 60 .
FIG. 2 illustrates a structural diagram of the feeding module 10 of the detecting system. The feeding module 10 can include a feeding portion 11 , a first station 12 opposite to the feeding portion 11 , a first slide 13 positioned between the feeding portion 11 and the first station 12 , and a first sliding member 14 coupled to the first slide 13 . The first sliding member 14 can move between the feeding portion 11 and the first station 12 . When the first sliding member 14 is positioned on the feeding portion 11 , and the products 200 to be detected can be loaded into the first sliding member 14 . The first sliding member 14 can convey the products 200 from the feeding portion 11 to the first station 12 . Then the first sliding member 14 can return to the feeding portion 11 .
FIG. 3 illustrates a structural diagram of the detecting module 20 of the detecting system. The detecting module 20 can include a first detecting unit 21 corresponding to the first station 12 (see in FIG. 2 ), a second detecting unit 22 , and a second station 23 corresponding to the second detecting unit 22 . The first detecting unit 21 can include a charge-coupled device (CCD) configured to get size and position images of the products 200 .
The second detecting unit 22 can include a measurement probe configured to detect a height difference between two planes 201 and 202 of the products 200 . In the illustrated embodiment, a product 200 can be detected by the first detecting unit 21 first, then the product 200 can be transported from the first station 12 (see FIG. 2 ) to the second station 23 by the conveying module 40 (see FIG. 1 ), and detected by the second detecting unit 22 .
FIG. 4 illustrates a structural diagram of the discharging module 30 of the detecting system. A function of the discharging module 30 can be opposite to a function of the feeding module 10 . The discharging module 30 can include an entrance 31 configured to receive the finished products 200 from the detecting module 20 , an exit 32 opposite to the entrance 31 , a second slide 33 connected between the entrance 31 and the exit 32 ; and a second sliding member 34 coupled to the second slide 33 . The second sliding member 34 can move between the entrance 31 and the exit 32 . When the second sliding member 34 moves to the entrance 31 , the second sliding member 34 can receive a product 200 , and drive the product 200 to the exit 32 .
FIG. 5 illustrates a structural diagram of the conveying module 40 . The conveying module 40 can include a third slide 41 , and a clamping assembly 42 coupled to the third slide 41 . The clamping assembly 42 can be configured to clamp the products 200 , and include a first clamping jaw 421 and a second clamping jaw 422 coupled to the first clamping jaw 421 . The first clamping jaw 421 can be move between the first station 12 and the second station 23 . The second clamping jaw 422 can move between the second station 23 and the entrance 31 of the discharging module 30 . In the illustrated embodiment, the first clamping jaw 421 and the second clamping jaw 422 can be linked together. When the first clamping jaw 421 is positioned at the first station 12 , the second clamping jaw 422 can be positioned at the second station 23 . When the first clamping jaw 421 moves to the second station 23 , the second clamping jaw 422 can move to the entrance 31 of the discharging module 30 .
FIG. 6 illustrates a method for using the detecting system 100 , which can include the following.
In block 101 , the first sliding member 14 can be positioned at the feeding portion 11 , and a product 200 can be inputted into the first sliding member 14 by workmen.
In block 102 , the first sliding member 14 can drive the product 200 to the first station 12 .
In block 103 , the first detecting unit 21 can get image information about plane dimension and plane position of the product 200 , and the image information can be transmitted to the data processing module 50 .
In block 104 , the product 200 can be transported from the first station 12 to the second station 23 by the first clamping jaw 421 of the conveying module 40 .
In block 105 , the second detecting unit 22 can detect a height difference between two planes 201 and 202 of the product 200 , and the height difference can be transmitted to the data processing module 50 .
In block 106 , the product 200 can be transported from the second station 23 to the entrance 31 by the second clamping jaw 422 of the conveying module 40 .
In block 107 , the second sliding member 34 can be positioned at the entrance 31 , receive the product 200 from the second clamping jaw 422 , and transport the product 200 from the entrance 31 to the exit 32 .
In block 108 , the data processing module 50 can analyze the image information and the height difference between two planes 201 and 202 of the product 200 , and determine whether the product 200 is qualified.
In use, a first product can be positioned at the first station 12 and detected by the first detecting unit 21 . At the same time, a second product 200 can be ready to enter into the detecting system 100 . When the first product 200 is transported from the first station 12 to the second station 23 by the first clamping jaw 421 of the conveying module 40 , the second product 200 can be driven to the first station 12 by the first sliding member 14 . Then the first product 200 can be detected by the second detecting unit 22 , and the second product 200 can be detected by the first detecting unit 21 . The first product 200 can be transported from the second station 23 to the entrance 31 by the first clamping jaw 422 of the conveying module 40 . Meanwhile, the second product 200 can be transported from the first station 12 to the second station 23 by the first clamping jaw 421 of the conveying module 40 . The second sliding member 34 drives the first product 200 to the exit 32 , and the second product 200 can be detected by the second detecting unit 22 .
The detecting system 100 can automatically detect a plurality of products 200 . Compared with the manual vision inspection (MVI), the detecting system 100 can enhance the efficiency of detecting products 200 .
The embodiments shown and described above are only examples. Many details are often found in the art such as the other features of a detecting system and a detecting method for products. Therefore, many such details are neither shown nor described. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the details, including in matters of shape, size, and arrangement of the parts within the principles of the present disclosure up to, and including the full extent established by the broad general meaning of the terms used in the claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the claims. | A detecting system for checking shapes, sizes, and/or positions of products, includes a feeding module configured to transfer the products into the detecting system, a detecting module configured to detect the products, a discharging module configured to remove the products out of the detection system, a conveying module configured to transport the products, a data processing module configured to deal with the data information measured by the detecting module, and an electronic control module configured to control the feeding module, the detecting module, the discharging module, the conveying module, and the data processing module. The detecting module includes a first detection module configured to get size and position images of the products, and a second detecting unit configured to detect a gap between two planes of the products. The present disclosure also discloses a detecting method for products. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a web layering device of the type including a plurality of sequentially disposed individual layering tables, or carriages, mounted to undergo back and forth movement, a stationary feed unit cooperating with the first layering table in the sequence, and a removal unit associated with a transporting unit for the web.
In known web layering units including individual layering tables, i.e., layering tables having single layering belts, the speed at which the web can be conveyed is limited to 40 to 60 m/min, depending on the fineness of the fiber material involved. At higher conveying speeds, the web will in part be lifted away from the layering tables, under the influence of an air stream produced by movement of the tables, so that the formation of wrinkles is possible.
In the case of ribbon layers, the web is guided between two sheets moved in the same direction so that no danger of lifting exists and consequently a higher production speed is possible. However, the drawback of the ribbon layers is, in particular, that the web is bunched at the points of direction reversal of the sheets and consequently is wrinkled, particularly if fine fiber material is involved. A further drawback of this type of device is that it affords poor accessibility on the occasion of malfunctions, for example when overlapping of the web occurs.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the above-noted shortcoming of web layering devices composed of individual layering tables by influencing the air streams occurring during the layering process in such a manner as to permit perfect web deposition at significantly increased layering speeds of up to, for example, 80 to 100 m/min.
This and other objects of the invention are accomplished in a machine for layering a web of textile fibers composed of a plurality of web conveying units including a stationary web delivery unit, a first layering carriage unit mounted to undergo a back and forth movement and to receive a fiber web from the delivery unit, a further layering carriage unit disposed in sequence with the first layering carriage unit and mounted to undergo a back and forth movement, an additional layering unit movable together with the further layering carriage unit for conveying a web away from the further layering carriage unit, and a transporting unit for transporting a layered web from the additional layering means, by the provision of air guidance means located at the region of transfer of such a web between two of the units for forming an air guidance channel with the two units to create during conveyance of a web in a web layering procedure, an air stream traveling substantially tangentially to the direction of travel of the web.
In a preferred embodiment of the web layering device, the air guidance members are constituted by plates which are stationary with respect to the locations at which the direction of web advance is changed.
The plates may be fastened in a simple manner to those transporting devices which do not move with respect to such direction change locations.
The effectiveness of the air guidance produced by the plates can be increased by providing them with sealing strips at those locations which are adjacent surfaces of the transporting units which move with respect to the plates.
According to a further feature of the present invention, foot plates are provided on both sides of the removal unit, which unit includes removal rollers. These footplates are inclined, at most, to a slight extent with respect to the supporting surface for the web on the transporting unit and are slightly spaced from the latter.
The distance between the foot plates and the supporting surface of the transporting unit is preferably no greater than 60 mm.
It has been found to be particularly advantageous to arrange the foot plates in such a manner that they are inclined at an angle of no more than 25° with respect to such supporting surface.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE is a simplified, elevational, cross-sectional view of a preferred embodiment of a web layering device provided with air guidance members according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the apparatus shown in the FIGURE, a web 3 removed from a card 1 by means of a doffer 2 is conducted by a first delivery table 4 composed of belt rollers 5 and a delivery belt 6, to a second delivery table 7 composed of belt rollers 8 and a delivery belt 9. From table 7, web 3 is conducted into the region of two sequentially arranged layering tables, or carriages, 10 and 11, table 10 including guide rollers 12, and a layering belt 14, and table 11 including guide rollers 13 and layering belt 15.
During the layering process, layering tables 10 and 11 each undergoes a back and forth movement in the direction indicated by the double arrows 16 and 17, respectively. The lower carriage 11 here moves twice as fast and twice as far as the upper carriage 10, both carriages, however, always moving in the same direction.
The layering belt 15 of the lower carriage 11 is guided by means of additional deflection guide rollers 13' to present two web conveying regions oriented at right angles to one another. Below the lower guide roller 13, there are provided two spaced removal, or layering, rollers 18 and 19 which are fixed to lower carriage 11. The web which is removed downwardly between the layering rollers 18 and 19 is deposited on a removal belt 20 whose longitudinal and movement direction extends transversely to the direction of movement of layering carriages 10 and 11.
If layering carriage 10 moves toward the left at a high layering speed, a bulge is produced in the web at the point of transfer to layering carriage 11, i.e., in the region of the right-hand guide roller 12, which bulge is transported on as a wrinkle in the web. To avoid this drawback, a plate 21 is provided at the side of the right-hand guide roller 12 which faces toward card 1 to prevent the creation of a horizontal air stream relative to the layering table 10. Plate 21 is fixed to upper carriage 10 by means of a connecting piece 22, and thus moves as a unit with carriage 10. The edges of plate 21 which face the delivery belt 9 and the layering belt 15 are provided with flexible sealing strips 23.
During the back and forth movement of the layering carriage 11, the creation of air streams relative to the carriage in the horizontal direction may produce flaws in the web in the region of the vertically oriented supporting surface of the layering belt 15 and layering rollers 18 and 19, such flaws being depicted at 24 and 25. The flaw 24, in the form of a bulge, would occur when layering carriage 11 is moving in the direction toward the card 1, i.e., toward the right; when layering carriage 11 is moving toward the left, the bulge 25 can be created in the area between the lower roller 13 and layering roller 19.
In order to prevent appearance of the two last described flaws in the web, a plate 26 serving as an air deflector is provided in front of the left side of the supporting surface defined by layering belt 15, which plate is fixed to layering carriage 11 by one or a plurality of connecting elements 27 and is provided with a flexible sealing strip 28 at its edge adjacent the lower reach of layering belt 14. In addition, a plate 29 also serving as an air deflector is positioned to that side of the gap between lower roller 13 and layering roller 19 which is directed toward card 1 and is fixed to carriage 11 by a connecting element 30 secured to the bearing of a roller 13' and a connecting element 31 secured to the bearing of layering roller 19. Plate 29 is provided with a flexible sealing strip 32 at its edge adjacent the lower reach of belt 15.
When the layering machine is operated at high layering speeds of, for example, 80 m/min there exists the danger that the uppermost web layer edges 3' and 3" will flip over under the action of the air streams generated by the movement of layering carriage 11, which streams reverse their direction with a time delay after the direction of carriage movement reverses, thereby producing particularly intensive surges of air directed toward the center of the removal belt 20 just after each direction reversal by carriage 11, which surges have the effect of lifting the web layers.
In further accordance with the invention, such flipping over of the edges of the layers is prevented by two foot plates 33 and 34 which are arranged at respectively opposite sides of removal rollers 18 and 19 and which are inclined slightly, preferably by an angle of no more than 25°, with respect to the supporting surface of removal belt 20. These foot plates 33 and 34 shield the layer edges 3' and 3" against the above-mentioned surges of air until they have lost their effect.
In this connection it has been found to be advantageous for the foot plate 33, which is inclined upwardly toward the left, and is located to the side of rollers 18 and 19 which is directed away from card 1, to have in front of it an additional sheet metal piece 35 which is inclined to the supporting surface of removal belt 20, the additional plate 35 here being upwardly inclined toward the center of belt 20, and toward card 1, and having the same direction of inclination of foot plate 34. The minimum vertical distance 40 between each of plates 33 and 34 and the supporting surface of belt 20 is preferably no greater than 60 mm.
According to a particularly preferred embodiment of the present invention, the additional plate 35 is spaced from its associated layering roller 18 by a distance 36 preferably of 10 to 50 mm. By suitable selection of the value for the distance 36 between the lower edge of additional plate 35 and the surface of layering roller 18, it is possible to utilize the air pumping effect produced between plates 26 and 21 due to the difference in speed between layering carriages 10 and 11 to aid in preventing flaws in the web. This pumping effect produces an underpressure between plates 21 and 26 when carriages 10 and 11 are traveling away from card 1 and an excess pressure when the carriages are moving toward card 1 and the resulting air streams will help to pevent the formation of flaws in the web.
According to a modification of the embodiment illustrated in the FIGURE, the apparatus may also be designed so that an air guiding device which corresponds in structure to plate 21 is associated with the second delivery table 7. The additional plate is here diposed to the left of table 7 and is fixed with respect thereto by means of one or more suitable connecting elements. This additional plate is provided with a sealing strip at its lower edge which faces layering belt 14 and extends above the upper reach of belt 9.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | In a web layering device composed of a series of conveyors disposed in sequence for conveying a web of textile fibers from a card and depositing the web in layered form on a transporting unit, at least some of the conveyors being mounted on carriages to undergo back and forth movement, the attainable web conveying speed is increased by disposing an air guidance member in the form of a plate at at least one region of transfer between two conveyors to create an air stream which travels substantially tangentially to the web travel path. | 3 |
STATEMENT OF GOVERNMENT INTEREST
This invention was made with United States Government support under Grant No. 38003-04 awarded by the National Institutes of Health. The government has certain rights in this invention.
FIELD OF THE INVENTION
This invention relates to attachment of specific ligands on a hydrophobic surface.
BACKGROUND OF THE INVENTION
Hydrophobic surfaces, such as those of polystyrene, are nonspecifically active to the adsorption of various substances, such as biomolecules with hydrophobic portions, proteins, and the like. In an attempt to form specifically active surfaces, ligands which have specific reactivity have been covalently bonded to these surfaces. However, the covalent bonding to the surface is difficult to control, frequently resulting in splotchy coverage by the bonded ligand and several regions that are still nonspecific. Exemplary of methods used to immobilize a biomolecule upon a solid phase by covalent coupling are the coupling to agarose, crosslinked dextran or polyacrylamide or other hydrophilic polymers. Generally, functional groups on the solid substrate, such as hydroxide groups, are used to react with and covalently bind the molecule to be immobilized. A problem with these methods of immobilization is that they are not applicable to materials that lack such functional groups.
Another problem with covalently bound coatings, is that they, as a rule, are not removed from the substrate, which prevents recycling of the substrate. The porous polystyrene beads used in chromatography are expensive and after being coated are used for a specific separation and discarded when resolution is lost. It would be a significant cost savings if these beads could be stripped of the reactive coating and recycled by applying a new coating.
Certain biological molecules, such as enzymes and antibodies, can be immobilized by simple adsorption onto the solid phase. For example, an antibody may be adsorbed upon the surface of polystyrene in the form of a microliter plate, which is then used for heterogeneous enzyme immunoassay. The adsorbed biomolecule provides a specific enzymatic reaction or specific antibody-antigen interaction. Polystyrene is commonly used because of its transparency for colorimetric and photometric measurement, and because antibodies spontaneously bind to the polystyrene hydrophobic surface in a manner that usually preserves the immunochemical activity. However, it is necessary that essentially all of the hydrophobic sites on the surface be covered since they are non-specific adsorption sites. The background of the non-specific adsorption, if strong enough, can obscure the results of the assay. In addition, some biomolecules are difficult to adsorb upon polystyrene, and cannot be adsorbed to a sufficient extent for a practical assay. Others will only adsorb sufficiently under optimal conditions, which are often determined by trial and error. Further, some enzymes and antibodies lose activity when adsorbed upon a hydrophobic surface. For example, sensitive monoclonal antibodies sometimes lose activity due to conformational changes caused by the interaction with the hydrophobic surface. Therefore, the method of simple adsorption of active biomolecules upon a hydrophobic surface is not generally applicable.
It is known that certain block copolymers having a hydrophobic center block with hydrophilic end blocks can be used to coat hydrophobic surfaces. The center blocks are adsorbed onto the surface, with the end blocks extending from the surface and waving freely in a seaweed-like fashion. The coverage of the hydrophobic center blocks and the action of the end blocks effectively blocks the nonspecific adsorption sites and creates a nonadsorbing surface to certain substances such as proteins. A class of polymers commonly used in this application are the so-called Pluronic™ surfactants, which are triblock copolymers with the structure PEO--PPO--PEO (where "PEO" is poly(ethylene oxide) and "PPO" is poly(propylene oxide). Polymers of this type are also available under the name Poloxamer™. In a specific application, Pluronic surfactants have been found to reduce the platelet adhesion and protein adsorption on surface treated glass or low density polyethylene. Pluronic surfactants have also been found to prevent bacterial adhesion on polystyrene surfaces. While a Pluronic coating essentially eliminates the non-specific reactivity of the substrate surface, the resulting hydrophilic surface has essentially no reactivity and is not a suitable surface for further adsorption of most biomolecules.
Many techniques for biochemical separation, such as low pressure affinity chromatography and immunological assays, are based on specific interactions between biomolecules of examination and chemical reagents immobilized on solid phase. However, because of the above difficulties encountered with covalently bound coatings and adsorbed coatings of reactive ligands, there is a need of a coating system that is generally applicable for different reactive ligands, has a higher degree of reactivity, and has little or no background non-specific reactivity.
Another aspect of biochemical separations are those based upon specific interaction between biomolecules to be examined and chemical reagents immobilized upon a solid phase. Such separations are the basis for, for example, low pressure affinity chromatography and solid phase immune assays.
SUMMARY OF THE PRIOR ART
U.S. Pat. No. 4,264,766 to Fisher discloses a water-insoluble immunological-reagent formed by covalently binding discrete particles of a water insoluble latex carrier and a water-soluble polyhydroxy compound. The latex carder has active groups that can form a covalent linkage with a polyhydroxy compound. The polyhydroxy compound has at least two hydroxyl groups and is capable of rendering the surface of the latex carrier hydrophilic and suitable for covalent attachment of immunologically active materials, e.g., myoglobin.
U.S. Pat. No. 5,006,333 to Saifer et at. discloses a biologically persistent, water-soluble, substantially non-immunogenic, substantially non-antigenic conjugate of superoxide dismutase prepared by coupling at least a portion of the superoxide dismutase amino, carboxyl, or sulfhydryl groups to polyalkylene glycol.
U.S. Pat. No. 5,043,278 to Nagaoka et al. discloses a fixing material for use with physiologically active substances comprising a water insoluble carrier, an alkylene oxide chain bonded at one end to the carder with a functional group at the nonbonded end capable of reacting with a physiologically active substance.
U.S. Pat. No. 3,966,580 to Janata et al., discloses a protein-immobilizing hydrophobic polymeric membrane comprising (a) an organic hydrophobic polymeric substrate swellable by a solvent, (b) a hydrocarbon chain partially absorbed into the surface with a reactive site reactive with one compound of an immunochemically reactive pair attached to the nonabsorbed portion, and (c) one member of an immunochemically reactive pair reacted with the reactive site. The result is a hydrophobic substrate with a preselected concentration of protein reactive groups pendant therefrom. The concentration of the protein reactive sites is sufficiently low such that the polymeric substrate retains its hydrophobic character. The hydrophobic polymeric membrane is prepared by forming a thin membrane of hydrophobic polymer that contains no pendant polar groups, e.g., poly(vinyl chloride), polystyrene. The polymeric membrane is then reacted with a solvent that can swell the membrane. The solvent contains an aliphatic compound with a reactive site, preferably at or near one end of the carbon chain. After the membrane has been swollen with the solvent, the polymeric membrane is dried without removing the aliphatic compound with reactive sites. After the membrane is dried, it is reacted with a compound with a protein-reactive site and a site reactive with the reactive site on the aliphatic compound. The membrane surface is then washed and placed in a solution containing the protein to be immobilized.
OBJECTS OF THE INVENTION
It is, therefore, an object of the invention to provide a coating for a hydrophobic substrate that provides the surface with specifically reactive sites at a predetermined concentration.
It is also an object of the invention to provide a hydrophilic protein compatible coating for hydrophobic substrates with little or no background nonspecific reactivity.
Further objects of the invention will become evident in the description below.
SUMMARY OF THE INVENTION
In the present invention, the ends of block surfactant polymers with hydrophilic pendant blocks attached to a hydrophobic block are reacted to form a derivative of the surfactant polymer with specifically active sites at the free ends of the hydrophilic blocks. The derivative is then adsorbed onto the hydrophobic substrate to produce a surface with a minimum of nonspecific activity from the hydrophobic substrate and with specific activity provided by the block copolymer derivative.
The derivative surfactant polymer may be diluted with unmodified polymer before coating on the surface. In this way, it is possible to predetermine the concentration of the active sites on the surface, which are evenly distributed on the surface. Thus, the surface may be made specific not only to certain chemical entities, but also to size by the spacing of the reactive sites. In addition, mixed functionality may be achieved by mixing different block copolymer derivatives. Both unmodified and modified block surfactant polymers adsorb upon a hydrophobic polymer substrate quickly (within minutes or hours) in an aqueous environment. The terminal substituents on the ends of modified block copolymers appear to have little effect on these adsorption properties. Accordingly, the proportion of active sites on the surface is essentially directly proportional with the fraction the modified surfactant polymer in the mixture.
In the preferred embodiment, the reactive group on the modified surfactant polymer includes a group that can participate in a rapid specific thiol exchange with a thiol-containing protein. The surface resulting from the modified polymer adsorbed on the hydrophobic substrate is hydrophilic and quite compatible with proteins that can be immobilized on the surface through the reactive sites. Accordingly, reactivation of the adsorbed protein is minimized as there is little surface and conformational effects resulting from the immobilization.
Compared to the prior-art surfaces formed by covalent linking or simple adsorption, the specific reactive surfaces of the invention are relatively easy to form and typically constitute surfaces with greater specificity and lower background reactivity. Unlike prior-art covalently linked surfaces, with the present invention the reactive coating can be stripped from the hydrophobic substrate and the substrate recycled. This represents a significant savings in chromatographic applications where the polymer beads used are expensive and have been discarded after a loss of activity because the covalently linked surfaces cannot be easily removed. Compared to surfaces wherein a protein has been simply adsorbed on the surface, the surfaces provided by the coatings of the invention have a higher specific reactivity per unit area of surface with an even distribution of reactivity. In addition, there is little or no background nonspecific reactivity resulting from adsorption to unshielded surfaces.
An embodiment of the invention is a hydrophilic surface with a specific chemical reactivity comprising;
(a) a hydrophobic polymer substrate,
(b) a modified polymeric surfactant adsorbed upon the surface of the substrate, the modified polymeric surfactant having pendant hydrophilic blocks with one end attached to a hydrophobic block and the other end attached to pendant reactive groups, said reactive groups being stable in water and providing the specific chemical reactivity to the surface.
Another embodiment of the invention comprises a method for forming a hydrophilic surface on a hydrophobic substrate with a specific chemical reactivity, which method comprises;
(a) providing a hydrophobic polymer substrate,
(b) adsorbing upon the substrate surface a modified polymeric surfactant, the modified polymeric surfactant having pendant hydrophilic blocks with one end attached to a hydrophobic center block and the other end attached to pendant reactive groups, said reactive groups providing the specific chemical reactivity to the surface.
The modified polymeric surfactant is a derivative of a polymeric block copolymer with pendant or dangling poly(ethylene oxide) (PEO) chains with a --OH group on one end and attached at the other end to a poly(propylene oxide) (PPO) chain. The polymeric block copolymer may be in the form of any arrangement of the PEO and PPO blocks with the general formula;
(HO--PEO).sub.a (PPO).sub.b ( 1)
where a and b are integers, are the same or different and are at least 1, preferably a is between 1 and 6, and b is between 1 and 3, more preferably a is 1 to 2, and b is 1. The polymeric block copolymer has a PEO (--C 2 H 4 --O--) content between 10 wt % and 80 wt%, preferably 50 wt % and 80 wt %, more preferably between 70 wt % and 80 wt %.
The PEO chains or blocks are of the general formula;
--(--C.sub.2 H.sub.4 --O--).sub.u -- (2)
where u is the same or different for different PEO blocks in the molecule. Typically, u is greater than 50, preferably between 50 and 150, more preferably between 80 and 130. The PPO blocks are of the general formula;
--(--C.sub.3 H.sub.6 --O--).sub.v -- (3)
where v may be the same or different for different PPO blocks in the molecule. Typically, v is greater than 25, preferably between 25 and 75, more preferably between 30 and 60.
The block copolymers may be branched structures and include other structures (e.g. bridging structures, or branching structures) and substituents that do not materially affect the ability of the block copolymer to adsorb upon and cover a hydrophobic surface. Examples include the following polymeric surfactants described in the following paragraphs.
Preferably, the modified polymeric surfactant of the invention is a derivative of a polymeric tri-block copolymer with pendant --OH groups, as in Formula (4), below. These tri-block copolymers have a hydrophobic center block of polypropylene oxide and hydrophilic end blocks of polyethylene oxide with terminal --OH groups, and can be represented by the formula;
HO--(--C.sub.2 H.sub.4 --O--).sub.x --(--C.sub.3 H.sub.6 --O--).sub.y --(--C.sub.2 H.sub.4 --O--).sub.z --H (4)
where y is between 25 and 75, preferably between 30 and 60, and x and z are preferably the same, but may be different, and are between 50 and 150, preferably 80 and 130. Certain of these polymeric surfactants are commercially referred to as "Pluronic™" or "Poloxamers™", and are available, for example, from BASF.
Another suitable class of polymeric block copolymers is the di-block copolymers where a=1 and b=1, and can be represented by the formula;
HO--PEO--PPO--H (5).
where PEO and PPO are defined above.
Another suitable class of polymeric block copolymers is represented by the commercially available Tetronic™ surfactants (from BSAF), which are represented by the formula;
(H--(O--C.sub.2 H.sub.4).sub.u --(O--C.sub.3 H.sub.6).sub.v).sub.2 N--CH.sub.2 --CH.sub.2 --N((--C.sub.3 H.sub.6 --O--).sub.v --(--C.sub.2 H.sub.4 --O--).sub.u --H).sub.2 ( 6)
As used herein, the terms "Pluronic" or "Pluronics" refer to the block copolymers defined in Equation (1), which include the Pluronics™ tri-block copolymer surfactants, the di-block surfactants, the Tetronic™ surfactants, as well as other block copolymer surfactants as defined.
The --OH end groups of the PEO chains of the polymeric surfactant are modified to introduce a small reactive organic group which is stable in water. When the modified polymeric surfactant is adsorbed in an aqueous environment upon a hydrophobic substrate, the reactive groups impart specific reactivity to the surface. Using the Pluronics represented by equation (4) as an example, if both --OH groups on the pendant PEO chains are substituted, the modified surfactant has the formula;
R--O--(--C.sub.2 H.sub.4 --O--).sub.x --(--C.sub.3 H.sub.6 --O--).sub.y --(--C.sub.2 H.sub.4 --O--) .sub.z --R (7)
where R is a reactive group. Accordingly, the general formula for the modified polymeric surfactants of the invention is;
(HO--PEO).sub.c (R--O--PEO).sub.d (PPO).sub.b ( 8)
where c+d is equal to a in formula (1), and c is 0 or a positive integer, and b is defined above for formula (1). The R group may be any reactive group that is stable in water and will impart the desired selective reactivity for the substrate surface when the modified surfactant is adsorbed upon the surface. The specific reactivity may be to any non-water entity or entities. By "non-water entity" is meant an entity that is not water.
The R group must be stable in an aqueous environment, as adsorption of the modified polymeric surfactant upon a hydrophobic surface requires an aqueous environment. The R group may, for example, contain a member of the group consisting of --NH 2 , --SH, --SO 3 --, --NHNH 2 , --COOH, and maleimide. As an example, the R group may impart reactivity for conjugating other functional groups or for radioisotope labelling. The reactive group may be further modified and conjugated with other functional groups to form a different R group. In this manner a reactive group can be provided, such that after adsorption of the modified polymer surfactant upon the surface a reactive specific surface is formed, for example, for the immobilization of proteins. The R groups are chosen such that they do not significantly impair adsorption of the modified polymeric surfactant on the hydrophobic surface.
In a preferred embodiment of the invention, the reactive R group contains a hydrazino group (by further reacting a p-nitrophenyl group), a thiopyridyl group, a tyrosyl residue, or a maleimide.
In a preferred embodiment the R group is for the immobilization of protein or polypeptide molecules and contains the structure;
--S--S--R" (9)
where R" is selected from the group consisting of (1) 2-benzothiazolyl, (2) 5-nitro-2-pyridyl, (3) 2-pyridyl, (4) 4-pyridyl, (5) 5-carboxy-2-pyridyl, and (6) the N-oxides of any of (2) to (5). The reactivity of these groups with proteins and polypeptides is discussed in U.S. Pat. No. 4,149,003 to Cadsson et al. and U.S. Pat. No. 4,711,951 to Axen et al.
In the present invention R may be, but is not limited to, a member of the group consisting of hydrozino, thiopyridyl, tyrosyl, maleimide, 2-pyridyl disulphide, 5-nitro-2-pyridyl disulphide, 4-pyridyl disulphide, 5-carboxy-2-pyridyl disulphide, and the nitrogen oxides of 2-pyridyl disulphide, 5-nitro-2-pyridyl disulphide, 4-pyridyl disulphide, and 5-carboxy-2-pyridyl disulphide.
R may also be; ##STR1## wherein n is between 1 and 4, or R may be chosen from the group consisting of; ##STR2## wherein n is greater than 1, preferably between 1 and 4, and R 1 is --NO 2 or --H.
R may also be; ##STR3## where R 2 is --(CH 2 ) n --, a phenyl group or a cyclohexyl group, and n is greater than 1, preferably between 1 and 4.
The modified polymeric surfactant is adsorbed upon a hydrophobic polymer substrate to provide a surface with specific reactivity. The hydrophobic polymer substrate comprises any suitable polymer which imparts a hydrophobic character to the surface of the substrate. By "hydrophobic" is meant that the surface has a water contact angle greater than about 60°, preferably greater than about 70°. Suitable polymers with surfaces having a water contact angle greater than 70° include, but are not limited to polystyrene (PS), polymethylmethacrylate (PMMA), polyolefins (e.g. polyethylene (PE), polypropylene (PP)), polyvinylchloride (PVC), silicones, and block copolymers containing these constituents.
The less hydrophobic polymer substrates (water contact angle between 60° and 70°), such as PVAc are also contemplated by the invention but are less preferred. Adsorption upon these polymers would be expected to be less than for more hydrophobic polymers such as PS and PMMA, and slow release of the surfactant from the polymer surface over time would be expected. Hydrophilic substrates such as silica, agarose, and polyvinyl alcohol are not contemplated by the present invention. However, it is contemplated that hydrophilic substrates may be treated to render them hydrophobic before adsorption thereon of the modified polymeric surfactant. For example, silica can be treated with dimethyl-dichloro silane to provide a hydrophobic surface.
The polymer may be porous or nonporous, or be in the form a flat surface (e.g. a microtiter plate), or any suitable shape, such as micro beads, and the like used in chromatography applications. The polymeric surfactant may also be adsorbed upon colloidal or latex particles of a suitable hydrophobic polymer.
The modified polymeric surfactant adsorbs with the PPO blocks upon the hydrophobic surface and the pendant PEO blocks dangling away from the surface into the aqueous surroundings. Using a triblock copolymer as an example, the adsorbed surface can be illustrated by the formula below; ##STR4##
In order to yield the desired number of reactive groups per unit area of surface, the modified polymeric surfactant may be mixed with unmodified polymeric surfactant and the mixture adsorbed upon the surface.
The modified surfactant polymer adsorbed upon the surface provides a much lower background of non-specific reactivity than the surface itself. In the prior-art, such as where moieties with specific reactivity are covalently bound to the hydrophobic surface, significant areas of the surface are left uncovered that have nonspecific reactivity. This can result, for example, from an uneven and incomplete distribution over the hydrophobic surface of the reactive moieties, leaving nonspecific reactive sites on the hydrophobic surface.
By practice of the invention, the structure of the adsorbed polymer, with the hydrophobic PPO portion adsorbed upon the surface and the hydrophilic PEO pendent blocks extending in a "sea-weed" fashion from the surface effectively blocks protein adsorption upon the surface. The reactive end groups on the modified surfactant polymer, therefore, provide essentially the only reactivity for the surface, which reactivity can be easily predetermined by choice of the reactive end group.
The means of providing the reactive R groups is by substituting the PEO end --OH groups of the Pluronic with a suitable --O--R group. This may be accomplished by adapting any known method or combination of methods for synthesizing poly(ethylene glycol) derivatives wherein pendant --OH groups are substituted to form --O--R groups that are stable in an aqueous environment.
In a preferred embodiment of the invention, the Pluronic is first modified in an organic solvent to introduce 4-nitrophenyl-carbonate groups by treatment of Pluronic with 4-nitrophenyl chloroformate. This forms an intermediate of the Pluronic which has a reactive group (R') that is not stable in an aqueous environment but is suitable for binding of various reactive groups, R, which are in turn stable in an aqueous environment. This embodiment is exemplified in Example 1.
An intermediate Pluronic that is not water-stable, but has suitably reactive R' groups for binding of water-stable R groups, may have a reactive R' that is, for example, n-hydroxysuccinimide or similar electrophilic structure, or p-nitrophenyl. In an embodiment of the invention, R' is chosen from the group disuccinimidyl carbonate generated esters or tosylchloride generated esters (as, for example, in Formulas (11)and (12), respectively). ##STR5## Any intermediate R' group, whether water-stable or not water-stable are contemplated by the invention if they can be further reacted to produce the water-stable R groups herein described. The R' groups which are not water-stable, but are stable in organic solvents, are bound to the block copolymers by suitable reaction with the --OH pendant groups on the PEO chains in organic solvents.
Preferably, the water-stable reactive organic groups, R, include a thiopyridyl group. The resulting thiopyridyl-modified Pluronic may then be used to bind a thiol containing protein. Since most proteins are either naturally thiol-containing or can be easily thiolated, this embodiment is applicable for most biomolecules of interest. An exemplary use of this embodiment is as an improved ELISA (enzyme linked immunosorbent assay). In an ELISA application of the invention, the surface adsorbed thiopyridyl-modified polymeric surfactant is bound with, for example, a thiolated anti-IgE antibody. In comparative tests to determine the amount of IgE antigen that binds to the attached antibody, it was found that amount of bound antigen per unit area was significantly higher for the invention than for a conventional ELISA method, wherein the antibody itself is allowed to adsorb passively upon a hydrophobic surface. This demonstrates a stronger response to the antigen for the ELISA of the invention than for the conventional ELISA.
In another embodiment of the invention, the reactive end groups, R, include a radioactive species, e.g., 125 I, or a group to which a radioactive species may be attached. This embodiment permits further study and direct quantification of the adsorption of the polymer surfactant upon the either a flat surface or on colloidal particles.
The present invention provides an improved means for immobilizing biomolecules upon a hydrophobic surface, by derivatizing the Pluronic surfactants with reactive groups that are reactive with the biopolymer to be immobilized. The modified Pluronic is adsorbed upon the hydrophobic surface, and because of the PPO/PEO block structure of the Pluronic, essentially all of the hydrophobic sites on the polymer surface are immobilized (either covered by the PPO blocks or "guarded" by the waving pendent PEO blocks). The biomolecule to be immobilized is then linked to this surface which is made specifically reactive due to reactive PEO-block end groups of the surfactant extending from the surface. Thus, the surface is highly specific in reactivity, and there is little or no residual activity from the hydrophobic surface of the polymer substrate. The surface provided by the adsorbed modified Pluronic molecules is also compatible with the adsorbed, immobilized molecules and will not affect activity to the degree of a plain hydrophobic surface.
By employing a reaction of hydroxide ends of Pluronic surfactants with 4-nitrophenyl chloroformate, one can efficiently introduce reactive carbonate groups to such PEO/PPO block copolymers. These activated Pluronics are very stable in organic milieu and in a dry state and hydrolyze readily in water. Since they react relatively easily in an organic solvent with amino groups, 2-pyridyl disulfides, peptide, hydrazino and other amino containing chemicals can be thus conjugated to the Pluronics. Using hydrazino groups as the bridge, tyrosyl groups for radioisotope labelling purpose can be subsequently coupled to the Pluronic by a reaction with the Bolton-Hunter reagent.
Based on the specific thiol-disulfide reaction and the surfactant properties of Pluronics, hydrophobic surfaces coated with the 2-pyridyl disulfides conjugated Pluronic provide a new way to have hydrophobic surfaces become much more protein compatible and at the same time to immobilize desired molecules under a certain control. The rate of hydrolysis of the 2-pyridyl disulfides groups at pH˜8.5 is almost negligible in comparison with the rate of the thiol-disulfide exchange reaction, and such a surface coating can be sensitively activated at very low concentration of thiol-containing biomolecules such as proteins. The coupling releases thiopyridone; its release constitutes a sensitive method for detecting the degree of substitution (exchange), since the thiopyridone can be readily and accurately quantified by spectroscopic detection at 343 nm with an extinction coefficient of 8060/cm -1 M -1 . Since the thiol-disulfide exchange is a reversible reaction, the bound molecules can be therefore released from the solid phase by adding small molecular weight of thiol-containing reagents. Thiol groups can be substituted to biomolecules without inactivation by a number of general methods, and the solid phase can be a hydrophobic surface in the form of particles (porous or nonporous) or small plates. This surface coating technique is, therefore, a very general and valuable method for the use in chromatography, enzyme immobilization, and solid-phase immunoassays, and is particularly attractive compared to the direct covalent immobilization techniques, which are complicated and expensive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing activity of anti IgE immobilized on a coated surface of the invention compared with a surface of the prior-art.
FIG. 2 is a graph showing activity of various adsorbed mixtures of activated Pluronic and non-activated Pluronic.
DETAILED DESCRIPTION OF THE INVENTION
In the examples below, the following materials were used;
Pluronic surfactants--P105, F68, F88 and F108, available from BSAF. Each have the formula as in (9) above where x and y are shown in Table A, and z is the same as x;
TABLE A______________________________________Pluronic Surfactants x y______________________________________P105 37 56F68 76 30F88 104 39F108 129 56______________________________________
The molecular weight of Pluronic surfactants P105, F68, F88, and F108, are 6500, 8400, 11400, 14600. P 105 comprises 50 wt. % PEO whereas F68, F88, and F108 consist of about 80 wt. % PEO. All were available from BASF under the tradename Pluronic™.
Polystyrene (PS) beads (10 μm diameter). Available from Pharmacia-BTG-LKB, Uppsala, Sweden.
4-nitrophenyl chloroformate. Available from Aldrich.
Hydrazine. Available from EM Science
Triethylamine (TEA). Available from Baker.
Bolton-Hunter reagent. Available from Pierce.
Chloramine-T. Available from Eastman Kodak.
Na 125 I (100 mCi/ml). Available from Amersham.
Sodium metabisulphite. Available from Fisher.
Dithiothreitol (DTT). Available from Bio-Rad.
Mercaptoethylamine hydrochloride, 2,2'-dithiopyridine, and β-galactosidase (Grade 8 from E. Coli). All available from Sigma.
PD-10 containing Sephadex G-25M columns from Pharmacia, and dialysis membranes (Spectra/Por) available from Spectrum Medical.
PBS--phosphate buffered saline.
EXAMPLE 1
Activation of Pluronic with 4-Nitrophenyl Chloroformate
Pluronic surfactants P105, F68, F88, and F108 were modified according to the invention. 2 g of Pluronic was first dissolved in 6 ml benzene and then this solution was slowly added to stirred solution of 4-nitrophenyl chloroformate in 6 ml benzene. The content of 4-nitrophenyl chloroformate varied with the molecular weight of the Pluronic used but the ratio of --OH:-nitrophenyl for the reaction was kept at 1:3. After 24 hours of shaking, the reaction activated product was precipitated at least twice using ether and was recovered by filtration followed by evaporative removal of the remaining solvent under vacuum overnight. For Pluronic P105, the precipitation was done by using 80 times excess petroleum ether (bp 35°˜60° C.). The degree of substitution was determined by measuring the released para-nitrophenolate ions in an alkaline solution using a spectrophotometer. This is shown below for Pluronic F108, where "F108--OH" represents a Pluronic F108 block molecule and one of its pendent --OH groups. ##STR6## After 1 hour under rotation, the absorbance was measured. An accurately weighed out sample of 4-nitrophenyl chloroformate activated Pluronic derivative was dissolved in 0.1M NaOH and measured at 402 nm using a molar extinction coefficient of 18400 cm -1 M -1 .
From the measure of released yellow para-nitrophenolate ions in an alkaline solution, the degree of substitution was calculated by assuming two available --OH groups in each Pluronic molecule. The results are summarized in Table B, and show a degree of substitution around 80%.
TABLE B______________________________________4-Nitrophenyl Chloroformate Modificationof Pluronic Surfactants Degree of Substitution (%)______________________________________Pluronic P105 82Pluronic F68 78Pluronic F88 85Pluronic F108 83______________________________________
The substitution rate of each Pluronic which was reported as the average value of at least three repeated experiments the same ratio --OH:-nitrophenyl of about 1:3. The substitution did not significantly increased when a larger excess of reagent was used. The activated Pluronic surfactants were stably stored in desiccator over P 2 O 5 at room temperature, and were not found to loose activity after months of storage.
The conjugation of para-nitrophenyl-carbonate groups to the PEO ends of Pluronic was found to be an efficient coupling chemistry and the substitution was essentially independent of the chemical composition of the Pluronic surfactant. Although the reactive end group of the modified Pluronic (II) is not stable is water and, therefore, the modified Pluronic cannot be adsorbed upon a surface in an aqueous environment with retained activity, it provides a useful intermediate for formation of other reactive end groups that are stable in water.
EXAMPLE 2
Radioisotope 125 I Labelling of Pluronic
A. Reaction with Hydrazine
1.5 g of activated Pluronic product (II) produced as in Example 1 was dissolved in 3 ml methanol and was mixed with 97% hydrazine. The molar ratio of hydrazine to Pluronic was kept as 100: 1. After 8 hours reaction, precipitation using ether was repeated at least twice and the final product was dried under vacuum overnight. The reaction was as follows, using activated Pluronic F108 as illustration; ##STR7## For Pluronic P105, the recovery of the product was by a dialysis process. The mixture after reaction was concentrated in a rotator vaporizer for 1˜1.5 hours and was then dissolved in 6 ml methanol. This solution was then transferred to a dialysis bag with molecular weight cut off of 1000 Daltons and was dialyzed against a 30% aqueous methanol solution. This methanol/water mixture (500 ml) was changed three times in 24 hours, and then replaced by 0.1M NaHCO 3 solution (500 ml). This weak alkaline solution was changed every 8 hours, and was continued 3˜4 times until essentially all nitrophenol was completely removed. Then, deionized water was used as the incubation solution and was changed three times in 24 hours. The product (III) was then recovered by lyophilization. The hydrazine-modified Pluronic (III) is stable in water and provides a useful intermediate for formation of other water-stable modified polymeric surfactants that can be adsorbed upon a surface in an aqueous environment.
B. Reaction with Bolton-Hunter reagent
The Bolton-Hunter reagent is an efficient chemical for coupling to --NH 2 groups for subsequent labelling with radioisotope 125 I. Bolton-Hunter reagent was conjugated with the hydrazine reacted product above (III) by mixing vigorously 1 volume of a 17 mM solution of product (III) in dimethyl sulfoxide with 4 volumes of a 43 mM Bolton-Hunter reagent in dimethyl sulfoxide. After 4 hours, the product was precipitated from the solution using ether, and then dried under vacuum overnight. The reaction for the F 108 derivative is shown below for illustration; ##STR8## For Pluronic P105, tetrahydrofuran instead of dimethyl sulfoxide was used as the solvent. After 4 hours reaction, this mixture was concentrated in a rotator vaporizer and then was dissolved in 3 ml methanol. This solution was then transferred to a dialysis bag with a molecular weight cut off of 1000 Daltons and was dialyzed against methanol for 8 hours, and then against deionized water for 8 hours. The incubation solution was then replaced by fresh deionized water and after 8 hours the product was sent to lyophilization to determine (IV). The substitution rate of such reagent can be calculated from measurements of the amount of conjugated tyrosyl groups in each Pluronic molecule. The degree of substitution is shown below in Table C;
TABLE C______________________________________Bolton-Hunter Modificationof Pluronic Surfactants Degree of Substitution (%)______________________________________Pluronic P105 64Pluronic F68 84Pluronic F88 93Pluronic F108 93______________________________________
A series of Bolton-Hunter reagent in samples with various concentrations were prepared in methanol and the UV absorptivity were determined at a wavelength of 270 nm using a Perkin-Elmer Lambda 6/PECSS spectrophotometer. From these measurements a molar extinction coefficient of such a tyrosyl group was calibrated as 1270 cm -1 M -1 . Finally, 0.5 ml of 0.6 mg/ml of product (IV) in PBS buffer (0.15 M, pH=7.4) was treated with 3 μL of Na 125 I and 50 μL of 4 mg/ml chloramine-T was added as oxidizing reagent. This ionization reaction was terminated after 4 hours by using 50 μL of 4.8 mg/ml sodium metabisulphite. The reaction to produce the iodated product (V) is shown as follows for F 108; ##STR9## The labelled polymers were separated from free Na 125 I by using a PD-10 column. To test the stability of the isotope labelled F-108 on a substrate, PS latex particles with product (V) adsorbed to their surface were suspended in a surfactant free buffer for 3 days and measurements showed no loss of surfactant from the surface.
The radioactive labelling of the Pluronic surfactant is useful for quantitative studies. In general, it is very difficult to quantify the Pluronic precisely because it has no functional groups which can be specifically determined by a common instrument. Although the turbidity measurement of Pluronic is the most common technique for this purpose, this method usually has many limitation and is usually available only for polymers in a dust-free solution. By introduction of tyrosyl groups onto the para-nitrophenyl-carbonate activated Pluronic molecules followed by iodination of such functional groups, the Pluronic molecules have been found to be easily labelled with radioactive iodine. The Bolton-Hunter reagent with a succinimidyl and a tyrosyl group is a good reagent for coupling with --NH 2 groups in proteins, and such conjugated biological molecules can subsequently be labeled with high specific radioactivities. This method is applied to Pluronics by first providing available --NH 2 groups on the Pluronic molecule. This was accomplished by substituting the hydrazino groups to the Pluronics by the reaction of hydrazine and para-nitrophenyl-carbonate activated Pluronics. This reaction usually went close to completion and the measure of released para-nitrophenol was in good agreement with the quantification of product (IV). High substitution rate indicated that the reaction of the hydroxyl succinimide ester of the Bolton-Hunter reagent and --NH 2 groups in modified Pluronic is also a very efficient chemistry.
The purified tyrosyl conjugated Pluronic was then ready for the radioactive iodine labelling. Following treatment with chloramine-T and Na 125 I, the 125 I labelled Pluronic and free Na 125 I were separated by passing through a PD-10 column, and the eluants were separated into 12 culture tubes. 20 μl of each 1 ml fraction of the eluant was transferred into a counting vial and the radioactivity was counted by a radioisotope detector (Beckman 170M). The GPC profile showed that the labelled Pluronic F108 was flushed out as the void, and the small molecular weight Na 125 I in the column and eluted out later. The radioisotope labelled polymers were collected and passed through column again to check the distribution of free Na 125 I in the solution. Following the same counting procedure as before, no Na 125 I was detected. The elution patterns for other Bolton-Hunter conjugated Pluronics that were tested were all similar. The labelling efficiency estimated by observing the second GPC profile was around 95˜96%.
In the above reaction system, Pluronic F68, F88 and F108 were all modified chemically in organic solvents and were successfully recovered by ether. The yield for each step was from 75% to 80%. However, P105 can not be likewise separated from nonreacted reagents and was often recovered by other elaborate procedures. This solubility difference in ether may result from the different chemical composition between P105 and other selected Pluronics because P105 contains only 50% PEO whereas other samples of Pluronics derivitized in these examples contain 80% PEO. In order to provide an efficient way to recover P105 in a general chemical reaction, we have tested its solubility in different solvents. It was found that P 105 can be easily dissolved in aqueous media and in most organic solvents including benzene, pyridine, chloroform, methanol, tetrahydrofuran, dimethyl sulfoxide, etc., and can be only precipitated well by 80 times volume excess of petroleum ether in such solvents except in methanol and dimethyl sulfoxide. In addition to the finding that the released para-nitrophenol during the hydrazine reaction was not dissolved well in petroleum ether, the yield of the dialysis and lyophilization method to purify the hydrazino and tyrosyl substituted P 105 was generally comparable to the precipitation methods by ether.
EXAMPLE 3
Preparation of Pluronic-2-Pyridyl Disulfide Derivative
A product (II)as in Example 1 was prepared using Pluronic F108. 2-(2-pyridyl dithio)ethylamine was then prepared for conjugating pyridyl disulfide group to Pluronic F108, according to the reaction below. ##STR10## In this step, the 2-(2-pyridyl dithio)ethylamine hydrochloride was first prepared by dissolving 1.13 g mercaptoethylamine hydrochloride into 2 ml methanol containing 0.8 ml acetic acid, which was then added dropwise to a stirred solution of 6.74 g 2,2'-dithio pyridine. The yellow reaction mixture was stirred for 30 minutes at room temperature and was then slowly poured into a beaker with 200 ml stirred ether. The product that was separated from the ether was dissolved in a small volume of methanol and was again precipitated with ether. This procedure was repeated until the crystal appeared white and then the product was recovered by evaporating the ether under vacuum. 2-(2-pyridyl dithio)ethylamine hydrochloride (0.6 g) was dissolved in 3 ml methanol and converted to 2-(2-pyridyl dithio)ethylamine after the addition of 300 mg of TEA.
1 g 4-nitrophenyl chloroformate activated F108 pluronic (II) was dissolved in 3 ml methanol and added to the above-stirred 2-(2-pyridyl dithio)ethylamine solution. The reaction mixture which immediately turned yellow was left at room temperature for 15˜20 hours. The TEA was then neutralized by adding 2˜2.5 ml 10M HCl. Deionized water (4 ml) was added to this mixture and this solution was transferred to a dialysis tubing (with a molecular weight cut off of 3,500 Daltons) and was dialyzed against 4 liter deionized water. During the 48-hour dialysis process, water was changed five times until the low molecular weight material was believed to be completely removed. The F108-2-pyridyl disulfide derivative (F108-PDS) (VI) was finally recovered by lyophilization. The derivative (VI) was stored in a desiccator over P 2 O 5 at room temp. The determination of the content of 2-pyridyl disulfide groups was carried out essentially as described in Carlsson et al. "Protein Thiolation and Reversible Protein-Protein Conjugation, N-Succinimidyl 3-(2-pydridyldithio)propionate, a New Heterobifuncional reagent," Biochem. J., 173,723 (1978). Exactly weighed F108-PDS was dissolved in phosphate-NaCl buffer (0.2M, pH 7.3). The UV absorbance at wavelength 343 nm was measured before and 10 minutes after addition of 0.1 ml of 25 mM DTT to both reference cuvette containing buffer and sample cuvette containing F108-PDS. The concentration of released 2-thiopyridone which is identical to the original concentration of F108-PDS was calculated using a molar extinction coefficient of 8060 cm -1 M -1
EXAMPLE 4
F108-2-pyridyl disulfide Coating of Porous Polystyrene Particles
20 mg dry porous PS particles with a size of 10 μm was incubated with 1.0 ml of ethanol. The suspension was mixed by end over end rotation for 2 hours at 25° C. After being settled down by centrifugation, porous PS particles were separated out by removing the ethanol and were then incubated in 1 ml of 0.2M phosphate-NaCl buffer. The PS particles were again centrifuged and were resuspended in 1 ml phosphate-NaCl buffer. After five consecutive washings, PS particles were incubated in 2.0 ml 4% F108-PDS solution. The solution was prepared by mixing FI08-PDS in 0.2M phosphate-NaCl buffer and rotating end over end for 20 hours at 25° C. The coated beads were then washed eight times using the same phosphate-NaCl buffer above. The coating reaction is shown below; ##STR11## The amount of coated modified Pluronic F108 was determined by measuring the disulfide reactive groups. The coated PS particles were first incubated in 25 mM DTT for thiolation. After 10 minutes incubation, such coated particles were consolidated by centrifugation and the supernatant containing the released 2-thiopyridone was carefully transferred to a new centrifuge tube and was subjected to one more centrifugation to remove possible remaining particles. The 2-thiopyridone content was then determined photometrically as described above.
The weight of the PS particles, which have been trapped on a preweighed Millipore filter, was then determined after drying extensively over P 2 O 5 , and the content of reactive disulfide groups per dry weight of PS porous particles was then calculated from the disulfide group content and the 2-thiopyridone content.
EXAMPLE 5
Immobilization of β-galactosidase on Porous Polystyrene Coated with F108-2-Pyridyl Disulfide
A protein was immobilized on the coated porous PS particles from Example 4. 11 mg β-galactosidase was dissolved in 1.0 ml 0.2M phosphate-NaCl solution containing 30 mM reduced glutathione. After 30 minutes reduction, the solution was passed through a PD-10 column equilibrated with phosphate-NaCl buffer, and 2.0 ml of β-galactosidase solution was collected, of which 1.0 ml was mixed with 0.5 ml suspension containing 10 mg F108-PDS coated porous particles (as in Example 4) and the other 1.0 ml was retained for thiol content determination.
In order to measure the amount of thiol groups, 0.2 ml of saturated solution of 2,2'-dithiopyridine in water (1.5 mM) was added to both the reference cuvette with 1 ml 0.2M phosphate-NaCl buffer and the sample cuvette with the above thiolated β-galactosidase. After 10 minutes incubation, the thiol concentration was calculated by measuring the concentration of released 2-thiopyridone as described above. The mixture of coated particles and β-galactosidase was rotated end over end for 48 hours at 4° C. and the particles were then washed with the 0.2M phosphate-NaCl buffer as described previously. The amount of immobilized β-galactosidase was determined by amino acid analysis.
Thiol-disulfide exchange is a specific and reversible reaction, and involves 2-pyridyl exchange reaction under release of 2-thiopyridone and formation of an stable aliphatic disulfide. The reaction occurs at both acidic and alkaline pH's and usually goes completely even if equal molar concentrations of reactants are used. When disulfide functional groups, designed to bind thiol-containing molecules, have is been immobilized on a solid phase, the bound molecules can be easily released and removed from the solid surface by adding low molecular weight thiol-containing reagents. The 2-pyridyl disulfide was thus substituted to Pluronic F108 by the reaction of para-nitrophenyl-carbonate activated F 108 and 2-(2-pyridyl dithio)ethylamine hydrochloride in the presence of TEA. F108 modified with the reactive disulfide (F 108-PDS) can be stably stored in solid form at room temperature in a desiccator over P 2 O 5 for months. It is known that the 2-pyridyl disulfide group is very stable both in solid form and in aqueous solutions at physiological conditions of pH and temperature. The substitution of such reactive groups was only about 60%. Since the degree of substitution was calculated based on two active sites of the Pluronic molecule, this low value may indicate that about one disulfide active group was coupled to each F108 molecule.
By coating a modified Pluronic on a hydrophobic substrate the substrate surfaces become much more hydrophilic, and such coated surfaces have almost no nonspecific protein uptake upon the substrate surface. In this example β-galactosidase was used as the model protein and highly porous PS particles were the potential solid substrates for immobilization. The enzyme β-galactosidase from E. coli is one of the most extensively investigated of enzyme and is very popular for the preparation of enzyme immunoassays. These monodisperse PS particles (10 μm) used here provide extremely large surface area, approximately 350 m 2 /g, and the advantage of easy sedimentation. By measuring the released 2-thiopyridone from the given amount of particles, the amount of adsorbed F108-PDS and the thiol content was determined. The results are shown in Table D, below. The immobilization of the protein is represented as follows; ##STR12##
Adsorption of F108-PDS on other particles with similar hydrophobicity was measured and compared. The measured values of adsorbed amount per surface area shows that the adsorption properties are similar for these other hydrophobic particles and therefore the coating procedure is useful for other hydrophobic materials. Such hydrophobic materials include those hydrophobic polymers previously mentioned. PVAc is less hydrophobic than polystyrene and the adsorption of Pluronic and modified Pluronic surfactants on PVAc substrates is about half of that for polystyrene and other polymer substrates with similar hydrophobicity to polystyrene.
As a comparative test, the thiol-containing enzyme β-galactosidase was adsorbed on unmodified F108 coated porous PS particles. The adsorption was significantly lower than for the same PS particles that were coated by F108-PDS. These results are shown in Table D below;
TABLE D______________________________________Specific Binding of β-galactosidase on Porous PolystyreneParticles Coated with F108-2-Pyridyl Disulfide.Amount of bound F108-2-Pyridyl Disulfide 45(μmoles/g particle)Thiol content of β-galactosidase 12(moles/mole protein)Amount of bound β-galactosidase (mg protein/g particle)On particles coated with F108-2-pyridyl disulfide 34On particles coated with unmodified F108 <1______________________________________
The above data demonstrates that β-galactosidase can be specifically immobilized on the particles through the thiol-disulfide exchange between F108-PDS and proteins. This shows the benefit of using modified Pluronic coatings according to the invention, as opposed to unmodified Pluronic without terminal reactive groups.
Other thiol proteins can be immobilized in a similar manner as β-galactosidase of this example. These include proteins that naturally contain thiol groups and proteins to which thiol groups have been introduced, such as γ-globulin.
EXAMPLE 6
Immobilization of thiolated anti IgE on Polystyrene Coated with F108-2-Pyridyl Disulfide
F108-PDS adsorbed to the wells of PS microtiter plates was shown to bind a thiolated anti-IgE antibody. In a subsequent step, the IgE antigen was added to the wells in different amounts and allowed to bind specifically to the previously attached antibody. The amounts of bound IgE were subsequently determined through addition of anti-IgE, conjugated with an enzyme which permitted quantification (β-galactosidase). In a parallel experiment, the anti-IgE was added to uncoated wells of the PS microtiter plate and allowed to adsorb via "passive coating". The IgE antigen was then added in the same concentrations as were added to the F108-PDS modified wells, and the amounts bound were determined in the same way. The passive coating procedure represents the conventional way of performing an ELISA (enzyme linked immunosorbent assay). 1. The results are shown in Table E and the graph of FIG. 1.
TABLE E______________________________________Antigen binding of coatings Antigen bound by Antigen boundKU IgE passive coating via F108-PDS______________________________________0 0.003 0.0240.35 0.010 0.0360.70 0.310 0.1087.5 0.147 0.543______________________________________
From results shown Table E and FIG. 1 it is clear that binding via passive coating results in a much weaker response to the antigen than binding via disulfide-exchange to the PDS moiety on adsorbed F108-PDS.
Because of its low adsorption of protein, an Pluronic coated surface will provide low background in protein quantification work. Typically, an ELISA test begins with the adsorption (to a PS microliter plate) of an antibody specific to the antigen of interest. The surface is then soaked with a solution of inconsequential protein which covers up remaining adsorption sites and reduces the risk of nonspecific adsorption of the enzyme-conjugated antibody added in the last step of the assay. As a model for these processes, PS microtiter plate wells were pre-exposed for 24 hours at 4° C. to either of: a) PBS (phosphate buffered saline), b) human plasma, c) BSA (bovine serum albumin, 100 mg/mL), d) F108 in PBS (2.2%) and e) F108-PDS in PBS (2.2%). The wells were subsequently well rinsed. To each of them was then added a solution of the enzyme β-galactosidase (0.1 mg/mL), which was allowed to adsorb for 24 hours at 4° C. Unadsorbed enzyme was then removed and discarded. After careful rinsing, the o-nitrophenyl β-galacto pyranoside (ONGP) substrate was added, and the color development was followed as a function of time. Visual color development was seen after 10 minutes in well a), after 30 minutes in well b), after 25 minutes in well c) and after more than 120 minutes in well d). Well e) with its ability to covalently attach the enzyme during the adsorption process, developed a strong color intensity within less than one minute.
This series of data clearly demonstrates the superior reduction in nonspecific adsorption caused by F108 (well d), as compared to the customary protein coating procedure (wells b and c). It also shows the F108-PDS analogue (well e) to be significantly more active than the passive coating (well a) in binding the enzyme to the surface.
This example illustrates the application of the F108-PDS coating to method to enhance the immunoaffinity of immobilized antibody by site-specific chemical coupling. Because of partial inactivation of antibody or the shielding of the antigen binding sites during the immobilization in prior-art adsorption or random coupling processes, immobilized antibody in these processes always has a low antigen binding capacity. In order to overcome these drawbacks, the orientation control of immobilization has been studied in many respects such as the improved specific binding by immobilizing Fab'-fragment and the importance of the chemical nature of solid phase to the antibody immobilization.
Comparative data indicates that antigen binding of the site specific immobilized antibody is eight times higher than that of passively coated antibody. Although other antibody of interest may not contain thiol groups, a number of techniques, e.g. modification through a nonessential amino group, have been used to thiolate antibodies and other molecules without changed activity or specificity. Thus, the coating by such Pluronic containing reactive disulfide groups becomes a general, yet very specific immobilization technique.
Regulating the Activity of the Adsorbed Surface
The content of adsorbed F 108-PDS on the PS surface can be controlled by incubating solid phase to solutions of modified and unmodified Pluronic F 108 with different ratio of mixture. This approach can be used to design a suitable distance between immobilized biological molecules in order to give an optimal microenvironment for their biological function. It is generally very difficult to do such an adjustable distribution of the reactive molecules by direct chemical modification of hydrophobic materials.
In a series of tests, mixtures of F108-PDS and unmodified F108 of differing proportion were adsorbed on the surface of a PS latex substrate and the amount of active F108-PDS was measured. The results are summarized in Table F and the graph of FIG. 2.
TABLE F______________________________________Adsorption of Mixtures ofModified and Unmodified F108Proportion of F108-PDS Amount of F108-PDS bound to(wt. %) particles (μ/moles/g)______________________________________ 0 025 0.1450 0.4075 0.52100 0.61______________________________________
As shown in FIG. 2, the amount of activity is essentially directly proportional to the fraction of F108-PDS in the mixture. Accordingly, by regulating the proportion of modified Pluronic it is simple to predetermine the amount of activity on the adsorbed surface.
While this invention has been described with reference to certain specific embodiments and examples, it will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of this invention, and that the invention, as described by the claims, is intended to cover all changes and modifications of the invention which do not depart from the spirit of the invention. | A surface of specific reactivity is formed by adsorbing a modified block polymeric surfactant of the Pluronic-type, i.e., containing pendant poly(ethylene oxide) blocks attached at an end to poly(propylene oxide) center blocks and with specifically reactive groups at the unattached ends of the poly(ethylene oxide) blocks, upon a hydrophobic surface. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority to application Ser. 61/901,980 having a filing date of Nov. 8, 2013, which is also incorporated herein by reference in its entirety.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] [Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[0003] [Not Applicable]
BACKGROUND OF THE INVENTION
[0004] The present invention relates to a plant cage, and more particularly, to a plant cage that may be assembled from component pieces that may lie flat during storage.
[0005] Plants may be caged by a support structure which is purchased by the user in a fully assembled state, having lateral supporting arms welded to vertical supports. Such support structure is pulled down over the top of a plant which is then allowed to grow up into the cage. The width or “bushiness” of the plant about which the support structure is positioned, makes the positioning of such support structure difficult. Plant branches may be broken or bent during cage positioning. Further, at the end of the plant growing season, the support structures are grouped together and stored in a large area to receive the structures.
[0006] It is therefore, an object of the present invention to provide a new and useful plant cage.
[0007] It is a further object to provide a plant cage that may be assembled and disassembled from discrete components.
[0008] It is yet another object of the present invention to provide a method for assembling a plant cage from discrete components.
BRIEF SUMMARY OF THE INVENTION
[0009] These and other objects of the invention are achieved in a plant cage of at least three rods, at least two rings and grommets for securing the rings to the rods. In one embodiment, circular shaped rings have two separate sections that are connected at the ends of the sections. The connectors provide a pivoting mode to present the cage in an open position to allow the cage to be positioned around the plant, and thereafter permit the cage to be closed to surround the plant.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a plant cage according to a preferred embodiment of the invention.
[0011] FIG. 2 is a perspective view of the plant cage of FIG. 1 shown in an open position.
[0012] FIG. 3 is a partial perspective view of a hinge mechanism of the plant cage of FIG. 1 .
[0013] FIG. 4 is a side view of a rod and grommet of the plant cage of FIG. 12 .
[0014] FIG. 5 is a side perspective view of four rods and one ring being assembled into the plant cage of FIG. 1 .
[0015] FIG. 6 is a partial perspective view of the plant cage of FIG. 1 .
[0016] FIG. 7 is a perspective view of the plant cage of FIG. 1 .
[0017] FIG. 8 is a partial perspective view of a plant cage embodiment having three rods and two rings, and showing the separated components of a hinge mechanism.
[0018] FIG. 9 is a perspective view of the plant cage of FIG. 1 shown in an open position.
[0019] FIG. 10 shows a partial perspective view of one rod, one ring and one grommet of the plant cage of FIG. 1 .
[0020] FIG. 11 shows a partial perspective view of the plant cage of FIG. 1 and showing the separated components of the hinge mechanism.
[0021] FIG. 12 is a perspective view of the plant cage of FIG. 1 shown in an open position.
[0022] FIG. 13 is a perspective view of the plant cage of FIG. 1 shown in a closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1 , a plant cage 11 aids in crop growing by providing a support structure to the limbs and the stalk of a plant. Cage 11 may be totally free standing, or it may be anchored into soil. Cage 11 may be located out of doors in an open field, for example, or may be located in a greenhouse free from weather concerns. Cage 11 is free standing and thus, serves to eliminate any stress on the limbs or on the roots of the plant that is caged.
[0024] As shown in FIG. 1 , cage 11 is formed of four separate rods 13 and three separate rings 15 , 17 and 19 . Rods 13 and rings 15 , 17 and 19 are of a green color.
[0025] Rods and rings 13 are cylindrical in shape, and may be formed from metal, wood, plastic, or any other material that will provide sufficient strength to allow the cage to stand upright, to hold the three rings, and to be sturdy against plant movement caused by the wind or weather. The length of each rod 13 may vary depending on the type of plant involved, but as an example, may be 36 inches in length. The diameter of each rod 13 is continuous along its length, and may be of various dimensions, for example, ¼ inches, ⅜ inches, ½ inches, ⅝ inches. Of course, smaller diameters may be used, again depending on the plant, the weather, etc. Larger diameters may also be used.
[0026] Rings 15 , 17 and 19 are each circular in shape having, for example, a 20 inch diameter. The rings are vertically adjustable along the rods 13 and may thus be positioned at several different heights. The user places the rings on rods 13 at a height that is needed. In view of the location of plant limbs, the rings may be located accordingly, making pruning and harvesting more easy, and removing stress on plant limbs.
[0027] Referring to FIG. 2 , each ring 15 , 17 , 19 is constructed of two separate portions that are pivotally mounted together. For example, ring 19 includes two portions 19 A and 19 B. The separate portions 19 A, 19 B are connected together at their ends. A hinge mechanism 21 is shown in FIG. 2 being located at one point along the circumference of ring 19 so as to permit ring 19 to be openable within the plane of the ring's circumference. Each of the two separate portions 19 A, 19 B are moveable relative to one another and may be opened to 180 degrees. The portions 19 A, 19 B pivot at the one point on the ring's circumference. Each ring 15 , 17 , 19 is formed of two separate portions, and thus, cage 11 may be completely opened in half, in two like-size segments as shown in FIG. 2 .
[0028] Cage 11 , in its open position of FIG. 2 , may be placed up against a plant, with portion 19 A located adjacent the plant. Thereafter, the open cage 11 is closed, by moving portion 19 B to pivot on hinge mechanism 21 and meet with portion 19 A to form a continuous circular or cylindrical shape about the plant. Once the rings are moved to a closed position, the other ends of the ring portions are secured together holding the rings closed. The cage, thus located around the plant, may be forced vertically into the soil, if so desired.
[0029] Cage 11 is easily disassembled into its component parts of four rods 13 and three rings 15 , 17 and 19 . The separate component parts may be stored flat when not in use.
[0030] As will suggest itself, less than or more than three rings may be positioned onto the rods 13 to form plant cage 11 . Also, rings 15 , 17 and 19 may be designed by the inclusion of less than or more than four rod-receiving holes to accept, for example three rods 13 or more than four rods 13 , if desired.
[0031] Referring to FIGS. 3 , 8 and 11 , hinge mechanism 21 is formed from a bolt 23 and a wing nut 25 . Wing nut 25 mates with bolt 23 to screwingly turn along the threads of bolt 23 to tighten or loosen the bolt to the wing nut, i.e., to vary the spacing between the head of the bolt and the wing nut.
[0032] As shown in FIG. 8 , the ends 27 , 29 of ring portions 19 A, 19 B are shaped in an L-shape to mate ends 27 , 29 with one another. A pair of holes 31 , 33 are formed in each end of ring portions 19 A, 19 B respectively, and are alignable and of a size for receiving bolt 23 . Corners 35 , 37 of ends 27 , 29 of ring potions 19 A, 19 B are shaped or rounded so as to permit rotational movement of one ring portion relative to another ring portion. As understood, the location of holes 31 , 33 and the dimension of the shape of L-shaped ends 27 , 29 allow free rotation to a certain angle, preferably 180 degrees in a full open position.
[0033] As shown in FIG. 8 at reference numeral 41 , the other two ends of ring portions 19 A, 19 B also have a hinge connection with similar bolt and wing nut connection and similar end shapes. Thus, either side of the cage may be opened and rotated. One of the bolts 23 and wing nut 25 is removed and the other bolt and wing nut is loosened to permit rotation on the bolt about the bolt's axis.
[0034] Referring to FIGS. 4 , 8 and 10 , a plurality of grommets 51 are slidable over rods 13 , and serve to hold a ring to a rod, in a secure fashion. Grommet 51 is sized with an aperture to engage and elastically mate with the rod 13 to grasp the rod. Grommet 51 is also sized at its outer periphery to engage the ring via an aperture 53 formed in the ring.
[0035] Grommet 51 may be made from rubber, plastic or other rubber like material that may elastically deformed and mate with the structure of the ring forming aperture 53 to hold the grommet in place and tightly to the ring. Thus, grommet 51 is formed of rubber or plastic that is inserted into a hole in a ring and frictionally retained there, while presenting an aperture to receive a rod and frictionally retain the rod. The grommets may be placed on the rods first and then the rings secured or located to the ring.
[0036] Referring to FIGS. 5 and 9 , four grommets 51 are initially slid over an end 55 of each of four rods, and each grommet is positioned approximately four inches from each end 55 of the rod. After which, a single ring 15 , including its two portions 15 A and 15 B, is slid over the four rods, the four rods slide through the holes 53 in ring 15 until ring 15 sets onto the four grommets as shown in FIG. 9 . The grommet may be pressed into the hole 53 so as to engagingly grasp the ring. Alternatively, as will suggest itself, the grommet may merely provide a rest stop for the ring to lie on top of the grommet.
[0037] After the first ring 15 is in place on the four rods and secured by the four grommets, the structure is stood upright. The cage at this point may be in an open or closed position. Then, another four grommets are slid over the four rod, about half way down the length of the rods. The second ring 17 is then slid onto the four rods until the ring 17 rests on the grommets. The rings are oriented so that the bolts are on the lower side of the rings, as shown in FIG. 9 .
[0038] After the second ring 17 is in place on the four rods, four more grommets are placed on the rods at a desired height, and the final ring 19 is slid over the rods and mated with the grommets. Thereafter, final adjustments may be made as to the height of each ring. The open cage is then placed relative to a plant and closed around it.
[0039] Alternatively, the four rods may first be placed around the plant and forced down into soil; thereafter, each of rings 15 , 17 , 19 in their closed circular state may be positioned and secured with grommets about the four rods and about the plant.
[0040] While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various modifications in form and detail may be made therein without departing from the scope and spirit of the invention. Accordingly, modifications such as those suggested above, but not limited thereto, are to be considered within the scope of the invention. | A plant cage for placement about a plant for assisting in plant growth. At least three vertical rods are arranged relative to one another to define a three-dimensional area into which the plant is locatable. One or more ring members have a circular shape and are formed from two separate components that are pivotal relative to one another to provide an open position for the cage. Two fasteners are connectable to each of the two ring ends. Grommets are disposed on the rods and connect to the ring member, and are positioned at a vertical height along the rods. | 8 |
This is a division of application Ser. No. 251,689, filed Apr. 6, 1981 now abandoned; which is a divisional of then copending application Ser. No. 34,808 filed Mar. 30, 1979 and now U.S. Pat. No. 4,277,868.
BACKGROUND OF THE INVENTION
Weight saving has long been an important consideration in the aircraft industry, as the weight saved gives an increase in the payload for the aircraft. One of many areas where weight can be saved lies in tapering of structural members to provide structural strength where needed while saving weight due to the tapering. Many shaped structural members are formed from a flat strip of metal that is tapered to effect a weight savings. These tapered strips have been formed in the past by placing a strip of metal on the bed of a milling cutter, holding the strip down, and passing the mill cutter head back and forth over the strip until the desired contour is obtained. This is an intermittent operation that is time consuming and costly. It has been found that a tapered strip of metal can be formed in a continuous single pass operation using the invention of this disclosure.
SUMMARY OF THE INVENTION
A drive and a tensioning wheel are located to move a strip of metal under tension over an anvil wheel. A milling cutter, programmed to move toward or away from the anvil based upon linear movement of the metal strip, contours that strip on a continuous basis as the strip passes over the anvil wheel. A punch makes a hole in the moving metal strip to provide indexing of a part in the continuous strip.
It is an object of this invention to provide continuous single pass taper milling of a metal strip.
It is another object of this invention to provide indexing of parts of the continuous metal strip.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a tapered mtal strip formed with this invention.
FIG. 2 is a perspective view of the apparatus of this invention.
FIGS. 3A and 3B show a side elevational view, and FIGS. 4A and 4B a plan view of the apparatus of FIG. 2.
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3A.
FIGS. 6, 7 and 8 show a perspective, plan and side elevational view of a punch mechanism of this invention.
FIGS. 9, 10 and 11 are fragmented sectional views taken along line 9--9 of FIG. 7 and show various positions of a cycling punch.
FIG. 12 shows a schematic of control apparatus for this invention.
DETAILED DESCRIPTION
A taper strip milling machine 10 is used to process a roll 12 of metal strip stock 14, and convert it into a roll having a series of contoured sections 16 each of which will be formed into a structured part having a tapered thickness. The strip in this embodiment has a pair of holes 18 punched by the milling machine; which will be used for indexing the part. The roll is unwound from roll holder 20, threaded through and processed in the machine and the contoured strip wound up on take up reel 22. In the machine the strip passes guide 24, retard roll 26, anvil wheel 28, drive roll 30, punch 32, oiler 34, support roll 36 and tension roll 38 before going to the take up reel 22. The strip is kept under tension as it passes over the anvil wheel and a milling spindle head 40 advances or retracts a milling cutter 42 toward and away from the anvil wheel to effect a cut on the strip as it passes by to contour the strip into sections or parts 16.
Contouring of the strip is programed from a numerical control cabinet 44 having two servo-controlled axes. The horizontal movement of the metal strip 14 over the anvil wheel is an X-axis of motion, and is only limited by the length of the roll of material 12. The vertical movement of the milling spindle head 40 referenced to the top of the anvil wheel 28 controls the height of the milling cutter above that wheel, and is the Y-axis of motion. The X-axis and the Y-axis are controlled from the numerical control cabinet with the Y-axis based on the linear movement of the metal strip or in other words the X-axis movement. The timing of actuation of the punch 32 is also programed and numerically controlled based on the linear movement of the metal strip.
Tension of the metal strip while on the anvil wheel 28 is controlled by the retard roll 26 and the drive roll 30. A pressure roll 46, as best shown in FIG. 3A, made up of a pair of rolls 48 mounted to a pivotally mounted yoke 50 is actuated by a cylinder 52 to force and hold the metal strip 14 against the retard roll to prevent slippage. A similar pressure roll 54 with rolls 56 and pivotally mounted yoke 58 is actuated by cylinder 60 to force and hold the metal strip against drive roll 30. The retard roll and the drive roll are both driven by motor 62, through common shaft 64 and gear boxes 66 and 68 respectively. The drive roll has a slightly larger diameter than the retard roll, and a magnetic clutch 70 is placed in the drive train 72 between the two gear boxes which continually places the metal strip in tension.
Even with the metal strip being under tension, if a deep cut is being milled, the cutter 42 may tend to raise the strip to give an out of tolerance contour. Pressure shoe 74, held with linkage 76, and positioned with cylinder 78 is located adjacent the cutter to hold down both edges of the strip. The pressure shoe is preferably of a modified teflon to permit slippage without scratching the surface of the metal strip.
A hood 80, around the cutter 42, leads into ducting 82, which is connected to a source of vacuum, not shown, for continuously removing chips generated by the cutter.
A burnishing wheel 84 driven by motor 86 is used for a polishing operation. Hood 88 and ducting 90 lead to a vacuum source, not shown, to remove the dust generated. Next the strip passes through oiler 34 where a film of oil is sprayed on, through support rolls 36, tension roll 38 and onto the take-up reel.
The punch 32, which is best shown in FIGS. 6 through 11, punches the indexing holes 18 as the metal strip 14 moves through the milling machine 10. The punch has two main portions. One is the drawer or sliding member 92. This member has a base 94 having a pair of female dies 96a and 96b vertically extending side members 98a and 98b each having an inwardly directed part 100a and 100b and each part having a tapered surface 102a and 102b respectively, a pair of laterally extending projections 104a and 104b, and a laterally extending drive member 106. A pair of hydraulic cylinders 108a and 108b are mounted to the sides of punch housing 110. Cylinder rods 112a and 112b are joined to the laterally extending projections to permit actuation of the sliding member. The other main portion of the punch is a punch block 114 having a pair of male dies 116a and 116b. The punch block is mounted to rotate in a complete cycle. This is accomplished with two sets of arms with a pair of arms 118a on one side of the punch block and another pair of arms 118b on the other side of the block. A pair of shafts 120 are rotatably mounted in the punch block and extend into and are joined adjacent one edge of oppositely located arms. Each arm is joined adjacent the free end to a shaft extending outwardly. These shafts are rotatably mounted to the housing 110 with shafts 122a joined to arms 118a and shafts 122b joined to arms 118b. The arms are sized and positioned to provide four bar linkage actuation of the punch block. One of the shafts 122b extends through the housing and has a cam 124 and a sprocket wheel 126 mounted on the extension. An air motor 128 with shaft 130 has a sprocket wheel 132 mounted to the shaft. A chain 134 is mounted between the two sprocket wheels to provide a drive for punch blocks 114. The air motor is energized with compressed air, from a source not shown, the air from the motor exhausts through line 136, and into normally open adjustable restrictor valve 138. As cam 124 rotates it is contacted by a cam follower 140 that controls the adjustable restrictor valve. The cam is proportioned to allow unrestricted air flow through most of a punching cycle, but to restrict air flow as the punch block 114 approaches the starting position.
The starting position for actuating the punch is as shown in FIG. 9. To actuate the punch the air motor is on and seeking to rotate the punch block. In the starting position the leading members of the arms 118a and 118b rest against and are restrained from rotating by the inclined plane surface 102a and 102b. The sliding block is fully back and against electrical switch 142; which switch signals the punch is in position and ready to be actuated. The signal feeds into punch control relay logic 144, the numerical control unit 44 checks and finds the punch is in position, sends a command signal and the punch is actuated. To accomplish the actuation the hydraulic cylinders 108a and 108b are actuated and sliding block 92 is moved forward. As the stop surface 102a and 102b advance the arms contacting those surfaces are rotated by the air motor and the dies 116a and 116b contact but do not penetrate the metal strip as the sliding block continues to advance the following transverse drive bar 106 contacts the punch block 114 driving it forward and punching the metal strip. Upon further advance by the sliding block the rounded ends 146a and 146b on the arms slide past the inclined stop surface, the punch block rapidly rotates upward and actuates proximity switch 148. This initiates a signal which is used to reverse the fluid to the cylinders and return the sliding block to starting position. Shortly after the punch block passes the proximity switch cam 124 acts on cam follower 140 restricting flow through valve 138 and the punch block slowly returns to starting position while allowing the sliding block to first return to starting position. The punched blanks are removed through slots 149 located in housing 110.
A limit switch 150 is used to limit the travel of the cutter toward the anvil wheel 28. When the limit of travel is reached and the limit switch is contacted, it activates a control logic 152 which retracts the cutter spindle head 40 and shuts down the machine.
In operation a tape for the numerical control cabinet 44 is programed to provide the desired X-axis travel to make the part, to determine the Y-axis travel of the milling cutter 42 based on the X-axis travel, and to determine the timing for the punch based on the X-axis travel. The strip of metal 14 stock is threaded under the retard roll 26, over the freely rotatable anvil wheel 28, under the drive roll 30, through the punch 32 and onto the take up roll 22. Pressure rolls 46 and 50 are actuated to press against retard and drive rolls respectively and the machine initiated to mill and roll up the parts. | A sliding block with a female die acts in conjunction with a four bar linkage mounted block with a male die to punch indexing holes in a moving metal strip. The block with male die continually seeks to rotate, but is held in position by the sliding block. The sliding block is programmed to periodically move forward at the speed of the moving metal strip and to return to starting position. This frees the male die to rotate to punch out the hole, and to continue to rotate back into the starting position to be held by the returned sliding block. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a behavior detection system for detecting an abnormal behavior, and more specifically, to a behavior detection system for detecting an abnormal behavior, which can perform dynamic control based on situation information and a profile of each user to cope with an element threatening security of an internal infrastructure of an enterprise, such as information leakage or the like, in a bring your own device (BYOD) and smart work environment.
[0003] 2. Background of the Related Art
[0004] Owing to construction of wireless Internet environments, generalization of smart devices such as a tablet PC, a smart phone and the like, desktop virtualization, increase of utilizing cloud services, putting emphasis on real-time communication and continuity of a work, and the like, development of a BYOD and smart work environment, which is a new IT environment, is accelerated.
[0005] From the standpoint of an enterprise, the BYOD tends to be actively adopted to enhance productivity and efficiency of a work and save cost for purchasing equipment or the like. As the age of BYOD is arriving like this, the internal infrastructure of an enterprise is changed from a closed environment to an open environment. A personal device is allowed to access the infrastructure of an enterprise regardless of time and space.
[0006] A personal device may access the infrastructure of an enterprise inside the enterprise through a wireless router (AP), a switch or the like, and the infrastructure of the enterprise may be accessed from outside of the enterprise through a mobile communication network, a public WiFi, a VPN or the like.
[0007] Although continuity and convenience of a work are obtained as the internal infrastructure of an enterprise is changed to an open environment as described above, threat to security, which is unimaginable before, also frequently occurs. Above all, as the personal device accesses the internal infrastructure of an enterprise, risk of leaking internal data of the enterprise is increased. That is, the internal data of the enterprise may be leaked when the personal device is lost or stolen, and IT assets of the enterprise may be threatened when a personal device infected with a malicious code connects to the internal intranet.
[0008] NAC and MDM may be illustrated as security techniques spotlighted recently in the BYOD and smart work environment in response to the threat to the IT assets described above. The NAC technique is a technique of controlling network access according to whether or not a terminal is abnormal by examining whether or not a user PC (terminal) abides by a security policy before the terminal connects to an internal network.
[0009] Since the main object of the NAC is user authentication and access control, the NAC is in lack of a function for detecting and coping with an abnormal behavior of a user or a terminal after they access a network. In addition, since the NAC is centered on authentication based on a registered user, it is also in lack of a function of authenticating a terminal device.
[0010] Above all, since the NAC is born to block network access itself, it is in lack of security specialties for protecting enterprise data by isolating a user of an abnormal behavior, none the less to say that it should guarantee utilization of various personal devices and continuity of a work as described above.
[0011] On the other hand, the MDM is a system which remotely provides functions such as registering/managing a terminal, suspending use of a lost terminal, tracing and managing a terminal and the like using an over the air (OTA) technique (a wireless transmission technique of a cellular phone) regardless of time and space if a mobile device is in a power-on state.
[0012] However, since the MDM is a kind of application, it is difficult to control and monitor accesses of other applications.
[0013] In addition, the MDM cannot access a network layer of a system level and cannot perform a behavior analysis on a network data. Above all, since users are unwilling to install an MDM agent in a personal device as personal privacy is requested to be protected, it is difficult to distribute and spread the MDM, and, in addition, the cost for continuously conducting version control on a variety of terminal devices is increased.
[0014] As described above, the conventional NAC and MDM described above have a limit in protecting internal resources in a BYOD and smart work environment.
SUMMARY OF THE INVENTION
[0015] Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a behavior detection system for detecting an abnormal behavior in a BYOD and smart work environment by processing situation information collected from a terminal device and an MDM agent device.
[0016] In addition, another object of the present invention is to provide a behavior detection system for detecting an abnormal behavior related to an abnormal connection of a user by profiling each user (which means identifying a specific entity and creating a set which can describe behaviors of the entity) and accumulating normal behaviors of the user stored while performing a work.
[0017] In addition, still another object of the present invention is to provide a behavior detection system for detecting an abnormal behavior, the system can detect in real-time abnormal connection elements which are compared with normal behavior patterning elements based on real-time situation information such as a connection time and location of a user, records of previous behaviors, a normal profile configuring average values and statistical values of all users in the system and the like.
[0018] The characteristics of the present invention for accomplishing the objects of the present described above and performing characteristic functions of the present invention described below are as follows.
[0019] According to one aspect of the present invention, there is provided a behavior detection system for detecting an abnormal behavior of a user in a BYOD and smart work environment, the system including: a situation information collection system for collecting situation information from a terminal device and an MDM agent device; an information database for processing and storing the collected situation information as connection, use and agent situation information and profiling the situation information at a time of disconnection to process and store the situation information as profile information; and an abnormal behavior detection system for detecting an abnormal behavior related to connection and use of the terminal device of the user using normal profile information included in the profile information.
[0020] Here, the abnormal behavior detection system according to one aspect of the present invention may detect connection, use and abnormal behavior of a connected terminal device of a user conducted on an agent based on the connect, use and agent situation information and further detect an abnormal behavior related to the connection and use of the terminal device of the user based on the profile information according to a security policy.
[0021] In addition, the abnormal behavior detection system according to one aspect of the present invention may include: a connection behavior pattern extraction unit for extracting a plurality of pieces of connection behavior pattern information having connection behavior elements of a same series from the normal profile information among the profile information; a matrix storage unit for creating a matrix of connection behavior pattern information by matching the plurality of pieces of connection behavior pattern information other than certain connection behavior pattern information among the plurality of pieces of connection behavior pattern information to the certain connection behavior pattern information for each piece of the connection behavior pattern information; a connection behavior element extraction unit for extracting a first connection behavior element of the first current behavior included in the certain connection behavior pattern information; and a first occurrence probability calculation unit for calculating a current behavior occurrence probability of the first connection behavior element under behaviors of the other connection behavior pattern elements.
[0022] In addition, the abnormal behavior detection system according to one aspect of the present invention may further include a second occurrence probability calculation unit for determining whether or not other second connection behavior elements for calculating the current behavior occurrence probability exist among the certain connection behavior pattern information and, if other second connection behavior elements for calculating the current behavior occurrence probability exist as a result of the determination, extracting the second connection behavior elements of a next current behavior included in the certain connection behavior pattern information and further calculating a current behavior occurrence probability for each of the second connection behavior elements.
[0023] In addition, the abnormal behavior detection system according to one aspect of the present invention may further include an abnormal connection confirmation unit for confirming, if it is determined that the other second connection behavior elements do not exist any more as a result of the determination, whether or not there is an abnormal connection behavior by calculating a weighted average and a standard deviation of the behavior occurrence probabilities for each of the first connection behavior element and the second connection behavior element and determining whether or not a connection behavior is within a range of a normal behavior occurrence probability and a normal standard deviation.
[0024] In addition, the abnormal behavior detection system according to one aspect of the present invention may include: a traffic use time extraction unit for inquiring first device profile information among the profile information and extracting average traffic volume information and average use time information per connection; a first traffic volume determination unit for determining whether or not a traffic volume per connection acquired from second device profile information generated while being connected exceeds the average traffic volume information; a use time determination unit for determining, if it is determined that the traffic volume per connection exceeds the average traffic volume information as a result of the determination of the first traffic volume determination unit, whether or not a use time per connection acquired from the second device profile information exceeds the average use time information; a traffic use time determination unit for determining, if it is determined that the use time per connection exceeds the average use time information as a result of the determination of the use time determination unit, whether or not a traffic volume generated with respect to the use time exceeds a preset threshold ratio; and a normal connection state determination unit for determining, if it is determined that the traffic volume exceeds the preset threshold ratio as a result of the determination of the traffic use time determination unit, connection of the terminal device currently connected and generating the second device profile information as an abnormal connection.
[0025] In addition, the abnormal behavior detection system according to one aspect of the present invention may further include a traffic tolerance determination unit for determining, if it is determined that the use time per connection does not exceed the average use time information as a result of the determination of the use time determination unit, whether or not the traffic volume tolerable with respect to the average traffic volume information per connection exceeds a threshold ratio.
[0026] In this case, the traffic allowance value determination unit according to one aspect of the present invention may determine connection of the terminal device currently connected and generating the second device profile information as a normal connection if the traffic volume tolerable with respect to the average traffic volume information per connection does not exceed the threshold ratio as a result of the determination of the traffic tolerance determination unit and as an abnormal connection if the traffic volume tolerable with respect to the average traffic volume information per connection exceeds the threshold ratio.
[0027] In this case, the first traffic volume determination unit according to one aspect of the present invention may determine connection of the terminal device currently connected and generating the second device profile information as a normal connection if the traffic volume per connection does not exceed the average traffic volume information as a result of the determination.
[0028] In this case, the traffic use time determination unit according to one aspect of the present invention may determine connection of the terminal device currently connected and generating the second device profile information as a normal connection if the traffic volume generated with respect to the use time does not exceed a preset threshold ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a view exemplarily showing a behavior detection system 1000 according to an embodiment of the present invention.
[0030] FIG. 2 is a view exemplarily showing the configuration of an abnormal behavior detection system 300 for detecting an abnormal connection behavior according to a first embodiment of the present invention.
[0031] FIGS. 3 to 7 are views showing states of data obtained from each configuration of the abnormal behavior detection system 300 according to a first embodiment of the present invention.
[0032] FIG. 8 is a view exemplarily showing the configuration of an abnormal behavior detection system 300 for detecting an abnormal use behavior based on a profile according to a second embodiment of the present invention.
[0033] FIG. 9 is a view showing a graph of traffic volume accumulated with respect to use time according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The preferred embodiments of the invention will be hereafter described in detail with reference to the accompanying drawings so that those skilled in the art may easily embody the present invention. Furthermore, in the drawings illustrating the embodiments of the present invention, elements having like functions will be denoted by like reference numerals and details thereon will not be repeated.
[0035] FIG. 1 is a view exemplarily showing a behavior detection system 1000 according to an embodiment of the present invention.
[0036] As shown in FIG. 1 , the behavior detection system 1000 according to an embodiment of the present invention is configured to include a situation information collection system 100 , an information database 200 , an abnormal behavior detection system 300 , a control system 400 , a terminal device 500 , and an MDM server 600 in order to detect abnormal behaviors in a BOYD and smart work environment.
[0037] First, the situation information collection system 100 according to the present invention collects situation information related to a time point of authentication, connection or disconnection from the terminal device and an MDM agent device.
[0038] At this point, the collected situation information includes a connection address (an ID, a company, authority, a current state and the like), a connection pattern (an authentication result, the number of authentication failures and the like), network behavior information (a connection time, a location and the like) and disconnection time information. Although the situation information is divided into a periodic transmission data and a non-periodic (real-time) transmission data, all situation information is considered as non-periodic transmission data and collected by the situation information collection system 100 .
[0039] Next, the information database 200 according to the present invention processes the situation information collected by the situation information collection system 100 into connection, use and agent situation information and, at the same time, performs profiling on the situation information at the time of disconnection to process and store the situation information as profile information.
[0040] At this point, the stored profile information includes a user profile, a terminal device profile and a connection behavior profile. At this point, the user profile includes user authority information, a total number of authentication failures, a recent connection date and time, an initial connection date and time, a total use time and a total number of connections, and the terminal device profile includes a device ID, a device type, an operating system (OS), a browser, a device name, a MAC address, an installation state of an agent, a locking state of a screen, information on installed programs, a setting of automatic log-in and a recent connection date and time. In addition, the connection behavior profile includes connection behavior pattern information.
[0041] Next, the abnormal behavior detection system 300 according to the present invention detects abnormal behaviors related to connection behaviors, use behaviors, authentication behaviors and the like of the terminal device 500 and/or the MDM server 600 using the profile information and the connection, use and agent situation information stored in the information database 200 . For example, the abnormal behavior detection system 300 detects abnormal behaviors related to connection and use of the terminal device of a user using normal profile information included in the profile information.
[0042] Next, the control system 400 according to the present invention receives information on the abnormal behaviors detected by the abnormal behavior detection system 300 and controls the information through a control GUI, sets and manages a security policy, and controls connection to an external security device. One end of such a control system 400 is connected to the information database 200 and/or the abnormal behavior detection system 300 , and the other end thereof is connected to the external security device (e.g., Genian, Wapples or the like).
[0043] Next, the terminal device 500 according to the present invention is a mobile device owned by an individual, such as a smart phone, a laptop computer, a tablet computer or the like, which is a terminal for assessing IT resources internal to a company, such as a database, an application, or the like, and processing a work.
[0044] In other words, the terminal device 500 generates situation information related to a time point of authentication, connection or disconnection in a BYOD and smart work environment. Since the situation information is described above, additional description thereof is omitted.
[0045] Finally, the MDM server 600 according to the present invention is located in a DMZ or a screened subnet and functions as a gateway for communications such as authentication connection between an intra network of a company and a mobile device, Direct Push Update and the like. A plurality of agents is connected to the MDM server 600 and generates the situation information described above.
[0046] Hereinafter, the abnormal behavior detection system 300 described above will be described in further detail.
First Embodiment
[0047] FIG. 2 is a view exemplarily showing the configuration of an abnormal behavior detection system 300 for detecting an abnormal connection behavior according to a first embodiment of the present invention, and FIGS. 3 to 7 are views showing states of data obtained from each configuration of the abnormal behavior detection system 300 according to a first embodiment of the present invention. FIGS. 3 to 7 will be subsidiarily described while describing FIG. 2 .
[0048] As shown in FIG. 2 , the abnormal behavior detection system 300 according to a first embodiment of the present invention is configured to include a connection behavior pattern extraction unit 305 , a matrix storage unit 310 , a connection behavior element extraction unit 315 , a first occurrence probability calculation unit 320 , a second occurrence probability calculation unit 325 , an abnormal connection confirmation unit 330 and a control unit 331 in order to detect an abnormal connection behavior using a normal profile among profile information extracted in a BYOD and/or smart work environment.
[0049] First, the connection behavior pattern extraction unit 305 according to the present invention extracts normal profile information among the profile information stored in the information database 200 described above in FIG. 1 and extracts a plurality of pieces of connection behavior pattern information having connection behavior elements of a same series from the normal profile information.
[0050] For example, the connection behavior pattern extraction unit 305 extracts a plurality of pieces of connection behavior pattern information (A and B) having connection behavior elements such as a 1 , a 2 and a 3 and connection behavior elements such as b 1 , b 2 and b 3 , which form a same series.
[0051] In other words, connection behavior pattern information A has connection behavior elements such as a 1 , a 2 and a 3 forming a similar connection behavior, and connection behavior pattern information B has connection behavior elements such as b 1 , b 2 and b 3 forming a similar connection behavior. This example may be summarized as shown in (Table 1).
[0000]
TABLE 1
Connection behavior information
A
B
C
Connection behavior elements
a1, a2,
b1, b2,
c1, c2,
a3 . . .
b3 . . .
c3 . . .
[0052] Next, the matrix storage unit 310 according to the present invention creates a matrix of connection behavior pattern information by matching the plurality of pieces of connection behavior pattern information other than certain connection behavior pattern information among the plurality of pieces of connection behavior pattern information of, for example, A, B and C, extracted by the connection behavior pattern extraction unit 305 to the certain connection behavior pattern information for each piece of the connection behavior pattern information.
[0053] For example, connection behavior pattern information B and C correspond to the other plurality of pieces of connection behavior pattern information when the certain connection behavior pattern information is A, and connection behavior pattern information A and C correspond to the other plurality of pieces of connection behavior pattern information when the certain connection behavior pattern information is B.
[0054] The matrix information (patterned behavior information) created as a matrix in this manner may be summarized as shown in FIG. 3 .
[0055] Next, the connection behavior element extraction unit 315 according to the present invention extracts a first connection behavior element of the first current behavior included in the certain connection behavior pattern information. For example, if current behaviors are occurred in order of a 2 , b 1 and c 3 , first connection behavior elements such as a 2 , b 1 and c 3 may be respectively extracted as current behavior elements. An example of the extracted first connection behavior elements a 2 , b 1 and c 3 is shown in FIG. 4 .
[0056] Next, the first occurrence probability calculation unit 320 according to the present invention matches the first connection behavior elements extracted by the connection behavior element extraction unit 315 under the behaviors of the other connection behavior pattern elements as shown in FIG. 4 . For example, the first connection behavior elements such as A{a 1 , a 2 } are matched under the behaviors of the respective connection behavior pattern elements such as B{b 1 , b 2 , b 3 } and C{c 1 , c 2 , c 3 } as shown in FIG. 4 .
[0057] Then, the first occurrence probability calculation unit 320 according to the present invention calculates current behavior occurrence probabilities of the first connection behavior elements such as a 1 and a 2 under the behaviors of the other connection behavior pattern elements such as B{b 1 , b 2 , b 3 } and C{c 1 , c 2 , c 3 } or calculates current behavior occurrence probabilities of the first connection behavior elements such as b 1 , b 2 and b 3 under the behaviors of the other connection behavior pattern elements such as A{a 1 , a 2 , a 3 } and C{c 1 , c 2 , c 3 }.
[0058] At this point, an example of the calculated behavior occurrence probabilities of the first connection behavior elements is as shown in FIG. 5 . That is, FIG. 5 shows only a probability of current occurrence of behavior a 1 (a 1 is a behavior of the first connection behavior element) when behaviors b 2 and b 3 are conducted, by applying the Bayesian theory. Current occurrence probabilities of the other current behaviors may be calculated in the same manner as calculating the probability of a 1 .
[0059] Next, the second occurrence probability calculation unit 325 according to the present invention determines whether or not other second connection behavior elements for calculating the current behavior occurrence probability exist among the certain connection behavior pattern information.
[0060] For example, as described above for the connection behavior element extraction unit 315 , when the first connection behavior element selected in the first place is a 2 , b 1 selected in the second place corresponds to the second connection behavior element, and, subsequently, when the first connection behavior element is b 1 , c 3 coming in next turn will correspond to the second connection behavior element. Accordingly, the second occurrence probability calculation unit 325 according to the present invention determines whether or not the second connection behavior elements such as b 1 and c 3 exist.
[0061] Subsequently, if it is determined that the second connection behavior elements such as b 1 and c 3 still exist as a result of the determination, the second occurrence probability calculation unit 325 according to the present invention extracts the second connection behavior elements such as b 1 and c 3 and further calculates current behavior occurrence probabilities for the second connection behavior elements b 1 and c 3 in the same manner as the calculation of the first occurrence probability calculation unit 320 described above.
[0062] Like this, the second connection behavior elements mean a plurality of currently occurring behaviors unlike the first connection behavior elements indicating only any one of connection behavior elements. Accordingly, it is possible to determine whether or not all subsequent connection behavior elements exist and further calculate respective current behavior occurrence probabilities like calculating the current behavior occurrence probability of the first connection behavior element.
[0063] Next, if it is determined that the second connection behavior elements do not exist any more as a result of the determination of the second occurrence probability calculation unit 325 , the abnormal connection confirmation unit 330 according to the present invention calculates a weighted average of the behavior occurrence probabilities for each of the first connection behavior element and the second connection behavior element.
[0064] For example, as shown in FIG. 6 , if the probability of occurrence of a 1 is defined as P(a 1 ), the probability of occurrence of b 3 is defined as P(b 3 ), the probability of occurrence of c 3 is defined as P(c 3 ), the weighting factor of behavior A is defined as W A =1, the weighting factor of behavior B is defined as W B =3, and the weighting factor of behavior C is defined as W C =5, the behavior occurrence probability based on the weighted average may be calculated as (P)=[(P(a 1 )*W A )+(P(b 3 )*W B )+(P(c 3 )*W C )]/W.
[0065] Subsequently, the abnormal connection confirmation unit 330 according to the present invention calculates the weighted average of the behavior occurrence probability for each of the confirmed first and second connection behavior elements and then calculates a standard deviation using a formula of a standard deviation SD (a behavior standard deviation) as shown in FIG. 7 based on a result of calculating the weighted average.
[0066] Then, the abnormal connection confirmation unit 330 according to the present invention confirms existence of an abnormal connection behavior in a BYOD and smart work environment by determining whether or not a connection behavior is within the range of a normal behavior occurrence probability and a normal standard deviation using the weighted average and the standard deviation for the behavior occurrence probabilities calculated as described above.
[0067] For example, if a normal behavior probability P and a normal standard deviation SD are confirmed according to a standard of normal as shown in tables 2 and 3, whether the behavior occurrence probability and the standard deviation are normal or abnormal may be known, and thus existence of an abnormal connection behavior such as a suspected behavior, a warned behavior or an abnormal behavior may be known.
[0000]
TABLE 2
Division
Standard of normal
Probability of normal behavior (P)
60 < P
Normal standard deviation (SD)
SD > 20
[0000]
TABLE 3
Division
Probability of
occurrence of
Standard
behavior
deviation
Final decision
Normal
Abnormal
Suspected behavior
Abnormal
Normal
Warned behavior
Normal
Abnormal
Abnormal behavior
[0068] Here, if the behavior probability is normal and the standard deviation is abnormal, it means that some of behavior elements are less probable to occur although a connection behavior is probable to occur, and if the behavior probability is abnormal and the standard deviation is normal, it means that the overall probability of occurring a connection behavior is low (the standard deviation is meaningless since the probability of occurrence of each of behavior elements is low).
[0069] Contrarily, a case in which both the behavior probability and the standard deviation are abnormal is generally difficult to occur, and it means that possibility of occurring such a situation is extremely low even for some behavior elements.
[0070] Finally, the control unit 331 according to the present invention controls flow of data among the connection behavior pattern extraction unit 305 , the matrix storage unit 310 , the connection behavior element extraction unit 315 , the first occurrence probability calculation unit 320 , the second occurrence probability calculation unit 325 and the abnormal connection confirmation unit 330 . Accordingly, a corresponding unique function is performed in each configuration.
[0071] As described above, in this embodiment, since existence of an abnormal connection behavior may be known using the finally calculated behavior occurrence probability and behavior standard deviation, further excellent security compared with that of the existing NAC and MDM techniques may be maintained in a BYOD and smart work environment.
Second Embodiment
[0072] FIG. 8 is a view exemplarily showing the configuration of an abnormal behavior detection system 300 for detecting an abnormal use behavior based on a profile according to a second embodiment of the present invention.
[0073] As shown in FIG. 8 , the abnormal behavior detection system 300 according to a second embodiment of the present invention is configured to include a traffic use time extraction unit 335 , a first traffic volume determination unit 340 , a use time determination unit 345 , a traffic use time determination unit 350 , a normal connection state determination unit 355 and a traffic tolerance determination unit 360 in order to detect an abnormal use behavior using profile information extracted in a BYOD and/or smart work environment.
[0074] First, the traffic use time extraction unit 335 according to the present invention inquires first device profile information (which means device profile information of a plurality of users) among the profile information stored in the information database 200 described above in FIG. 1 and extracts average traffic volume information and average use time information per connection.
[0075] Here, the profile information includes a user profile configured of user authority information, a total number of authentication failures, a recent connection date and time, an initial connection date and time, a total use time and a total number of connections, a first device profile configured of a device ID, a device type, an OS, a browser, a device name, a MAC address, an installation state of an agent, a locking state of a screen, information on installed programs, a setting of automatic log-in, and a recent connection date and time, and a connection behavior profile configured of connection behavior pattern information.
[0076] In this case, the traffic use time extraction unit 335 according to the present invention extracts average traffic volume information and average use time information generated per connection from the first device profile among the profile information described above. At this point, an average traffic volume of the average traffic volume information may be calculated by a formula of ‘number of transmitted and received packets (targeting a destination)/total number of connections of device’, and an average use time of the average use time information may be calculated by a formula of ‘total use time of device/total number of connections of device’.
[0077] Next, the first traffic volume determination unit 340 according to the present invention determines whether or not a traffic volume per connection acquired from second device profile information generated while being connected exceeds the average traffic volume information extracted by the traffic use time extraction unit 335 .
[0078] The average traffic volume information applied as the standard of determination means an average amount of data generated per connection by the user through a currently used device. Meanwhile, the second device profile information means device profile information acquired from the currently used device.
[0079] If the traffic volume per connection does not exceed the average traffic volume information, the first traffic volume determination unit 340 determines connection of the terminal device currently connected and generating the second device profile information as a normal connection.
[0080] Next, if it is determined that the traffic volume per connection exceeds the average traffic volume information as a result of the determination of the first traffic volume determination unit 340 , the use time determination unit 345 according to the present invention assumes the connection of the currently connected terminal device as an abnormal connection and determines whether or not a use time per connection acquired from the second device profile information exceeds the average use time information.
[0081] The average use time information applied as the standard of determination means an average use time when the user connects through a currently used device (a terminal device), and the use time means a final communication time, i.e., a connection time.
[0082] Next, if it is determined that the use time per connection exceeds the average use time information as a result of the determination of the use time determination unit 345 , the traffic use time determination unit 350 according to the present invention determines whether or not a traffic volume generated with respect to the use time exceeds a preset threshold ratio.
[0083] At this point, the threshold ratio means a range of an allowed traffic volume larger than the average traffic volume within the average use time. Contrarily, a traffic volume with respect to the use time means an average amount of data used by the user through the currently used device at a specific use time (targeting a destination), which can be calculated by a formula of ‘number of transmitted and received packets (targeting a destination)/total use time of device×time of using measurement target’.
[0084] Next, if it is determined that the traffic volume does not exceed the preset threshold ratio as a result of the determination of the traffic use time determination unit 350 , the normal connection state determination unit 355 according to the present invention determines whether or not a traffic volume tolerable with respect to the average traffic volume information per connection exceeds a threshold ratio.
[0085] At this point, if it is determined that the traffic volume tolerable with respect to the average traffic volume information per connection exceeds the threshold ratio as a result of the determination of the normal connection state determination unit 355 , connection of the terminal device currently connected and generating the second device profile information is determined as an abnormal connection.
[0086] Next, if it is determined that the use time per connection does not exceed the average use time information as a result of the determination of the use time determination unit 345 , the traffic tolerance determination unit 360 according to the present invention determines whether or not the traffic volume tolerable with respect to the average traffic volume information per connection exceeds the threshold ratio.
[0087] If it is determined that the traffic volume tolerable with respect to the average traffic volume information per connection does not exceed the threshold ratio as a result of the determination of the traffic tolerance determination unit 360 , connection of the terminal device currently connected and generating the second device profile information is determined as a normal connection, and if it is determined that the traffic volume tolerable with respect to the average traffic volume information per connection exceeds the threshold ratio, connection of the terminal device currently connected and generating the second device profile information is determined as an abnormal connection.
[0088] As described above, in the embodiment, since it may be determined whether or not a currently connected terminal device is abnormal through the determination steps described above, security in a BOYD and smart work environment may be enhanced.
[0089] FIG. 9 is a view showing a graph of traffic volume accumulated with respect to use time according to a second embodiment of the present invention.
[0090] As shown in FIG. 9 , in the graph of traffic volume accumulated with respect to use time according to a second embodiment of the present invention, it may be possible to confirm various graph states for detecting abnormal use, including a graph of an average use time per connection and a range of traffic volume which may be generated in each use time zone based on an average traffic volume in an average use time.
[0091] Meanwhile, although the abnormal behavior detection system 300 described above detects an abnormal behavior based on past behavior information as described with reference to FIGS. 2 to 8 , it may further detect an abnormal behavior based on real-time behavior information.
[0092] That is, the abnormal behavior detection system 300 according to the present invention may further detect connection, use and abnormal behavior of a connected terminal device of a user conducted on an agent, based on real-time behavior information stored in the information database 200 , such as the connection, use and agent situation information, and may further detect an abnormal behavior related to the connection and use of the terminal device of the user based on the profile information according to a security policy.
[0093] As described above, according to the present invention, since situation information is processed as connection, use and agent situation information and profile information and an abnormal behavior such as connection, use and the like of a terminal device is detected using the information, it is effective in that security in the BYOD and smart work environment may be improved.
[0094] In addition, according to the present invention, since an abnormal connection behavior and a malicious behavior may be easily determined by calculating a current behavior occurrence probability for a corresponding connection behavior element under the behaviors of the other connection behavior pattern elements after extracting a plurality of connection behavior elements, it is effective in that security in the BYOD and smart work environment may be improved.
[0095] In addition, according to the present invention, since an abnormal use behavior may be easily determined by determining whether or not an average traffic volume and an average use time per connection are exceeded, it is effective in that security in the BYOD and smart work environment may be improved.
[0096] Particularly, as described above, if an abnormal connection behavior is detected, it is effective in that the existing NAC and MDM techniques which are limited in protecting internal resources in a BYOD and smart work environment may be replaced.
[0097] While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention. | Disclosed is a behavior detection system for detecting an abnormal behavior, can perform dynamic control based on situation information and a profile of each user to cope with an element threatening security of an internal infrastructure of an enterprise, such as information leakage, in BYOD and smart work environment. The system calculates probabilities of behaviors occurring for respective connection behavior elements, calculates standard deviations of the probabilities based on weighting factors and determines whether or not the calculated behavior occurrence probabilities and behavior standard deviation correspond to a normal behavior, existence of an abnormal connection behavior in a BYOD and smart work environment is detected and an abnormal user is detected by examining whether or not an average traffic volume, an average use time and traffic volume with respect to a use time exceeds respective standard values. | 7 |
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