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BACKGROUND OF THE INVENTION
There is a definite need for a mechanical circle-cutter today, particularly in view of the advent of plasma cutters and the need for efficiency in making such cuts, as in the commercial manufacture of metal discs. The conventional method in prevalent use today is to utilize a template to aid in inscribing the desired circle upon the workpiece which is frequently of sheet steel. Making a template involves a considerable waste of time.
Another method is to establish a pivot point on the workpiece and then inscribe circle with the pivot point as the center. The use of marking the pivot point mars the surface, making the end-product less desirable, sometimes to such an extent as to require remedial welding to obviate the scar.
One additional way of making a circular cut has been to utilize a magnet as a pivot point. This procedure, however, has a distinct disadvantage in that the magnet often covers the workpiece area to be cut, which limits the size of the circle which can be cut.
The closest prior art with which I am familiar is U.S. Pat. No. 2,483,229 issued to Parker in 1949, which we developed in a patentability search. For some unknown reason, to the best of my knowledge, this circle-cutting machine is not available on the market. It would appear that, since the weight of the entire cutting structure is off-set relative to the support arm 12, the key 18 and keyway 15 will quickly wear and, as a consequence, cause the nozzle 36 of the torch to be oriented off-vertical and introduce error into the cutting operation. The keyways will fill readily with grit, requiring frequent cleaning and introducing error in the cuts.
It will also be noted that the support arm is not capable of free swinging movement since the sleeve 5 has been positioned to lock the device at a predetermined elevation, for operation of the cutter. There is a limit as to how close an operator can cut a hole, to the edge of the workpiece. In addition, material to be cut must have at least a minimum of thickness in order to be able to support the Parker cutter. Also, it is impossible to adjust the height of the cutting torch without losing your center because it requires rotation of arm 12 and shaft 3.
In addition to the above, the bushing in the pivot point will wear rapidly since grit will enter same, requiring substantial maintenance and cleaning. No ready means is provided for setting the torch so as to produce a circle having a predetermined radius. Having the main frame off-center, as in the Parker patent, makes it difficult to measure from the edge of the material to the center of the circle and causes parts to wear excessively, the torch to tip, and cut to be made at an angle. No provision is made to adjust in small increments the radius of the circle to be cut. No provision is made for supporting the handle of the torch or plasma lines or for attaching automatic turning apparatus for making the cut. Also, there is a limit as to how far the circle to be cut can be disposed from the edge of the workpiece.
U.S. Pat. No. 2,523,237 issued to Richardson shows a torch cutting tool which utilizes a punched center hole and a scribed line along which the workpiece is to be cut. A wheeled carriage 11,52 moves about the center-points 16,54 to guide the torch along the desired line.
U.S. Pat. No. 2,603,475 issued to Rotsch also utilizes a carriage which rides upon the workpiece and supports the cutting torch as it is carried around the pivot point 90.
U.S. Pat. No. 2,886,305 issued to Strahan also uses a carriage 20 which carries the torch 16 as it rides over the surface to be cut.
U.S. Pat. No. 3,547,424 issued to Brown shows a template guided circle-cutting attachment driven by gear boxes and a motor.
U.S. Pat. No. 4,021,025 issued to Frame discloses a circle-cutter which utilizes a circular platform which is attached to the plate to be cut and a cutting torch carried by, and adjustable relative to, the rotatable platform and being movable in a circular path therewith.
U.S. Pat. No. 4,173,333 issued to Wise discloses a torch guide for cutting a beveled edge, incapable of cutting a circle.
U.S. Pat. No. 4,411,410 issued to Sumner discloses a complicated apparatus for cutting openings in pipes, which use a locator 82 about which the torch 96 is rotated in response to pipe contour tracking means.
None of the above patents are constructed and operate in the manner disclosed and claimed herein.
BRIEF SUMMARY OF THE INVENTION
My circle-cutter is a portable, simple and inexpensive mechanical device by means of which circular cuts may be made from a workpiece, such as a section of sheet steel, without requiring a marring center-point and with a maximum of convenience. It includes a support arm which supports a freely rotatable pivot block, the axis of pivot of which extends through the support arm. Extending through the pivot block in sliding relation thereto is a shaft or sliding beam which supports a depending platform or base which is adjustable longitudinally of the shaft for minor adjustments. A cutting torch holder is mounted on the platform adjacent one end thereof in depending relation for free rotation about its vertical axis, which is parallel to the axis of pivot of the pivot block. Thus, the torch holder can be located farthest from the pivot block when the opposite end of the platform abuts the opposite side of the pivot block, and can be shifted to any point between that location and the axis of pivot of the pivot block. At any one of such positions it can be directed along a 360° path defined by its arc having a radius equal to the distance between the axis of pivot of the pivot block and the axis of pivot of the torch holder.
Extending laterally from the torch holder is a handle and support for plasma fuel lines by means of which such movement can be directed, to cause the cutting torch to make a circular cut in a workpiece positioned immediately below the cutting torch, that cut having a radius equal to the distance between the axis of the pivot block and the axis of the torch holder.
My invention obviates the need for a mark on the surface of the workpiece to identify the pivot point, which frequently mars the surface of the workpiece. When utilizing my invention, the pivot point is automatically selected by the positioning of the circle-cutter relative to the workpiece in directly overhead relation. All that is needed is to secure the workpiece so that it will not move relative to the circle-cutter. Another advantage is that it is possible to cut multiple holes at the same setting. Also, you can cut concentric circles at the same setting. In addition, it is less time-consuming to cut a hole of desired size when utilizing my invention. It takes only approximately thirty seconds to set up to cut a circle when using my invention, in contrast to the fifteen (15) minutes required to make a template and set up the cutting equipment known heretofore.
My circle-cutter can be set upon a piece of sheet metal and used to cut a circle at any location thereon, regardless of the size of the workpiece. The height of the cutting torch can be adjusted at any time without losing the center of the circle to be cut. The bearings are sealed to preclude the entrance of grit and attendant wear, so that maintenance requirements are minimal. It has a built-in measuring system for setting the torch at exactly the right location to cut a circle of prescribed radius. The supports for the cutting mechanism are centered relative to the frame, for good balance. Means for micro-adjustment is provided to insure that the cut will have the exact desired radius. A motor assembly can be mounted on my circle-cutter to provide automatic turning, and a cut can be accomplished at any desired location upon a workpiece of any size. The torch can be installed in the torch-holder with a minimum of effort and maximum of accuracy in the cutting operation.
My circle-cutting device is much easier to use. A user can cut an entire circle while standing at one location, in contrast to earlier devices with which it is necessary to walk around the cutting equipment in order to complete the cut. My above device produces a substantial labor-saving, since it saves 80%-90% in labor over earlier cutting devices and is simple to operate. There is also substantially less waste of material when using my circle-cutter. It is particularly adaptable to custom fabrication and manufacturing, requires minimum maintenance, and can be power driven.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will more fully appear from the following description, made in connection with the accompanying drawings, wherein like reference characters refer to the same or similar parts throughout the several views, and in which:
FIG. 1 is a perspective view of the preferred embodiment of my invention;
FIG. 2 is a fragmentary front end elevational view on an enlarged scale of my above circle-cutter, with the sliding beam and cutting torch holder swung to a transverse position;
FIG. 3 is a fragmentary side elevational view, on a similar scale, of the torch holder of my above invention, shown partly in elevation and partly in vertical section;
FIG. 4 is a fragmentary side view of the torch holder of my invention taken along line 4--4 of FIG. 1, with the torch holder shown in section and the torch locked in cutting position and shown in elevation;
FIG. 5 is a top plan view of my above invention, with various positions of the sliding beam support and torch holder during the cutting operation, shown in broken lines;
FIG. 6 is a top plan view of my above invention, showing the support arm and sliding beam support in alternative positions relative to the vertical axis of pivot of the support arm.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of my invention, as shown in FIGS. 1-6, is comprised of a frame F having a U-shaped base 10 and a pair of upstanding supports 11 and 12 spaced along the bottom of the base 10. At the upper end of the two supports 11,12, there is a horizontal panel 13 which extends laterally from the two supports and terminates in an arcuately shaped edge 14. A suitable brace member such as brace 15, is secured to the underside of the panel 13 and to the upper end of each of the supports 11 and 12.
Pivotally mounted upon the panel 13 at the medial portions thereof and adjacent the rear end of the panel 13, which is connected to the two supports 11 and 12, is an elongated support arm 16. As shown in the drawings, support arm 16 is free to pivot about the axis of the pivotal mounting 17 within a sealed bearing provided for that purpose. A clamp member 18 is carried by the support arm 16 at the edge 14 and moves with the support arm 16 along that edge. When the clamp 18 is tightened by tightening the knurled knob 18a, the position of the support arm 16 becomes fixed relative to the panel 13. When the knob 19 is loosened, the panel 16 is free to swing between the side edges of the panel 13 to any desired out-of-way position, as shown in FIG. 6.
The outer end of the support arm 16 is tapped to threadedly receive a threaded height-adjusting rod 19, the height of which can be adjusted by turning the knob 20 which is fixedly connected thereto. As shown, the threaded height-adjusting rod 19 extends through the outer end of the internally threaded support arm 16 and has a pivot block 21 pivotally mounted on its lower end for free pivotal movement therearound, by means of suitable sealed bearings 22 which are carried by the upper end portion of the pivot block 21. The lower end of the pivot block 21 has a transverse bore as shown at the numeral 23 to accommodate a sliding shaft or beam 24. The position of the sliding beam 24 relative to the pivot block 21 is secured by means of a thumb screw 25.
Carried by the sliding beam 24 is a rectangular bar 26 which has a pair of upstanding rectangular supports 27 and 28 at its opposite end portions. Cap screws, such as indicated by the numerals 29 and 30, extend through the bar 26 upwardly into the supports 27 and 28, respectively, to fixedly secure the same to the bar 26. A third upstanding support 31 is mounted on the bar 26 in a similar fashion and in spaced relation to support 28.
Each of the supports 27 and 31 has an aligned transverse bore which accommodates the sliding beam 24 for relative sliding motion of the beam 24 therethrough. Thus, when the thumb screw 25 is released, the sliding beam 24 is free to slide longitudinally in either of its longitudinal directions, relative to the pivot block 21 and to carry the bar 26 and supports 27, 28 and 31 therewith, while doing so. Support 27 is secured to beam 24 via Allen set screw 27a, and support 31 is secured to said beam via Allen set screw 31a.
Mounted in the support 28 for rotation about its longitudinal axis is a micro-adjustment member 32. This adjustment member is in the form of a shoulder screw and, therefore, has a snap-ring groove machined in it to accommodate a snap ring on the inside of the support 28, to thereby secure the adjustment member thereto for free rotation about its longitudinal axis. The adjacent end of the sliding beam 24 is tapped and the inner end of the adjustment member 32 is threaded thereinto. Allen set screws 27a and 31a must be loosened to enable beam 24 to shift relative to supports 27 and 31, respectively, thereafter. Upon rotation of the adjustment member 32 in either direction, the beam or shaft 24 is caused to shift longitudinally relative to the bar 26 and through the supports 27 and 31. It will be seen that the horizontal bar 26 and the sliding beam 24 constitute a mounting base for the torch holder 33, so that they all move with the beam 24.
As best shown in FIG. 1, the mounting bar 26 has a scale 34 attached to its side edge and showing the radius of a circle which will be cut in accordance with the numeral which is disposed immediately below the pivot block 21 when in position directly opposite the axis of pivot of that pivot member. Thus, when the numeral 7 is positioned directly opposite the axis of pivot of the pivot block 21, the device will cut a circle having a 7-inch radius. The scale is located so that, when the support 31 abuts against the side of the pivot block 21, the zero figure on the scale will be disposed directly opposite the vertical axis of the pivot block 21. In that same position, the axis of pivot of the torch holder 33 will be aligned with the axis of pivot of pivot block 21 or, in other words, at zero position, as shown in broken lines in FIG. 2.
The torch holder 33 is comprised of an elongated member 35 which is tubular in its lower portions and has a window 36 formed in its lower walls. The upper portion of the tubular member and has its upper end 37 rotatably mounted on and supported by the bar 26. Suitable bearings (not shown) are provided to mount the upper end 37 thereof in the bar 26 so that it will rotate freely about a vertical axis, which is parallel to the axis of pivot of the pivot block 21.
The lower end of the tubular member 35 is open, as shown in FIG. 3, and has an inwardly extending shoulder 38 which serves to support either the center-finder 39 or a circle cutting torch 40, as shown in FIG. 4. The center-finder 39 is made of suitable plastic and has a reduced lower end portion 41 and a central bore which accommodates a metal rod 42, the lower end of which is beveled to a sharp central point 43. The center-finder 39 can be inserted through the window 36 and, of course, removed in the same manner.
Pivotally mounted on the side of the upper end portion of the torch holder 33 is a torch lock 44. This member has a metal over-dead-center strip 44a extending laterally therefrom and through an opening provided therefor in a concave pressure-applying plate 45 which, as shown in FIG. 3, is secured to the torch holder by a screw 46. Thus, when the lock 43 is in the dead-center position shown in FIG. 3, it is held in that position by the pressure plate 45 and, as the lock is swung downwardly, beyond the horizontal dead-center position, it snaps into depending locking position shown in FIG. 4. In that position, it engages the top portion of the torch 40 to hold the same snugly in alignment with the vertical axis of the torch holder 33, which is parallel to the vertical axis of the pivot block 21.
Mounted on the exterior surface of the torch holder 33 is a handle member 47 which supports a fuel line holder 48. The latter supports the fuel lines 49 of the torch 40, when the torch is disposed within the torch holder 33, and throughout the cutting action. The handle 47 is of great assistance in guiding the torch holder 33 throughout its 360° arc of travel, and in holding the fuel lines 49 in an out-of-way position throughout said travel.
As shown, the handle 47 is a strip of metal and the fuel-line holder 48 is an L-shaped metal member welded to the lower edge of the outer end thereof.
In use, the entire frame F and the cutting device attached thereto is set upon the upper surface of the plate of metal to be cut or, in the alternative, the sheet metal plate may be placed to rest upon the legs of the base 10. In the former, the legs of the U-shaped base 10 can be utilized to hold the sheet of metal in a fixed position relative to the cutting device. The knob 19 is then loosened to swing the support arm 16 to whatever position is desired, preferably one approximately midway between the side edges of the panel 13 so as to provide the best balance. After the knob 19 has been thereafter tightened to secure the support arm 16 in the desired position, the center-finder 39 is inserted in the window 36 of the torch holder 33. The thumb screw 25 is then released and the mounting base, comprised of the sliding beam 24 and bar 26, is moved horizontally relative to the pivot block 21 until the upstanding support 31 bears against the adjacent side of the pivot block 21. This brings the vertical axis of the torch holder 33 into alignment with the vertical axis of the pivot block 21.
Thereafter, the workpiece W on the frame F is moved so that the center of the desired circle is disposed immediately below the low pointed end 43 of the center-finder. The center of the circle to be cut is either marked previously with a center-punch, or it is applied to the upper surface of the workpiece with a pencil-mark or similar removable mark. If the workpiece is not large, it will fit between the opposing legs 10 of the base of the frame F. If it is too large, it can be placed on top of the two legs 10 and moved until the center of the circle to be cut is directly below the centering point 43. By so doing, the center-point is incorporated into my circle-cutter.
Once the center-point has been located, as described, all that is necessary is that the sliding beam 24 be moved horizontally through the pivot block 21 until the numeral on the scale 34, which represents the radius of the circle to be cut, is directly opposite the vertical axis of the pivot block 21. Thumb screw 25 is then tightened, the center-finder is replaced with the cutting torch 40, the cutting torch is locked in position with lock 44, and the cutting device is ready to cut the opening in the workpiece. The height of the cutting torch is then adjusted by turning the knob 20 in the appropriate direction, after loosening the lock nut 50. Once the height of the torch has been adjusted to the desired elevation relative to the workpiece, the lock nut 50 is tightened to lock the cutting torch at that elevation. The cutting torch is then lighted and the operator seizes the handle 47 and guides the cutting torch throughout its 360° line of travel about the axis of the cutting torch holder 33. The result will be a circle cut at the prescribed radius, with the operator being enabled to accomplish the cut while standing at a single point of location, and without the need for walking around the cutting device, or getting the fuel lines entangled with other portions of the equipment.
The locking of the torch into position with lock 44 brings the axis of the torch into alignment with the axis of the torch holder 33 and into parallel relation with the axis of pivot block 21. It also insures that, when the beam 24 is rotated 360° about the axis of the pivot member 21, the torch will cut out a circular piece having the desired radius.
In the event the user finds that the hole which he has cut is not of the exact size desired, he has a ready adjustment available. He simply loosens the two Allen-head set screws 27a and 31a to free the sliding beam 24 relative to the supports 27 and 31, respectively. He then loosens thumb screw 51, which frees micro-adjustment member 32. He then turns the latter in the appropriate direction to cause the bar 26, torch holder 33, and supports 27, 28, 31 to be moved longitudinally of beam 24 appropriately, to move the torch holder 33 in the desired direction to increase or decrease the radius, as desired. Thumb screw 51 is thereafter tightened. Thus, a simple and effective means for accomplishing micro-adjustments in the diameter of the circular cut is provided.
In the event that there is a need for a plurality of cut pieces having the same diameter, the circle-cutter described in the immediately preceding paragraph may be utilized to cut as many as desired, without any adjustment. To accomplish this purpose, all that is needed is to shift the workpiece sufficiently relative to the axis of the pivot block 21, after each cut is made, to provide adequate material to perform the cut, and then merely cause the torch 40 to be guided by the handle 47 throughout a 360° line of travel.
In the event a substantial number of circular pieces of various diameters are needed, the user can form a gauge block 52 (see FIG. 1), for each size of width dimensions equal to the distance between the support 31 and the adjacent side of pivot block 21, when the gauge 34 is moved to the appropriate radius. The user can then insert the appropriate gauge block 52 between the support 31 and the adjacent side of the pivot block 21, instead of setting the position of the sliding beam 24, as previously described, to insure that he will always obtain cuts of identical desired diameter, with a minimum of delay.
The advantages of my above circle-cutter are many. First of all, it obviates the need for a scarring mark on the workpiece to locate the center of the circle to be cut. In addition, it avoids losing the center-point if it is desired to make more than one cut of the same radius. It is not limited as to the number of times the user can turn the torch holder about the pivot point. The pivot point is automatically selected and retained within the cutting device, once the axis of pivot of the pivotal block 21 is located immediately directly above the center-point. Thus, it is possible to cut multiple holes of the same diameter at the same setting. This effects a substantial savings in time amounting to approximately 80-90% of a savings in labor.
It should be noted that the height of the cutting torch can be adjusted at any time without losing the center of the circle to be cut. Also, the bearings for the pivot block 21 and the torch holder 33 are sealed and thereby preclude the entrance of grit and the wear which results therefrom. Thus, maintenance requirements are maintained at a minimum. As described above, means is provided for micro-adjusting the position of the beam 24 relative to the mounting bar 26. If desired, a motor assembly can be mounted to provide automatic turning. It will be seen that a torch can be installed in the torch holder with a minimum of effort and a maximum of accuracy in the cutting operation.
One of the big advantages of my circle-cutter is that a user can cut an entire circle while standing at a single location. This is in sharp contrast to earlier devices which require that the user walk around the cutting equipment in order to complete the cut and to move the accessories, particularly the fuel lines, for the torch therewith. Another advantage is that there is substantially less wasted material when utilizing my circle-cutter. Thus, it is particularly valuable for use in custom fabrication and manufacturing. Since it is portable, it can be moved to whatever location is needed for cutting a circular hole at any location in a piece of sheet metal.
In addition to the above, it is readily possible to cut out a circular piece of sheet metal by first cutting out a disc, and then moving the sliding beam to a larger radius, and making a larger cut at that dimension. This will produce such a circular piece without the need for locating a second pivot point. Also, with my circle-cutter, a user can cut a circle at any point on a workpiece, regardless of its planar dimensions or its thickness, or the location of the cut relative to the side edge of the workpiece.
It will, of course, be understood that various changes may be made in the form, details, arrangement and proportions of the parts without departing from the scope of the invention which comprises the matter shown and described herein and set forth in the appended claims. | A double-pivot circle-cutter including a pivot member pivotally mounted on a support arm and having a sliding beam slidably extending therethrough. The pivot member is vertically adjustable, and its axis of pivot extends through the support arm. The sliding beam carries a platform which in turn pivotally supports a holder for a cutting member adjacent one end of the platform. The axes of pivot of the pivot member and of the cutting-member holder are parallel, and the latter shifts with the sliding beam to make the distance between the axes equal to the radius of the desired circular cut. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to and claims priority from prior provisional application Ser. No. 61/622,075, filed Apr. 10, 2012 which application is incorporated herein by reference.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of trailer coupling means and more specifically relates to a pivoting trailer coupler system for use in coupling a trailer to a tow vehicle.
2. Description of the Related Art
Many individuals use a trailer to haul objects between locations. Trucks or tractors may be used to pull trailers. Trailers must be coupled to the prime mover in a safe and efficient manner to prevent accidents that may be dangerous to life and limb. The traditional trailer coupler attaches to a tow vehicle by means of a ball hitch, adding extra components between the tow vehicle receiver and the trailer itself. Extra components increase the probability of equipment failure, while also increasing the potential for human error during attachment. Equipment failure due to either of these reasons can have devastating results in the form of trailer de-coupling accidents. A de-coupled trailer while driving, whether by human error or component failure can cause injury or death to individuals or livestock, and/or expensive property damage. A trailer coupler that eliminates excessive components while ensuring a more secure trailer attachment is desirable.
Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. No. 6,779,808 to Connor; U.S. Pat. No. 3,612,576 to Marler; and U.S. Pat. No. 2,692,150 to Maier. This art is representative of trailer couplers. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
Ideally, a trailer coupler should provide ease of use and, yet would operate reliably and be manufactured at a modest expense. Thus, a need exists for a reliable triple- or double-pivoting trailer coupler system to easily, safely, and securely attach a trailer to a tow vehicle and to avoid the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known trailer coupler art, the present invention provides a novel pivoting trailer coupler system. The present invention provides a triple- and double-pivoting trailer coupler assembly that easily and securely attaches a tow vehicle to a trailer providing an excellent turning radius for trailer when used.
The triple- and double-pivoting trailer coupler system(s) are designed to replace a standard trailer coupler that attaches to the tow vehicle by a ball hitch. They are designed to slide into the existing tow hitch receiver mounted to the frame of the tow vehicle, eliminating the need for the ball hitch connector between the tow vehicle and the trailer itself. This design reduces the possibility of equipment or human failure, effectively ensuring a secure connection between the tow vehicle and trailer. The double-pivoting trailer coupler system dramatically reduces the risk for accidental trailer de-coupling, which may prevent damage to property and equipment (as does the triple-pivoting embodiment). It provides a simple, time-saving manner to connect the trailer to the tow vehicle while reducing the chance for mistake due to human error. The pivoting trailer coupler system can be used on trailers of all types, from a light duty trailer to a heavy-duty camper trailer and the like.
A double-pivoting trailer coupler system is disclosed herein, in an embodiment, comprising a double-pivoting trailer coupler assembly having a housing with an inner volume, an outer enclosure, a first and second end, and a first and second mounting bolt aperture. It further comprises a first and second pin aperture, a pivoting tongue assembly with a proximate and distal end, and a first and second pin. The device further comprises a first, second, third, and fourth bearing assembly in preferred embodiments.
The vehicle coupling assembly comprises a front and back end, a coupler pin aperture, and a receiver pin aperture. The double-pivoting trailer coupler assembly comprises in combination: a housing, a pivoting tongue assembly, and vehicle coupler assembly. The vehicle coupler assembly, pivoting tongue assembly, and housing occupy a same plane when used for pulling. The inner volume of the housing is defined by the outer enclosure. The outer enclosure of the housing is preferably square tubing, attachable to a trailer frame. The opening of the second end of the housing is able to receive the trailer frame for fixable attachment thereto. The outer enclosure of the housing has a first aperture and second aperture for placement of mounting bolts to the trailer frame.
The housing, pivoting tongue assembly and vehicle coupling assembly preferably comprise ferrous material given its relative inexpensive, yet durable nature and the ease by which it may be maintained. The vehicle coupling assembly may comprises solid square stock. The first end of the housing is recessed to receive the pivoting tongue assembly. The first and second pin aperture of the housing are rotatably attached to the distal end of the pivoting tongue assembly via the second pin, third and fourth bearing. In combination they act in a capacity of a first universal joint.
The third and fourth bearing assembly are parallel to each other and horizontally oriented in the first and second pin aperture of the housing. The proximate end of the pivoting tongue assembly is rotatably attached to the back end of the vehicle coupling assembly via the coupler pin aperture. The first pin, and first and second bearing act in a capacity of a second universal joint. The first and second bearing assembly are oriented parallel to each other, and vertically oriented in the coupler pin aperture of the vehicle coupling assembly. The first and second universal joint work in combination to promote ease of swiveling and decrease the turning radius when a trailer is being pulled.
The first and second pin(s) may be retained in the housing by snap rings. The double-pivoting trailer coupler assembly allows security and ease of connection with a tow vehicle via double-pivoting action. The vehicle coupling assembly comprises a brake safety switch, a receiver pin, and an aperture for removable attachment to a vehicle receiver. The double-pivoting trailer coupler assembly does not comprise a ball connector. The front end of the vehicle coupling assembly attaches to the vehicle receiver, being coupled with a receiver pin. The housing attaches directly to the trailer frame via mounting bolts, completing the attachment. The vehicle coupling assembly is available in at least three sizes: 1¼″, 2″, and 2½″ square material to fit the vehicle receiver. The vehicle coupler assembly and housing are in coupled communication through the pivoting tongue assembly. The double-pivoting trailer coupler assembly is useful to promote ease of movement when towing a pull-trailer, thereby increasing safety and allowing for a shorter turning radius when in an in-use condition.
A triple-pivoting trailer coupler system is also disclosed herein having two more axis of movement over and above what is offered via the double-pivoting trailer coupler version; wherein a first axis of movement in the triple-pivoting embodiment allows a trailer to follow in a turn; a second allows the trailer to ‘pitch’ for inclines and a third allows the trailer to ‘roll’.
A kit is also disclosed herein including at least one double-pivoting trailer coupler assembly, one receiver pin, two mounting bolts, two mounting bolt nuts, and at least one set of user instructions.
A method of use for a double-pivoting trailer coupler system (and triple-version) is also disclosed herein comprising the steps of: attaching a double-pivoting trailer coupler assembly to a trailer frame; backing a tow-vehicle to the front of the pull-type trailer; attaching the double-pivoting trailer coupler assembly to the vehicle coupling assembly; towing the trailer; and disconnecting the double-pivoting trailer coupler assembly from the tow-vehicle.
The present invention holds significant improvements and serves as a pivoting trailer coupler system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, pivoting trailer coupler system, constructed and operative according to the teachings of the present invention.
FIG. 1 shows a perspective view illustrating the double-pivoting trailer coupler system in an in-use condition according to an embodiment of the present invention.
FIG. 2 is an exploded view illustrating a pivoting trailer coupler assembly of the double-pivoting trailer coupler system according to an embodiment of the present invention of FIG. 1 .
FIG. 3 is a top view illustrating the pivoting trailer coupler assembly of the double-pivoting trailer coupler system according to an embodiment of the present invention of FIG. 1 .
FIG. 4 is a side view illustrating the pivoting trailer coupler assembly according to an embodiment of the present invention of FIG. 1 .
FIG. 5 shows a perspective view illustrating a triple-pivoting trailer coupler system in an in-use condition according to an embodiment of the present invention.
FIG. 6 is a flowchart illustrating a method of use for the double-pivoting trailer coupler system according to an embodiment of the present invention of FIGS. 1-5 .
The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
As discussed above, embodiments of the present invention relate to a trailer coupler device and more particularly to a (double- and triple-) pivoting trailer coupler system as used to improve the ease of use and security of tow vehicle and trailer connections.
Generally speaking, the double-pivoting trailer coupler system of the present invention is a double-pivoting trailer hitch alignment assembly for swiveling the coupling assembly to easily align and couple a trailer to a tow-vehicle. The steel-fabricated joint system will mount directly onto the trailer frame and attach to most trucks and SUV's frame mounted receiver hitch. The bottom of the mounting point will sit in the coupler and have a 360 degree pivot point for the trailer to rotate during a turn from the tow vehicle. There may be three size variations depending upon the class of trailer. One variation may be 1¼″ square for up to 2,000 lbs of towing capacity. The second variation may be 2″ square for up to 12,000 lbs of towing capacity. Yet another variation may be 2½″ square for up to 18,000 lbs of towing capacity. Other embodiments may be considered within the scope of the present disclosure.
A triple-pivoting trailer coupler system is also disclosed herein having two more axis of movement over and above what is offered via the double-pivoting trailer coupler version; wherein a first axis of movement in the triple-pivoting embodiment allows a trailer to follow in a turn; a second allows the trailer to ‘pitch’ for inclines and a third allows the trailer to ‘roll’.
Referring now to the drawings by numerals of reference there is shown in FIGS. 1-4 , various views of double-pivoting trailer coupler system 100 as used within double-pivoting trailer coupler assembly 105 according to an embodiment of the present invention.
Referring now to FIG. 1 , a perspective view illustrating double-pivoting trailer coupler system 100 in an in-use condition 101 according to an embodiment of the present invention.
Double-pivoting trailer coupler system 100 comprises double-pivoting trailer coupler assembly 105 having housing 120 , an inner volume 122 , outer enclosure 124 , first end 126 , and second end 128 . The present invention further preferably comprises first aperture 130 , second aperture 132 , first pin aperture 134 , and second pin aperture 136 . Pivoting tongue assembly 140 comprises proximate end 142 , distal end 144 , first pin 146 and second pin 148 . Further, the device comprises first bearing assembly 150 , second bearing assembly 152 , third bearing assembly 154 , and fourth bearing assembly 156 .
Referring now to FIG. 2 , an exploded view illustrating double-pivoting trailer coupler system 100 according to an embodiment of the present invention of FIG. 1 .
Vehicle coupling assembly 160 comprises front end 161 , back end 162 , coupler pin aperture 164 , and receiver pin aperture 166 . Double-pivoting trailer coupler assembly 105 comprises in combination: housing 120 , pivoting tongue assembly 140 , and vehicle coupling assembly 160 . Vehicle coupling assembly 160 , pivoting tongue assembly 140 , and housing 120 occupy a same plane when a trailer is being pulled. Inner volume 122 of housing 120 is defined by outer enclosure 124 . Outer enclosure 124 of housing 120 preferably comprises square tubing, attachable to trailer frame 168 . The opening of second end 128 of housing 120 is able to receive trailer frame 168 for fixable attachment. Outer enclosure 124 of housing 120 has first aperture 130 and second aperture 132 for placement of mounting bolts 170 to trailer frame 168 .
Housing 120 , pivoting tongue assembly 140 , and vehicle coupling assembly 160 comprise ferrous material in preferred embodiment due to the durable nature and ease of manufacture/repair. Vehicle coupling assembly 160 may comprise solid square stock for strength and safety in use. First end 126 of housing 120 is recessed to receive pivoting tongue assembly 140 . First pin aperture 134 and second pin aperture 136 of housing 120 are rotatably attached to distal end 144 of pivoting tongue assembly 140 via second pin 148 , third bearing assembly 154 and fourth bearing assembly 156 . In combination they act in a capacity of a first universal joint.
Third bearing assembly 154 and fourth bearing assembly 156 are parallel to each other and horizontally oriented in first pin aperture 134 and second pin aperture 136 of housing 120 . Proximate end 142 of pivoting tongue assembly 140 is rotatably attached to back end 162 of vehicle coupling assembly 160 via coupler pin aperture 164 . First pin 146 , first bearing assembly 150 and second bearing assembly 152 are able to act in a capacity of a second universal joint. First bearing assembly 150 and second bearing assembly 152 are oriented parallel to each other, and vertically oriented in coupler pin aperture 164 of vehicle coupling assembly 160 . The first and second universal joint(s) work in combination to promote ease of swiveling and decrease turning radius.
Referring now to FIG. 3 , a top view illustrating double-pivoting trailer coupler system 100 according to an embodiment of the present invention of FIG. 1 .
First pin 146 and second pin 148 are retained in housing 120 by snap rings 138 . Double-pivoting trailer coupler assembly 105 allows security and ease of connection with a tow vehicle 172 via double-pivoting action. Vehicle coupling assembly 160 comprises brake safety switch 174 , receiver pin 176 , and receiver pin aperture 166 for removable attachment to a vehicle receiver. Double-pivoting trailer coupler assembly 105 does not have a ball connector. Front end 161 of vehicle coupling assembly 160 attaches to a vehicle receiver, being coupled with receiver pin 176 . Housing 120 attaches directly to trailer frame 168 via mounting bolts 170 , completing the attachment. Vehicle coupling assembly 160 is available in three standard sizes: 1¼″, 2″, and 2½″ square material to fit the vehicle receiver. Vehicle coupling assembly 160 and housing 120 are in coupled communication through the pivoting tongue assembly 140 .
Referring now to FIG. 4 , a side view illustrating double-pivoting trailer coupler system 100 according to an embodiment of the present invention of FIG. 1 . Double-pivoting trailer coupler assembly 105 is useful to promote ease of movement when towing a pull-trailer, thereby increasing safety and allowing for a shorter turning radius when in an in-use condition 101 .
Double-pivoting trailer coupler system 100 may further comprise kit 440 including the following parts: at least one double-pivoting trailer coupler assembly 105 , one receiver pin 176 , two mounting bolts 170 , two mounting bolt nuts 171 , and at least one set of user instructions for installation. Double-pivoting trailer coupler system 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, different pin/fastener/retaining means and combinations thereof, parts may be sold separately. Double-pivoting trailer coupler system 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of trailering/towing/pulling applications.
A triple-pivoting trailer coupler system, as shown in FIG. 5 comprises two more axis of movement over and above what is offered via the double-pivoting trailer coupler version (with similar components but extra necessary bearing, pins and the like as indicated in the present figure); wherein a first axis of movement (labeled A) in the triple-pivoting embodiment allows a trailer to follow in a turn; a second axis of movement (labeled B) allows the trailer to ‘pitch’ for inclines and a third axis of movement (labeled C) allows the trailer to ‘roll’.
Referring now to FIG. 6 , a flowchart illustrating method of use 500 for double-pivoting trailer coupler system 100 according to an embodiment of the present invention of FIGS. 1-5 .
A method of using (method of use 500 ) the double-pivoting trailer coupler system comprises the steps of: step one 501 attaching a double-pivoting trailer coupler assembly to a trailer frame; step two 502 backing a tow-vehicle to the front of the pull-type trailer; step three 503 attaching the double-pivoting trailer coupler assembly to the vehicle coupling assembly; step four 504 towing the trailer; step five 505 disconnecting the double-pivoting trailer coupler assembly from the tow-vehicle.
It should be noted that step 505 is an optional step and may not be implemented in all cases. Optional steps of method 500 are illustrated using dotted lines in FIG. 6 so as to distinguish them from the other steps of method 500 .
It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. | The double-pivoting trailer coupler system and/or triple-pivoting trailer coupler system are designed to replace a standard trailer coupler with a ball hitch. It is designed to slide into the existing bumper hitch mounted to the frame of the tow vehicle, eliminating the need for a ball hitch between the frame mounted receiver and the trailer. The coupler systems reduce the possibility of equipment failure, making a secure connection between the tow vehicle and trailer hitch. They increase safety and allow for a shorter turning radius when in-use minimizing wear on the trailer, prime mover and tires. | 1 |
FIELD OF THE INVENTION
The present invention relates to a road scarifier; and more particularly, it relates to a quick mount attachment for an hydraulically-actuated four bar linkage at the front of a construction vehicle when it is desired to use the vehicle for scarifying a road or the like.
BACKGROUND OF THE INVENTION
Road construction vehicles, such as graders, typically are designed so that various attachments can be mounted to the vehicle, as desired. This permits the vehicle, which is normally quite expensive, to perform more than one function.
It is known, for example, that a conventional motorgrader having a large blade mounted in the center beneath the vehicle frame for road grading purposes, can be converted to a scarifier by removing the blade and installing a straight scarifier blade which extends in a straight line transverse of the vehicle, but slightly inclined, in place of the leveling blade.
Such scarifiers perform well, but they have two disadvantages. The first is that it is time-consuming and somewhat difficult to replace the large grader blade with an equally large and heavy scarifier structure, working beneath the machine frame. It is also sometimes difficult and awkward to store whichever of these structures is not in use.
Secondly, when an existing motorgrader is modified to perform a scarifying function by replacing the existing grader blade, the machine is adapted to perform only one function at a time. That is, it is sometimes desirable to both scarify a road structure (or remove ice from the road) and use a trailing blade to clear the swath being worked on from the materials removed or loosen by the scarifier.
There is also a scarifier structure known in the art which is mounted on an hydraulically-actuated four bar linkage at the front of the vehicle. This structure has a scarifier mount, described in more detail below, which receives individual teeth, rather than a scarifier blade, which is generally more desirable as providing a smoother surface.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned problems, first, by providing an attachment with a quick mount scarifier frame which is mounted to the front end of a construction or other vehicle having a hydraulically-actuated, four bar linkage. Two separate quick mount structures are disclosed for adapting the invention to different types of hydraulically-actuated, four bar linkages.
The scarifier frame includes two hardened steel moldboards mounted in the form of a chevron with the point of the chevron shape located on the centerline of the vehicle and at a forward location so that the moldboards extend to the sides and rearwardly of the centerline.
Scarifier blades are mounted to the bottom of the moldboards. Thus, the scarifier blades are themselves in the form of a chevron with the center of the chevron on the center of the machine and with the scarifier blades extending laterally and rearwardly across the width of the machine.
Reinforcing structure is added to maintain the shape and position of the moldboards; and each of the two disclosed embodiments is adapted for quickly mounting to the front of a vehicle having an hydraulically-actuated four bar linkage.
Because of the chevron shape of the scarifier, it is stable when set to rest on a generally horizontal surface, for storage or mounting to a machine. That is, unlike a straight scarifier or grader blade, the scarifier of the present invention can be rested for storage or the like in its normally used position. This permits the operator of a vehicle to drive up to the scarifier blade when it is desired to mount it, and though operation of the four bar linkage, couple the four bar linkage to the scarifier frame. Adaptions are made for securing each attachment to the vehicle. Removing the scarifier frame from the four bar linkage is equally convenient.
Thus, the scarifier frame of the present invention is removably mounted, as an attachment, to a front four bar linkage of the vehicle. This permits the vehicle to perform dual functions simultaneously, when the vehicle is, for example, a motorgrader or the like.
The chevron shape also allows the scarifier to bridge across "washboard" road surfaces, thus, cutting away and removing the "peaks" of a serrated road surface, and leaving a smooth surface. Moreover, when the vehicle is used to remove ice from a road surface, the chevron shape moves material toward the edge of the roadway by "plowing" the material sideways, permitting the main grader moldboard or blade to clean the surface as it trails the scarifier.
Other features and advantages of the present invention will be apparent to persons skilled in the art from the following detailed description of preferred embodiments, accompanied by the attached drawing wherein identical reference numerals will refer to like parts in the various views.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front perspective view of a road construction vehicle with a scarifier attachment constructed according to the present invention mounted to its front four bar linkage;
FIG. 2 is an upper rear perspective of the four bar linkage of the vehicle of FIG. 1, taken from above and slightly toward the rear, with the scarifier separated forwardly from the mount on the vehicle;
FIG. 3 is a top view of the scarifier attachment of FIG. 1, with the front of the scarifier at the top of the drawing;
FIG. 4 is a front elevational view of the scarifier frame of FIG. 1;
FIG. 5 is a cross sectional view taken through the sight line 5--5 of FIG. 3;
FIG. 6 is a vertical cross sectional view taken through the sight line 6--6 of FIG. 3;
FIG. 7 is a perspective view of a locking pin used to secure the scarifier in place after it is mounted to the vehicle;
FIG. 8 is a partial side view of the hydraulically-actuated four bar linkage and scarifier mount of the vehicle of FIG. 1;
FIG. 9 is perspective view, taken from an upper, right and front side of a second embodiment of a quick mount scarifier adapted to a second type of vehicle, with only the forward portion of the vehicle shown in phantom;
FIG. 10 is a front elevational view of the scarifier of FIG. 9, shown in fragmentary form and the mounting structure for the scarifier, and a portion of the forward linkage of the vehicle; and
FIG. 11 is a vertical sectional view taken through the sight line 11--11 of FIG. 10.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, reference numeral 10 generally designates a conventional motorgrader machine having a pair of front tires 11 and an hydraulically-actuated front four bar linkage generally designated 12. As can be seen in FIG. 1, the four bar linkage 12 includes right and left side four bar linkages, 13, 14, but they are connected together by means of a transverse link 15 so that they operate in unison, as persons skilled in the art are aware.
Turning briefly to FIG. 8, the left side linkage 14 is seen in greater detail as including upper and lower parallel links 17, 18, each having their rear ends pivotally mounted to a bracket 19. The bracket, in turn, is rigidly mounted to the frame 20 of the vehicle. The forward end of the links 17, 18 are pivotally mounted to a tower 22 which is secured to the upper portion of a scarifier mount 23. An hydraulic cylinder 25 has its cylinder end pivotally mounted to a bracket 26 which is mounted to the frame 20. The rod end of the hydraulic cylinder 25 is pivotally mounted to the transverse link 15, as best seen in FIG. 1. When the hydraulic cylinder is retracted (by the operator), the linkage is raised by rotating links 17, 18 clockwise, as viewed in FIG. 8.
Turning now to FIG. 2, the scarifier mount 23 is of a type known in the prior art which includes an upper plate 27 and a lower plate 27A, each having a chevron shape as shown in FIG. 2. The plates are mounted to form a single, rigid mount. Each plate has a plurality of rectangular openings or slots such as those designated by reference numeral 28 for the upper plate 27. The lower plate 27A has corresponding rectangular slots in vertical alignment with the slots 28 in the upper plate 27. Each pair of aligned slots receives a scarifier shank, and there are thus nine pairs of slots, and thus nine separate shanks received in the slots, although only seven slots are seen in FIG. 2 because two of the slots are obscured by the towers mounting the four bar linkages to the scarifier mount.
The present invention does not contemplate using the slots 28 nor the individual shanks received therein. Rather, the present invention contemplates a unitary attachment generally designated by reference number 30 which is received on the scarifier mount 23 which, in turn, is mounted to the hydraulically-actuated four bar linkage 12.
As best seen in FIGS. 1 and 4, the scarifier attachment 30 includes a reinforced frame comprising left and right moldboards 31, 32.
The moldboards 31, 32 are similar in structure. The moldboards are welded together in a general chevron shape best seen in FIG. 3 with the point of the V, generally designated 33 in FIG. 3, being located in the center and at the forward most position of the scarifier attachment. The moldboards 31, 32 are also provided with a reinforcing structure in the form of a lower, horizontal plate 36; and the area adjacent to the point 33 is reinforced by means of a triangular plate 37. Thus, the frame of the attachment is a rigid weldment.
Behind the center sections of the moldboards 31, 32 are first and second elongated channels designated respectively 38 and 39. Each of the channels is similar, so only the channel 39 need be described in detail. It includes a top wall 40 and a right side wall 41. The walls 40, 41 are flared outwardly toward the rear, the two flared portions being designated 40A and 41A, respectively. The flared portions serve as guides for receiving the scarifier mount 23 when assembling the attachment to the machine, as diagrammatically illustrated in by the arrows FIG. 2. The two channels 38, 39 cooperate with the reinforcing plate 36 of the frame to provide boots for receiving the side edges of the scarifier mount 23.
Triangular gusset plates 45, 46 are welded to the top of the channels 38, 39 respectively and to the outboard upper edges of the moldboards 31, 32 for further reinforcement of the frame of the attachment.
Thus, the reinforcing plate 36 and the channel members 38, 39 form a receptacle or "sock" for receiving the scarifier mount 23 in the manner illustrated in FIG. 2, with the socks encompassing and holding the outer portions of the scarifier mount.
The channels 38, 39 are provided with lower wall portions 50, 51 as best seen in FIG. 2 so as to complete the retaining portions of the channels, and to lock the attachment in place. That is, each of the upper walls of the channels 38, 39 as well as the extensions 50, 51 are provided with an angular aperture, such as those designated 52 and 53 in FIG. 2. The corresponding apertures of the extensions 50, 51 are located directly beneath their associated rectangular apertures 52, 53. Each pair of associated apertures is adapted to receive a rectangular pin 55 as shown in FIG. 7. Pin 55 has an upper, extended flange 56 to hold it in place and a pull ring 57 for removing the pin. When the scarifier mount 23 is fully assembled into the sock formed in the reinforced attachment 30, pins 55 are placed in the apertures 52, 53 and the pins are long enough to extend through the aligned apertures in the extensions 50, 51 to securely hold the attachment to the scarifier mount.
The lower portions of the moldboards 31, 32 are provided with apertures 58 for receiving bolts which secure the upper portions of left and right scarifier blades 60, 61 (FIG. 1) which are mounted to the lower edges of the mold-boards 31, 32 respectively. The scarifier blades 60, 61 are of a conventional design which, as can be seen from FIG. 1, includes a steel mounting plate and a plurality of immediately adjacent scarifying teeth 63 welded to the lower portions of the associated plate.
Turning now to the embodiment of FIGS. 9-11, the vehicle (shown in phantom) has a different four bar linkage structure including a pair of upper links 80 and a pair of lower links, one of which is seen in FIG. 9 and designated 81. Referring to FIG. 11, the forward ends of the links 80, 81 are pivotally connected to short extension links of 82, 83 respectively. The forward ends of the extension links 82, 83 are welded to a rigid quick mount structure including an upper rigid bar 84 and a lower rigid bar 85. The left end of the horizontal bars 84, 85 are secured together by two reinforcing vertical plates 87, 88 (FIGS. 9 and 10) which are spaced laterally from each other; and the right sides of the horizontal bars 84, 85 are similarly connected by another set of laterally spaced plates 89, 89A.
The scarifier attachment of the embodiment of FIGS. 9-11 is modified to accommodate the existing structure on the four bar linkage of the vehicle shown in FIG. 9 (the hydraulic actuating portion of which is well-known and not shown for brevity).
The attachment of FIG. 9 does include left and right moldboards 90, 91, the lower portions of which are provided with scarifier blades 92, 93 respectively (FIG. 10). Moreover, reinforcing structure including an upper horizontal plate 95 is welded to the upper edges of the moldboards 90, 91 to maintain the moldboards in place during operation. An additional horizontal reinforcing plate 96 is provided at a location behind the moldboards but beneath the upper reinforcing plate 95.
A pair of upright plates 100, 101 which are welded to the horizontal reinforcing plates 95, 96. A pair of horizontal bars 104, 105 are welded between opposing surfaces of the upright plates 100, 101; and the outboard ends of the transverse rods 104, 105 are braced by plates 106, 107. The outboard edges of the plates 106, 107 are also welded to the adjacent surfaces of the upright plates 100, 101 for additional strength.
As best seen in FIG. 11, the upper portions of the upright plates 100, 101 are formed into hooks such as designated at 110 in FIG. 11, and a semi-cylindrical seat 112 is welded to the outboard surface of the plate 100 for engaging the top of the bar 84 of the four bar structure of the vehicle to reduce wear and to distribute the stress caused by loading.
Similarly, a lower portion of the plate 100 is cut out to receive the lower bar 85 of the four bar linkage (see also FIG. 11), and similar curved seats 114, 117 are welded to the outer and inner surfaces of the upright plate 100 for engaging the front surface of the bar 85. The right upright plate 101 is similarly structured.
The plate 100 is apertured to receive a pin 115 which fits through corresponding, aligned apertures in the two laterally spaced plates 88, 87 on the four bar linkage of the vehicle, to hold the quick mount scarifier attachment in place when it is assembled to the four bar linage. A corresponding pin designated 116 in FIG. 10 is provided for the right side of the scarifier attachment to secure it to the spaced vertical bars 89, 89A of the four bar linkage of the vehicle.
The procedure for mounting and removing the scarifier attachments of the two embodiments will be apparent to persons skilled in the art. It will equally well be appreciated by those skilled in the art that the scarifier attachment of the present invention is designed for fitting to the forward four bar linkage of a vehicle which, when hydraulically powered, not only facilitates mounting of the attachment without the need of separate hoists or the like, but also permits the vehicle to be used for a single purpose, such as grading, when it is not desired to use the scarifier, without removing the scarifier.
Finally, if it is desired to remove the scarifier attachment, it is quickly and readily done simply by removing a pair of pins which lock the scarifier attachment to the four bar linkage of the vehicle and, through operating the vehicle in reverse and/or the four bar linkage, withdrawing the vehicle from the attachment. Because of the triangular shape of the moldboards and scarifier blades, the scarifier will stably rest on a horizontal surface for the storage as well as for the mounting and demounting the attachment.
Having thus disclosed in detail a preferred embodiment of the invention, persons skilled in the art will be able to modify certain of the structure which has been illustrated and to substitute equivalent elements for those disclosed while continuing to practice the principle of the invention; and it is, therefore, intended that all such modifications and substitutions be covered as they are embraced within the spirit and scope of the appended claims. | An attachment is disclosed for mounting to the front end of a road construction vehicle having a four bar linkage and an hydraulic actuator. A scarifier attachment includes first and second moldboards arranged in a chevron shape, when viewed from above, with the bottom of the V being in the center and forward most position so that the moldboards are inclined outwardly and rearwardly relative to the centerline of the vehicle. At the bottom of each of the moldboards is a scarifier plate which is removably mounted to its associated moldboard. Reinforcing structure is added to the moldboards for strength. In one embodiment, the reinforcing structure forms a receptacle for receiving a conventional scarifier mount, and in a second embodiment, the attachment is mounted to upper and lower horizontal bars forming an integral part of the hydraulically-actuated linkage. | 4 |
BACKGROUND AND SUMMARY OF THE INVENTION
The invention is in the field of structures for covering large areas, such as full size stadiums, and is particularly directed to a structure having a retractable roof. A structure having a partially retractable roof is illustrated at FIG. 6 of U.S. Pat. No. 4,581,860, in which the applicant herein is the inventor and which is hereby incorporated by reference. Other large-span structures for enclosing stadium-size spaces are discussed in a presentation of the inventor herein to the International Symposium on Spatial Roof Structures at Dortmund, Germany, Sept. 10, 1984 entitled "A Decade of Fabric Tension Structures for Permanent Buildings," and in the 12 references cited at pages 19 and 20 of the presentation. The presentation and its 12 references are hereby incorporated by reference in this specification.
It is believed that there is an increasing demand for covered full-size stadiums and similar structures to make sports and other events independent of the weather. On the other hand, there is a desire to retain the outdoor character of certain events whenever possible, which leads to the demand for retractable roofs. A major difficulty in designing and building a stadium-size structure with a retractable roof is the combination of size and movable parts. Full-size stadiums require free-span roof areas in the area of several hundred thousand feet, and roofs of this size and span to be economically and practically built and used require special structural techniques. In particular, structures of this type can make use of efficient geometries such as domes, saddles, etc., which have a circular, elliptic, or super elliptic boundary condition. Making the roof, or at least the central part of the roof, retractable generally makes those closed structural shapes difficult to implement, although one implementation of a partially retractable roof is shown in said prior patent of the inventor herein. A further consequence of a retractable design is that the movable sections of the roof have to fit the geometry of the structure in the open and closed positions, and this requirement can tend to dominate the geometry choices. One such requirement can be that the edges of the movable roof panels run on straight lines or circles. A further such requirement can be that the superimposed loads, such as wind and snow, have to be safely supported in the open and closed positions, and preferably in any intermediate state as well. Also, rain water has to run off in any position. The combined difficulty of these and other considerations is underscored by the fact that to the knowledge of the inventor herein no retractable stadium roofs have been built so far.
This invention provides a functional, structurally efficient, and economical solution for a full-size stadium roof which, in one nonlimiting example, has a retractable central portion which can open up approximately one-half of the total roof area. This is achieved by the choice of a unique geometric configuration and a unique combination of structural systems, materials and construction methods.
In one exemplary embodiment a central rectangular opening of the roof is covered by two retractable roof panels which are rectangular in plan and can cover an area substantially larger than a football field. The panels are substantially rigid, using trussed steel construction or similar rigid lightweight framing. They are covered with a structural fabric membrane or other lightweight roofing system, and move in the direction of the main axis of the stadium (in the case of a football or soccer field, the main axis is along the long direction of the field, and in the case of baseball it is a line through home plate and third base). The roof panels are high in the middle and low at the ends, thus allowing water to run off in any position of the panels. In the direction of the main axis the retractable panels follow a slight circular curve, to thereby ride on similarly curved tracks supported on track girders. Rollers between the panels and the track girders are arranged to resist downloads, uploads (e.g. from wind uplift), and lateral loads. The movement of the panels is generated by a hoist system similar to that of an elevator or cable car, with cables running along the track girders, which form the inboard edges of two fixed portions of the roof that flank the sides of the stadium field. Two other fixed portions of the roof flank the ends of the stadium field, and are under the curve along which the retractable panels move to their open positions. The track girders are the main longitudinal support members of the roof, running the total length of the stadium. They are suspended from the arches by respective cable systems similar to those used in a stay cable bridge. The upper support points of these suspension cables are a part of an arch which gathers the loads from all of the cables on one side, spanning over the length of the structure. Each arch in turn is laterally supported by a triangulated set of inclined struts which rest on a horizontal edge ring at the stadium perimeter. Horizontal tie cables extend between the two track beams to provide continuity of the system, spanning across the opening in the retractable portion of the roof.
An exemplary embodiment of the invention comprises two tracks which in plan view are parallel to each other and to a first axis of the stadium field, and in elevational view along the first axis are convex and conform an arc of a circle. Two arches in plan view are convex and circumscribe the tracks such that each track is along a chord of a respective arch. In elevational view along the first axis the arches are convex and have curvatures greater than those of the tracks to thereby extend above them. A substantially rigid, laterally extending edge ring in plan view generally follow the outline of the arches and in elevational views along the first axis extends along chords of the arches and tracks. A support, such as a system of columns, can be used to raise the edge ring above grade. The ends of the arches rest on rigid abutments which carry the arch forces into the foundations. Between these abutments the arches are laterally braced by two respective sets of triangulated, inwardly inclined struts, such as steel struts, which rest on the edge ring. The track girders are suspended from the arches by two respective triangulated sets of cables. Horizontal tie cables span from one track girder to another, and two respective sets of stabilizing cables connect the track girders to the edge ring. This system is prestressed and, together with the track girders, forms a sufficiently rigid support for the tracks. The roof panels form substantially rigid space frames covered with fabric or other lightweight roofing material shaped to drain water laterally onto the rigid, fixed portions of the roof at the sides of the stadium field. A system of hoist cables and winches is provided to selectively move the roof panels toward and away from each other along the tracks, to thereby close or open the roof of the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the invention.
FIG. 2 is a plan view showing retractable roof panels in their open positions.
FIG. 3 is a plan view showing the retractable roof panels in their closed positions.
FIG. 4 is a sectional view along a first axis.
FIG. 5 is a sectional view along a second girder.
FIG. 6 is a sectional view along a track girder.
FIG. 7 is a sectional view across a track girder.
FIG. 8 is a partial sectional view taken at line 8--8 in FIG. 3.
FIG. 9 shows a detail of FIG. 8.
FIG. 10 is a partial sectional view taken at line 10--10 in FIG. 3.
FIG. 11 show a detail of FIG. 10.
DETAILED DESCRIPTION
A retractable roof structure embodying an example of the invention covers a stadium field 10, such as a football, soccer or baseball field, and has a first axis 12 and a second axis 14. In the plan view of FIG. 2, track girders 16 and 18 are parallel to each other and to axis 12 and are spaced from each other by a substantial distance, which can be greater than the width of a football field. As best seen in FIGS. 1 and 6, in elevational view along axis 12 each track girder is convex and forms an arc of a circle. Track girders 16 and 18 are suspended from the respective arches 20 and 22 by respective sets of suspension cables 32 and 34, which are arranged in respectrve triangulated (or parallel) and outwardly inclined patterns, as best seen in FIGS. 1 and 5. Track girders 16 and 18 are stabilized by two respective sets of stabilizing cables 40 and 42, which are anchored to edge ring 24. The horizontal components of forces on the suspension cables and the stabilizing cables are balanced by a set of horizontal tie cables 48. In plan view, as seen in FIG. 2, arches 20 and 22 are convex and circumscribe track girders 16 and 18 such that each track girder is along a chord of the respective arch. In an elevational view along axis 12, as seen in FIG. 4, arches 20 and 22 also are convex, and have curvatures greater than those of track girders 16 and 18 to thereby extend above them. A substantially rigid, laterally extending edge ring 24 in plan view generally (but not necessarily exactly) follows arches 20 and 22 (as seen in FIG. 2) and in elevational view along axis 12 ring 24 extends along chords of the arches and track girder (as seen in FIG. 4. The ends of the arches are supported by abutments 60 which also form the anchor points of track girders 16 and 18 and of edge ring 24. These abutments 60 carry the resultant loads from the components anchored thereon into the foundations. A support, e.g. comprising columns 26, can be used to raise edge ring 24 above grade. Edge ring 24 can be polygonal, or elliptic at the sides of the stadium field and straight at the ends of the field. It need not be a complete ring if elements of the supports for stadium seats 90 are designed to carry the required loads from the roof system. Two sets of substantially rigid struts 28 and 30 extend up from edge ring 24 to the respective arches 20 and 22. Struts 28 and 30 can be in triangulated sets, as illustrated in FIGS. 1-4, or can be in parallel sets. Fixed side roof portions 36 and 38 extend generally laterally from the side portions of edge ring 24 to the respective track girders 16 and 18, and end fixed roof portions 62 and 64 extend from the ends of the roof structure to the rectangular opening for retractable panels 44 and 46. Retractable panels 44 and 46 run on tracks 16a and 18a of girders 16 and 18 on rollers 44a and 46a, which in plan view overlap the track, and in elevational view along axis 12 are on rotational centers on loci matching the curvature of the tracks, as best seen in FIG. 6. In elevational view along axis 14, as seen in FIG. 5, roof panels 44 and 46 are convex. Retracting means are provided for selectively moving the roof panels 44 and 46 toward and away from each other along track girders 16 and 18 to thereby close or open the roof of the structure. These means comprise hoist cables 50 and 52 trained over sheave wheels 54 and guide wheels 56 and moved in the desired direction by winch systems 58 housed at abutments 60, to form a system similar to those used in cable cars and elevators.
FIG. 7 illustrates the retracting system at track girder 16 and roof panel 44, but the same method is used for the other girder and roof panel. Suspended on struts 100 from an edge beam 120 of panel 44 are axles 102 each carrying rollers 44a which are similar to railroad wheels and ride on tracks 104 supported on girder 16. Upper tracks 106 are affixed to girder 16 through posts 105 and overlap the outboard ends of axles 102, to prevent lifting of panel 44 under extreme uplift loads. The forWard and return runs of hoist cables 56 are carried by guide whels 56. Some relative lateral movement is allowed between panel 44 and girder 16 by allowing strut 100 to ride on axle 102, but its extent is restricted by wheels 44a.
FIG. 8 illustrates the joint between the fixed end roof portion 64 and the retractable panel 46 when in its closed position; the joint between 66 and 44 is similar. Each fixed roof portion can comprise a truss structure, such as the structure of truss members 64b, and can have roof skin such as at 64 a and a black-out curtain such as at 64c. Similarly, each retractable roof panel can comprise a truss structure of members such as 44b and truss members such as 44c, covered with roof skin such as 44a and if desired using a black-out curtain such as 46d. As seen in FIG. 9, the joint can be maintained watertight by ensuring that the edge member of the retractable panel overlaps the fixed roof end portions, for example by using the edge members illustrated in FIG. 9. FIG. 10 illustrates the joint between retractable panels 44 and 46 when they are in their closed positions. As visible in the detail of FIG. 11, a ledge member 80 on panel 44 overlaps the edge member of panel 46, and a compressible rubber tube 82 can be used to complete the seal. A similar tube 84 can be used for the same purpose in the joint illustrated in FIG. 9.
The structure can be erected using generally conventional construction materials and methods. For example suitable foundations are provided and columns 26 and abutments 60 are erected, using reinforced concrete. Edge ring 24 is cast, preferably one segment at a time. Each arch is erected in sections, starting at an abutment 60. For example, starting at one abutment, the two nearest struts 28 are erected on edge ring 24, using structural steel frames, and are joined at a top node and held at the correct inward inclination, for example by temporary bracing cables or struts. A section of an arch steel frame is then assembled and moved into place to span from its anchor point on the abutment to the strut node. The next two struts 28 are then similarly erected and held in place, and another steel frame section of the arch is used to span between the two strut nodes, and so on until the steel frame of an arch is completed. Concrete can then be pumped into forms supported on the steel frame of the arch, using the frame as reinforcing steel. The track girders can be assembled on the ground, preferably in sections, and lifted in position using the completed arches as support points, and the sections affixed to each other to complete the girders and tracks. Tie cables 48 can then be strung and prestressed. The fixed roof portions can be erected using conventional truss techniques. The retractable panels can be assembled on the ground, one truss span at a time, lifted in position by canting them relative to tie cables 48, and the assembly and attachment of roof skin completed in place. | A structure, such as for a full-size stadium roof, which has a retractable central portion capable of opening up about one-half of the total roof area. Two retractable roof panels, rectangular in plan, cover an area that can be larger than a football field, and move in the direction of the main axis of the stadium. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and incorporates by reference co-pending application Ser. No. 09/542,756, filed Apr. 4, 2000, now U.S. Pat. No. 6,372,028, which is a continuation-in-part application of application Ser. No. 09/238,818, filed Jan. 28, 1999, now U.S. Pat. No. 6,045,869 and PCT application PCT/US99/24048, filed Oct. 25, 1999, designating the United States, all of which are commonly owned with the present application which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to surface coatings, and, more particularly, to such coatings for use in or on an aqueous environment or in contact with an aqueous fluid or solid.
[0004] 2. Description of Related Art
[0005] Coatings for application to structures in or on aqueous environments and static underwater structures are known for use to preserve surfaces, improve their appearance, and reduce drag for moving structures or devices. Such structures or devices may comprise, but are not intended to be limited to, movable boats such as sailboats, yachts, inboard and outboard motor boats, rowboats, motor launches, canoes, kayaks, inflatable watercraft, waterskis, snow skis, jetskis, snowboards, snowmobiles, toboggans, bobsleds, surfboards, sailboards, waterbikes, ocean liners, tugboats, tankers, cargo ships, submarines, aircraft carriers, pontoons for sea planes, and destroyers. Underwater static structures may include, but are not intended to be limited to, wharves, piers, pilings, bridges, and other structures that may comprise wood, metal, plastic, fiberglass, glass, or concrete.
[0006] Some coatings known in the art include those described in U.S. Pat. Nos. 3,575,123; 4,100,309; 4,119,094; 4,373,009; 4,642,267; 5,488,076; 5,554,214; and 5,700,559. Antifouling compositions have also been known to be used against such organisms as barnacles, algae, slime, acorn shells (Balanidae), goose mussels (Lepodoids), tubeworms, sea moss, oysters, brozoans, and tunicates (e.g., U.S. Pat. No. 5,919,689).
[0007] Coatings may be hydrophilic or hydrophobic, the latter incurring friction between the moving surface and the water and including Teflon-like, paraffin wax, and fluorocarbon/silicone materials. The former maintains an adhering layer of water, the kinematic friction occurring with the water through which the craft moves.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to provide a method of reducing kinematic friction between a watercraft or water-contacting surface and the water through which the watercraft moves.
[0009] It is an additional object to provide a coating for a watercraft for reducing kinematic friction.
[0010] It is a further object to provide such a coating that is hydrophilic.
[0011] It is another object to provide such a coating that also possesses antifouling properties.
[0012] It is yet an additional object to provide a new use for a novolak-type polymeric composition.
[0013] An additional object is to provide a composition and method for improving fuel efficiency in watercraft.
[0014] A further object is to provide a composition and method for coating a surface intended to contact water in either a liquid or frozen state to improve kinematic friction.
[0015] Another object is to provide a composition and method for coating a surface to reduce noise associated with contact with water.
[0016] It is an additional object to provide a composition and method for coating a surface to absorb shock associated with water and wave contact.
[0017] It is a further object to provide a composition and method for coating a surface to protect against corrosion and/or blistering.
[0018] These objects and others are attained by the present invention, a composition and method for coating water-contacting surfaces having the property of reducing kinematic friction. It is to be understood by one of skill in the art that by “water” is meant any aqueous environment, freshwater or marine, as well as in a frozen state, i.e., ice or snow. An embodiment of the composition comprises a solution including a polymer comprising a polyhydroxystyrene of the novolak type. The polymer may be present in a concentration range of trace to the solubility limit, approximately 75% in alcohol. In a preferred embodiment the composition further comprises an antifouling agent.
[0019] In a first subembodiment of the composition, the polyhydroxystyrene is blended in a low-molecular-weight oxygenated hydrocarbon solvent. In a second subembodiment, the polyhydroxystyrene is incorporated into a gel-type coating. In a third subembodiment, the polyhydroxystyrene is incorporated into an epoxy, such as a one- or a two-part epoxy, for forming a permanent or semipermanent coating.
[0020] A first embodiment of the method of the present invention comprises applying the composition as described above to an outer surface of a marine watercraft or to any water-contacting surface to achieve a coating thereof. Preferably the composition is applied in a solution in an appropriate solvent, which may comprise a low-molecular-weight oxygenated hydrocarbon such as an alcohol or ketone. The coated surface is smooth and free of tackiness and thus is not fouled by common water debris such as sand and weeds. The coating is insoluble in water and resists abrasion, giving a functional lifetime that has been estimated to be a few years of continuous use.
[0021] A second embodiment comprises a method for increasing the kinematic efficiency of a marine watercraft, including applying the composition to a submersible surface of a marine watercraft.
[0022] A third embodiment comprises a method for making the composition, including blending the polyhydroxystyrene in a low-molecular-weight oxygenated hydrocarbon solvent, a gel coat, or an epoxy.
[0023] A fourth embodiment comprises a method for reducing noise of water and wave impact, including applying the composition to a water-contacting surface such as a roof.
[0024] A fifth embodiment comprises a method for absorbing shock experienced by water-contacting surfaces, such as boat hulls, including applying the composition thereto.
[0025] A sixth embodiment comprises a method for protecting a water-contacting surface from corrosion or blistering, including applying the composition to the affected surface.
[0026] An application of the composition of the present invention to a water-submersible surface results in a hydrophilic surface having a considerably reduced contact angle. For example, when the composition is applied to a fiberglass/polyester surface with an initial contact angle of approximately 60° with water as determined by the tilting plate method (see N. K. Adam, The Physics and Chemistry of Surfaces , Oxford Univ. Press, 1941), the contact angle is reduced to about 15°. Thus the use of the coating is beneficial on watercraft to increase the speed thereof and/or to improve the fuel utilization.
[0027] The features that characterize the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description used in conjunction with the accompanying drawing. It is to be expressly understood that the drawing is for the purpose of illustration and description and is not intended as a definition of the limits of the invention. These and other objects attained, and advantages offered, by the present invention will become more fully apparent as the description that now follows is read in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The FIGURE illustrates the laboratory apparatus used to test the effect of the coating of the present invention upon the speed of an object falling through water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] A description of the preferred embodiments of the present invention will now be presented with reference to the FIGURE.
[0030] A first embodiment of the composition comprises polyhydroxystyrene dissolved in methanol as a 5-20 wt/vol % solution and an antifouling agent also present at 5-10 wt/vol %. An antifouling agent comprises at least one compound selected from the group consisting of copper powder, copper oxide, zinc oxide (Kadox 911), titanium oxide (Degussa P-25), tin oxide, Irgarol 1051 algicide (Ciba), and the antibiotic Compound X (Starbright), although other antifouling agents known in the art or to be conceived in the future may also be used. The best mode at present is believed to comprise zinc oxide, although this is not intended as a limitation. A pigment may also be included.
[0031] A copolymerization of the polyhydroxystyrene with at least one other hydroxylated polymer such as polyhydroxylethylmethacrylate, polymethacrylic acid, and polyhydroxymethylene or with another hydrophilic polymer such as polyallylamine, polyaminostyrene, polyacrylamide, or polyacrylic acid allows a variation of the coating without reducing the solubility of the copolymer in the solvent, while also not increasing the solubility of the dry coated polymer in water.
[0032] A second embodiment of the composition comprises a polymer comprising polyhydroxystyrene incorporated into a gel coat as is known in the art for treating the surfaces of marine watercraft.
[0033] A third embodiment of the composition comprises a polymer comprising polyhydroxystyrene incorporated into an epoxy, including a one- or a two-part epoxy.
[0034] A fourth embodiment of the composition comprises a polymer comprising polyhydroxystyrene incorporated into isopropyl alcohol (IPA). The polymer may be dissolved in amounts ranging from trace to the solubility limit, here approximately 75%. Although not intended to be limiting, various ranges may be contemplated for different applications and different durabilities as follows: trace-5%, skis, scuba gear, jet skis, smaller boats; 5-10%, competition coatings; 10-30%, antifouling product, also adds in bonding of antifouling component(s); 30-40%, propeller coating; 40-75%, ships and applications requiring great durability; 75%-solubility limit, for applications requiring extreme wear or those subject to high abrasion, such as propeller coatings for ships or in high-speed applications.
[0035] A fifth embodiment of the composition includes a substance known as a “fugitive dye.” This substance, which imparts a color, such as violet, to the composition, may be added to the polymer solution prior to applying the composition to a surface. The user can then check the surface during the coating proces to ensure complete coverage, and the dye disappears over time.
[0036] Test Apparatus
[0037] A laboratory apparatus 10 used to test the effectiveness of the first embodiment of the coating of the present invention on a plastic bob 12 to affect the speed with which the bob 12 drops 1.3 m through sea water under the influence of gravity. An exemplary bob 12 comprises a plastic hydrophobic pointed cylinder approximately 1.26 cm in diameter and from 7.62 to 25.40 cm in length.
[0038] The apparatus 10 includes a glass tube 14 1.52 m long and having an inner diameter of 3.5 cm filled with artificial seawater. The bob 12 was allowed to fall from an initial position 20 to a second position 22 1.3 m apart. A photoelectric detector 16 at the initial position 20 starts a digital electronic timer 18 . A second photoelectric detector 24 at the second position 22 stops the timer 18 . The time recorded, typically in the second range, depending upon the size and mass of the falling bob 12 , represents the time taken for the bob 12 to fall from the initial position 20 to the second position 22 .
[0039] The bob 12 also has a thread 26 attached to its top end, which enables the bob 12 to be raised after resetting the timer 18 to ready it for another test. The initial position 20 should be set carefully in order to achieve reproducible results with a low standard deviation from the mean when ten identical, or as close to identical as possible, tests are averaged.
[0040] Exemplary Test Results 20 Tests undertaken on the apparatus described above have shown that the falling time, which ranges from 1.5 to 6 sec depending upon the size and mass of the object, decreases by 100-300 msec when a coating of the present invention has been applied (Table 1). This represents an improvement in the speed of 2-8%. The maximum speed at which these tests were performed correspond to the equivalent of about 2.5 knots. This is far below the 9-20 knots of ocean tankers or the 20-30 knots of passenger ships and ocean cargo vessels. However, the results of Table 1B show that the degree of improvement of the coating increases as the speed of the moving object increases for a fixed surface-to-water contact area.
TABLE 1 Some typical results showing (a) the effect polyhydroxystyrene coatings on bobs of various materials by a determination of the time for the bob to fall (in milliseconds, ms), and (b) the effect of speed on the improvement due to the coatings for a fixed surface. Anti- Time (ms) Time (ms) fouling Before After Percentage (a) Material* Agent Coating Coating Improvement 1. Polyethylene ZnO 3869.4 ± 44 3567.0 ± 30 7.9% 2. Nylon None 4283 ± 79 4179 ± 41 2.4% 3. Nylon ZnO 3098.2 ± 26 2988 ± 27 3.5% 4. Polyvinyl- ZnO 4561 ± 38 4404 ± 34 3.4% chloride 5. Polyvinyl- None 1519.3 ± 13 1489.0 ± 10 2.0% chloride Mass of Bob Time (ms) Time (ms) Percentage (b) Grams Before Coating After Coating Improvement 6. 32.9 5047.6 ± 56 4959 ± 72 1.8% 7. 34.2 2011.7 ± 27 1947.6 ± 20 3.2% 8. 38.3 1711.3 ± 21 1664.4 ± 12 6.0
[0041] It has been shown that an application of a 5-20% solution of polyhydroxystyrene in methanol changes a hydrophobic surface into a hydrophilic one. The contact angle of flat metal, plastic, and wood surfaces were determined by the tilting plate method before and after application of the coating. The results are given in Table 2, where the contact angles are the averages of the advancing and receding angles. These data show that the coating causes a significant decrease in the contact angle of water with the surface. Similar data were obtained when an antifouling agent such as listed previously is added.
TABLE 2 Contact angles of water on various surfaces before and after coating with a solution of Polyhydroxystyrene Surface Contact Angle Before Contact Angle after Polyethylene 56 16 Stainless Steel 42 20 61 18 Aluminum 70 15 Fiberglass/polyester 53 22 60 17 Silicone rubber 48 18 Plexiglass 60 12 63 14 Polystyrene 58 15 Wood (oak) 33 18
[0042] The coating was also applied to a test boat having an onboard computer to monitor the power, speed, and rpm. The characteristics of this exemplary test boat are given in Table 3, and the results of three tests under different conditions of speed and rpm for the uncoated and coated boat are given, respectively, in Tables 4A and 4B, with a summary given in Table 5. For fixed power, the coating effected an increase in speed of 8%, and the fuel savings was approximately 10% when the boat was fully in the water, i.e., prior to planing. The coated boat tended to plane at lower throttle speed and felt more slippery in the water than the uncoated boat.
TABLE 3 Boat Characteristics Gas Test Number Test 1 Boat Model 26 Nova Spyder Boat Number WELP 340 E788 Engine Manufacturer Mercruiser Twin Engine Model 350 Magnum Stern Drive Model Alpha One Gear Ratio (X:1) 1.50:1 Propshaft Hp 500 Stbd Idle Timing 8 Degrees BTDC Port Idle Timing 8 Degrees BTDC Stbd Adv Timing 32 Degrees BTDC Port Adv Timing 32 Degrees BTDC Rpm Range 4400-4800 RPM X″ Dimension 5 1/4 (1 1/4″ Above) Fuel Load 60.0 Gallons 4900 Lbs Aft Fuel Capacity 120 Gallons 2800 Lbs Fwd Boat Weight at Test 9011 Pounds 7700 Lbs Ttl Center of Gravity 104.7 Inches 24.00 Ft. Dist. Trim Tabs Bennett 9″ × 12″ (Performance) Exhaust System Thru-transom 100 Pounds Gear Driver Willie Petrate 200 Pounds Passengers Don, Ken, Lee 640 Pounds Location Sarasota Bay Water Conditions Lite Chop Wind Conditions Northwest @ 10 MPH Radar Stalker Fuel Flow Meter Floscan 7000 G″ Meter Vericom 2000r Propeller Model Quicksilver Prop Material Stainless Steel Wellcraft PN 1405=== Manufacturer's PN 48-163184 Number of Blades Three Rh Diameter 13 3/4″ Pitch 21< True Pitch 22.0 Inches Hull Constant 280,6633 Minimum Rpm to Maintain Plane 2400 RPM Boat Position Angle at Rest 4 Degrees Boat List Angle at Rest 0 Degrees Bow Measurement (Inches) N/A Inches Transom Measurement (Inches) N/A Inches NMMA Boat Maneuverability Test OK Backdown Test Use Caution Sight Anti-ventilation Plate Well Defined Total Fuel this Test 12.0 Gallons Total Engine Time this Test One Hour Recommended Cruising Rpm 3500 RPM Acceleration Test Test Seconds Feet Time to Plane 1 4.10 60 0-20 Mph 2 4.17 61 Drive Trim 100% dn 3 5.00 74 Avg 4.42 65 Recommended Propeller Yes
[0043] [0043] TABLE 4A BOAT TEST REPORT MARINE ENGINE FUEL INJECTION TEST NUMBER: Test 1 Normal Hull 1000 RPM ZERO LIST slip % 48.4% 1 7.7 mph 83 DB mpg 1.99 2 6.6 mph 4.25 BPA trim 100% DN 3 7.2 mph 3.6 GPH plates None avg 7.2 mph 227 RANGE 1500 RPM ZERO LIST slip % 55.4% 1 9.9 mph 85 DB mpg 1.45 2 8.7 mph 6.5 BPA trim 100% DN 3 9.3 mph 6.4 GPH plates None avg 9.3 mph 156 RANGE 2000 RPM ZERO LIST slip % 66.4% 1 10.5 mph 86 DB mpg 0.77 2 8.0 mph 7.75 BPA trim 100% DN 3 9.5 mph 12.2 GPH plates None avg 9.3 mph 87 RANGE 2500 RPM ZERO LIST slip % 21.4% 1 27.0 mph 87 DB mpg 1.72 2 27.6 mph 3.75 BPA trim 100% DN 3 27.3 mph 15.9 GPH plates None avg 27.3 mph 196 RANGE 3000 RPM ZERO LIST slip % 20.8% 1 32.6 mph 88 DB mpg 1.73 2 33.4 mph 3.75 BPA trim 20% UP 3 33.0 mph 19.1 GPH plates None avg 33.0 mph 197 RANGE 3500 Cruise RPM ZERO LIST slip % 15.5% 1 40.7 mph 90 DB mpg 1.74 2 41.4 mph 3.50 BPA trim 35% UP 3 41.1 mph 23.6 GPH plates None avg 41.1 mph 193 RANGE 3500 RPM ZERO LIST slip % 15.5% 1 40.7 mph 90 DB mpg 1.74 2 41.4 mph 3.50 BPA trim 35% UP 3 41.1 mph 23.6 GPH plates None avg 41.1 mph 193 RANGE 4000 RPM ZERO LIST slip % 14.7% 1 47.8 mph 91 DB mpg 1.51 2 47.0 mph 3.25 BPA trim 60% UP 3 47.4 mph 31.4 GPH plates None avg 47.4 mph 172 RANGE 4500 RPM ZERO LIST slip % 14.5% 1 54.0 mph 95 DB mpg 1.35 2 53.4 mph 3.00 BPA trim 70% UP 3 53.0 mph 39.5 GPH plates None avg 53.5 mph 154 RANGE 4760 MAX RPM ZERO LIST slip % 14.3% 1 56.0 mph 97 DB mpg 1.22 2 57.2 mph 3.00 BPA trim 80% UP 3 56.8 mph 46.6 GPH plates None avg 56.7 mph 139 RANGE
[0044] [0044] TABLE 4B BOAT TEST REPORT MARINE ENGINE FUEL INJECTION TEST NUMBER: Test 2 Hull Coated with PHS 1000 RPM ZERO LIST slip % 48.2% 1 7.6 mph 83 DB mpg 2.06 2 6.8 mph 4.25 BPA trim 100% DN 3 7.2 mph 3.5 GPH plates None avg 7.2 mph 235 RANGE 1500 RPM ZERO LIST slip % 52.5% 1 9.7 mph 85 DB mpg 1.52 2 10.1 mph 7.00 BPA trim l00% DN 3 9.9 mph 8.5 GPH plates None avg 9.9 mph 174 RANGE 2000 RPM ZERO LIST slip % 61.2% 1 10.0 mph 86 DB mpg .90 2 11.5 mph 8.25 BPA trim 100% DN 3 10.8 mph 12.0 GPH plates None avg 10.8 mph 102 RANGE 2500 RPM ZERO LIST slip % 15.1% 1 29.2 mph 87 DB mpg 1.84 2 29.7 mph 4.25 BPA trim 100% DN 3 29.5 mph 16.0 GPH plates None avg 29.5 mph 210 RANGE 3000 RPM ZERO LIST slip % 14.1% 1 36.0 mph 88 DB mpg 1.85 2 36.4 mph 4.00 BPA trim 20% UP 3 35.0 mph 19.3 GPH plates None avg 35.8 mph 211 RANGE 3500 Cruise RPM ZERO LIST slip % 13.6% 1 42.1 mph 90 DB mpg 1.79 2 42.6 mph 3.50 BPA trim 35% UP 3 41.3 mph 23.5 GPH plates None avg 42.0 mph 204 RANGE 3500 RPM ZERO LIST slip % 13.6% 1 42.1 mph 90 DB mpg 1.79 2 42.6 mph 3.50 BPA trim 35% UP 3 41.3 mph 23.5 GPH plates None avg 42.0 mph 204 RANGE 4000 RPM ZERO LIST slip % 12.5% 1 49.0 91 DB mpg 1.54 2 48.7 mph 3.50 BPA trim 60% UP 3 48.1 mph 31.5 GPH plates None avg 48.6 mph 176 RANGE 4500 RPM ZERO LIST slip % 12.4% 1 55.0 mph 95 DB mpg 1.37 2 54.5 mph 3.50 BPA trim 70% UP 3 54.8 mph 40.1 GPH plates None avg 54.8 mph 156 RANGE 4785 MAX RPM ZERO LIST slip % 12.4% 1 58.0 mph 97 DB mpg 1.25 2 58.2 mph 3.25 BPA trim 80% UP 3 58.5 mph 46.5 GPH plates None avg 58.2 mph 143 RANGE
[0045] [0045] TABLE 5 SO-BRIGHT INTERNATIONAL TEST RESULTS Test One - Prior to Chemical Application Test Two - After Chemical Application Changes TEST NR Test 1 Test 2 Changes Test 1 Test 2 Changes Test 1 Test 2 IN 20 Nova Spyder RPM MPH MPH IN MPH MPG MPG IN MPG RANGE RANGE RANGE Mercruiser 1000 7.2 7.2 0.0 2.0 2.1 0.07 227 235 7.6 350 Magnum 1500 9.3 9.9 0.6 1.5 1.5 0.07 166 174 8.0 Alpha One 2000 9.3 10.8 1.4 0.8 0.9 0.13 87 102 15.1 Sarasota Bay 2500 27.3 29.5 2.2 1.7 1.8 0.12 196 210 14.2 Quicksilver 3000 33.0 35.8 2.8 1.7 1.9 0.13 197 211 14.5 Stainless Steel 3500 41.1 42.0 0.9 1.7 1.8 0.05 198 204 5.4 Three Blades RH (2) 4000 47.4 48.6 1.2 1.5 1.5 0.03 172 176 3.8 21″ 4500 53.5 54.8 1.3 1.4 1.4 0.03 154 158 3.8 4760 4785 56.7 58.2 1.6 1.2 1.3 0.04 121 124 3.6 ACCELERATION (0-20 MPH): Test 1 Test 2 SECONDS TO PLANE: 4.4 3.9 FEET TO PLANE: 65.0 57.0
[0046] The results clearly show that a boat coated with the composition of the present invention moves faster than an uncoated boat under substantially identical power consumption; similarly, for the same speed the coating reduces the rate of fuel consumption or increase the distance the boat will travel on a full tank of fuel. The difference varies with speed or power of the boat, and Table 5 shows that in the tests the maximum improvement of 17% at 2000 rpm corresponded to 10.8 miles/hour. At higher speeds the boat started to plane, resulting in less boat surface area in contact with water, and therefore a reduced beneficial effect of the coating is observed. For the case of ocean liners, cargo boats, or sailboats, which do not plane, it is expected that the beneficial effects of the coating of the present invention would continue to increase with an increase in power and speed since the surface-to-water contact area would not change under these changing conditions.
[0047] Further tests have been undertaken with different boats to study speed (two tests), fuel efficiency, and range, and with an aircraft to study water distance to takeoff. The test results are shown, respectively, in Tables 6-10.
TABLE 6 Improvement in Speed with Coated Hull a RPM PRE AVG POST AVG DIFF. % GAIN 650 5.50 6.35 0.85 15.45 1000 7.30 8.50 1.20 16.44 1500 9.10 11.60 2.50 27.47 2000 14.90 15.95 1.05 7.05 2500 20.90 22.60 1.70 8.13 3000 26.50 27.80 1.30 4.91 3500 31.10 32.30 1.20 3.86 4000 34.00 36.50 2.50 7.35 4500 37.10 38.90 1.80 4.85 4775 39.30 40.50 1.20 3.05
[0048] [0048] TABLE 7 Improvement in Speed with Coated Hull a RPM PRE AVG POST AVG DIFF. % GAIN 1000 4.5 5.4 0.9 20 1500 6.3 6.9 0.6 9 2000 8.1 8 [0.1] [1] 2500 9.2 9.7 0.5 5 3000 12.7 15.3 2.6 20 3500 20.7 21.8 1.1 5 4000 29.7 28.7 [1.0] [3] 4500 33.8 34.7 0.9 3 5000 36.4 37.2 0.8 2
[0049] [0049] TABLE 8 Improvement in Fuel Efficiency with Coated Hull a RPM PRE AVG POST AVG DIFF. % GAIN 1000 1.9 2.3 0.4 21.1 1500 1.9 2.2 0.3 15.8 2000 1.7 1.8 0.1 5.9 2500 1.4 1.5 0.1 7.1 3000 1.6 2.0 0.4 25.0 3500 2.1 2.3 0.2 9.5 4000 2.4 2.5 0.1 4.2 4500 2.3 2.3 0 0 5000 1.6 1.9 0.3 18.8 Max 1.7 1.8 0.1 5.9 Min plane rpm 2200 2000 −200 −9.1
[0050] [0050] TABLE 9 Improvement in Range with Coated Hull a RPM PRE AVG POST AVG DIFF. % GAIN 1000 232.0 281.0 49.0 21.1 1500 229.0 258.0 29.0 12.7 2000 201.0 213.0 12.0 6.0 2500 166.0 178.0 12.0 7.2 3000 197.0 236.0 39.0 19.8 3500 257.0 271.0 14.0 5.4 4000 284.0 301.0 17.0 6.0 4500 273.0 275.0 2.0 0.7 5000 192.0 222.0 30.0 15.6 Max 199.0 210.0 11.0 5.5
[0051] [0051] TABLE 10 Improvement in Takeoff Distance (ft) with Coated Aircraft a % REDN. IN RPM PRE AVG POST AVG DIFF. TAKEOFF DISTANCE 1000 1272.6 969.6 −303.0 23.8 1500 1271.9 948.4 −323.5 25.4 2000 1275.8 959.0 −316.8 24.8 AVG 1273.4 959.0 −314.4 24.7
[0052] Therefore, it can be seen that the composition and methods of the present invention represent a significant increase in speed, fuel efficiency, and range of boats, and an improvement (reduction) in takeoff distance required in an amphibious aircraft, thus conferring concomitant ecological, economic, and safety benefits.
[0053] Methods of Using the Compositions
[0054] Any of the compositions of the present invention may be used on virtually any water- or snow-contacting surface to reduce kinematic friction between the surface and the water or snow. Such surfaces may include, but are not intended to be limited to, marine watercraft hulls; ski, snowmobile, or snowboard bottom surfaces; engine outdrives; trim tabs; K-planes and other underwater hardware; propellers; shafts; personal submersible propulsion devices; amphibious aircraft; underwater dive equipment (wet suits, tanks, fins); pipes; roofs; fishing lures; fishing lines; scuba gear and masks; and the inner walls of pipes and tubing intended for carrying an aqueous solution, wherein the hydrophilic coating enhances the flow therethrough.
[0055] In the case of pipes, for example, an application of the coating of the present invention to the walls of a pipe will permit a greater volume of an aqueous solution to flow therethrough, hence permitting fluid transfer more economically and efficiently.
[0056] For fishing gear application, a lure becomes more hydrophilic, experiencing less drag, giving off less turbulence, and making it easier to retrieve. A coated fishing line is also hydrophilic, having less drag and creating less turbulence, and making it easier to retrieve.
[0057] Scuba gear also benefits from the application of the composition of the present invention. Again, the gear becomes hydrophilic, has less drag, creates less turbulence, and is easier to maneuver. A scuba mask lens also becomes hydrophilic, presenting the inner surface from fogging, and providing a long-lasting, durable, antifogging coating.
[0058] An application of the coating to the cooling systems of outboard and inboard engines is also advantageous, since the efficiency of the system is increased by allowing a greater amount of water to flow therethrough. In addition, corrosion will be minimized, since a barrier is formed between the water and the corrosible parts of the engine.
[0059] The compositions may also be applied to such surfaces to reduce corrosion and prevent paint blistering.
[0060] The compositions may further be applied to such surfaces to provide shock-absorbing properties.
[0061] The compositions may additionally be applied to such surfaces to provide noise reduction, such as on a metal roof against rain noise.
[0062] It may be appreciated by one skilled in the art that additional embodiments may be contemplated, including compositions comprising polymers having characteristics imparting the desired properties and other antifouling agents.
[0063] In the foregoing description, certain terms have been used for brevity, clarity, and understanding, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such words are used for description purposes herein and are intended to be broadly construed. Moreover, the embodiments of the apparatus illustrated and described herein are by way of example, and the scope of the invention is not limited to the exact details of construction.
[0064] Having now described the invention, the construction, the operation and use of preferred embodiment thereof, and the advantageous new and useful results obtained thereby, the new and useful constructions, and reasonable mechanical equivalents thereof obvious to those skilled in the art, are set forth in the appended claims. | A composition for coating a water-contacting surface for reducing kinematic friction, preventing corrosion and blistering, reducing water impact noise, and absorbing water shock includes a polymer including a polyhydroxystyrene of the novolak type. In alternate embodiments the composition also includes an antifouling agent, a gel coating material, and/or an epoxy. A method includes coating a water-contacting surface with the composition, preferably in a solution in an appropriate solvent, such as a low-molecular-weight oxygenated hydrocarbon such as an alcohol or a ketone. Application of the composition to a water-submersible or contacting surface results in a hydrophilic surface having a considerably reduced contact angle, permitting increased speed and improving fuel efficiency. | 2 |
RELATED U.S. APPLICATION DATA
This application claims the benefit of U.S. Provisional Application No. 61/528,825, filed Aug. 30, 2011.
FIELD OF THE INVENTION
The invention pertains to a method and apparatus for improving the heating capacity of steam-heated hot plates, and in particular, to steam-heated hot plates used in the corrugating industry.
BACKGROUND
Corrugated containerboard is manufactured on machines that combine one or more “liners” in a stack with fluted webs (“medium”) in between with the peaks of the medium flutes glued to the surfaces of the liners. The adhesive between the fluted medium and the liners of the combined board (that is, the corrugated containerboard) is then dried by passing the board through a double face heating section. The double face heating section (“double-backer”) consists of a series of steam-heated “steam chests” or “hot plates”. Individual steam chests and hot plates are generally less than two feet in machine direction length and extend to the width of the corrugator, which is typically 100 ″ to 120″ in width. The containerboard is held against these steam chests and hot plates by belts and ballast rollers that serve to keep the board in good thermal contact with the top surfaces of the hot plates/steam chests.
FIG. 1 shows a steam chest 10 according to the prior art. FIG. 2 shows a hot plate according to the prior art. Steam chests 10 and hot plates 40 are examples of steam heating devices designed to transfer heat from steam to a heating surface. Steam chests 10 can be constructed as large metal boxes 12 that are designed to hold the steam input at “A” the box interior 16 under pressure. The steam condenses on the top inside surface of the box 12 and the condensed steam (“condensate”) falls onto and collects on the bottom of the box 12 . From there, the condensate is drained by gravity to a steam trap 22 from which the condensate is returned to the boiler at “B.” The box upper surface 14 is in contact with a containerboard 15 to be dried, which is held down to the upper surface 14 by a belt 20 . Steam chests 10 are conventionally heated by steam that is supplied under pressure to each of the steam chests. The steam pressure to each group of steam chests 10 is typically controlled by a pressure control valve (not shown) working in conjunction with a pressure transmitter and a pressure indicating controller.
FIG. 2 shows the “hot plate” 40 (herein distinguished from the “steam chest” 10 ), which is similar in function to the steam chest 10 , except the hot plate 40 has drilled internal passages 44 adjacent to a hot plate surface 46 . The hot plate surface 46 and internal passages 44 are formed as part of a hot plate frame 42 . These passages 44 generally extend from one side of the hot plate frame 42 to the opposite side, and then back again, forming several loops before the passage leaves the plate. The steam flows into inlet 43 and through these internal passages 44 and condenses as it transfers its heat to a corrugated containerboard 48 on the outside of surface 46 . The condensate flows slowly by gravity toward a drain 45 . The drain line is conventionally connected to a steam trap. Steam traps open to drain the condensate from the hot plate and then close to prevent the passage of uncondensed steam. The condensate that leaves the steam trap is returned to the boiler. At high condensing rates, the condensate that forms inside the passages of the hot plates 40 tends to accumulate and result in a reduction in rate and uniformity of heat transfer. The corrugated containerboard 48 can be held down to the hot plate surface 46 by a belt 50 .
A typical corrugated containerboard making machine 300 with its associated double backer section 314 is shown in FIG. 3 . The corrugated containerboard making machine 300 includes supply rollers 302 for the first liner, supply rollers 304 for the medium and supply rollers 306 for the second liner. The corrugated containerboard making machine 300 also includes a corrugator 308 , drive rollers 310 and adhesive applicator 312 . The corrugated containerboard making machine also includes a hot plates section 318 in a double backer section 314 for drying the adhesive applied at 312 .
In order to minimize the non-uniformity of heat transfer, a multitude of hot plates are used in each double backer section 314 . The pressure is adjusted on the belt 316 that holds the board to the hot plates 318 in an attempt to correct for these reductions in rate and uniformity of heat transfer. In conventional corrugators, the hot plate performance is controlled by the belt pressure, adding backing rolls, loading the backing rolls, increasing the steam pressure, venting some steam to atmosphere, adding more hot plates, or running the corrugating machine at a slower speed.
An example of prior art hot plates and their steam control system 400 are shown in FIG. 4 . FIG. 4 shows a steam line 402 inputting steam at “A.” The steam line 402 delivers steam either directly to a hot plate 408 via delivery lines 414 or to pressure control valves 404 , 406 , which regulate the steam pressure and deliver steam to hot plates 410 , 412 via delivery lines 416 , 418 . The steam heats the hot plates 408 , 410 , 412 and condenses, forming a condensate that is collected by condensate trap lines 420 , 422 , 424 and carried to separators 426 , 428 which separate condensate from steam and return separated steam to the delivery lines 416 , 418 or directly to a pump 432 . Condensate is routed to pumps 430 , 432 to be returned to the steam boiler (not shown) via a return line 434 at “B.”
The prior art hot plates and their steam systems are not suitable for high-speed corrugated boxboard production where uniformity, high heat transfer rates, and energy efficiency are important.
SUMMARY OF THE INVENTION
Aspects of disclosed embodiments include an improved method for transferring heat from a steam heating device including introducing steam into the steam heating device with a steam supply system; circulating the steam through the steam heating device creating steam condensate and collecting the steam and steam condensate with a separator tank which separates the steam from the steam condensate; returning the steam condensate to the boiler to be reheated; returning the steam to a thermocompressor which heats and pressurizes the steam and introduces it back into the steam supply system; and wherein the steam heating device includes a ratio of steam to steam condensate of at least 20:1 by volume.
Aspects of disclosed embodiments also include an apparatus for transferring heat from a steam heating device including a steam supply system for supplying steam; a steam heating device; a separator tank which separates the steam from the steam condensate; a thermocompressor which heats and pressurizes the steam and introduces it back into the steam supply system; and wherein the steam heating device includes a ratio of steam to steam condensate of at least 20:1 by volume.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a prior art steam box;
FIG. 2 is a diagram of a prior art hot plate;
FIG. 3 is a diagram of a prior art corrugating system;
FIG. 4 is a diagram of a prior art steam control system;
FIG. 5 is a diagram of a steam control system according to disclosed embodiments; and
FIG. 6 is a diagram of a steam control system according to disclosed embodiments.
DETAILED DESCRIPTION
The method and apparatus of the subject disclosure includes a steam-heated hot plate of the type typically used in the double-face heating section of machines that manufacture corrugated board, a steam pressure transmitter, a steam pressure indicator controller, a steam and condensate separator tank, a blow-down valve, a steam jet thermocompressor, and a pressure powered condensate pump.
The subject disclosure is applicable both to steam chests and to hot plates. Steam chests and hot plates can be referred to collectively as steam heating devices. If, when the steam chests or hot plates are first heated, the residual non-condensing gases (mostly air) are not purged, this can result in a further reduction in rate and uniformity of heat transfer. Steam heating devices can be equipped with a trap or separator which separates the live steam from condensed steam (water). In order to help purge air from the steam heating devices, a small line or passageway can be installed around the trap to by-pass the trap and allow “live” (uncondensed) steam to purge the air. The discharge of the live steam, however, gives rise to poor thermal efficiency and lack of process control. This escape of live steam with residual non-condensing gasses is called blow through.
Further, the collection of sub-cooled condensate in the bottom of the steam chest or on the bottom of the cross-machine flow passages of the hot plate gives rise to a thermal bowing of the heaters. This thermal bowing causes non-uniform thermal contact between the steam chest/hot plate surfaces and the corrugated container board which in turn results in non-uniform setting of the adhesive bonds.
In an embodiment of this disclosure, a steam pressure indicating controller maintains the desired steam pressure in the header that feeds one or more of the hot plates in the double-backer section. The drain line from the hot plate(s) discharges to the steam and condensate separator. The condensate is returned to the boiler through the pressure powered condensate pump. The blow through steam from the separator is piped to the suction port of the thermocompressor from where it is boosted in pressure by the thermocompressor and recirculated back to the supply header for the hot plate section. With this concept, the entire blow through steam is re-used.
FIG. 5 is a diagram showing a steam control system 500 for supplying steam to a number of steam heating devices, in this example hot plates 508 . The steam pressure indicating a controller 530 is used to maintain a hot plate header 506 pressure. This is accomplished by modulating the actuator on a thermocompressor 504 using the controller 530 . The controller 530 is connected to a transducer 532 which can measure steam pressure and temperature. Steam enters a high pressure steam input 502 at “A” and is routed to the thermocompressor 504 and a blow down valve 528 via a line 518 . Steam from the high pressure steam input 502 is combined with pressurized circulated steam at the thermocompressor 504 an routed to the hot plate header 506 , which distributes the steam to the hot plates 508 , under the direction of the controller 530 .
The steam circulates through the hot plates 508 and partially condenses. The circulated steam and condensate is output from the hot plates 508 through the return lines 510 . The return lines 510 route the circulated steam and condensate to a separator tank 512 where circulated steam is separated from condensate. The condensate is removed from the separator tank 512 via condensate line 514 to pump 516 , which pumps the condensate back to the steam boiler (not shown) via line 520 in direction “B”.
Circulated steam exits the separator tank 512 via re-circulation line 522 which can, in cooperation with valves 524 and 528 , permit the system to blow-down at start up to remove non-condensable gasses from the hot plates. Otherwise the circulated steam is returned to the thermocompressor 504 via the re-circulation line 522 to be pressurized and blended in with the new steam arriving from the high pressure steam header 502 to be returned to the hot plate header 506 and thereby to the hot plates 508 .
In FIG. 5 , the amount of blow through flow and the differential steam pressure across the hot plates 508 depend on the operation of the thermocompressor 504 and are not primary control parameters. The thermocompressor 504 ensures the drainage of condensate from the hot plate(s) 508 and maintains high and uniform heat transfer from the hot plates 508 by a continuous and appropriate flow of blow through steam through the hot plate section.
FIG. 6 shows another disclosed embodiment of a steam supply system 600 . In FIG. 6 , the amount of blow through flow and the differential steam pressure across hot plates 608 are alternatively selected as control parameters for a thermocompressor 604 . The steam pressure in a hot plate steam supply header 606 is controlled directly by a steam pressure control valve 638 . The thermocompressor 604 set point ensures the drainage of condensate from the hot plate(s) 608 and maintains high and uniform heat transfer from the hot plates 608 by a continuous and appropriate flow of blow through steam through the hot plate section.
The thermocompressor 604 is supplied with steam at a pressure that is equal to or suitably higher than the steam supply header 606 to the hot plates 608 . The high pressure (“motive”) steam that is supplied to the thermocompressor 604 is mixed with the low pressure steam from a separator tank 612 and discharges the mixture to the steam supply header 606 at a pressure that is at least as high as the steam supply header 606 . The thermocompressor 604 mixes high pressure steam from a high pressure steam inlet 602 with pressurized circulated steam from the separator tank 612 under the control of a differential pressure transmitter 630 , which gets information from a digital pressure transducer 632 . The output of the thermocompressor 604 is controlled by the control valve 638 that mixes high pressure steam from the high pressure steam inlet 602 with pressurized circulated steam under the control of a pressure indicating controller 636 , which gets information from a pressure transducer 636 .
Circulated steam and condensate exit the hot plates 608 via return lines 610 which route the circulated steam and condensate to the separator tank 612 , which separates the circulated steam from the condensate. The condensate is sent through condensate line 614 to a pump 616 , which pumps the condensate back to the steam boiler (not shown) via boiler return line 620 . Circulated steam is routed from the separator tank 612 via steam return line 622 . The returning steam can be routed through valve 624 to blow down line 626 to blow down the system upon start-up or be routed to thermocompressor 604 .
This method and apparatus maintains a flow of blow through steam that is by volume that can be 20-30 times higher than the condensate flow volume. This high volume of steam quickly purges the hot plate section 608 of all non-condensable gases, flushes the condensate through the passages in the hot plate 608 to decrease the amount of sub-cooled water that is in the passages, and prevents passages from flooding with condensate, thermally bowing, and losing heat transfer.
This concept allows the simultaneous achievement of high and uniform heat transfer and high operating efficiency, because the high volume of blow through steam is reused in the hot plate section 608 . Still further, this concept can quickly purge non-condensable gases from the heaters and reduce the amount of sub-cooled condensate in the heaters that would otherwise cause thermal bowing of the heaters and the corresponding loss of adhesive bond uniformly.
In an embodiment of this disclosure, the discharge from the thermocompressor 604 can be directed to the hot plate steam header of a down-stream hot plate section (not shown). This would be termed a “cascade thermocompressor system.” Embodiments of this disclosure include aspects in which the differential pressure transmitter 630 of FIG. 6 is configured to measure the pressure drop across an appropriate orifice plate (not shown) in the uncondensed steam (blow through) line 622 so that the position of the control spindle in the thermocompressor 604 will be adjusted to maintain a fixed flow rate of uncondensed steam.
A further feature of the subject invention is the addition of a blow-down system to facilitate the start-up of the corrugator by purging air and other non-condensable gases from the corrugator system. This is accomplished by suitable control of the blow-down valves 524 , 624 that discharge as shown in FIGS. 5 and 6 to blow-down lines 526 , 626 . A suitable thermostatic trap 540 , 640 is used to clear non-condensable gases from the separator tank 512 , 612 intermittently directing the discharge flow as needed to the blow-down lines 526 , 626 .
The above-described implementations have been described in order to allow easy understanding of the present invention and do not limit the present invention. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structure as is permitted under the law. | Disclosed herein is a method and apparatus for improving the heating capacity of steam-heated hot plates, and in particular, to steam-heated hot plates used in the corrugating industry. One or more separators and thermocompressors are added to the output of the hot plates to separate blow through steam from condensate and pressurize and inject the steam back into the hot plates. | 3 |
FIELD OF THE INVENTION
This invention relates generally to humidifiers, and more particularly, control of evaporation in a humidifier used in conjunction with a furnace or heating system and connected to the plumbing system of a building. Humidifiers of this type typically use an air circulation arrangement to move air across a water-soaked evaporative pad. The humidifier is associated with the furnace or heating system so that the humidifier moist air can be combined with the warm, generally dry, heated air and distributed through a building.
BACKGROUND OF THE INVENTION
Humidifiers generally characterized by a housing having an evaporative water panel constructed of slit and expanded non-wicking paper, removably disposed in a reservoir at the bottom thereof. The housing also has a mechanical float valve which is connected to a water supply of a heated building. A water feed tube is connected to the mechanical float valve for supplying water to a distributor from which water flows by gravity down through the water panel. Air is forced through the water panel and the air evaporates water on the water panel, so that humidified air is delivered to the building.
Such humidifiers typically employ a device such as a humidistat, for establishing predetermined humidity set point and reading humidity levels in the building. The humidistat is connected in a circuit with a pump and operates, in the presence of low humidity, to automatically deliver water from a lower reservoir to the top of the water panel and downwardly therethrough. Some of the water evaporates from the water panel and is air blown to provide humidity to the building. The remainder of the water collects in the reservoir at the bottom of the water panel. As the reservoir level drops due to loss of evaporated water, the float valve opens to allow water in from supply and maintains reservoir level. The pump recirculates water from the reservoir over the non-wicking water panel. This cycle continues as long as the humidistat reads low humidity. Once the humidity set point is reached, the circuit is opened and water flow ceases.
There also exist drum-type humidifiers wherein a motor and gear system is used to rotate a drum in a reservoir of standing water.
While such designs generally provide the desired humidification, there arises problems in the cost, noise, maintenance, electrical power needs and reliability associated therewith. Another problem with these designs is that the reservoir remains filled no matter if humidity is needed or not. As a result, there is a possibility of undesirable bacteria, algae, fungus, mold, etc.
Accordingly, it is desirable to provide a humidifier which is responsive to the changing water level in the reservoir. It is also desirable to provide a humidifier which is more economical in cost, runs more quietly, requires less maintenance and lessens the electrical power needs.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide a humidifier employing a float switch which responds to the water level in the reservoir.
It is also an object of the present invention to provide a humidifier which employs a wicking-type evaporative water panel.
It is a further object of the present invention to provide a humidifier which allows for complete evaporation of water in the reservoir.
It is an additional object of the present invention to provide a humidifier which operates normally without the need for a drain.
Still another object of the present invention is to provide a humidifier which is easier to manufacture and maintain and which is safer to operate.
In one aspect of the invention, a housing is permanently connected to a water supply of a building and includes an evaporative water panel allowing water to flow downwardly and wick upwardly. A circulation device is provided for directing air from the building to the water panel. A reservoir is positioned in the housing for supporting the water panel and for holding excess water deposited from the water panel. A water distributor is provided for moving the water from the water supply to the top of the water panel. A water control arrangement is responsive to the water level within the reservoir for automatically controlling the flow of water to the water panel to provide a desired humidity level in the building. The water panel is comprised of a multi-layer, slit and expanded, wicking paper. In the preferred embodiment, the air circulating device includes a blower associated with a furnace, or a fan built integrally into the humidifier and the reservoir includes first and second vertical walls connected to a horizontal base wall. The water control arrangement includes a solenoid valve connected to a water level sensor. The water level sensor is preferably comprised of a float switch having a float member provided with a magnet therein, and a reed switch connected to the solenoid valve. The float member and magnet are positioned above the horizontal base wall of the reservoir, and the reed switch is aligned with the magnet and positioned below the reservoir, isolated from any water contact therewith. In the preferred embodiment, the reservoir includes a tubular chamber and the float member is a ball-shaped float.
The invention also contemplates various other methods for movably mounting the float member. In one embodiment the reservoir includes a post having one end of the hinge slidably attached thereto and another end of the hinge attached to the float member. In another alternative embodiment, the reservoir includes a post having one end of a solid folding hinge attached thereto and the other end of the solid folding hinge attached to the float member. In yet another alternative embodiment, the reservoir includes a set of posts upon which the float member is slidably mounted. In still another alternative embodiment, the reservoir includes a post provided with a pivoted edge having one end of a float arm pivotally attached. thereto and another end of the float arm attached to the float member. In still another alternative embodiment, the reservoir includes a horizontal ledge having one end of a flexible hinge attached thereto and another end of the flexible hinge attached to the float member.
The water distributor is a tube extending from the solenoid valve to an outlet nozzle and a weir-type distributor trough which is positioned over the water panel. The water distributor may also take the form of a feed tube extending from the solenoid valve to an outlet manifold positioned over the water panel. An overflow tube is molded directly to the side of the reservoir for receiving any water which overflows the reservoir. The humidifier typically includes a humidistat for establishing a desired humidity level.
In another aspect of the invention, the humidifier has a device for controlling the flow of water to an evaporative water panel positioned in a reservoir and allows water to flow downwardly and wick upwardly. The humidifier also has a humidistat for establishing a desired humidity level and an operative circulating means for directing air through the water panel. The humidifier includes a water level sensor which is associated with the reservoir and which is responsive to the water level therein to alternatively open and close a circuit to control the flow of water to the water panel. With this construction, when the water level in the reservoir is low, the circuit is closed to deliver water to the water panel such that some water evaporates from the water panel and the remainder collects in the reservoir. A rising water level in the reservoir causes the sensor to open the circuit, stopping water delivery, humidification continuing as water wicks upwardly through the water panel. The falling water level in the reservoir causes the sensor to close the circuit, delivering further water to the panel, the reservoir eventually drying out once the desired humidity is reached. The humidistat forces the circuit open when the desired humidity level is reached so as to prevent the water cycling on and off indefinitely. Stoppage of the circulating means will have the same effect.
Various other features, objects, and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
FIG. 1 is a side cross sectional view of a humidifier embodying the present invention;
FIG. 1A is a view of an alternative distributor in the form of an outlet manifold;
FIG. 2 is a fragmentary view of a reservoir and float switch arrangement of the humidifier of FIG. 1 with a low water level as taken on line 2 — 2 of FIG. 1;
FIG. 3 is a cross sectional view showing an overflow tube molded directly to the reservoir;
FIG. 4 is a diagrammatic view showing a typical start-up mode for the humidifier of FIG. 1;
FIGS. 5 and 6 are diagrammatic views depicting a humidification cycle for the humidifier of FIG. 1;
FIGS. 7 and 8 are diagrammatic views depicting a dry-down mode for the humidifier of FIG. 1; and
FIGS. 9-13 are alternative embodiments of various arrangements for movably mounting a portion of the float switch.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIG. 1, a humidifier 10 embodying the present invention includes a base portion 12 and cover 14 which define a housing that is mounted on a portion of the furnace or on a wall or ceiling. Base portion 12 includes an evaporative water panel 16 preferably formed of a slit and expanded construction of wicking paper mounted in a framework or scale control 18 . Base portion 12 also includes a water feed tube 20 having one end which supplies water to a nozzle 22 and distributor 24 for the water panel 16 . Another end of feed tube 20 is joined to a solenoid valve 26 which controls the flow of water through the feed tube 20 . Solenoid valve 26 is, in turn, permanently connected to the plumbing or water supply 28 of a building. As depicted in FIG. 1A, distributor 24 may also take the form of a manifold 25 for conducting water therethrough. The humidifier 10 also includes air circulation means such as a furnace blower fan 30 (FIG. 4) for directing air through the wetted water panel 16 . A humidistat 31 (FIG. 4) is commonly used to set a desired humidity set point.
In accordance with the invention, part of the scale control 18 is provided with either an integral or separate small reservoir 32 for holding excess water supplied to the water panel 16 . As seen best in the preferred embodiment of FIGS. 2, reservoir 32 includes a tubular chamber 34 having a main well formed by a base wall 36 and first and second vertical walls 38 , 40 . A water level sensing float member 46 takes the form of a ball float 47 having a magnet 48 mounted internally within and supported on base wall 36 when the water level is low. Depending on the water level in the reservoir well, the ball 47 will be enabled to move up or down in chamber 34 . Referring to FIG. 3, molded to the side of the reservoir 32 is an overflow tube 54 for receiving any water which overflows the reservoir 32 . Reference numeral 51 indicates the normal water level in the reservoir 32 . If solenoid valve 26 fails and the water level goes too high, water drains over the lip 53 of overflow tube 54 and into a drain before it floods over the top of reservoir 32 . Attached to the base portion 12 beneath base wall 36 and between vertical walls 38 , 40 is a reed switch 62 which is suitably electrically connected to the solenoid valve 26 . As seen in FIG. 2, the reed switch 62 is aligned beneath the magnet 48 in ball float 47 . As will be understood more fully hereafter, the magnet 48 in the ball float member 47 cooperates with the reed switch 62 to define a float switch 70 . With water in the reservoir well at the low level, the float switch 70 has a closed position which will allow the solenoid valve 26 to remain open. With water in the reservoir well at a high level, the float switch 70 has an open position which will close the solenoid valve 26 .
Referring now to FIGS. 4-8, the operation of the humidifier 10 will now be described. It can be seen that a transformer 72 , a furnace sensor 74 , solenoid valve 26 , humidistat 31 , and float switch 70 are serially connected in a circuit and are responsive to the on/off condition of the motor-driven furnace fan 30 . When furnace fan 30 is “on”, sensor 74 closes, humidistat 31 senses low humidity when the water level in the reservoir 32 is low, and magnet 48 in float member 46 holds reed switch 62 closed, so that the float switch 70 is closed (FIG. 4 ). A circuit is completed to the solenoid valve 26 which opens and supplies water to the distributor 24 at the top of the humidifier 10 . Water drains from the distributor 24 and runs downwardly through the water panel 16 . Some water evaporates from the water panel 16 to provide humidity to the building. The remainder of the water collects in the reservoir 32 at the bottom of water panel 16 . As the water level rises (FIG. 5 ), the float member 46 lifts the magnet 48 away from the reed switch 62 to a point where the reed switch opens a circuit and causes the solenoid valve 26 to close. Humidification continues as water now wicks upwardly (FIG. 5) from reservoir 32 into the water panel 16 . This action is made possible by purposely constructing the water panel 16 with the slit and expanded wicking paper. Eventually, the water level drops (FIG. 6) and the magnet 48 again closes the circuit to solenoid valve 26 , so that more water enters the humidifier 10 . This cycle continues (FIG. 7) as long as the furnace fan 30 runs and the humidistat 31 reads low humidity. When the humidity set point has been satisfied, the reservoir 32 will dry out (FIG. 8) because water continues to wick into the water panel 16 and evaporates while the humidistat 31 holds the circuit open and prevents more water from entering the humidifier.
It should be appreciated that the humidifier 10 of the present invention provides a magnetic level sensing device in which the float member 46 and magnet 48 are placed in a separate assembly from reed switch 62 . This feature allows for easy replacement of the water panel 16 without having to disconnect any wires. It also maintains the electrical switch outside the water containing reservoir 32 which is safer and easier to manufacture because waterproofing is not needed. By downsizing the reservoir 32 and eliminating the pump of prior humidifiers. there is a reduction in cost, noise, and electrical power needs. Because the present invention is designed to dry out the reservoir 32 , undesirable biological growths are limited. Whereas the prior art relied on non-wicking paper for allowing downward migration of moisture, the present invention by virtue of the wicking paper also enables upward migration of moisture which aids the evaporation.
It should also be noted that while in the preferred embodiment the water level sensor has float member 46 in the form of a ball with a magnet 48 which floats in a tubular channel of the reservoir 32 , there are other arrangements contemplated to perform the same result. In the alternative embodiment in FIGS. 9, a flexible hinge 49 has one end connected to a float member 46 and another end having a mechanical pivot point, such as that of a stepped vertical shaft 76 in a hole formed in the flexible hinge 49 . In FIG. 10, a solid articulating or folding hinge 78 has one end connected to the float member 46 and another end connected to a vertical post 80 . In FIG. 11, float member 46 is mounted for sliding up and down movement on a pair of vertical posts 82 , 84 . In FIG. 12, a rocker arm 86 has one end connected to float member 46 and another end pivotably mounted on a pointed edge of a vertical post 90 .
In FIG. 13, a forward portion of the reservoir 32 includes a stepped compartment 92 having a main well formed by a base wall 94 and first and second vertical walls 96 , 98 . The shorter vertical wall 98 is formed with an outwardly projecting horizontal ledge 100 which turns into a third vertical wall 102 . A water level sensing float member 104 having a magnet 106 mounted internally within is supported on the base wall 94 when thew water level is low. A flexible hinge 108 has one end 110 secured to the top of float member 104 and has another end 112 anchored to the ledge 100 . A bottom wall 114 has a raised boss 116 creating an interior space for a reed switch 118 . Bottom wall 114 is also formed with a set of upright ribs 120 , 122 which function to locate vertical walls 96 , 98 therebetween with the base wall 94 of stepped compartment 92 resting upon an upper horizontal wall 124 of the boss 116 . The ribs 120 , 122 provide alignment of the reservoir 32 and its float member 104 , and magnet 106 with the reed switch 118 .
It is also noted that other means may be used to sense water, such as with electrical conductivity sensors, or optical, sound wave or weight sensing arrangements.
It should be mentioned that the reservoir 32 can be provided, if desired, with a downwardly depending conduit used to lead water away to a drain. This is a desirable safety feature which is useful should the solenoid valve 26 become jammed open or otherwise held open due to an electrical failure. However, in the intended operation, all water supplies would be evaporated and the drain would not be used.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. For example, in humidifiers having an internal fan, the furnace sensor 74 would not be used, and the fan would be controlled via a relay added to the circuit. | A housing is permanently connected to a water supply of a building and includes an evaporative water panel allowing water to flow downwardly and wick upwardly. A circulating device is provided for directing air from the building through the water panel. A reservoir is positioned in the housing for supporting the water panel and holding excess water deposited from the water panel. A water distributor is supplied for moving water from the water supply to a top of the water panel. A water control arrangement is responsive to the water level therein for automatically controlling the flow of water to the water panel to provide a desired humidity level in the building. | 5 |
FIELD OF THE INVENTION
[0001] The present invention is generally in the field of methods for controlling pitch and stickies deposition in pulp and paper making processes.
BACKGROUND OF THE INVENTION
[0002] Organic contaminants in the pulp and papermaking processes cause serious problems for both paper quality and pulp and paper making efficiency. These contaminants generally include naturally occurring wood pitch or wood resin and synthetic materials such as stickies found in fibers from recovered fiber sources or from mill processes. Wood pitch includes triglycerides, fatty acids, resin acids, steryl esters and sterols. Wood resins, as well as other extractives such as lignans, pectins, and phenols, are the major components of pitch deposits. During the mechanical pulping process and subsequent treatments, the wood pitch is released from the surfaces of fibers and accumulates in the whitewater in the form of colloid particles. The pitch can also contain inorganic compounds such as calcium carbonate, talc, clay, titanium oxide and alum hydroxide or reaction products of resin or fatty acids with metal ions.
[0003] Stickies generally refer to the undesirable organic contaminants present in the recycled fibers. Stickies often contain the same natural materials found in pitch deposits as well as synthetic materials including adhesives such as styrene-butadiene copolymer, polyacrylate and polyethylene, hot melts such as ethylene vinyl acetate and polyvinyl acetate, waxes, mineral oils, styrene-acrylate, and wet-strength chemicals such as melamine-formaldehyde. Since stickies are composed mainly of synthetic materials, they are more inclined to deposit on equipment surfaces containing plastic materials such as paper machine wires, wet felts, dryer felts and dryer cans.
[0004] Pitch and stickies have a detrimental impact on the pulp and papermaking process, reducing paper machine efficiency and paper quality. Wood pitch and stickies have very low surface energy and tend to deposit on pipe surfaces, chest walls, wires, uhle boxes, doctor blades, fabrics, wet felts, dryer felts, dryer cans and calendar stacks. Deposition of pitch and stickies results in operational difficulties and the malfunctioning of mill equipment. When recycled paper is used, the stickies in the waste paper can accumulate on mill equipment resulting in similar problems. When mechanical pulp is co-present with recycled paper, the combination of wood pitch and stickies generally increases the amount of deposition. Accumulated pitch or stickies particles contaminate the paper sheet when they break free from metal, ceramic, and plastic surfaces of mill equipment causing off quality paper and paper machine breaks. The increased use of recycled fiber can significantly aggravate the problem.
[0005] Conventional techniques for pitch and stickies control include dispersion, detackification, adsorption and cationic fixation. Dispersion chemicals include surfactants, polymers, and inorganic dispersants such as polyphosphates. Adsorption materials include talc which interacts with pitch or stickies surfaces to render them less tacky. Talc can be effective for synthetic stickies materials, particularly stickies particles, by adsorbing the particles which aids in dispersing the pitch in the stock and whitewater system and reduces the deposition of pitch on the machine wires and felts.
[0006] Various kinds of surfactants and water soluble polymers have been investigated to control the deposition of organic contaminants contained in the fibers of the pulp and papermaking processes.
[0007] U.S. Pat. No. 3,992,249 to Farley discloses a chemistry for preventing the deposition of adhesive pitch particles on pulp-making equipment using anionic vinyl polymers containing at least 25-85% of hydropobic-olephilic linkages selected from styrene, isobutylene, methyl styrene, ally stearate, octadecyl acrylate, octadecene, dedecene, n-octadecylarylamide, vinyl stearate and vinyl dodecyl ether and at least 15-75% hydrophilic acid linkages selected from acrylic acid, methacrylic acid, and maleic acid, itaconic acid, acrylamidoacetic acid, maleamic acid and styrenesulfonic acid. The copolymers are anionic in nature.
[0008] U.S. Pat. Nos. 4,871,424, 4,886,575, and 4,956,051 describe the use of water soluble polyvinyl alcohols having 50% to 100% hydrolysis to inhibit pitch deposition from pulp in paper-making systems. The polymer is a water-soluble copolymer having recurring entities of nonionic hydrophilic units of vinyl alcohol and hydrophobic units of vinyl acetate. The molecular weight of the polyvinyl alcohol ranges from 90,000 to 150,000. It is preferred that the degree of hydrolysis is in the range of 85% to 90% and that the polymer has a molecular weight around 125,000. Polyvinyl alcohol is often used as an industry standard for comparing different organic contaminant control chemicals.
[0009] EP 0568229A1 describes the use of hydrophobically modified hydroxyethyl cellulose (HMHEC) for preventing the deposition of pitch and stickies.
[0010] WO2004/113611 and U.S. Pat. No. 7,166,192 to Steeg describe methods for controlling pitch and stickies by adding HMHEC and cationic polymers to a cellulosic fiber slurry.
[0011] The prior art describes the use of different surfactants and polymers in the prevention of pitch and stickies. Each of those chemistries has their own limitations, however, and is only effective for a narrow range of organic contaminants.
[0012] There exists a need for improved materials and methods for the prevention and/or control of pitch and stickies deposition.
[0013] Therefore, it is an object of the invention to provide materials and methods for the control and/or prevention of pitch and stickies deposition.
[0014] It is a further object of the invention to provide materials and methods for preventing and/or controlling pitch and stickies deposition wherein the materials and methods are effective for a variety of pitch and stickies components.
SUMMARY OF THE INVENTION
[0015] Methods for controlling the deposition of pitch and stickies in pulp and papermaking processes are described herein. In one embodiment, a water soluble aminoplast ether copolymer is administered to control pitch and stickies deposition. The water soluble aminoplast ether copolymers possess a unique chemical structure, wherein the hydrophobes are located not only at both ends of the polymer, but also within the polymer backbone. The hydrophobes of the polymers interact with hydrophobic organic contaminants surfaces rendering the contaminants less hydrophobic and less tacky. The polymers described herein prevent the deposition of organic contaminants on the surfaces of equipment, pipe walls, chest walls and a buildup in the whitewater system.
[0016] The polymers described herein can be added continuously or in batch prior to or near to the site where deposition problems occur. The polymers can be used in different pulp and papermaking processes, including wastepaper recycling, Kraft pulping, sulfite pulping, tissue making, paper and linerboard production.
[0017] The use of water soluble aminoplast ether copolymers to control or prevent pitch and stickies deposition improves down stream performance of papermaking equipment increasing mill efficiency and improving paper quality.
DETAILED DESCRIPTION OF THE INVENTION
I. Definitions
[0018] “Pitch deposits” as used herein refers to a composition composed of low molecular weight olephilic materials (primarily triglycerides, resin acids, fatty acids, waxes, resin esters, fatty alcohols, sterols, and terpenes), as well as pectins, lignans, and phenolic compounds, which are released from wood fibers during chemical and mechanical pulping processes. Some of these resinous substances precipitate as aluminum, calcium and magnesium salts, causing problems with the wet end components of paper machines and affecting paper quality.
[0019] “Mechanical pulp” refers to pulp produced by reducing pulpwood logs and chips into fiber component by the use of mechanical energy, comprising stone ground wood pulp, pressurized ground wood pulp and thermomechanical pulp.
[0020] “Stone ground wood pulp” or “SOW” as used herein, refers to pulp which is produced by grinding wood into relatively short fibers with stone grinding. This pulp is used mainly in newsprint and wood-containing papers, such as lightweight coated (LWC) and super-calendered (SC) papers.
[0021] “Pressurized groundwood pulp” or “PGW” refers to pulp produced by a stone grinder where the whole grinder casing is pressurized and increased shower water temperature is used.
[0022] “Thermomechanical pulp” or “TMP” as used herein, refers to pulp that is produced in a thermo-mechanical process where wood chips or sawdust are softened by steam before entering a pressurized refiner. TMP generally has the same end-uses as stone groundwood pulp.
[0023] “Semi-chemical pulp” as used herein, refers to pulp produced by a combination of some chemicals (less than those used in Kraft pulping) and unpressurized mechanical processes. A variety of this pulp with pretreated chips at a temperature over 100° C. followed by refining at atmospheric pressure is called “semichemical mechanical pulp” or “SCMP”. This pulp has properties suitable for tissue manufacture.
[0024] “Chemo-Thermomechanical Pulp” or “CTMP” as used herein, refers to mechanical pulp produced by treating wood chips with chemicals (usually sodium sulfite) and steam before mechanical defiberization.
[0025] “Chemical pulp”, as used herein, refers to pulp produced by the treatment of wood chips or sawdust with chemicals to liberate the cellulose fibers by removing the binding agents such as lignin resins and gums. Sulphite and Sulphate or Kraft are two types of chemical pulping. Kraft is the predominant pulping process in chemical pulp production.
[0026] “Recycled pulp” or “recycled fibers” refers to fiber component of a paper or paperboard furnish that is derived from recycled paper and paperboard or wastepaper.
II. Methods for Controlling or Preventing Pitch and Stickies Deposition
[0027] Methods for preventing and/or controlling pitch and stickies deposition are described herein. In one embodiment, a water-soluble aminoplast ether copolymer is administered to control and/or prevent pitch and stickies deposition.
[0028] The water soluble aminoplast ether copolymers suitable for the methods described herein contain aminoplast segments interlinked through ether bond segments as represented by the following structure:
[0000]
[0000] where Z represents aminoplast central units that are condensation products of an aldehyde (e.g., formaldehyde) with one or more amine-containing monomers. Suitable amine-containing monomers include, but are not limited to, Glycoluril, Ureas, melamine, and benzoguanamine. The structures of these amine-containing monomers are shown below,
[0000]
[0029] The aminoplast central units can be unsubstituted or substituted by a reactive OR group where R is an alkyl, alkylene, alkyl ether or alkyl ester group.
[0030] “Alkyl”, as used herein, refers to the radical of saturated or unsaturated aliphatic groups, including straight-chain alkyl, alkenyl, or alkynyl groups, branched-chain alkyl, alkenyl, or alkynyl groups, cycloalkyl, cycloalkenyl, or cycloalkynyl (alicyclic) groups, alkyl substituted cycloalkyl, cycloalkenyl, or cycloalkynyl groups, and cycloalkyl substituted alkyl, alkenyl, or alkynyl groups. Unless otherwise indicated, a straight chain or branched chain alkyl has 30 or fewer carbon atoms in its backbone (e.g., C1-C30 for straight chain, C3-C30 for branched chain), preferably 20 or fewer, preferably 10 or fewer, more preferably 6 or fewer, most preferably 5 or fewer.
[0031] In a preferred embodiment, R is a lower alkyl group. “Lower alkyl”, as used herein, refers to a group having 1-4 carbons. In one embodiment, the lower alkyl group is a methyl or ethyl group.
[0032] B is a radical of a hydrophobic or a water-insoluble oligomer or polymer. “Hydrophobic”, as used herein, refers to oligomers or polymers which lack an affinity for water. “Water-insoluble”, as used herein, means an oligomer or polymer that is not soluble in water. Suitable hydrophobic oligomers and polymers include, but are not limited to, poly-n-butyl acrylate, poly-n-butyl methacrylate, polyethyl acrylate, polytetrahydrofuran, polyethyl methacrylate, polymethyl acrylate, polymethyl methacrylate, polymethyl acryalte, polymethyl methacrylate, aliphatic polycarbonates, aromatic polycarbonates, and combinations thereof. B typically contains one or more reactive functional groups which allow the oligomer or polymer to react with the OR group on the aminoplast unit.
[0033] R1 is a radical of a hydrophilic organic compound containing at least one functional group which is able to react with the OR function of the aminoplast unit to form an ether bond. “Hydrophilic”, as used herein, refers to a radical or moiety that has an affinity for water, “Water soluble”, as used herein, means the compound, oligomer, or polymer is soluble in water. Suitable hydrophilic moieties include, but are not limited to, methylcellulose, polyacrylic acid, polymethacrylic acid, ethylene/acrylic acid/sodium acrylate copolymer, polyalkylglycol, polyvinyl alcohol, and polyvinylpyrrolidone preferably having at least one hydroxyl function group.
[0034] The mole ratio of R1 to B is preferably greater than 1, most preferably in the range of 1.0 to 4.0. The index number “n” is from 1 to 2000, preferably from 1 to 1000, more preferably from about 2 about 500. The molecular weight of the polymer is generally from 1000 to 500,000, preferably from 1000 to 200,000, more preferably from 1,000 to 100,000, most preferably from 2,000-80,000
[0035] R1 has a molecular weight generally from 500 to 100,000, preferably from 1500 to 20,000. B has a molecular weight from 100 to 100,000, preferably from 300 to 80,000.
[0036] The mole ratio of B:Z is generally from 0.1:1.0 to 4.0:1.0, preferably from 0.3:1.0 to 3.0:1. The mole ratio of R1:13 is from 1:0.25 to 1:5.
[0037] The aminoplast ether copolymers can be manufactured as described in U.S. Pat. Nos. 5,914,373 and 5,627,232 to Glancy and U.S. Patent Application Publication No. 2004/010285 to Steinmetz.
[0038] A. Additives
[0039] The aminoplast copolymers described herein can be administered alone or with one or more additives. The additives can be co-administered with the aminoplast copolymers or can be added prior to, or after, addition of the aminoplast copolymers. The additives can be added at the same point in the pulping and/or papermaking process as the aminoplast copolymers or at different points in the pulping and/or paper making processes.
[0040] 1. Enzymes
[0041] The water soluble aminoplast copolymers described herein can be added to the pulp and papermaking process either alone or in combination with enzymes such as lipases, esterases, and oxidative enzymes. Enzymes have been used to control both pitch and stickies in the pulping and paper making process. Different enzymes such as hydrolases, redoxidases and lysases are known to modify different components in pitch or stickies particles, and therefore provide benefits on pitch and stickies deposition in the pulping and papermaking process. Suitable enzymes include, but are not limited to, hydrolyzing enzymes, such as cellualses, amylases, hemicellulases and pectinases; oxidizing enzymes, such as fatty acid oxidases, glucose oxidases, alcohol oxidases, polyvinyl alcohol oxidases and polyphenol oxidase; esterases, such as lipase and cholesterases; and lyases, such as pectate lyases. Treatment of the stickies and pitch particles with both enzymes and hydrophobically modified aminoplast esters enhance the physiochemical modifications for better control through better removal, dispersion and pacification.
[0042] 2. Other Additives
[0043] The water soluble aminoplast copolymers described herein can be added to the pulp and papermaking process either alone or in combination with other chemical additives, which can be surfactants and/or polymers. Suitable surfactant dispersants include, but are not limited to, primary and branched alkoxylates, fatty acid alkoxylates, phosphate esters and their alkoxylates, alkylphenol alkoxylates, block copolymers of ethylene and propylene oxide, alkanesulfonates, olefinsulfonates, fatty amine alkoxylates, glyceride alkoxylates, glycerol ester alkoxylates, sorbitan ester alkoxylates, polyethylene glycol esters, polyalkylene glycols, polyacrylic acids, sodium polyacrylate, acrylic acid copolymer, acrylate copolymer, acrylic crosslinked copolymer, and their derivatives; maleic acid and acrylic acid or acrylate copolymer, maleic acid/olefin copolymer, and their derivatives; methy cellulose, ethyl cellulose and their derivatives; polyvinyl alcohol/polyvinyl acetate copolymers, polyvinyl pyrrolidone, and their derivatives, cationic polymers, and combinations thereof.
[0044] Suitable cationic polymer is selected from the group consisting of, but not limited to, epichlorohydrin/dimethylamine polymers (EPI-DMA) and cross-linked solutions thereof, polydiallyl dimethyl ammonium chloride (DADMAC), polyethylenimine (PEI), hydrophobically modified polyethylenimine, polyamines, resin amines, polyacrylamide, DADMAC/acrylamide copolymers, and ionene polymers.
[0045] M. Methods of Treatment
[0046] The methods described herein may be used with any pitch-containing pulp. Exemplary pulps include mechanical pulps, such as thermomechanical pulps and groundwood pulps; chemical pulps such as chemo-thermomechanical pulps and kraft pulps; and pulps produced from recycled paper.
[0047] The addition point for the polymer can be at any of one or more various locations during in the pulping and paper manufacturing processes. Suitable locations include, but are not limited to, latency chest, reject refiner chest, disk filter or Decker feed or accept, whitewater system, pulp stock storage chests (either low density (“LD”), medium consistency (MC), or high consistency (HC)), blend chest, machine chest, headbox, saveall chest, paper machine whitewater system, and combinations thereof.
[0048] The polymer is typically applied as a solution to the pulp stock. Suitable solvents include, but are not limited to, water, copolymers of propylene and ethylene glycol, polypropylene glycol, butyldiglycol, polyethylene glycol and 1,6-Hexanediol. The polymer treatment is effective at a temperature of between about 10° C. to about 95° C., more preferably from about 30° C. to about 75° C. The pH of the pulp stock is from about 3.0 to about 11.0, more preferably from about 4.0 to 7.5. The pH of the stock can be adjusted using a pH modifying agent, such alum or aluminates. The amount of the polymer added depends on several factors such as pH, temperature, presence of other pulp and papermaking additives, and/or the types and amount of pitch and stickies in the pulp. The dosage ranges from 0.005% to 1.0% based on O.D. The consistency of the pulp stock to be treated is typically between about 0.1% and about 35%, more preferably between about 0.5% and about 10%. The pulp can be treated for a period of time from about 0.1 to about 36 hours, more preferably from about 0.5 to about 12 hours.
[0049] The aminoplast ether copolymers can effectively reduce the deposition of pitch and stickies on various surfaces in the pulp and paper making processes, which include metal, plastic, and ceramic surfaces such as pipe walls, chest walls, machine wires, felts, foils, uhle boxes, and any equipment surfaces that contact with fibers. Reducing pitch and stickies deposition reduces downstream equipment fouling increasing papermaking efficiency and paper quality.
EXAMPLES
[0050] The polymers used in the following examples are summarized in Table 1
[0000]
TABLE 1
Polymers Used in Examples
Name
Main components
Company
Cevol 540
Polyvinyl alcohol-co-vinyl acetate
Celanese Corporation,
with 87~89% hydrolysis
Dallas, TX
EDT-X1
Ethoxylated aminoplast copolymer
Enzymatic Deinking
MW: 5,000~15,000
Technologies, LLC
EDT-X2
Ethoxylated aminoplast copolymer
Enzymatic Deinking
MW: 35,000~45,000
Technologies, LLC
EDT-X3
Ethoxylated aminoplast copolymer
Enzymatic Deinking
MW: 55,000~65,000
Technologies, LLC
Example 1
Deposition Test of Sulfite Pulp and Deinked Pulp Mixture from Mill A
[0051] The standard mixing test procedure is used to evaluate the impact of chemicals on deposition tendency on mixing bowls and paddles. A KitchenAid® stand mixer with coated flat paddles, such as the Commercial 5 series from KitchenAid®, was used. The stainless steel mixing bowls were used to hold fiber stocks at consistencies from about 3% to about 20%, preferably from about 8% to 10%. The mixing temperature was controlled with a water jacket at 55° C. The pulp stocks were mixed at speeds between “1” and “4”, preferably “2”. The stocks were mixed for a period of time ranging from about 5 minutes to about 2 hours, preferably from about 20 minutes to about 1.5 hours.
[0052] Representative stock samples consisted of sulfite pulp stock with a consistency of about 12%. 100 g of oven-dried (OD) fiber was used for each test. Hot water (˜55° C.) was used to obtain a pulp consistency of about 11% and a desired amount of each chemical was added into the stocks just before mixing. The pH of the pulp stocks was around 8. If the stock pH needed to be adjusted, 1 M HCl and 1 M NaOH solutions were used. The stock was mixed at 55° C. for 45 min after which the mixer paddles were observed and the amount of deposit on paddles and bowls was recorded. The total pitch and stickies deposit on the paddles and mixing bowls was rated visually as a percentage with the non-treated paddle being 100%.
[0053] Table 2 shows the relative deposit for sulfite pulp treated with different chemicals. The results indicate that the aminoplast ether compositions, EDT-X1, EDT-X2 and EDT-X3, provided much better reduction on paddle deposition than the polyvinyl alcohol-co-vinyl acetate, a commercially available product used for stickies control. The aminoplast ether copolymers almost completely eliminated pitch deposit on the mixing bowls at the two dosages tested (0.8 lbs/ton and 1.20 lbs/ton), except EDT-X3 at 0.80 lbs/ton which exhibited 10% bowl deposition. However, this was still a substantial reduction compared to Cevol 540.
[0000]
TABLE 2
Standard Mixing Test Results
Test
Relative Paddle
Relative Bowl
Number
Chemicals
Dosage
Deposition %
Deposition %
1
Control
No Chemicals
100
40
2
Cevol 540
0.80 #/ton
80
35
3
Cevol 540
1.20 #/ton
35
25
4
EDT-X1
0.80 #/ton
75
0
5
EDT-X1
1.20 #/ton
12
0
6
EDT-X2
0.80 #/ton
15
0
7
EDT-X2
1.20 #/ton
4
0
8
EDT-X3
0.80 #/ton
10
10
9
EDT-X3
1.20 #/ton
7
0
Example 2
Deposition Test of Sulfite Pulp from Mill a at Different pH Conditions
[0054] The standard mixing test procedure was used in this example. The pH was adjusted using 1 M HCl or 1 M NaOH before the chemical addition. The dosage for all the chemicals was 1.20 lbs/ton. The results are shown in Table 3. The control showed deposit on both paddles from pH4.0 to 8.5. The mixing bowl also showed deposits at about pH 7.9. For Cevol 540, the paddle deposit ranged from 35-80% at all pH values tested, and bowl deposits were around 25% at pH 7.71 and pH 8.57. However, in the presence of EDT-X2 at 1.20 lbs/ton, the paddle deposits were significantly reduced and ranged from 5 to 10% compared to the control paddle. Bowl deposits were completely eliminated at all pH values tested. This further confirmed that the use of aminoplast ether copolymers is more effective in reducing deposition of sulfite organic contaminants compared to polyvinyl alcohol.
[0000]
TABLE 3
Standard Mixing Test Results at Different pH Conditions
Test
Relative Paddle
Relative Bowl
Number
Conditions
pH
Deposition %
Deposition %
1
Control
4.03
63
0
2
Control
5.80
81
0
3
Control
6.58
90
0
4
Control
7.93
100
40
5
Control
8.50
100
5
6
Cevol 540
4.81
5
0
7
Cevol 540
6.67
70
0
8
Cevol 540
7.71
35
25
9
Cevol 540
8.57
85
25
10
EDT-X2
5.09
7
0
11
EDT-X2
6.69
5
0
12
EDT-X2
7.87
7
0
13
EDT-X2
8.47
10
0
Example 3
Deposition Test of 100% Recycled Wastepaper from Tissue Mill B
[0055] Mill B uses coated book stock (CBS) and sorted office paper (SOP) wastepaper to produce tissue. Pulp from the washer accept having a consistency of about 12% was collected in the mill. Two pulp batch samples were collected at two different times. The standard mixing test procedure was used in this example with the water jacket temperature maintained at 55° C. and mixing times of 45 mins. 100 g oven dried fibers were used for each mixing test. The amount of stickies deposits on the paddles and mixing bowls for the control were rated visually as 100%, and other testing paddles and bowls were rated comparatively.
[0000]
TABLE 4
Standard Mixing Test Result for CBS/SOP Stocks
Test
Relative Paddle
Relative Bowl
Number
Conditions
Dosage
Deposition %
Deposition %
1
Control
No Chemicals
100
0
2
Celvol 540
0.80
#/ton
95
0
3
EDT-X2
0.80
#/ton
20
0
4
EDT-X3
0.80
#/ton
30
0
5
EDT-X1
0.80
#/ton
75
0
6
Control
No Chemical
100
0
7
Cevol 540
1.0
#/ton
45
0
8
EDT-X2
1.0
#/ton
2
0
9
EDT-X1
1.0
#/ton
6
0
Note:
Test Number 1-5 used Pulp Batch 1. Test Number 6-9 used Pulp Batch 2.
[0056] As shown in Table 4, the aminoplast ether copolymers showed superior deposition reduction compared to Cevol 540 for both pulp batches at different dosages. For pulp batch 2 at 1.0 lb/ton, EDT-X1 and X2, reduced the paddle deposit to as low as 2˜6% compared with 45% paddle deposit with Cevol 540.
Example 4
Deposition Test of MOW Pulp from Mill C
[0057] Wastepaper consisting of sorted office pack and sorted white ledger from Mill C was collected for standard mixing tests. The organic contaminants were predominantly stickies. The wastepaper was pulped for 20 min using a batch pulper at pH 7.5 and a consistency of 12%. The whitewater had 400 ppm calcium carbonate hardness. After pulping, the stock was diluted with whitewater to 5% and allowed to soak for 30 minutes. After soaking, the stock was diluted further to 1% with whitewater and thickened to about 12% with a cloth filter bag to remove ash. 100 g oven dried fibers of the 12% prepared stock stated above was used for each mixing test. The bowl with stock was heated to a temperature of 55° C. using a water jacket. Chemical was added to the mixing bowl, and the stock was mixed for 45 minutes. The amount of pitch and stickies deposit on the paddles and mixing bowls for the control were rated visually as 100%, and other testing paddles and bowls were rated comparatively.
[0000]
TABLE 5
Standard Mixing Test Result for MOW Stocks
Test
Relative Paddle
Number
Conditions
Dosage
Deposition %
1
Control
No Chemicals
100
2
Cevol 540
0.40 #/ton
75
3
EDT-X1
0.40 #/ton
6
4
EDT-X2
0.40 #/ton
5
5
EDT-X3
0.40 #/ton
23
6
Cevol 540
0.80 #/ton
33
7
EDT-X1
0.80 #/ton
14
8
EDT-X2
0.80 #/ton
4
9
EDT-X3
0.80 #/ton
4
[0058] As shown in Table 5, the water soluble aminoplast ether copolymers, EDT-X1, EDT-X2 and EDT-X3, showed much higher reduction in paddle deposits than Celvol 540. At 0.40 lbs/ton, Cevol 540 had paddle deposits of 100% and 40%, while most of the EDT-X products had deposit less than 20%. At 0.80 lbs/ton, Cevol 540 had paddle deposits of 45% and 20%. However, most of the EDT-X products had deposits less than 10%. In some tests, the paddle deposits were nearly eliminated. | Method for controlling the deposition of organic contaminants from the pulp and papermaking systems using water soluble aminoplast ether copolymers is described herein. The aminoplast ether copolymer can be used alone or in combination with one or more additives. The pulps to be treated include mechanical, chemical, semi-chemical pulps; sulfide pulp; recycled old newspapers; mixed office wastes; corrugated boxes; and their combinations. The use of water soluble aminoplast ether copolymers to control or prevent pitch and stickies deposition improves down stream performance of papermaking equipment increasing mill efficiency and improving paper quality. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This patent application claims priority to U.S. Provisional Application No. 61/369,379, which was filed on Jul. 30, 2010. The content of U.S. Provisional Application No. 61/369,379 is hereby incorporated by reference into this patent application as if set forth herein in full.
TECHNICAL FIELD
This patent application relates to managing facilities.
BACKGROUND
Companies often conduct business at many locations. This is particularly true of retailers, which can have stores located throughout the country. At different stores, problems can arise that require attention, such as servicing or repair. For example, an air conditioning system at a store in Boston may be in need of repair, or outdoor lighting at a location in San Diego may need to be replaced. Oftentimes, coordination of such service and repair is left in the hands of a local store manager. This can lead to problems. For example, there may be disparity in terms of how service and repair is handled, leading to an experience that is not consistent among stores. For many companies, this is undesirable. This is especially true for retailers and, in particular for chain stores, which try to make the shopping experience at their many locations as consistent as possible.
SUMMARY
This patent application describes methods and apparatus, including computer program products, for managing facilities.
Among other things, this patent application describes a system that performs operations which may comprise: maintaining a database comprising information relating to facilities that are subject to a first entity, where the facilities are dispersed geographically, and the information comprises geographic locations for at least some of the facilities; receiving a first message from a facility for which information is in the database, where the first message identifies a fixture of the facility that requires attention, and where information in the database for the facility identifies the fixture by at least one of a designation of the fixture and a characteristic of the fixture; sending a second message to a second entity that has contracted with the first entity to provide service within a geographic location of the facility; and enabling the second entity to access the database to identify the fixture. Any features described in this patent application may be incorporated into the foregoing system, examples of which are as follows.
The foregoing system may also comprise hosting a portal configured to enable messaging to one or more servers configured to implement the system. The first message may be received through the portal. The portal may be a Web page.
The foregoing system may also comprise hosting a portal configured to enable the second entity to access the database; and receiving a communication from the second entity, where the communication is for accessing the database to identify the fixture. The portal may be a Web page comprising a security feature to restrict access to the database.
The information in the database for the facility may identify the fixture by both a designation of the fixture and a characteristic of the fixture. The designation may comprise a part number and the characteristic may comprises a functionality associated with the fixture. The database may comprise information relating to entities that have contracted with the first entity to provide services for the facilities. The system may also comprise generating a report based on the information relating to the entities, where the report organizes the information relating to the entities; and providing the report to the first entity. The information relating to the entities may comprise at least one of responsiveness of the entities, costs of the entities, and capabilities of the entities.
The foregoing system may also comprise sending a third message to the second entity. The third message may be for confirming that the second entity provided the necessary attention to the fixture. Prior to receiving the first message, a reminder may be sent to the facility regarding an upcoming event associated with the fixture.
All or part of the systems and processes described herein may be implemented as a computer program product that includes instructions that are stored on one or more non-transitory machine-readable storage media and that are executable on one or more processing devices. Examples of non-transitory machine-readable storage media include e.g., read-only memory, an optical disk drive, memory disk drive, random access memory, and the like. All or part of the systems and processes described herein may be implemented as an apparatus, method, or electronic system that may include one or more processing devices and memory to store executable instructions to implement the stated functions.
Any two or more of the features described herein may be combined to form implementations not specifically described in this patent application.
The details of one or more examples are set forth in the accompanying drawings and the description below. Further features, aspects, and advantages will become apparent from the description, the drawings, and the claims.
DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 4 shows a facilities management process conceptually.
FIG. 5 shows a system on which the facilities management process of FIGS. 1 to 4 may be implemented.
FIG. 6 is a flowchart showing actions that may be performed in the facilities management process depicted in FIGS. 1 to 4 .
FIGS. 7 to 17 are examples of user interfaces that may be part of the facilities management process depicted in FIGS. 1 to 4 and 6 .
Like reference numerals in different figures indicate like elements.
DETAILED DESCRIPTION
Described herein is a system for managing facilities. A feature of the system includes a distinct fixture placed on a floorplan model of each location that is modeled by the system. Some implementations show this as a prominent fixture in the upper right or lower left of a floorplan display area, and typically label it a “General Maintenance” fixture. It is also possible to use different fixture types for different location types, or even to have more than facilities-related fixture on each floorplan.
Another feature of the system includes an administrator setup feature that allows multiple issues types to be related to each facilities-related fixture type. For each issue type, it is also possible to relate a specific user or user distribution list that should be notified when an issue of a particular type is reported. An advanced feature also permits each user distribution list to be further associated with a “location filter”, so that it is possible to localize who will be notified when an issue is reported. For example, a certain user distribution list could be used for locations in one geographical or organization category (e.g. when the location's state is “Illinois”, or the location's zip code is 12345 or the location is in Midwest region), while other user distribution lists may be used for other geographical or organizational categories.
Another feature of the system includes an issue/problem reporting and resolution process that allows store personnel to report an issue/problem and then have parties that receive the notifications escalate the issue for approval and/or resolve the issue.
Another feature of the system includes a set of issue tracking and resolution reports that allows company personnel to understand and measure compliance, coverage, and response times for each issue type. These facilities-manager-related reports are available on a reports tab and are generally restricted to administrative level personnel, although it is possible to allow other classes of personnel to see these reports.
The system described herein for managing facilities may be centralized in order to maintain relatively consistent management of facilities across different locations. FIGS. 1 to 4 depict the facilities management process conceptually. In this example, a central authority 10 maintains a database 11 . Database 11 includes information about fixtures at facilities 12 to 15 . These fixtures may include anything that requires attention (e.g., servicing, repair, replacement), including, but not limited to, windows, lighting, HVAC (heating, ventilating and air conditioning) systems, alarms, surveillance systems, parking lots, and roofs. The database may correlate the facilities to their fixtures, so that each fixture is associated with a facility.
Referring to FIG. 1 , central authority 10 hosts a portal 16 , e.g., a Web page, which allows a facility (e.g., facility 15 ) to advise the central authority that there is an issue (e.g., a problem) with a fixture at the facility or to enable the central authority to send a reminder to the facility about an upcoming event (e.g., a warranty expiration or scheduled maintenance of a fixture at the facility). A user at the facility may identify the fixture through the Web page, along with information about the issue. The Web page provides the information to central authority 10 . Referring to FIG. 2 , in response to the information, central authority 10 may send a message 19 to an agent 20 with which the company that owns the facility has previously contracted. The message identifies the facility and the fixture that is in need of attention. Referring to FIG. 3 , agent 20 may access database 11 to obtain information (e.g., a part number) about the fixture that is in need of attention. Referring to FIG. 4 , agent 20 may then perform whatever actions are necessary to attend to (e.g., service, repair, replace) the fixture or a part thereof that needs attention.
FIG. 5 shows a system 25 , on which the process depicted conceptually in FIGS. 1 to 4 may be implemented. System 25 includes computers 27 to 29 at corresponding facilities 30 to 32 , a network 34 , a server 35 at central authority 37 , and network connections to various agents 40 to 42 with which companies that own the facilities have established contracts or that are otherwise available to attend to issues at the facilities. Each agent may also include one or more computers, as shown in FIG. 5 .
Network 34 may include one or more networks, such as a local area network, a wide area network, and/or the Internet. One or more of the networks in network 34 may be wireless, such as a cellular telephone network and a Wi-Fi network.
As shown in FIG. 5 , server 35 may include one computing device 44 or multiple computing devices 44 to 46 that are at a same location or at different locations (devices 45 and 46 are depicted using dashed lines since more than one device need not be used). Each of devices 44 to 46 may have the same, or similar, hardware and/or software configuration. In an implementation, devices 44 to 46 act together to perform various functions described herein. In other implementations, a single device may perform all of the server functions. In the case of multiple devices, device 44 may act as a controller or “load balancer” for the remaining devices 45 and 46 . In this role, device 44 may route data, requests, and instructions between a client (e.g., computer(s) at facilities and/or computer(s) at agent(s)) and a “slave” device, such as device 46 . Device 44 may store information locally, then route data to another device, such as device 46 . For the purposes of the following, such internal communications between device 44 and slave devices will be assumed.
Server 35 includes a processing device 47 , memory 49 , and a network interface 50 . A bus system 51 , including, for example, a data bus and a motherboard, can be used to establish and control data communication between various components of server 35 .
Generally speaking, processing device 47 may include any appropriate processor and/or logic that is capable of receiving storing and processing data, and of communicating over network 34 . For example, processing device 47 may include one or more microprocessors. Memory 49 can include a hard drive and a random access memory (RAM) storage device, such as a dynamic random access memory (DRAM), or other type(s) of machine-readable medium memory devices.
As shown in FIG. 5 , memory 49 stores computer programs 52 that are executable by processing device 47 . Among these computer programs is a Web hosting program 54 . Web hosting program 54 is executable to host a Web site that is accessible over network 34 . The Web site may include a portal, through which users accessing the Web site can provide information to central authority 37 . The information may include, e.g., the identity and location of a facility and the condition of one or more fixtures at the facility, as described below. The information entered into the portal constitutes a message to the central facility that a fixture or fixtures requires attention.
Server 35 also maintains a database 55 . Database 55 may store, among other things, information about facilities, such as facilities 30 to 32 . The information may include, but is not limited, to a geographic location of each facility, including its zip code, area code, street address, town/city, state/province, country, continent, time zone, and telephone number. The information may also include information identifying fixture(s) at each facility. A fixture may be anything at the facility, including those items that require attention, e.g., servicing, repair, and/or replacement. As noted above, fixtures may include, but are not limited to, windows, lighting, HVAC systems, alarms, surveillance systems, parking lots, and roofs. Also stored in database 55 is information about each fixture in the database. This information may include, but is not limited to, part number(s) for a fixture, a manufacturer of the fixture, a size of the fixture, a capacity of the fixture (e.g., volts, watts, volume), an origin of the fixture, a type of the fixture, a date that the fixture was manufactured, a location of the fixture at its facility, a cost of the fixture, acceptable alternatives to the fixture, and a color of the fixture. This list is not exhaustive, and the database may store any information that, e.g., describes or relates to each fixture in the database. The same types of information may, or may not, be stored for each fixture.
Database 55 may store information for different entities (e.g., companies) and their corresponding facilities. For example, the database may store information for Wal-Mart® and for its stores worldwide. The information that is stored may be the same for each company and for each facility owned by that company, or it may be different for each company and for each facility owned by that company. In an implementation, a company may specify which information is to be stored for that company and its facilities. In an alternative implementation, each facility may specify which information is to be stored for that facility.
Information may be input to database 55 via a Web site hosted by server 35 . For example, an employee at a facility may survey the facility and input the relevant information into the database via the Web site. Alternatively, each facility may be surveyed by a specialist and the fixture information input to the database by the specialist. The specialist may be an employee of a proprietor of the database.
Database 55 associates fixtures and their information to corresponding facilities. For example, database 55 may store information for retail locations owned by a company. We present the following example with a fictitious company called ABC Corporation. ABC Corporation may have retail locations (e.g., facilities) in Boston, New York, Los Angeles and London, UK. Database 55 may store information for each retail location of ABC Corporation, and associate that information to ABC Corporation. Database 55 may also store, in association with each facility (and ABC Corporation) the identities of one or more agents that have been contracted to attend to fixtures at each facility. For example, ABC Corporation may have service contracts with agent(s) nearby each facility, which are capable of servicing, repairing and/or replacing fixture(s) at the facility. There may be a separate agent per fixture or the same agent may attend to two or more fixtures. The information for each agent may include the location of the agent, contact information for the agent, such as an electronic mail (e-mail) address, a telephone number of the agent, a street address of the agent, contact personnel at the agent, a zip code of the agent, and any other information that the agent wishes to provide.
In the fictitious example provided above, ABC Corporation may have contracted with agents to service, repair, replace, etc. fixtures at the various retail locations. The contracts may be based on the geographic location of each agent and each retail location. For example, an HVAC service in the Boston area may be contracted to service the HVAC system in the Boston location; a roofer in the New York area may be contracted to service the roof in the New York location, and so on. The same may be true for other fixtures of the various locations. In this regard, not all services may be required for all locations. For example, ABC Corporation may contract with a snow removal company in Boston to remove snow from the parking lot of its Boston location. However, this service will not typically be needed in the Los Angeles location and, therefore, there will be no corresponding contract. Database 55 may store, in association with each facility, identifying information each agent contracted for that facility, as noted above.
In addition, database 55 may store identities of one or more back-up agents for each facility. A back-up agent may be a secondary agent in the event that a primary agent for a particular fixture is unavailable. Contact information for one or more back-up agents for one or more fixtures may also be stored in association with an appropriate facility, along with conditions under with the back-up agent(s) are to be contacted.
Server 35 may track the performance of the agents for various facilities. For example, after an agent performs a service on a facility, the central authority may query the agent and/or the facility to confirm that the service was performed, how long it took, when it was performed, the quality of the service, etc. Server 35 may store this information in database 55 in association with each agent. This information may form the basis of report(s) that may be generated by server 35 to provide the company contracting with the agent(s) (or other(s)) information about their performance. The report(s) may be sent to computer(s) at the companies, where they may be displayed and viewed.
Database 55 may store information like that described above for numerous companies. Information for each company, such as that described above, may be updated, via a Web site hosted by server 35 , by authorized representatives of each company, by authorized representatives of each facility, and/or by the central authority. The information for each company and its facilities may be only accessible to authorized personnel. Information for one company is not generally accessible to other companies.
Referring back to FIG. 5 , each facility and agent may include one or more computers at their locations for communicating with server 35 over network 34 . Additional hardware and/or software may be provided at each location. For example, instead of using a Web site to update database 55 , computers at the various facilities may include a desktop application, which may be provided by the central authority for communication therewith. The desktop application may be configured to communicate with database 55 over network 34 , and to update its contents as described herein.
FIG. 6 is a flowchart showing a process 60 . Process 60 may be performed, at least in part, by software running on server 35 to manage facilities in the system of FIG. 5 . In FIG. 6 , process 60 is split into a left part 61 , which is performed on server 35 ; a middle part 62 , which is performed on a computer at a facility (e.g., facility 30 ); and a right part 63 , which is performed on a computer at an agent (e.g., agent 42 ). It is noted, however, that the actions shown in FIG. 6 may be assigned differently. For example, in other implementations, actions performed by server 35 may be performed at the facilities and/or agents, and actions performed at the facilities and/or agents may be performed at the server.
As shown in FIG. 6 , central authority 37 maintains ( 65 ) database 55 via server 35 . Database 55 may be constructed based on survey(s) of companies and their facilities and/or based on input provided electronically, e.g., via a Web site. Database 55 may likewise be updated ( 66 , 67 ) as changes are made to its subjects. As noted, database updates may be obtained by surveying a facility and/or by receipt of updates provided electronically by the facility, its company, and/or associated agent(s).
Process 60 receives ( 68 ) a message from facility 30 ( 69 ). The message identifies the facility, e.g., by geography, company name, or any other information. In this implementation, the message is sent via a Web site hosted by server 35 . That is, a user at facility 30 signs onto the Web site, and enters information relating to a fixture of the facility that requires attention. In alternative implementation, an electronic monitoring system may be employed to automatically identify fixtures that require attention. In such an implementation, the electronic monitoring system may communicate an appropriate message to server 35 automatically over network 34 .
In response to receipt of the message from facility 30 , process 60 consults ( 70 ) database 55 using information from the message. In this example, process 60 identifies a facility and fixture(s) that require attention from information in the message. Process 60 uses this information to look-up, in database 55 , an agent that is contracted to service (or otherwise attend to) the fixture at the facility. In an example, process 60 uses the geographic location of the facility and the identity of the fixture to look-up the appropriate agent in database 55 . Process 60 then sends ( 71 ) a message to agent 42 . The message identifies the fixture and the facility that require attention. The message may also include other information, such as a suggested timetable for service. The message may be sent electronically (e.g., via e-mail) or via a post on a portal maintained by the agent for the company/facility whose fixtures are managed by the central authority. In an implementation, the message may be relayed, e.g., by phone, from an employee of the central authority to an employee at the agent.
Agent 42 receives ( 72 ) the message from process 60 . If agent 42 is unable to perform the required service, or to do it within a time specified in the message or elsewhere, the agent may notify process 60 . In that case, process 60 may consult the database for a secondary agent that is contracted to perform the service.
Assuming that agent 42 is able to perform the requested service, agent 42 proceeds with the service request. To this end, agent 42 identifies information about the facility and fixture(s) that require service by consulting database 55 . That is, the agent may have access to database 55 , e.g., through a secure Web site hosted by server 35 . The agent may use the information provided in the message to obtain information about the facility and fixture(s). For example, agent 42 may log onto a Web site hosted by server 35 and, in conjunction with software stored on server 35 , look-up ( 73 ) information relating to the facility and fixture(s) that is stored in the database. Agent 42 may obtain, from the database, information about the fixture including, e.g., one or more designations of the fixture (e.g., its part number, model number, manufacturer) and/or one or more characteristics of the fixture (e.g., its wattage, size, shape, color). For example, if an HVAC system in a facility in Boston requires repair, the agent contracted to service HVACs in Boston may identify the facility and the fixture that needs attention based on the message from the central authority. The agent may then look-up, in the database, the type, manufacturer, and identities of parts that make-up the HVAC system at the facility in Boston. By doing so, the agent is able to prepare itself to perform the service. For example, the agent can ensure that it has the correct parts, tools, and personnel to complete the service. In another example, if outdoor lighting at a facility in Los Angeles goes out, an agent contracted to service lighting at that facility in Los Angeles may consult the database to identify the type, wattage and, e.g., preferred manufacturer lighting for that facility.
Agent 42 services ( 74 ) the fixture based on the information obtained from the database. Thereafter, the agent 42 may confirm to process 60 that the service has been completed. Alternatively, the agent may respond to a query ( 75 ) issued by process 60 requesting confirmation that the service has been completed. In its response ( 76 ), if required, the agent may include other information, such as when the service was completed, the cost of the service, the amount of time it took to complete the service, etc. In another alternative, the query ( 75 ) may be sent to the facility at which service was performed instead of, or in addition to, the agent that performed the service. The facility may respond ( 77 ) to the query with information relating to the service performed by the agent. The facility may provide information similar to that provided by the agent, along with an indication of whether the agent performed the work satisfactorily. Database 55 may be updated ( 78 ) with information from agent 42 and/or facility 30 relating to the service that was performed by agent 42 . The information may be associated with the agent, since it relates to the agent's performance. The information may also be stored on a per-service basis. That is, the database may include a record of each service, and associate that record to a facility, fixture, company, and/or agent that performed the service.
The operations performed at the central authority may be automatic, e.g., performed without the intervention of, or interaction with, a person. Alternatively, portion(s) of the operations performed at the central authority may be interactive.
A facility or company that owns the facility may request a report for a particular agent, facility or service. Process 60 may respond by consulting database 55 , retrieving the appropriate information from database 55 , formatting a report (or reports), and providing ( 79 ) the report for display, e.g., on a computer display peripheral, such as a liquid crystal display (LCD) screen. Reports such as these may be useful, e.g., to monitor the performance and cost of contracted agents, and to compare the performance and costs of various agents. Alternatively, statistical data relating, e.g., to cost, service time, responsiveness, and the like may be generated for various agents and made available by process 60 to companies considering employing those agents.
FIGS. 7 to 17 show examples of user interfaces (UIs) that may be generated by one or more computer programs (comprised of executable instructions) running on server 35 to implement at least part of process 60 . These UIs may be accessible over network 34 . For example, these UIs may be Web pages that are part of a Web site that is hosted by server 35 and that is accessible to company/facility personnel to perform various functions, including alerting the central authority about issues (e.g., problems) at a facility that require attention. These UIs may also be accessible to personnel at a central authority to perform facilities management, as described herein.
FIG. 7 shows a UI 80 that depicts staging 81 at a facility (e.g., facility 30 ). The UI of FIG. 7 may be accessible, e.g., to personnel at the central authority to view a facility. In this context, staging may include the layout or floor plan of fixtures at a facility. For example, FIG. 7 shows a floor plan 82 of a facility, which may be consulted to perform general maintenance on the facility. In this example, floor plan 82 shows the actual arrangement and locations of fixtures in a facility. These fixtures may include features such as display cases, furniture, and built-in or portable electronics. These fixtures may also include features, such as HVAC system equipment, lighting fixtures, and other systems that may require attention (e.g., service/maintenance/repair).
UI 80 includes options 83 to view different campaigns (e.g., advertising campaigns, for which fixtures are defined), individual fixtures, contents of a facility, comments by facility or central authority personnel, references, surveys of fixtures in a facility that may require attention, reports on a facility, and announcements, e.g., by the central authority. UI 80 also includes options 84 to edit the location of a subject facility; to identify issues associated with that facility (e.g., fixtures that require attention); to delete a current location of the facility; to edit floor plan 82 , e.g., to change the layout of the floor plan; to view an image gallery showing, e.g., other floor plans or fixtures of those floor plans; to edit an album of floor plans; to view all content relating to the floor plan; to view orders relating to the floor plan, e.g., orders to service a fixture at the subject facility; and to return to a list of facilities. UI 80 includes a pull-down menu 85 to view the subject floor plan or others, and tabs 86 for introductions and new items. UI 80 also information relating to general maintenance to display maintenance issues for a fixture in the subject facility layout.
To report an issue/problem, one can just click on the “General Maintenance” tab 87 of FIG. 7 , and the fixture will expand with additional text and a “Report Problem” button as shown in FIG. 8 , which is described below.
FIG. 8 shows a UI 90 that is generated to view information about elements in the floorplan of FIG. 7 . Selecting may be made through pointing and clicking via a mouse. Selecting the appropriate option causes display of general maintenance information 87 for a selected fixture of floor plan 82 . More specifically, window 91 is generated. Window 91 is partitioned into two parts. A first part 91 a includes an amplified (“zoomed”) version of the original floor plan, with the general maintenance option 87 shown. A second part includes a window 91 b and a scroll bar 92 . Window 91 b includes icons 93 corresponding to fixtures in floor plan 82 . Selecting an icon causes display of an image 94 of the fixture that is represented by the selected icon, along with a summary 92 of information relating to the fixture. The UI may include information 95 identifying the fixture, information 96 on any issues with the fixture that require attention, and an option 97 to report a problem with the fixture that requires attention. Comments on the fixture, other than problem reports, may also be provided via window 98 . Selecting option 99 brings a user back to the floor plan view shown in FIG. 7 .
When one clicks on the “Report Problem” button 97 of FIG. 8 , a list of potential issue/problems that can be reported on appears, as shown in FIG. 9 . Note that to report an issue/problem, one selects one of the issue/problem categories, and then completes the additional information at the bottom of the form. Some of this data at bottom of the form, such as name and email, may be auto-filled from a user's login information.
More specifically, in an implementation, selecting option 97 to report a problem causes UI 100 ( FIG. 9 ) to be displayed. UI 100 includes a customized (e.g., facility-specific) list 101 of fixtures in the facility including those in the floor plan shown in FIG. 7 . In this regard, a facility may have more than one floor plan, with a different floor plan for each area of a room, room, building, etc. of the facility.
UI 100 includes radio buttons 102 next to corresponding fixtures in the facility. The fixtures listed are specific to the particular facility. In this implementation, associated with each fixture is a corresponding problem. Consequently, list 101 may include the same fixture multiple times—one for each potential problem. In this example, HVAC 103 is listed three times—once for the “no air conditioning” problem, once for the “no heat” problem, and once for the “water leak” problem. Other problems, which are not shown here, may also be included. Furthermore, fixtures may be listed without associated problems. Those problems may be added in the message field 104 . Regardless of whether a selected fixture includes an associated problem, message field 104 provides a user with the opportunity to elaborate on a problem with a selected fixture and/or to provide additional identifying information for the fixture. Any information that one desires to communicate to the central authority may be included in message field 104 .
UI 100 also includes fields 105 for identifying the name of a person or facility that is providing input to UI 100 , a contact e-mail address, and a phone number. UI 100 also includes an option 106 to attach an electronic image of the fixture (or any other image). Upon selecting option 107 , UI 100 generates an electronic message to central authority 37 based on the input provided, and sends that message over network 34 . As explained above, process 60 running on server 35 at central authority uses the information provided, including, e.g., an identity of the facility and its location (which may be specified or inferred from, e.g., the phone number, name or address) to look-up, in database 55 , an agent that can attend to the issue identified for the fixture, and to arrange for service with that agent. This process may be performed automatically, e.g., without further human interaction by personnel at the facility or at the central authority. In other implementations, confirmation from appropriate personnel at the facility and/or central authority may be requested and received. UI 100 also provides an option 107 to report another problem, and options 109 to print out the information provided and to close UI 100 .
FIG. 10 is an example of a UI 110 that includes a report 111 that is generated from information retrieved from database 55 . In this example, report 111 includes reports for the facility relating to compliance with requirements (e.g., of an advertising campaign, of scheduled maintenance, etc.), issues at the facility, fixture counts, content counts, content counts by planogram (e.g., a predefined fixture arrangement), locations list, changes, requests, and questionnaire reports. Report 111 also includes options 112 for viewing, downloading, and e-mailing report(s) to a specified e-mail address.
FIG. 11 is an example of a UI 114 that includes options 115 for selecting reports based on selections in a list, based on a type of merchandising, and issues in need of attention. UI 114 also allows a user to include issues that remain unresolved 116 and enables report(s) on issues to be sorted by comment 117 .
FIG. 12 is an example of a UI 120 that enables access to reports generated from information in database 55 . In this example, UI 120 includes a list of the fixtures 121 , along with a report summary section 122 . The report summary section 122 allows a user to obtain information about a particular issue, fixture or facility. In this example, report summary section 122 identifies, for a particular fixture, an issue 123 (e.g., a problem with a fixture), a service status 124 (e.g., “In Progress”), and a type 125 , including an identity of the fixture and/or its location. A hyperlink 126 provides access to one or more pages containing detailed information in the report, such as the agent who is performing the service, or the like. A hyperlink 127 provides access to one or more pages describing the fixture, and a hyperlink 129 provides access to one or more pages describing fixtures and other information at a specific location (in this case, the location of the facility containing the fixture that requires service).
FIG. 13 is an example of a UI 130 containing a detailed report for a fixture listed in the report summary section 122 of FIG. 12 . After an issue has been reported, there will be a flashing yellow dot placed on the fixture to indicate that the “General Maintenance” fixture has at least one unresolved. An appropriately privilege user may remove the yellow dot and mark the issue/problem as resolved by clicking on the update issue status link 135 shown at the bottom of FIG. 12 .
More specifically, FIG. 12 shows an identifier (ID) 131 of 30020 for a fixture/issue in report summary section 122 . FIG. 13 shows a detailed report for ID 30020 that is generated in response to selecting hyperlink 126 . The report contains the information shown there, along with a hyperlink 132 to one or more pages containing information about the facility and an option 134 to e-mail a person who identified the issue. UI 130 also contains a hyperlink 135 to one or more pages for updating the status of an issue associated with ID 30020. For example, an agent performing service, a manager at the central authority, and/or an authorized person at the facility or parent company may update the status. The central authority, at the instruction of the facility or the company that owns the facility, may designate who can update the issue status.
FIG. 14 is an example of a UI 140 allowing users to download one or more reports generated by process 60 .
The system described herein also provides administrative features that may be implemented/performed, e.g., at the central authority or by an appropriate administrator. To set up an issue/problem reporting category for a “General Maintenance” fixture, it is first necessary to create the fixture itself. After a “General Maintenance” fixture has been set up, the next steps are to create any desired issue/problem categories and then associate these issue/problem categories with the fixture. For example, in FIG. 15 , a user (e.g., an administrator) may click on “add a new category” feature 200 to create a new issue or problem category. In FIG. 16 , a user may associate a fixture type 201 with a corresponding problem category 202 . In FIG. 17 a user may associate one or more notifications 204 (e.g., e-mail notifications) with the problem category 203 . The features of FIGS. 15 to 17 thus add, to the system, a fixture and possible problems with that fixture.
The system described herein for managing facilities may also include proactive alert mechanisms when certain scheduled events (e.g., warranty expiration dates) come within a specified number of days or weeks before the event is scheduled to occur. An alert (or reminder) may be a precursor to actually scheduling maintenance of a device or system in a facility. The alert may also act as a trigger for instructing an agent to perform a scheduled or unscheduled maintenance. Examples of types of events that the system is configured to monitor include, e.g., warranty expirations, scheduled maintenance calls, and planned retirement dates. For each of these alert classes, correct information should be pre-entered into the system for each equipment fixture or item to be covered. Examples of this information include, but are not limited to, warranty expiration dates, planned retirement dates, or last actual maintenance dates for annual, quarterly, or other scheduled maintenance. However, after the data is entered, the system automatically detects when these dates approach, and sends email alerts to specified parties. The system may also post alerts on a dashboard displaying floorplan of a facility, and cause the affected fixture items to flash visually on the displayed floorplan.
In an example, a system administrator may request that email alerts be sent eight weeks prior to the warranty expiration dates for any kitchen oven or dishwashing equipment. This enables such equipment to be reviewed and tested for problems prior to the warranty expiration date while any repairs and replacement items will be paid for the equipment manufacturer, potentially saving the administrator's company thousands of dollars in equipment repair costs. For simpler equipment, such as food preparation tables or dishware, this time horizon can be set to a shorter period, such as a week or two, since the review and testing of this simpler equipment may not take as long. All thresholds and email notifications may be set on individual instances of equipment (e.g. Serial No. 7856-JHZ of a Bruce SH200 Convection Oven), as well as at the equipment category level (e.g. all convection ovens). Warranty expiration, retirement, and last scheduled maintenance dates should be set on individual instances of equipment when the data for these instances is entered into the system, since these tend to be specific to individual equipment items and not equipment categories. Also, if the equipment item has multiple types of scheduled maintenance sessions, such as a quarterly check-up and tuning scheduled maintenance session as well as an annual parts inspection and replacement session, then the administrator may enter the last performed date for each type of maintenance session. When this is done, the system will not only activate all requested proactive alert mechanisms when scheduled dates approach, but it will also provide an additional notification that it may be possible to combine multiple maintenance sessions (e.g., a quarterly and an annual session) in one visit when these next scheduled session dates fall within a user-specified date range, such as within the same week.
The processes described herein extend issue/problem reporting and tracking capabilities beyond just the merchandising collateral issues to any conceivable and appropriate issue that can be reported at the store level, including issue/problems related to the physical plant, electrical or plumbing equipment, signage, staffing or other miscellaneous issues. A sample of those issues is shown in FIG. 9 above.
All or part of process 60 and its various modifications described herein (hereinafter referred to as “the processes”) can be implemented, at least in part, via a computer program product, i.e., a computer program tangibly embodied in one or more information carriers, e.g., in one or more tangible, non-transitory machine-readable storage media, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers
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, component, 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 network.
Actions associated with implementing the processes can be performed by one or more programmable processors executing one or more computer programs to perform the functions described herein. All or part of the processes can be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) and/or an ASIC (application-specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only storage area or a random access storage area or both. Elements of a computer (including a server) include one or more processors for executing instructions and one or more storage area devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from, or transfer data to, or both, one or more machine-readable storage media, such as mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Machine-readable storage media suitable for embodying computer program instructions and data include all forms of non-volatile storage area, including by way of example, semiconductor storage area devices, e.g., EPROM, EEPROM, and flash storage area devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks.
Reports and other information that are generated by process 60 may be displayed on a computer peripheral (e.g., a monitor) associated with a computer, e.g., at a company at a facility, at an agent, at the central authority, or elsewhere. The display physically transforms the computer peripheral. For example, if the computer peripheral is an LCD display, the orientations of liquid crystals are changed by the application of biasing voltages in a physical transformation that is visually apparent to the user. As another example, if the computer peripheral is a cathode ray tube (CRT), the state of a fluorescent screen is changed by the impact of electrons in a physical transformation that is also visually apparent. Moreover, as indicated above, the display of a report on a computer peripheral is tied to a particular machine, namely, the computer peripheral.
The processes described herein are not limited to use with the system shown in FIG. 5 , and may be implemented on any appropriate system. The processes are not limited to use in the context of service/repair/replacement. For example, the processes may be used to replenish missing or low stock at a retail outlet. For example, the “issue” at a particular facility may be low stock (e.g., a store has run out of canned soda). The facility may alert the central authority, which may communicate to an agent who is contracted to supply the stock—in this case, canned soda—to the facility. The process may be automatic, as described above, or it may include human intervention (e.g., to confirm that the new stock is actually needed).
The processes are not limited to use in a retail context. For example, the processes may be used to provide service/repair/replacement for medical facilities, such as hospitals. In this regard, hospital equipment can require periodic servicing and/or maintenance to comply with government regulations. The processes may be used to schedule such servicing and/or maintenance to ensure such compliance.
Elements of different implementations described herein may be combined to form other implementations not specifically set forth above. Elements may be left out of the processes, computer programs, Web pages, etc. described herein without adversely affecting their operation. Furthermore, various separate elements may be combined into one or more individual elements to perform the functions described herein.
Other implementations not specifically described herein are also within the scope of the following claims. | One or more servers perform functions that include: maintaining a database including information relating to facilities that are subject to a first entity, the facilities being dispersed geographically, the information including geographic locations for at least some of the facilities; receiving a first message from a facility for which information is in the database, the first message identifying a fixture of the facility that requires attention, where information in the database for the facility identifies the fixture by at least one of a designation of the fixture and a characteristic of the fixture; sending a second message to a second entity that has contracted with the first entity to provide service within a geographic location of the facility; and enabling the second entity to access the database to identify the fixture. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to forming fabrics for paper-making machines, this term being understood in its widest sense to include in particular machines for the manufacture of paper pulp, cellulose, Kraft paper, cardboard etc. It relates more particularly to endless multiply or multilayer forming fabrics having at least two plies or layers of transverse threads (i.e. threads running transversely to the direction of movement of the forming fabric in the paper-making machine) and one layer or ply of longitudinal threads (i.e. running in the direction of movement of the fabric during operation).
In a paper-making Fourdrinier machine the paper sheet is generally formed either on an endless forming fabric, or between two endless forming fabrics, or between an endless forming fabric and other members such as hollow fabric-covered cylinders or heated cylinders. The endless fabrics may be entirely of threads or yarns of synthetic or metal material or they may include, in combination, metal threads and mono- or multifilament synthetic threads. The multifilament synthetic threads are obtained by spinning out synthetic fibres or endless synthetic fibres; they may also be made by twisting such threads. The synthetic material is generally polyester or polyamide although other polymers or copolymers can be used. Before or during manufacture of the forming fabrics, the threads may be coated with a synthetic material.
The forming fabrics for paper-making machines must fulfil conditions which are to some extent contradictory.
The transverse rigidity of the forming fabric should be as high as possible, especially for fabrics of great length and width (respectively up to approx. 80 m and 10 m) which move at high speeds (e.g. 1100 m/min.). Insufficient transversal rigidity may result in the formation in the fabric of a fold which first deteriorates the sheet of paper formed on the fabric and ultimately ruins the fabric.
To increase rigidity, "double ply" fabrics have been used instead of single ply fabrics which have a single layer of longitudinal threads and a single layer of transverse threads. Such fabrics have two layers of transverse threads which both contribute to increase the transverse stiffness which is consequently much higher than in single ply fabrics.
For simplicity's sake, I shall call "upper layer" the layer of transverse threads located on the paper side when the fabric is on the paper-making machine. The lower layer of transverse threads will be the layer which, on the paper-making machine, is on the side of the fabric supporting members and dewatering elements (foils, suction boxes and the like).
It is well known that the fabric must impress on the material to be formed (typically a sheet of paper) a roughness or "mark" as faint as possible. Numerous attempts have been made to reduce the mark. Grinding the fabrics prior to use to make smoother the surface in contact with the paper has been proposed. But while the marks are less deep, they are wider. The number of threads per unit of surface has been increased to support the sheet of paper on a fabric having as many contact points as possible with the paper sheet but it results in a finer, therefore less resistant, fabric.
Up to now, it was generally felt that, in order to reduce the mark, it was advisable to increase the number of crossing points between longitudinal and transverse threads of the upper layer and to arrange that the outer surfaces of the undulations formed by all the threads towards the side of the sheet of paper are approximately tangential to a same plane. Such an assumption has led to use double layer fabrics wherein the longitudinal threads and the transverse threads of the upper layer are interwoven according to a "plain" weave at each crossing point, i.e. each longitudinal thread or yarn binds separately with one transversal thread or yarn of the upper layer at each crossing point.
Furthermore, the paper forming fabrics must have as high a resistance to abrasion as possible. In paper-making machines, the fabrics are supported on the inside by abrasive members, some of which support the fabric to keep it flat while others exert a suction on it to eliminate through the fabric a great part of the water in which the cellulose fibres and additives forming the paper pulp are in suspension.
The dewatering elements wear the fabric which must be replaced after a period of use. One of the principal concerns of manufacturers has been to increase the resistance to abrasion of the forming fabrics. For that purpose, attempts have been made to replace polyester yarns with polyamide yarns which are more resistant to abrasion. Unfortunately, the more abrasion resistant yarns are more flexible than the polyester yarns and it has been found that polyamide fabrics lack transverse stiffness and stretch too much under the tension necessary for use in paper-making machines.
In double ply fabrics, it has been suggested to increase the length of longitudinal threads in contact with the machine members causing abrasion by forming loops taking in several transverse threads at a time (U.K. Patent Specification No. 1,415,339 and U.S. Pat. No. 3,915,202).
This solution is only a palliative, for again the longitudinal threads are subjected to wear. As soon as the fabric is used, as wear increases, the tensile strength of the fabric diminishes. At a certain stage of wear, the fabric tears under the tensile forces to which the fabric is subjected during use in a paper-making machine.
It is a first object of the invention to provide an improved multilayer fabric for forming paper and the like which has a high transverse stiffness and at the same time does not impress an excessive mark on the paper.
It is another object to provide a multiply or multilayer forming fabric for a Fourdrinier machine which has a high resistance to wear by abrasion and consequently a long useful life.
An important step in conceiving the present invention was the determination of the surprising fact that the transverse threads mark the paper more than the longitudinal threads, even when the sheet of paper is supported by a fabric whose longitudinal and transverse threads have outer surfaces which are tangential to a same plane on the paper supporting side. That may be due to the anisotropy of the paper caused by the orientation given to the cellulose fibres during manufacture of the paper. Anyway, according to a first aspect of the invention, that finding is used by providing a multilayer fabric in which the threads are so interwoven that the outer loops formed by the longitudinal threads contacting the paper on the paper supporting side of the fabric, cover from three to seven transverse threads of the upper layer, the first crossing points of said outer loops and transverse threads being distributed according to a repeating weaving pattern comprising at least five longitudinal threads. The weaving pattern on the paper side of the fabric is additionally selected so as to avoid full alignment of said outer loops on adjacent threads and diagonal effects. The outer loops formed by the longitudinal threads on the machine side of the fabric pass each time only under a single transverse thread of the lower layer.
Preferably, the "filling coefficient" for the longitudinal threads (i.e. the cumulative width of the longitudinal threads--supposed to be side by side--per unit width of the fabric) is between 1.05 and 2.0.
By increasing the length of the loops of the longitudinal threads in contact with the sheet of paper, contact of the transverse threads with the sheet of paper is avoided. Alignment of loops in a particular direction and diagonal effects are avoided by not using, for the upper loops, the patterns which are called semitwill and twill in the textile industry. The "beginnings" of the loops (the beginning being the location where the longitudinal thread forming the loop crosses with the first transverse thread which it binds) are typically distributed in the upper layer in the form of a regular or irregular satin weave using five or more longitudinal threads.
The fabric typically has two layers of transverse threads and a layer of longitudinal threads all of synthetic material, is flat woven and junctioned to make it endless. The upper loops formed by the longitudinal threads (warp threads) of synthetic material on the paper receiving side of the fabric cover from three to seven transverse threads (generally three or four transverse threads) of the upper layer. The first crossing points of the loops with the transverse threads may be distributed according to a satin weave of at least five threads. The lower loops formed by the longitudinal threads on the machine side of the fabric pass each time only under one transverse thread of the lower layer.
Advantageously, the transverse threads of the lower layer may have different characteristics from those of threads used for the other layer(s) of transverse threads and may have a higher resistance to abrasion. The transverse threads of at least one of the layers can have a diameter greater than that of the longitudinal threads, the ratio between the diameters being then advantageously equal to 1.05 at least and 2.5 at most, different threads may be used (for instance alternate polyester and polyamide threads).
The forming fabric is advantageously woven, or treated after weaving (e.g. subjected to a fixing heat treatment while maintained under longitudinal tension) under such conditions that, when the fabric is new, only transverse threads are in contact with the fabric supporting members of the machine.
In particular embodiments, each longitudinal thread forms either one lower loop, i.e. a separate binding with a thread of lower layer, or two successive such lower loops between two successive upper loops, i.e. two successive loops over transverse threads of the upper layer. Then, the transverse threads withstand abrasion until their thickness has substantially decreased due to wear out. During this phase, the resistance of the fabric to longitudinal tension does not substantially decrease.
The invention will be better understood from the following description of particular embodiments given by way of non limiting examples.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic cross section along line I--I of FIG. 2 of a portion of a first fabric according to the invention;
FIG. 2 is a diagram showing the weaving pattern of the fabric of FIG. 1 as seen from the paper side (upper layer);
FIG. 3 shows on an enlarged scale the arrangement of the threads following tensioning of the longitudinal threads;
FIGS. 4 and 5, respectively similar to FIGS. 1 and 2, illustrate another embodiment;
FIGS. 6 and 7, also similar to FIGS. 1 and 2, illustrate yet another embodiment.
FIGS. 8 and 9 are cross-sectional views along a longitudinal thread and along a transversal or cross-machine thread of the upper layer, respectively, of an actual double ply fabric according to the embodiment of FIGS. 4-5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As indicated above, the fabrics are typically woven so that the filling coefficient for the longitudinal threads is 1.05 or more, typically 1.2. However, for more clarity, the diagrams of the drawings correspond to filling coefficients which are much smaller and in addition the threads are represented at even intervals rather than in their actual respective locations.
Taking into account the high value of the filling coefficient, it will be appreciated that the sheet of paper is essentially supported by long loops of the longitudinal threads, which do not exhibit abrupt curvatures or "knees" at the crossing points with the cross machine threads. The mark impressed on the sheet of paper is thereby considerably diminished.
The surface of the illustrated fabrics which is in contact with the dewatering elements of the machine is designed to increase the useful life. Contrary to the usual technique which consists in forming, on the machine side, loops of the longitudinal threads passing under at least two transverse threads of the lower layer (U.K. Patent Specification No. 1,415,339), each loop binds with a single transverse thread at each crossing.
Referring to FIGS. 1 and 2, there is shown a fragment of a fabric which has a lower layer of transverse threads 10 and an upper layer of transverse or cross-machine threads 11 connected by longitudinal threads 12 1 , 12 2 , . . . 12 8 . Assuming that the fabric has been flat woven and then junctioned by splicing the ends, the longitudinal threads are formed by warp threads and the transverse threads by weft threads.
Each longitudinal thread 12 passes successively, from a crossing point 13 at which it passes from under to above the upper layer of threads 11, over three transverse threads 11, then between two threads 11 and the two associate threads 10 of the lower layer, then under one transverse thread 10 of the lower layer with which it has a plain binding, then between two threads 11 and the two corresponding threads 10; the pattern then is repeated.
As shown on FIG. 2, the points 13 are distributed according to an eight thread satin weaving pattern with a shift of three between two successive longitudinal threads.
Each loop 15 over the upper layer binds three threads 11. Each loop 14 of a longitudinal thread below the lower layer binds with or passes under a single thread 10 of this layer. Due to this arrangement and taking into account the tension exerted on the warp threads during weaving and/or finishing treatments, the longitudinal thread 12 forces the bindings with the transverse threads of the lower layer 10 to locations 14 as shown on FIG. 3 rather than as shown on FIG. 1. Thus transverse threads 10 remain on the surface of the fabric, on the machine side and, at locations 14, the longitudinal threads are "buried" in the fabric and they are tangent to a plane deeper in the fabric than the plane tangent to the outer surfaces of the cross machine threads 10. This is apparent on FIG. 3 where the surface of the longitudinal thread at point 14 is offset relative to the transverse threads 10 by a distance d which may be equal to approx. half the diameter of transverse threads 10.
As a consequence, the lower surface of the fabric is principally covered by transverse threads 10 which withstand the abrasion caused by the machine elements. The wear of the fabric affect the longitudinal threads 12 only after wear out from the transverse threads 10 of material corresponding to distance d. The fabric has then the advantage that the wear does not affect the tensile strength of the fabric before the transverse threads have worn to a considerable amount.
It may be noted at this stage that the possibility of "burying" the longitudinal warp threads by tensioning them for delaying wear thereof has been recognized for long in single layer fabrics and is known as "weft effect". However, that result is much more easily obtained in a double layer fabric according to the invention since the longitudinal threads take a strong support on the groups of cross-machine threads of the upper layer with which it binds (groups of three threads in FIGS. 1-5, groups of four threads in FIGS. 6-7).
Due to the inherent transverse rigidity of multiply fabrics, a thread selected taking into account other requirements can be used for one of the layers. This thread can have characteristics different from those of the threads of the other layers without loss of the transverse stiffness necessary for proper operation in a paper-making machine. The different characteristics can be chemical composition, resistance to abrasion, stiffness, tensile strength, resilient yield, etc.
A fabric can be made for example having lower layer transverse threads 10 with a better resistance to abrasion than the other threads 11 and 12; this fabric, whose transverse threads of lower layer 10 will withstand abrasion, will last longer. Among the special threads having a better abrasion resistance than polyester monofilament threads used currently in the manufacture of forming fabrics, are polyamide monofilaments, different types of coated multifilaments, and threads coated with a resin highly resistant to abrasion, such as certain polyurethanes. Special threads having a low stiffness can be accepted, up to the point that if the special threads were used for manufacturing the whole fabric, the fabric would be unusable in a paper-making machine due to lack of transverse stiffness.
The fact that the longitudinal threads are practically alone in supporting the sheet of paper results in further advantages. The diameter of the transverse threads may be increased without affecting the mark impressed in the paper. The result is a possible increase in the transverse stiffness of the fabrics as well as a longer life since the transverse threads of the lower layer initially withstand the wear.
Referring now to FIGS. 4 and 5 (where the same reference numerals as in FIGS. 1-3 are used to designate corresponding parts) there is shown a fabric which differs from that of FIGS. 1-3 in that:
instead of forming a single loop 14, the threads 12 form two successive loops, each below a single transverse thread 10 of the lower layer,
points 13 (shown by dotted line squares in FIG. 5) are distributed according to a satin weaving pattern of eight longitudinal threads with a shift of five.
Referring now to FIGS. 8 and 9, it appears that the material to be formed is essentially supported by long loops of the longitudinal wires and there are no zones of abrupt curvatures or acute knuckles in contact with the material. The longitudinal threads exhibit gentle ondulations over the cross-machine threads of the upper layer. Due to the high value of the filling ratio, the material to be formed is supported by the longitudinal threads at points which are close to each other.
Referring last to FIGS. 6 and 7, there is shown a fabric in which:
loop 15 passes over four transverse threads of the upper layer 11,
instead of forming a single loop 14, each thread 12 passes successively twice under a respective transverse thread 10 of the lower layer, thread 12 passing, between two successive loops, over two threads 10 of that same lower layer,
points 13 are distributed according to a satin weave of ten longitudinal threads with a shaft of three.
Tensioning of longitudinal threads 12 which occurs during weaving if the fabric is flat woven and may be complemented off loom during a finishing treatment, which will be the case most often, or which occurs during later heat treatment for fixing, tends to straighten them from the position shown with a continuous line to the broken line position (FIG. 6). Following this deformation, the lower loops 14 are buried in the thickness of the fabric, so that the latter will bear on the supporting and suction members of the machine (not shown) essentially by the transverse threads 10.
The film of material to be formed (such as paper pulp) shown schematically with dashed lines in FIGS. 1, 4 and 6, is essentially supported by loops 15 formed by the longitudinal threads, which will result in a faint mark.
It will be appreciated that the types of satin weave patterns shown schematically in FIGS. 2, 5 and 7 are not only the patterns which can be used in combination with the types of weaving illustrated in FIGS. 1, 4 and 6. Other regular or irregular satin weave patterns, as well as other patterns, can be used.
All the fabrics described can, particularly when they are formed entirely from synthetic fibres, be woven on existing heavy looms. The loom should be provided with two warp beams when the threads of the two layers are not identical and the fabric is circular woven. For fabrics which are flat woven and then spliced (the longitudinal threads corresponding to warp threads and the transverse threads to weft threads), the loom must be provided with means for insertion of two types of weft thread to attain the same result. | An endless forming fabric for paper-making machine comprises at least two layers of transverse threads and one layer of longitudinal threads. The upper loops formed by the longitudinal threads cover from three to seven transverse threads of the upper layer. The leading crossing points of these upper loops with the transverse threads are distributed in a weave pattern using at least five longitudinal threads. The weave pattern on the paper side of the fabric is selected so as to avoid alignment of the upper loops of adjacent threads and diagonal effects. The lower loops formed by the longitudinal threads, on the machine side of the fabric, pass each time only underneath a single transverse thread of the lower layer. | 3 |
BACKGROUND OF THE INVENTION
In the preparation of paper, woven fabric belts are utilized to support the cellulosic pulp fibers as they are moved through the papermaking process and converted from a thin slurry into finished paper. It has been found that mechanical stability and permeability control of these belts is critical to the production of consistent, high quality paper. As paper machine speeds have increased, fabrics designed for use in the dryer sections of papermaking machines have had their targeted permeability reduced from 500 cubic feet per minute per square foot with a pressure differential of one half inch of water to 100 or less. There has also been a trend toward use of thinner fabric constructions to minimize differential forces on the paper as it passes over and under the belts in certain process steps. These two papermakers' fabric requirements are in conflict, since the common way to reduce permeability is to increase size of the weft yarn or the number of picks per inch, both of which can result in increased fabric thickness.
DESCRIPTION OF THE PRIOR ART
As the demand for papermakers' and industrial fabrics has moved toward thinner, reduced permeability fabrics, suppliers of such fabrics have shifted from use of round monofilament wefts to use of twisted and cabled yarn constructions which have more capability to conform into the interstitial spaces formed at the crossings of warp and weft yarns. This switch has been moderately successful in regards to production of lower permeability and improved fabric stability. Some negative results of this practice are that the smaller monofilaments used in cabled constructions are more easily damaged by severe environmental exposure and that cabled yarns tend to become contaminated with process "tars" faster than true monofilament wefts. The extra handling and processing stages required to produce these twisted and cabled yarns also makes their cost significantly higher than that of monofilament.
There has also been a shift toward use of more ribbon-like warp yarns. These warps give improved paper contact and reduce the number of interstices, thus resulting in reduced fabric permeability. Wear due to the thin profile of these warp yarns and a tendency toward reduced fabric stability have been the key drawbacks to more widespread use of this concept.
Fabric stability is improved by increasing the interaction between warp and weft yarns. Current methods of improving stability include increasing pick count, use of multifilament warps and/or wefts, use of cabled weft yarns, and application of resinous fabric treatments. Each of the listed methods is acceptable in selected areas, but all carry a cost or performance penalty which prevent them from being generally acceptable.
In U.S. Pat. No. 5,097,872, Laine et. al. teach the use of an X shaped fiber to achieve improved fabric stability, but their application requires almost complete flattening of the fiber on one side by bending and the design use described would not contribute to improved permeability control. In contrast, the current patent application requires that weft fiber lay relatively flat in the fabric and that the fins distort only at warp and weft intersections, otherwise remaining erect to block fabric interstitial spaces.
In U.S. Pat. No. 4,633,596, Josef teaches the use of warp fibers having a center thinner than the edges and which improves fabric dimensional stability by minor distortion at warp and weft crossings. This is in marked contrast to the use of finned weft fibers which will always be thicker at their center than at their edges. The drawings and discussion of this patent tend to lead toward production of fabric designs targeted toward high permeability fabrics.
SUMMARY OF THE INVENTION
The present invention provides thin papermaking fabrics, especially dryer fabrics, with the capability of being easily woven on standard industrial looms, which can be produced with a wide range of permeabilities, especially including the desired low permeability targets of less than 100 cubic feet per minute per square foot with a pressure differential of one half inch of water. Fabrics utilizing this invention also have improved dimensional stability over that achieved by the now common use of twisted and plied monofilament wefts.
Specifically, this invention provides, in a woven papermakers' fabric, the improvement wherein some or all of the weft yarns are monofilaments designed to have two or more finned extensions which are deformed when crossed by warp yarns and which otherwise extend into and block the interstitial spaces of said fabric. Preferably these weft yarns will have four or more fins so as to not be sensitive to the minor twist insertion present in normal weaving operations. Preferred maximum dimensions of these wefts will generally range from 0.7 to 1.5 times the cross-sectional thickness of the warp yarn with which it is used. Any appropriate polymer type and additive package used to produce yarns for papermakers' fabrics may be used. Significant economic benefits are realized due to reduced denier of finned wefts over other weft yarns previously used for this service.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional perspective view of the preferred embodiment for the weft yarn of the invention.
FIGS. 2 through 5. are examples of other cross sections which yarns of this invention could assume.
FIG. 6 shows local distortion of the weft fins by the crossing warp yarn.
FIG. 7 shows a cross sectional view of a fabric illustrating the concepts of this invention. The weft yarns are easily deformed into the spaces between the warp yarns and provide both a locking together of the fibers and blockage of the volume between the warps.
DETAILED DESCRIPTION OF THE INVENTION
The finned monofilaments used in the present invention can be prepared from a variety of thermoplastic materials. Polyethylene terphthalate, polyphenylene sulphide and 1,4-polydicyclohexanol terphthlate are currently widely used. In order to obtain the desired fin flexibility, these new weft yarn designs often require addition of polymer specific plasticizing agents during the monofilament extrusion process. Use of standard additive recipes which may include heat and hydrolysis stabilizers, contaminant release agents, and other such processing aids common to production of papermakers' yarns is considered as standard.
Modifications to customary techniques for monofilament production are required in order to achieve acceptable filament smoothness and uniformity for these new weft shapes. This is caused by the large overall monofilament width to fin thickness ratio necessary to obtain the required flexibility without fracture. This ratio can be used as a specification for these weft monofilament shapes and will be greater than 2.5, most preferably in the range from 5 to 20. In FIG. 3, this concept is illustrated by showing the effective fiber width as W and the effective fin thickness as T. W divided by T is the shape factor considered for the purpose of this invention. Since these heavy denier monofilaments are water quenched during production, there is a tendency for water to collect at the interior intersections of the fins and the central body of the filament. Unless this water is removed, significant diameter and size irregularities occur in subsequent drawing and stabilizing stages of the yarn production process. It is thought that the difficulty of achieving smooth, uniform fibers using standard monofilament production techniques has contributed to fibers of this type not being conceived for use in the quality demanding industrial fabric market. It has been found that passing these finned monofilaments through an air jet system after each water or fluid immersion is sufficient to prevent this type problem by forcibly removing fluid from internal intersections. Care must also be exercised in the drawing and winding operations to minimize permanent distortion of the filament shape.
Fabrics are woven from these new finned wefts in the same manner as with round monofilament and twisted and plied weft constructions currently in common use. In FIGS. 6 and 7, warp yarn is shown as 1 and weft yarn as 2. Bending of the weft fins by the warp during weaving is shown. FIG. 7 shows a fabric cross section showing use of all finned weft yarns. The important concept here is that the wefts easily conform to fill the available volume between the warp yarns and by so doing, lock the woven structure together and significantly reduce the openess of the fabric. Wefts containing less than four finned extensions are often found to be sensitive to the slight twist inserted into the weft as it is supplied to the process over the top of supply bobbins. This twist insertion results in small surface and permeability irregularities which can be significant in critical product areas. The X design has been found to very closely match the rectangular or diamond open area common to most weave patterns and is also a very good compromise for economy of material and ease of water removal during spinning. Use of more than four lobes reduces the importance of weft yarn orientation in the fabric, but at a cost of more monofilament extrusion difficulty. Fins with curved or tapered shapes may be used.
The use and advantages of the invention will be illustrated by the following examples. Values for woven fabric permeability are determined by measurements utilizing the industry standard Frazier permeometer test method and fabric stability measurements are made by determination of the deflection under load of a 10 inch square fabric sample mounted in a hinged frame.
1. A papermakers' dryer fabric is made utilizing a rectangularly shaped warp yarn with dimensions of 0.35 by 0.53 mm with 53 ends per inch and a weft yarn 0.50 mm in diameter inserted at 32 picks per inch. Permeability is determined to be 450 cfm and fabric deflection is 0.90 inch. Denier of this weft is 2500 and the cost is $2.80 per pound.
2. A papermakers dryer fabric is made in the same manner as in example 1, but an X shaped monofilament weft yarn with overall width of 0.60 mm and fin thickness of 0.08 mm is used. This weft yarn is characterized by a width to thickness ratio of 7.5. Permeability is determined to be 125 cfm and fabric deflection is 0.45 inch. Denier of this weft is 1150 and the cost is $3.30 per pound.
3. A papermaker's dryer fabric is made in the same manner as in example 1, but twisted and plied yarn containing a total of eight 0.2 mm monofilaments is used as the weft. Permeability is determined to be 250 cfm and fabric deflection is 0.60 inch. Denier of this weft is 3200 and the cost is $5.75 per pound.
4. A papermakers' dryer fabric is made in the same manner as in example 1, but an X shaped monofilament weft yarn with overall width of 0.50 mm and fin thickness of 0.10 mm is used. This weft yarn is characterized by a width to thickness ratio of 5. Permeability is determined to be 300 cfm and fabric deflection is 0.55 inch. Denier of this weft yarn is 1350 and the cost is $3.30 per pound.
In the examples shown, the lower denier of the finned weft yarns makes their effective product cost approximately half that of the competing round monofilament weft and about one quarter that of the plied and cabled monofilament weft. Permeability variation can be obtained both by pick count adjustment or by use of different shapes. Fabric stability is well below the acceptable limit of 1.0 for all products except the round monofilament design. | A woven papermakers' fabric containing warp and weft yarns wherein the weft yarns are monofilaments characterized by having two or more thin readily deformable fins or lobed extensions. By replacing the currently used round monofilaments or twisted and cabled weft yarns, these inventive finned monofilaments produce fabrics with significantly broadened permeability range control and stabilize the fabric against mechanical distortion. | 3 |
FIELD OF THE INVENTION
The present invention relates to a cemented carbide cutting tool with a surface layer (hereinafter referred to as coated cemented carbide tool) in which a hard coating layer has excellent heat resistance so as to show high wear resistance even when it is applied to a high-speed cutting operation on various steels and cast irons accompanied by high heat generation.
In general, many kinds of cutting tools are known. Indexable type cutting inserts are used in various cutting operations such as turning or planing of a workpiece made of various steels or cast irons while being exchangably attached on a tip of a cutting tool. Twist drills and micro drills that are used for drilling of the above-mentioned workpiece are also well known. Furthermore, solid type end-milling cutters, used in various operations such as face milling, slotting and shoulder milling of the workpiece are widely used. In an analogous fashion to the solid type end-milling cutters, indexable type end-milling cutters for cutting operation are also known as cutting tools to which the indexable cutting inserts are exchangably attached.
As such a cutting tool, a coated cemented carbide tool is well known in which a hard coating layer with an average thickness of 2 to 15 μm consisting of a layer of Ti—Al nitride compound (hereinafter referred to as (Ti, Al)N) is deposited on a substrate made of tungsten carbide (hereinafter referred to as WC) based cemented carbide or titanium carbonitride (hereinafter referred to as TiCN) based cermet (hereinafter the substrate is generically referred to as cemented carbide substrate) by using physical vapor deposition. Here, the composition formula of the Ti—Al nitride compound layer is expressed by (Ti 1−Z Al Z )N, wherein Z ranges from 0.45 to 0.65 by atomic ratio. It is also well known that such coated cemented carbide tool is preferably used for continuous cutting operation as well as interrupted cutting operation on various steels or cast irons.
It is known that the above-mentioned coated cemented carbide tool is made by vapor deposition of the hard coating layer consisting of the (Ti, Al)N layer on the surface of the cemented carbide substrate as follows: First, the cemented carbide substrate is set into a chamber of an arc ion plating system, which is one of the physical vapor deposition processes, having an arrangement as shown in FIG. 5 ; the (Ti, Al)N layer is then coated under the following conditions, that is, for example, at first, in a condition of about 0.5 Pa and 500° C. achieved by a heater inside the chamber, an arc discharge is generated between an anode and a cathode (an evaporation source) in which an Ti—Al alloy having predetermined composition is set, by loading electrical potential of 35V and electrical current of 90A, while nitrogen gas is introduced as a reaction gas into the chamber, and the bias DC voltage of, for example −200V, is applied to the substrate.
Another coated cemented carbide tool is also well known as a cutting tool in a similar fashion to the above described tool, wherein a hard coating layer with an average thickness of 2 to 10 μm consisting of a layer of A—Ti—Si nitride compound (hereinafter referred to as (Al, Ti, Si)N) is deposited on a substrate made of WC based cemented carbide or TiCN based cermet by using physical vapor deposition. Here, the composition formula of the A—Ti—Si nitride compound layer is expressed by (Al 1−(A+B) Ti A Si B )N, wherein A ranges from 0.35 to 0.55 and B ranges from 0.05 to 0.20 by atomic ratio. It is also well known that such coated cemented carbide tool is preferably used for continuous cutting operation as well as interrupted cutting operation on various steels or cast irons.
It is known that the above-mentioned coated cemented carbide tool is made by vapor deposition of the hard coating layer consisting of the (Al, Ti, Si)N layer on the surface of the cemented carbide substrate as follows: First, the cemented carbide substrate is set into a chamber of an arc ion plating system, which is one of the physical vapor deposition processes, having an arrangement as shown in FIG. 5 ; the (Al, Ti, Si)N layer is then coated under the following conditions, that is, for example, at first, in a condition of about 450° C. achieved by a heater inside the chamber, an arc discharge is generated between an anode and a cathode (an evaporation source) in which an Al—Ti—Si alloy having predetermined composition is set, by loading electrical potential of 40V and electrical current of 130A, while nitrogen gas is introduced as a reaction gas into the chamber up to 2 Pa, and the bias DC voltage of, for example, −50V, is applied to the substrate.
In recent years, cutting operation apparatuses tend to have significantly high performance on one hand, and it is strongly demanded that cutting operations be performed with less power and less energy as well as low cost on the other hand. Therefore, cutting operations tend to be performed at high speed. With regard to various kinds of coated cutting tools conventionally proposed, as long as they are used in cutting operations under the usual cutting conditions, they have almost no problem. However, once they are used in high speed cutting operations accompanied by high heat generation, their operation lifetime becomes shorter due to accelerated abrasion of the hard coating layer.
In view of the above circumstances, the inventors have conducted research to develop coated cemented carbide tools having excellent wear resistance in high-speed cutting operations while focusing attention on the hard coating layer formed on the conventional coated cemented carbide tool, and found the following results (a1) and (b1):
(a1) Measurements by Cu K a radiation using an X-ray diffractometer show that the hard coating layer consisting of the (Ti, Al)N layer formed on the coated cemented carbide tool exhibits an X-ray diffraction pattern in which a peak of not less than 0.9 degrees FWHM (full width at half maximum) in 2θ (abscissa) is found at a (200) plane as shown in FIG. 2 . Forming a layer of carbonitride compound containing Ti and Al (hereinafter referred to as (Ti, Al)NC) expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ) (wherein X: 0.05 to 0.20, and Y: 0.01 to 0.15 by atomic ratio) with an extremely thin average thickness of 0.05 to 0.5 μm on the surface of the cemented carbide substrate by vapor deposition before the hard coating layer is formed on the substrate by physical vapor deposition, the (Ti, Al)NC layer is well oriented in a (200) plane so that it exhibits an X-ray diffraction pattern in which a peak of not more than 0.6 degrees FWHM in 2θ is found at the (200) plane. Due to the crystal orientation of the (Ti, Al)NC layer with a hysteresis effect, as the (Ti, Al)N layer (or the hard coating layer) is formed on the (Ti, Al)NC layer by physical vapor deposition, it will also exhibit an X-ray diffraction pattern in which a peak of not more than 0.6 degrees FWHM in 2θ is found at a (200) plane, indicating a high degree of crystallinity as shown in FIG. 1 , although the (Ti, Al)N layer would inherently exhibit an X-ray diffraction pattern, in which a peak of not less than 0.9 degrees FWHM in 2θ be found at the (200) plane, without the (Ti, Al)NC layer.
(b1) The (Ti, Al)N layer with a well oriented crystal structure having a peak of not more than 0.6 degrees FWHM in 2θ at a (200) plane in the X ray diffraction pattern exhibits excellent heat resistance (i.e., resistance to oxidation and hardness at high temperature) in comparison with a (Ti, Al)N layer having a peak of not less than 0.9 degrees FWHM. That leads to the result that the coated cemented carbide tool performs high-speed cutting operations on steels and mild steels at high temperature and has excellent wear resistance, in which the hard coating layer consisting of the (Ti, Al)N layer with a well oriented crystal structure (or having a narrow FWHM) is formed on the surface of the cemented carbide substrate by physical vapor deposition.
Moreover, from another viewpoint, the inventors have conducted research to develop coated cemented carbide tools having excellent wear resistance in high-speed cutting operations while focusing attention on the hard coating layer formed on the conventional coated cemented carbide tool, and found the following results (a2) and (b2):
(a2) Measurements by Cu K a radiation using an X-ray diffractometer show that the hard coating layer consisting of the (Al, Ti, Si)N layer formed on the coated cemented carbide tool exhibits an X-ray diffraction pattern in which a peak of not less than 0.9 degrees FWHM (full width at half maximum) in 2θ (abscissa) is found at a (200) plane as shown in FIG. 4 . Forming a layer of Ti based carbonitride compound (hereinafter referred to as (Ti, Al)NC) expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ) (wherein X: 0.01 to 0.15, and Y: 0.01 to 0.15 by atomic ratio) with an extremely thin average thickness of 0.05 to 0.5 μm on the surface of the cemented carbide substrate by vapor deposition before the hard coating layer is formed on the substrate by physical vapor deposition, the (Ti, Al)NC layer is well oriented in a (200) plane so that it has a peak of not more than 0.6 degrees FWHM in 2θ at the (200) plane. Due to the crystal orientation of the (Ti, Al)NC layer with a hysteresis effect, as the (Al, Ti, Si)N layer is formed on the (Ti, Al)NC layer by physical vapor deposition, it will exhibit an X-ray diffraction pattern in which a peak of not more than 0.6 degrees FWHM in 2θ is found at the (200) plane, indicating a high degree of crystallinity as shown in FIG. 3 , although the (Al, Ti, Si)N layer would inherently exhibit an X-ray diffraction pattern, in which a peak of not less than 0.9 degrees FWHM in 2θ be found at the (200) plane, without the (Ti, Al)NC layer.
(b2) The (Al, Ti, Si)N layer with a well oriented crystal structure having a peak of not more than 0.6 degrees FWHM in 2θ at a (200) plane in the X ray diffraction pattern exhibits excellent heat resistance (i.e., resistance to oxidation and hardness at high temperature) in comparison with a (Al, Ti, Si)N layer having a peak of not less than 0.9 degrees FWHM. That leads to the result that the coated cemented carbide tool performs high-speed cutting operations on steels and mild steels at high temperature and has excellent wear resistance, in which the hard coating layer consisting of the (Al, Ti, Si)N layer with a well oriented crystal structure (or with a narrow FWHM) is formed on the surface of the cemented carbide substrate by physical vapor deposition.
DISCLOSURE OF THE INVENTION
The present invention was conceived based on the above research results, and the present invention provides a coated cutting tool made of cemented carbide in which a hard coating layer has excellent wear resistance in high-speed cutting operations, wherein:
(a) a layer affecting the crystal orientation by a hysteresis effect (hereinafter referred as a crystal orientation hysteresis layer) which consists of a layer of carbonitride compound is formed on the surface of a cemented carbide substrate, preferably on the surface of a tungsten carbide based cemented carbide or titanium carbonitride based cermet; and
(b) a hard coating layer that consists of a layer of nitride compound and has a well defined crystal orientation and/or degree of crystallinity is formed on the crystal orientation hysteresis layer by physical vapor deposition.
According to the first embodiment of the present invention,
(a1) the carbonitride compound layer has an average thickness of 0.05 to 0.5 μm and is a Ti—Al carbonitride compound layer expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ) (wherein X: 0.05 to 0.20, Y: 0.01 to 0.15 by atomic ratio); and
(b1) the nitride compound layer has an average thickness of 2 to 15 μm and is a layer of Ti—Al nitride compound expressed by the composition formula as (Ti 1−Z Al Z )N (wherein Z: 0.45 to 0.65 by atomic ratio).
Here, the Ti—Al carbonitride compound layer is preferably a layer which exhibits an X-ray diffraction pattern having a peak found at a (200) plane with FWHM of not more than 0.6 degrees in 2θ measured by Cu K a radiation using an X-ray diffractometer, and the layer of Ti—Al nitride compound is also preferably a layer which exhibits an X-ray diffraction pattern having a peak found at a (200) plane with FWHM of not more than 0.6 degrees in 2θ measured by Cu K a radiation using an X-ray diffractometer.
In the following, regarding the coated cemented carbide tool according to the first embodiment of the present invention, the reason that the average thickness and the composition of the crystal orientation hysteresis layer and the hard coating layer formed on the coated cemented carbide tool were limited as described above will be explained.
(a1) Crystal Orientation Hysteresis Layer ((Ti, Al)NC Layer)
The aluminum (Al) component in the (Ti, Al)NC layer plays an important role in defining a (200) plane of this layer to be aligned parallel to the face and the flank of the cutting edge; if the Al ratio is less than 0.05 by atomic ratio, the degree of the alignment of the crystal in the (200) plane is not sufficiently high, and on the other hand, if the Al ratio is more than 0.20, the degree of crystallinity is decreased so that it becomes difficult to adjust FWHM of the peak at the (200) plane to a width of not more than 0.6 degrees in 2θ; therefore, the ratio (X-value) was set from 0.05 to 0.20.
Also, the carbon (C) component in the (Ti, Al)NC layer improves adhesion for both the cemented carbide substrate surface and the hard coating layer; if the C ratio is less than 0.01 by atomic ratio, the desired effect to improve the adhesion cannot be obtained anymore; and on the other hand, if the C ratio is greater than 0.15, the crystal orientation is so disordered that it becomes difficult to align the crystal orientation in the (200) plane in a high degree; therefore, the ratio (Y-value) was set from 0.01 to 0.15.
Further, if the average thickness of the crystal orientation hysteresis layer is less than 0.05 μm, the hysteresis effect to align the crystal orientation, in which the texture or alignment of the (Ti, Al)NC layer to the (200) plane in a high degree is transferred to the hard coating layer, is not fully used; and the cemented carbide substrate surface and the hard coating layer are not sufficiently adhered; and on the other hand, in the case in which the average thickness of the crystal orientation hysteresis layer is up to 0.5 μm, the hysteresis effect to align the crystal orientation and the effect to improve the adhesion are fully achieved; therefore the average thickness of the layer was set to from 0.05 to 0.5 μm.
(b1) hard coating layer ((Ti, Al)N layer)
The Al component is contained in the (Ti, Al)N layer in order to increase thermal resistance and hardness of the TiN layer having high tenacity and so improve wear resistance thereof; if the ratio of Al to the sum of Al and Ti (i.e., atomic ratio of Al) is less than 0.45, the desired effect to improve the wear resistance cannot be obtained anymore; and on the other hand, if the ratio of Al is more than 0.65, the cutting edge tends to easily chip (small chipping); therefore, the ratio was set from 0.45 to 0.65.
Also, if the average thickness of the hard coating layer is less than 2 μm, desired wear resistance cannot be obtained; and the other hand, if the average thickness is more than 15 μm, the cutting edge tends to easily chip; therefore, the average thickness was set to from 2 to 15 μm.
Further, a value of not more than 0.6 degrees (2θ) for FWHM of the peak at the (200) plane in the X-ray diffraction pattern was chosen on the basis of the experimental result: This is because, in the case of FWHM of not more than 0.6 degrees, the hard coating layer has excellent wear resistance especially in high-speed cutting operation; and on the other hand, in the case of FWHM of more than 0.6 degrees or the lowered degree of the crystallinity in the (200) plane, desired wear resistance cannot be achieved anymore.
Next, according to the second embodiment of the present invention,
(a2) the carbonitride compound layer has an average thickness of 0.05 to 0.5 μm and is a Ti—Al carbonitride compound layer expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ) (wherein X: 0.01 to 0.15, Y: 0.01 to 0.15 by atomic ratio).
(b2) the nitride compound layer has an average thickness of 2 to 10 μm and is a A—Ti—Si nitride compound layer expressed by the composition formula as (Al 1−(A+B) Ti A Si B )N (wherein A: 0.35 to 0.55, B: 0.05 to 0.20 by atomic ratio).
Here, the Ti—Al carbonitride compound layer is preferably a layer which exhibits an X-ray diffraction pattern having a peak found at a (200) plane with FWHM of not more than 0.6 degrees in 2θ measured by Cu K a radiation using an X-ray diffractometer, and the A—Ti—Si nitride compound layer is also preferably a layer which exhibits an X-ray diffraction pattern having a peak found at a (200) plane with FWHM of not more than 0.6 degrees in 2θ measured by Cu K a radiation using an X-ray diffractometer.
In the following, regarding the coated cemented carbide tool according to the second embodiment of the present invention, the reason that the average thickness and the composition of the crystal orientation hysteresis layer and the hard coating layer formed on the coated cemented carbide tool were limited as described above will be explained.
(a2) Crystal Orientation Hysteresis Layer ((Ti, Al)NC Layer)
The aluminum (Al) component in the (Ti, Al)NC layer plays an important role in defining the (200) plane of the layer to be aligned parallel to the face and the flank of the cutting edge; if the ratio of Al to the sum of Al and Ti (i.e., atomic ratio of Al) is less than 0.01, the degree of the alignment of the crystal in the (200) plane is not sufficiently high, and on the other hand, if the Al ratio is more than 0.15, the degree of crystallinity is decreased so that it becomes difficult to adjust FWHM of the peak at the (200) plane to a width of not more than 0.6 degrees in 2θ; therefore, the ratio (X-value) was set from 0.01 to 0.15.
Also, the C component in the (Ti, Al)NC layer improves adhesion for both the cemented carbide substrate surface and the hard coating layer; if the C ratio is less than 0.01 by atomic ratio, a desired effect to improve the adhesion cannot be obtained anymore; and on the other hand, if the C ratio is greater than 0.15, the crystal orientation is so disordered that it becomes difficult to align crystal orientation in the (200) plane in a high degree; therefore, the ratio (Y-value) was set from 0.01 to 0.15.
Further, if the average thickness of the crystal orientation hysteresis layer is less than 0.05 μm, the hysteresis effect to align the crystal orientation, in which the texture or alignment of the (Ti, Al)NC layer to the (200) plane in a high degree is transferred to the hard coating layer, is not fully used; and on the other hand, in the case in which the average thickness of the crystal orientation hysteresis layer is up to 0.5 μm, the hysteresis effect to align the crystal orientation is fully achieved; therefore the average thickness of the layer was set to from 0.05 to 0.5 μm.
(b2) Hard Coating Layer ((Al, Ti, Si)N Layer)
The Ti component in the (Al, Ti, Si)N layer increases strength and toughness of the layer itself; if the ratio of Ti to the sum of Ti, Al and Si (i.e., atomic ratio of Ti) is less than 0.35, the effect increasing strength and toughness is not obtained as one desires; and the other hand, if the ratio is more than 0.55, wear resistance of the layer is decreased; therefore, the ratio was set to from 0.35 to 0.55.
Also, the Si component in the (Al, Ti, Si)N layer improves heat resistance and hardness at high temperature of the layer so that wear resistance of the layer is affected to be improved; if the ratio of Si to the sum of Si, Al and Ti (i.e., atomic ratio of Si) is less than 0.05, the effect improving wear resistance is not obtained as one desires; and the other hand, if the ratio is more than 0.20, strength and toughness are decreased and the cutting edge tends to easily chip; therefore, the ratio was set from 0.05 to 0.20.
Also, if the average thickness of the hard coating layer is less than 2 μm, desired wear resistance cannot be achieved; and the other hand, if the average thickness is more than 10 μm, the cutting edge tends to easily chip; therefore, the average thickness was set to from 2 to 10 μm.
Further, a value of not more than 0.6 degrees (2θ) for FWHM of the peak at the (200) plane in the X-ray diffraction pattern was chosen on the basis of the experimental result: This is because, in the case of FWHM of not more than 0.6 degrees, the hard coating layer has excellent wear resistance especially in high-speed cutting operation; and on the other hand, in the case of FWHM of more than 0.6 degrees or the lowered degree of the crystallinity in the (200) plane, desired wear resistance cannot be achieved anymore.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an X-ray diffraction pattern of a hard coating layer of a coated cemented carbide insert according to the first embodiment of the present invention;
FIG. 2 shows an X-ray diffraction pattern of a hard coating layer of a conventional coated cemented carbide insert;
FIG. 3 shows an X-ray diffraction pattern of a hard coating layer of a coated cemented carbide insert according to the second embodiment of the present invention;
FIG. 4 shows an X-ray diffraction pattern of a hard coating layer of another conventional coated cemented carbide insert;
FIG. 5 shows an explanatory drawing of the arc ion plating equipment;
FIG. 6A shows a perspective diagram of a coated cemented carbide insert, and FIG. 6B a cross-sectional view of the coated cemented carbide insert;
FIG. 7A shows a side view of a coated end mill, and FIG. 7B a cross-sectional view of the cutting edge of the coated end mill; and
FIG. 8A shows a side view of a coated drill, and FIG. 8B a cross-sectional view of the flute of the coated drill.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, a coated cemented carbide tool according to the first embodiment of the present invention will be explained based on examples.
EXAMPLE 1
Ingredient powders, i.e., WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder, TaN powder, and Co powder, all of which have an average grain size in a range from 1 to 3 μm, were prepared and mixed in accordance with compounding ratios as presented in TABLE 1. The ingredient powders were mixed under wet conditions using a ball mill for 72 hours, were dried, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was held in a vacuum (pressure of 6 Pa) at a predetermined temperature of 1400° C. for 1 hour so as to be sintered. After sintering, the honing of R: 0.05 is given to the part of the cutting edge so that cemented carbide substrates made from the WC base cemented carbide A1–A10 meeting ISO CNMG120408 geometrical configuration of insert were made, respectively.
Also, ingredient powders, i.e., TiCN (wherein TiC/TiN=50/50 by mass ratio) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder, Co powder, and Ni powder, all of which have an average grain size in a range from 0.5 to 2 μm, were prepared and mixed in accordance with compounding ratios as shown in TABLE 2. The ingredient powders were mixed under wet conditions using a ball mill for 24 hours, were dried, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was held in a nitrogen atmosphere (pressure of 2 kPa) at a predetermined temperature of 1500° C. for 1 hour so as to be sintered. After sintering, the honing of R: 0.03 is given to the part of the cutting edge so that cemented carbide substrates made from the TiCN based cermet B1–B6 meeting ISO CNMG120408 geometrical configuration of insert were made, respectively.
Next, these cemented carbide substrates A1–A10 and B1–B6 were subjected to ultrasonic cleaning in an acetone solvent, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Meanwhile, the Ti—Al alloys for the hard coating layer and the Ti—Al alloys for the crystal orientation hysteresis layer having various compositions were set to form the cathode (evaporation source), and the inside of the apparatus is evacuated to keep 0.5 Pa and heated to 500° C. by the heater. Then, Ar was introduced in the apparatus to make the Ar atmosphere of 10 Pa. Under this condition, the DC bias voltage of −800V was applied to the cemented carbide substrate, and the surface of the substrate was cleaned by Ar bombardment. Next, while introducing mixed gas of nitrogen gas and methane gas at a predetermined mixture ratio as reaction gas in the apparatus and setting to a reaction pressure of 3.5 Pa, the bias voltage applied to the above-mentioned substrate was lowered to −70 V, and the arc discharge was generated between the above-mentioned cathode (Ti—Al alloy for the crystal orientation hysteresis layer) and the anode. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) having the designated composition and thickness, which is shown in TABLES 3 and 4, was formed on the surface of the cemented carbide substrates A1–A10 and B1–B6, respectively. For the next step, while introducing nitrogen gas as reaction gas in the apparatus and setting to a reaction pressure of 4 Pa, the bias voltage applied to the above-mentioned substrate was lowered to −20 V, and the arc discharge was generated between the above-mentioned cathode (Ti—Al alloy for the hard coating layer) and the anode so that the hard coating layer ((Ti, Al)N layer) having the designated composition and thickness, which is shown in TABLES 3 and 4, was formed by vapor deposition. In this way, indexable type cutting inserts made of cemented carbide with surface coating of the present invention 1–20 (hereinafter referred to as a coated cemented carbide inserts of the present invention) having a geometrical configuration as shown in FIG. 6A as a perspective view and in FIG. 6B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional indexable type cutting inserts made of cemented carbide with surface coating 1–20 (hereinafter referred to as a conventional coated cemented carbide insert) as conventional coated cemented carbide tools were made as control samples as presented in TABLES 5 and 6, which are configured as with the inserts of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide inserts of the present invention 1–20 and the conventional coated cemented carbide inserts 1–20 were subjected to a high-speed, dry, turning operation test, by screw setting these inserts at the top of the cutting tool made of a tool steel. The detailed test conditions were set as follows:
for a test of high-speed, dry, continuous turning of alloyed steel;
workpiece: JIS (Japanese Industrial Standard) SCM440 round bar; cutting speed: 250 m/min.; depth of cutting: 1.5 mm; feed: 0.2 mm/rev.; and time: 10 min.;
for a test of high-speed, dry, interrupted turning of carbon steel;
workpiece: JIS S45C round bar with four flutes evenly spaced in the direction of the length; cutting speed: 280 m/min.; depth of cutting: 2.0 mm; feed: 0.3 mm/rev.; and time: 5 min.;
for a test of high-speed, dry, interrupted turning of cast iron;
workpiece: JIS FC300 round bar with four flutes evenly spaced in the direction of the length; cutting speed: 180 m/min.; depth of cutting: 1.5 mm; feed: 0.3 mm/rev.; and time: 5 min.;
The flank wear of the cutting edge was measured in each test. These results of the measurements are shown in TABLES 7 and 8, respectively.
TABLE 1
COMPOSITION (wt. %)
TYPE
Co
TiC
ZrC
VC
TaC
NbC
Cr 3 C 2
TiN
TaN
WC
CEMENTED
A-1
10.5
8
—
—
8
1.5
—
—
—
balance
CARBIDE
A-2
7
—
—
—
—
—
—
—
—
balance
SUBSTRATE
A-3
5.7
—
—
—
1.5
0.5
—
—
—
balance
A-4
5.7
—
—
—
—
—
1
—
—
balance
A-5
8.5
—
0.5
—
—
—
0.5
—
—
balance
A-6
9
—
—
—
2.5
1
—
—
—
balance
A-7
9
8.5
—
—
8
3
—
—
—
balance
A-8
11
8
—
—
4.5
—
—
1.5
—
balance
A-9
12.5
2
—
—
—
—
—
1
2
balance
A-10
14
—
—
0.2
—
—
0.8
—
—
balance
TABLE 2
COMPOSITION (wt. %)
TYPE
Co
Ni
ZrC
TaC
NbC
MO 2 C
WC
TiCN
CEMENTED
B-1
13
5
—
10
—
10
16
balance
CARBIDE
B-2
8
7
—
5
—
7.5
—
balance
SUBSTRATE
B-3
5
—
—
—
—
6
10
balance
B-4
10
5
—
11
2
—
—
balance
B-5
9
4
1
8
—
10
10
balance
B-6
12
5.5
—
10
—
9.5
14.5
balance
TABLE 3
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Ti, Al)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Ti
Al
N
(μm)
(degree)
CUTTING
1
A-1
0.95
0.05
0.97
0.03
0.05
0.28
0.45
0.55
1.00
3
0.52
INSERT
2
A-2
0.93
0.07
0.89
0.11
0.5
0.42
0.50
0.50
1.00
6.5
0.50
OF THE
3
A-3
0.91
0.09
0.90
0.10
0.1
0.20
0.55
0.45
1.00
8
0.60
PRESENT
4
A-4
0.89
0.11
0.93
0.07
0.2
0.35
0.35
0.65
1.00
2
0.45
INVENTION
5
A-5
0.88
0.12
0.99
0.01
0.05
0.38
0.40
0.60
1.00
9.5
0.41
6
A-6
0.87
0.13
0.90
0.10
0.5
0.29
0.55
0.45
1.00
5
0.40
7
A-7
0.86
0.14
0.96
0.04
0.1
0.31
0.50
0.50
1.00
15
0.58
8
A-8
0.84
0.16
0.99
0.01
0.4
0.39
0.45
0.55
1.00
4
0.42
9
A-9
0.82
0.18
0.98
0.02
0.05
0.33
0.40
0.60
1.00
3
0.53
10
A-10
0.80
0.20
0.99
0.01
0.3
0.37
0.35
0.65
1.00
10
0.59
TABLE 4
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Ti, Al)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Ti
Al
N
(μm)
(degree)
CUTTING
11
B-1
0.95
0.05
0.93
0.07
0.2
0.36
0.45
0.55
1.00
12
0.43
INSERT
12
B-2
0.93
0.07
0.87
0.13
0.1
0.40
0.50
0.50
1.00
5
0.52
OF THE
13
B-3
0.91
0.09
0.95
0.05
0.05
0.43
0.55
0.45
1.00
3
0.46
PRESENT
14
B-4
0.89
0.11
0.85
0.15
0.2
0.30
0.35
0.65
1.00
7.5
0.38
INVENTION
15
B-5
0.88
0.12
0.91
0.09
0.1
0.48
0.40
0.60
1.00
8
0.59
16
B-6
0.87
0.13
0.97
0.03
0.3
0.28
0.55
0.45
1.00
2
0.54
17
B-1
0.86
0.14
0.94
0.06
0.05
0.24
0.50
0.50
1.00
7
0.49
18
B-3
0.84
0.16
0.88
0.12
0.3
0.38
0.45
0.55
1.00
4.5
0.59
19
B-4
0.82
0.18
0.86
0.14
0.1
0.32
0.40
0.60
1.00
4
0.57
20
B-6
0.80
0.20
0.92
0.08
0.5
0.31
0.35
0.65
1.00
14
0.39
TABLE 5
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Ti, Al)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Ti
Al
N
(μm)
(degree)
CONVENTIONAL
1
A-1
—
—
—
—
—
—
0.45
0.55
1.00
3
1.12
CUTTING
2
A-2
—
—
—
—
—
—
0.50
0.50
1.00
6.5
1.01
INSERT
3
A-3
—
—
—
—
—
—
0.55
0.45
1.00
8
1.30
4
A-4
—
—
—
—
—
—
0.35
0.65
1.00
2
0.95
5
A-5
—
—
—
—
—
—
0.40
0.60
1.00
9.5
1.35
6
A-6
—
—
—
—
—
—
0.55
0.45
1.00
5
0.90
7
A-7
—
—
—
—
—
—
0.50
0.50
1.00
15
1.35
8
A-8
—
—
—
—
—
—
0.45
0.55
1.00
4
1.29
9
A-9
—
—
—
—
—
—
0.40
0.60
1.00
3
1.02
10
A-10
—
—
—
—
—
—
0.35
0.65
1.00
10
1.41
TABLE 6
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Ti, Al)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Ti
Al
N
(μm)
(degree)
CONVENTIONAL
11
B-1
—
—
—
—
—
—
0.45
0.55
1.00
12
0.98
CUTTING
12
B-2
—
—
—
—
—
—
0.50
0.50
1.00
5
1.23
INSERT
13
B-3
—
—
—
—
—
—
0.55
0.45
1.00
3
1.40
14
B-4
—
—
—
—
—
—
0.35
0.65
1.00
7.5
1.18
15
B-5
—
—
—
—
—
—
0.40
0.60
1.00
8
0.96
16
B-6
—
—
—
—
—
—
0.55
0.45
1.00
2
1.31
17
B-1
—
—
—
—
—
—
0.50
0.50
1.00
7
1.24
18
B-3
—
—
—
—
—
—
0.45
0.55
1.00
4.5
1.20
19
B-4
—
—
—
—
—
—
0.40
0.60
1.00
4
1.48
20
B-6
—
—
—
—
—
—
0.35
0.65
1.00
14
1.42
TABLE 7
Flank Wear Width (mm)
high-speed,
high-speed,
high-speed,
continuous
interrupted
interrupted
turning of
turning of
turning of
TYPE
alloyed steel
carbon steel
cast iron
CUTTING
1
0.14
0.16
0.19
INSERT
2
0.09
0.20
0.18
OF THE
3
0.11
0.19
0.20
PRESENT
4
0.10
0.19
0.24
INVENTION
5
0.15
0.14
0.23
6
0.10
0.15
0.18
7
0.08
0.17
0.21
8
0.15
0.18
0.19
9
0.08
0.16
0.23
10
0.13
0.18
0.24
CONVENTIONAL
1
0.68
0.77
0.82
CUTTING
2
0.57
0.94
0.74
INSERT
3
0.80
0.67
0.80
4
0.88
0.72
0.72
5
0.79
0.90
0.92
6
0.64
0.74
0.77
7
0.70
0.80
0.94
8
0.75
0.68
0.83
9
0.80
0.81
0.77
10
0.80
0.80
0.85
TABLE 8
Flank Wear Width (mm)
high-speed,
high-speed,
high-speed,
continuous
interrupted
interrupted
turning of
turning of
turning of
TYPE
alloyed steel
carbon steel
cast iron
CUTTING
11
0.11
0.15
0.25
INSERT
12
0.13
0.15
0.20
OF THE
13
0.09
0.16
0.25
PRESENT
14
0.07
0.14
0.22
INVENTION
15
0.08
0.14
0.22
16
0.10
0.17
0.21
17
0.12
0.20
0.19
18
0.13
0.14
0.18
19
0.16
0.17
0.18
20
0.09
0.20
0.20
CONVENTIONAL
11
0.62
0.92
0.73
CUTTING
12
0.56
0.64
0.75
INSERT
13
0.79
0.76
0.64
14
0.64
0.71
0.70
15
0.70
0.87
0.96
16
0.80
0.68
0.86
17
0.83
0.68
0.89
18
0.54
0.83
0.98
19
0.69
0.77
0.87
20
0.66
0.90
0.69
EXAMPLE 2
Ingredient powders, i.e., middle coarse grain WC powder having 5.5 μm for the average particle diameter, fine WC powder having 0.8 μm for the average particle diameter, TaC powder having 1.3 μm for the average particle diameter, NbC powder having 1.2 μm for the average particle diameter, ZrC powder having 1.2 μm for the average particle diameter, Cr 3 C 2 powder having 2.3 μm for the average particle diameter, VC powder having 1.5 μm for the average particle diameter, (Ti,W)C powder having 1.0 μm for the average particle diameter, Co powder having 1.8 μm for the average particle diameter were prepared and mixed in accordance with compounding ratios as presented in TABLE 9. Furthermore, wax was added to the ingredient powders and these were mixed in acetone using a ball mill for 24 hours, dried under a reduced pressure, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was heated up to a predetermined temperature in a range from 1370 to 1470° C. at a rate of 7° C./min. under a pressure of 6 Pa and held at this temperature for 1 hour so as to be sintered. After that, it was cooled in the condition of a furnace cooling so that a sintered compact was formed. In this way, three types of the sintered compact were made as round bars each having a diameter of 8 mm, 13 mm, and 26 mm, respectively, for making cemented carbide substrate. These three types of sintered compact as round bar were subjected further to a grinding work so that cemented carbide substrates (end mills) from “a” to “h” were made. Here, each substrate has dimensions, i.e., the diameter and the length, of the part of the cutting edge of 6 mm×13 mm, 10 mm×22 mm, and 20 mm×45 mm, respectively, as presented in TABLE 9.
Next, these cemented carbide substrates (end mills) a-h were subjected to ultrasonic cleaning in an acetone solvent, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) and the hard coating layer ((Ti, Al)N layer) having the designated composition and thickness, which are presented in TABLE 10, were formed on the surface of the cemented carbide substrates by vapor deposition under the same condition as for Example 1, respectively. In this way, end mill made of cemented carbide with surface coating of the present invention 1–8 (hereinafter referred to as a coated cemented carbide end mill of the present invention) having a geometrical configuration as shown in FIG. 7A as a perspective view and in FIG. 7B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional end mills made of cemented carbide with surface coating 1–8 (hereinafter referred as a conventional coated cemented carbide end mill) as conventional coated cemented carbide tools were made as control samples, as presented in TABLE 11, which are configured as with the end mills of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide end mills of the present invention 1–8 and the conventional coated cemented carbide end mills 1–8 were subjected to a high-speed, dry, slotting operation test. The detailed test conditions were set as follows:
for a test of high-speed, dry, slotting of alloyed steel using the coated cemented carbide end mills of the present invention 1–3 and the conventional coated cemented carbide end mills 1–3;
workpiece: JIS-SNCM439 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 150 m/min.; depth of the groove (depth of cutting): 3 mm; table-feed: 650 mm/min.;
for a test of high-speed, dry, slotting of carbon steel using the coated cemented carbide end mills of the present invention 4–6 and the conventional coated cemented carbide end mills 4–6;
workpiece: JIS-S55C plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 160 m/min.; depth of the groove (depth of cutting): 5 mm; table-feed: 600 mm/min.;
for a test of high-speed, dry, slotting of cast iron using the coated cemented carbide end mills of the present invention 7 and 8 and the conventional coated cemented carbide end mills 7 and 8;
workpiece: JIS-FC250 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 160 m/min.; depth of the groove (depth of cutting): 10 mm; table-feed: 320 mm/min.
In all slotting tests, the cut groove length was measured; when the flank of the peripheral cutting edge is worn away by 0.1 mm, this is a guide for the end of the usual tool life. These results of the measurements are shown in TABLES 10 and 11, respectively.
TABLE 9
diameter × length
COMPOSITION (wt. %)
of the cutting edge
TYPE
Co
(Ti, W)C
TaC
NbC
ZrC
Cr 3 C 2
VC
WC
(mm)
CEMENTED
a
5
5
—
—
—
—
—
middle, coarse
6 × 13
CARBIDE
grain: balance
SUBSTRATE
b
6
—
1
0.5
—
—
—
fine
6 × 13
(END MILL)
grain: balance
c
6
—
1
—
1
0.5
0.5
fine
6 × 13
grain: balance
d
8
—
—
—
—
0.5
0.5
fine
10 × 22
grain: balance
e
9
25
10
1
—
—
—
middle, coarse
10 × 22
grain: balance
f
10
—
—
—
—
1
—
fine
10 × 22
grain: balance
g
12
17
9
1
—
—
—
middle, coarse
20 × 45
grain: balance
h
16
—
10
5
10
—
—
middle, coarse
20 × 45
grain: balance
TABLE 10
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
END MILL
1
a
0.94
0.06
0.97
0.03
0.1
0.43
OF THE
2
b
0.91
0.09
0.99
0.01
0.4
0.32
PRESENT
3
c
0.90
0.10
0.95
0.05
0.2
0.39
INVENTION
4
d
0.88
0.12
0.93
0.07
0.1
0.25
5
e
0.86
0.14
0.86
0.14
0.5
0.35
6
f
0.83
0.17
0.85
0.15
0.1
0.37
7
g
0.81
0.19
0.89
0.01
0.05
0.29
8
h
0.80
0.20
0.91
0.09
0.3
0.40
Hard Coating Layer ((Ti, Al)N Layer)
Designated Composition
Designated
FWHM at
(atomic ratio)
Thickness
(200) plane
cutting
TYPE
Ti
Al
N
(μm)
(degree)
length (m)
END MILL
1
0.45
0.55
1.00
4
0.60
160
OF THE
2
0.40
0.60
1.00
7
0.54
170
PRESENT
3
0.55
0.45
1.00
2
0.48
140
INVENTION
4
0.50
0.50
1.00
3
0.42
180
5
0.50
0.50
1.00
9
0.56
175
6
0.55
0.45
1.00
2.5
0.48
180
7
0.35
0.65
1.00
15
0.40
100
8
0.45
0.55
1.00
4.5
0.46
110
TABLE 11
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
degree
CONVENTIONAL
1
a
—
—
—
—
—
—
END MILL
2
b
—
—
—
—
—
—
3
c
—
—
—
—
—
—
4
d
—
—
—
—
—
—
5
e
—
—
—
—
—
—
6
f
—
—
—
—
—
—
7
g
—
—
—
—
—
—
8
h
—
—
—
—
—
—
Hard Coating Layer ((Ti, Al)N layer)
Designated Composition
Designated
FWHM at
cutting
(atomic ratio)
Thickness
(200) plane
length
TYPE
Ti
Al
N
(μm)
(degree)
(m)
CONVENTIONAL
1
0.45
0.55
1.00
4
0.99
40
END MILL
2
0.40
0.60
1.00
7
1.29
40
3
0.55
0.45
1.00
2
1.12
45
4
0.50
0.50
1.00
3
0.90
55
5
0.50
0.50
1.00
9
1.20
50
6
0.55
0.45
1.00
2.5
1.38
60
7
0.35
0.65
1.00
1.5
0.93
25
8
0.45
0.55
1.00
1.5
1.42
20
EXAMPLE 3
The three types of sintered round rod each having a diameter of 8 mm (for cemented carbide substrates a–c), 13 mm (for cemented carbide substrates d–f), and 26 mm (for cemented carbide substrate g, h), respectively, which were made through the process as described in Example 2, were used again and further subjected to a grinding work so that cemented carbide substrates (twist drills) from “a′” to “h′” were made in which each substrate has dimensions, i.e., the diameter and the length, of 4 mm×13 mm (cemented carbide substrates a′–c′), 8 mm×22 mm (cemented carbide substrates d′–f′), and 16 mm×45 mm (cemented carbide substrates g′, h′), respectively.
Next, these cemented carbide substrates (twist drills) a′–h′ were subjected to ultrasonic cleaning in an acetone solvent for the surface, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) and the hard coating layer ((Ti, Al)N layer) having the designated composition and thickness, which are presented in TABLE 12, were formed on the surface of the cemented carbide substrates by vapor deposition under the same condition as for Example 1, respectively. In this way, drills made of cemented carbide with surface coating of the present invention 1–8 (hereinafter referred to as a coated cemented carbide drill of the present invention) having a geometrical configuration as shown in FIG. 8A as a perspective view and in FIG. 8B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional drills made of cemented carbide with surface coatings 1–8 (hereinafter referred as a conventional coated cemented carbide drill) as conventional coated cemented carbide tools were made as control samples, as presented in TABLE 13, which are configured as with the drills of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide drills of the present invention 1–8 and the conventional coated cemented carbide drills 1–8 were subjected to a high-speed, wet, drilling operation test in which a blind hole with 2.5 times the diameter of the drill-diameter was drilled. The detailed test conditions were set as follows:
for a test of high-speed, wet, drilling of alloyed steel using the coated cemented carbide drills of the present invention 1–3 and the conventional coated cemented carbide drills 1–3;
workpiece: JIS-SCM440 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 100 m/min.; feed: 0.12 mm/rev.;
for a test of high-speed, wet, boring of carbon steel using the coated cemented carbide drills of the present invention 4–6 and the conventional coated cemented carbide drills 4–6;
workpiece: JIS-S50C plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 120 m/min.; feed: 0.25 mm/rev.;
for a test of high-speed, wet, boring of cast iron using the coated cemented carbide drills of the present invention 7 and 8 and the conventional coated cemented carbide drills 7 and 8;
workpiece: JIS-FC300 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 90 m/min.; feed: 0.27 mm/rev.;
In all high-speed, wet, boring tests, the numbers of drilled holes were measured when the flank wear width of the cutting edge came down to 0.3 mm. These results of the measurements are shown in TABLES 12 and 13, respectively.
TABLE 12
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
DRILL
1
a′
0.95
0.05
0.97
0.03
0.5
0.23
OF THE
2
b′
0.93
0.07
0.90
0.10
0.4
0.45
PRESENT
3
c′
0.91
0.09
0.94
0.06
0.3
0.38
INVENTION
4
d′
0.88
0.12
0.89
0.11
0.05
0.29
5
e′
0.86
0.14
0.99
0.01
0.2
0.45
6
f′
0.83
0.17
0.87
0.13
0.4
0.42
7
g′
0.82
0.18
0.92
0.08
0.4
0.33
8
h′
0.80
0.20
0.85
0.15
0.5
0.40
Hard Coating Layer ((Ti, Al)N Layer)
Designated Composition
Designated
FWHM at
number
(atomic ratio)
Thickness
(200) plane
of
TYPE
Ti
Al
N
(μm)
(degree)
holes
DRILL
1
0.45
0.55
1.00
15
0.45
6500
OF THE
2
0.55
0.45
1.00
2
0.42
5500
PRESENT
3
0.35
0.65
1.00
10
0.48
7000
INVENTION
4
0.45
0.55
1.00
12
0.53
10000
5
0.40
0.60
1.00
8
0.58
11000
6
0.50
0.50
1.00
10
0.60
9500
7
0.55
0.45
1.00
9
0.53
2500
8
0.35
0.65
1.00
5
0.51
3200
TABLE 13
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
CONVENTIONAL
1
a′
—
—
—
—
—
—
DRILL
2
b′
—
—
—
—
—
—
3
c′
—
—
—
—
—
—
4
d′
—
—
—
—
—
—
5
e′
—
—
—
—
—
—
6
f′
—
—
—
—
—
—
7
g′
—
—
—
—
—
—
8
h′
—
—
—
—
—
—
Hard Coating Layer ((Ti, Al)N layer)
Designated Composition
Designated
FWHM at
number
(atomic ratio)
Thickness
(200) plane
of
TYPE
Ti
Al
N
(μm)
(degree)
holes
CONVENTIONAL
1
0.45
0.55
1.00
15
1.42
3000
DRILL
2
0.55
0.45
1.00
2
0.92
2500
3
0.35
0.65
1.00
10
1.03
3800
4
0.45
0.55
1.00
12
1.29
4800
5
0.40
0.60
1.00
8
1.33
6000
6
0.50
0.50
1.00
10
0.98
5500
7
0.55
0.45
1.00
9
1.22
800
8
0.35
0.65
1.00
5
1.18
1200
Incidentally, the compositions of the above-mentioned layers, i.e., the crystal orientation hysteresis layer ((Ti, Al)NC layer) and the hard coating layer ((Ti, Al)N layer) on the coated cemented carbide inserts of the present invention 1–20, the coated cemented carbide end mills of the present invention 1–8 and the coated cemented carbide drills of the present invention 1–8 as the coated cemented carbide tools of the present invention, as well as the hard coating layer ((Ti, Al)N layer) on the conventional coated cemented carbide inserts 1–20, the conventional coated cemented carbide end mills 1–8, and the conventional coated cemented carbide drills 1–8 as the conventional coated cemented carbide tools, were measured in the thickness direction at the center area by using Auger Electron Spectral analysis equipment. The results of these measurements indicated that the composition of the layers was substantially the same as the designated value.
Also, cross sectional measurements of the thickness of the layers formed on the coated cemented carbide tools of the present invention and the conventional coated cemented carbide tools were done by using a scanning electron microscope. Then, the average thickness (the average of 5 points measurements) was indicated with the same value substantially as the designated thickness.
Moreover, the layers formed on the coated cemented carbide tools of the present invention and the conventional coated cemented carbide tools were inspected at the face and/or the flank of the cutting edge using an X-ray diffractometer. Through these inspections, FWHM of the peak at the (200) plane in the X-ray diffraction pattern was determined (here, when it was difficult to measure the tools itself, the sample pieces for measurement, which were set in the arc ion plating apparatus at the time of manufacturing the tools, were inspected and the X-ray diffraction pattern thereof was used to determine FWHM of the peak). These results are shown in TABLES 3–6 and TABLES 10–13.
The experimental results which are presented in TABLES 3–13 obviously show the following: The coated cemented carbide tool of the present invention on which the hard coating layer having a peak of a narrow FWHM at the (200) plane due to the existence of the crystal orientation hysteresis layer and so having excellent heat resistance (i.e., resistance to oxidation and hardness at high temperature) exhibits an excellent wear resistance even in cutting operations not only of steels but also of cast irons accompanied by high heat generation: This is because both of the increase of the heat resistance and the improvement of the adhesion between the hard coating layer and the cemented carbide substrate surface due to the C component in the crystal orientation hysteresis layer provide a synergetic effect; As opposed to this, with regard to the conventional coated cemented carbide tool in which the degree of crystallinity at the (200) plane of the hard coating layer is low, abrasion proceeds rapidly and the operating life reaches an end in a short time when it is used in high-speed cutting operation accompanied by high heat generation.
As described above, the coated cemented carbide tool according to the first embodiment has an excellent wear resistance even in high-speed cutting operations on various steels and cast irons, and exhibits outstanding ability for cutting so that it sufficiently meets the requirements that cutting apparatus should have high performance, and that cutting operations should be performed with less power, less energy and low cost.
In the following, a coated cemented carbide tool according to the second embodiment of the present invention will be explained based on examples.
EXAMPLE 4
Ingredient powders, i.e., WC powder, TiC powder, ZrC powder, VC powder, TaC powder, NbC powder, Cr 3 C 2 powder, TiN powder, TaN powder, and Co powder, all of which have an average grain size in a range from 1 to 3 μm, were prepared and mixed in accordance with compounding ratios as presented in TABLE 14. The ingredient powders were mixed under wet conditions using a ball mill for 72 hours, were dried, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was held in a vacuum (pressure of 6 Pa) at a predetermined temperature of 1400° C. for 1 hour so as to be sintered. After sintering, the honing of R: 0.03 is given to the part of the cutting edge so that cemented carbide substrates made from the WC base cemented carbide A1–A10 meeting ISO CNMG120408 geometrical configuration of insert were made respectively.
Also, ingredient powders, i.e., TiCN (wherein TiC/TiN=50/50 by mass ratio) powder, Mo 2 C powder, ZrC powder, NbC powder, TaC powder, WC powder, Co powder, and Ni powder, all of which have an average grain size in a range from 0.5 to 2 μm, were prepared and mixed in accordance with compounding ratios as shown in TABLE 15. The ingredient powders were mixed under wet conditions using a ball mill for 24 hours, were dried, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was held in a nitrogen atmosphere (pressure of 2 kPa) at a predetermined temperature of 1500° C. for 1 hour so as to be sintered. After sintering, the honing of R: 0.03 is given to the part of the cutting edge so that cemented carbide substrates made from the TiCN based cermet B1–B6 meeting ISO CNMG120408 geometrical configuration of insert were made respectively.
Next, these cemented carbide substrates A1–A10 and B1–B6 were subjected to ultrasonic cleaning in an acetone solvent, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Meanwhile, the Al—Ti—Si alloys for the hard coating layer and the Ti—Al alloys for the crystal orientation hysteresis layer having various compositions were set to form the cathode (evaporation source), and the inside of the apparatus is evacuated to keep 0.5 Pa and heated to 500° C. by the heater. Then, Ar was introduced in the apparatus to make the Ar atmosphere of 1.3 Pa. Under this condition, the DC bias voltage of −800V was applied to the cemented carbide substrate, and the surface of the substrate was cleaned by Ar bombardment. Next, while introducing mixed gas of nitrogen gas and methane gas at a predetermined mixture ratio as reaction gas in the apparatus and setting to a reaction pressure of 3.5 Pa, the bias voltage applied to the above-mentioned substrate was lowered to −70 V, and the arc discharge was generated between the above-mentioned cathode (Ti—Al alloy for the crystal orientation hysteresis layer) and the anode. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) having the designated composition and thickness, which is shown in TABLES 16 and 17, was formed on the surface of the cemented carbide substrates A1–A10 and B1–B6, respectively. For the next step, while introducing nitrogen gas as reaction gas in the apparatus and setting to a reaction pressure of 2.7 Pa, the bias voltage applied to the above-mentioned substrate was lowered to −50 V, and the arc discharge was generated between the above-mentioned cathode (Al—Ti—Si alloy for the hard coating layer) and the anode so that the hard coating layer ((Al, Ti, Si)N layer) having the designated composition and thickness, which is shown in TABLES 16 and 17, was formed by vapor deposition. In this way, indexable type inserts made of cemented carbide with surface coating of the present invention 1–20 (hereinafter referred to as a coated cemented carbide inserts of the present invention) having a geometrical configuration as shown in FIG. 6A as a perspective view and in FIG. 6B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional indexable type inserts made of cemented carbide with surface coating 1–20 (hereinafter referred as a conventional coated cemented carbide insert) as conventional coated cemented carbide tools were made as control samples as presented in TABLES 18 and 19, which are configured as with the inserts of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide inserts of the present invention 1–20 and the conventional coated cemented carbide inserts 1–20 were subjected to a high-speed, dry, turning operation test, by screw setting these inserts at the top of the cutting tool made of a tool steel. The detailed test conditions were set as follows:
for a test of high-speed, dry, continuous turning of alloyed steel;
workpiece: JIS (Japanese Industrial Standard) SCM440 round bar; cutting speed: 330 m/min.; depth of cutting: 1.3 mm; feed: 0.5 mm/rev.; and time: 15 min.;
for a test of high-speed, dry, interrupted turning of carbon steel;
workpiece: JIS S45C round bar with four flutes evenly spaced in the direction of the length; cutting speed: 300 m/min.; depth of cutting: 1.8 mm; feed: 0.5 mm/rev.; and time: 18 min.;
for a test of high-speed, dry, interrupted turning of cast iron;
workpiece: JIS FC300 round bar with four flutes evenly spaced in the direction of the length; cutting speed: 380 m/min.; depth of cutting: 1.3 mm; feed: 0.3 mm/rev.; and time: 30 min.;
The flank wear of the cutting edge was measured in each test. These results of the measurements are shown in TABLE 20.
TABLE 14
COMPOSITION (wt. %)
TYPE
Co
TiC
ZrC
VC
TaC
NbC
Cr 3 C 2
TiN
TaN
WC
CEMENTED
A-1
10.5
8
—
—
8
1.5
—
—
—
balance
CARBIDE
A-2
7
—
—
—
—
—
—
—
—
balance
SUBSTRATE
A-3
5.7
—
—
—
1.5
0.5
—
—
—
balance
A-4
5.7
—
—
—
—
—
1
—
—
balance
A-5
8.5
—
0.5
—
—
—
0.5
—
—
balance
A-6
9
—
—
—
2.5
1
—
—
—
balance
A-7
9
8.5
—
—
8
3
—
—
—
balance
A-8
11
8
—
—
4.5
—
—
1.5
—
balance
A-9
12.5
2
—
—
—
—
—
1
2
balance
A-10
14
—
—
0.2
—
—
0.8
—
—
balance
TABLE 15
COMPOSITION (wt. %)
TYPE
Co
Ni
ZrC
TaC
NbC
MO 2 C
WC
TiCN
CEMENTED
B-1
13
5
—
10
—
10
16
balance
CARBIDE
B-2
8
7
—
5
—
7.5
—
balance
SUBSTRATE
B-3
5
—
—
—
—
6
10
balance
B-4
10
5
—
11
2
—
—
balance
B-5
9
4
1
8
—
10
10
balance
B-6
12
5.5
—
10
—
9.5
14.5
balance
TABLE 16
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Al, Ti, Si)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Al
Ti
Si
N
(μm)
(degree)
CUTTING
1
A-1
0.99
0.01
0.85
0.15
0.35
0.42
0.25
0.55
0.20
1.00
8.0
0.51
INSERT
2
A-2
0.95
0.05
0.99
0.01
0.30
0.33
0.50
0.35
0.15
1.00
2.0
0.49
OF THE
3
A-3
0.90
0.10
0.92
0.08
0.05
0.32
0.40
0.50
0.10
1.00
7.5
0.44
PRESENT
4
A-4
0.85
0.15
0.90
0.10
0.45
0.53
0.45
0.50
0.05
1.00
4.5
0.58
INVENTION
5
A-5
0.99
0.01
0.95
0.05
0.15
0.40
0.45
0.35
0.20
1.00
3.5
0.50
6
A-6
0.95
0.05
0.90
0.10
0.20
0.33
0.30
0.55
0.15
1.00
7.0
0.41
7
A-7
0.90
0.10
0.92
0.08
0.50
0.55
0.40
0.50
0.10
1.00
10.0
0.58
8
A-8
0.85
0.15
0.85
0.15
0.15
0.45
0.60
0.35
0.05
1.00
3.5
0.51
9
A-9
0.95
0.05
0.90
0.10
0.25
0.50
0.45
0.40
0.15
1.00
8.0
0.55
10
A-10
0.90
0.10
0.93
0.07
0.40
0.48
0.45
0.45
0.10
1.00
4.5
0.58
TABLE 17
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Al, Ti, Si)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Al
Ti
Si
N
(μm)
(degree)
CUTTING
11
B-1
0.85
0.15
0.91
0.09
0.15
0.43
0.40
0.55
0.05
1.00
5.0
0.51
INSERT
12
B-2
0.90
0.10
0.97
0.03
0.50
0.51
0.55
0.35
0.10
1.00
10.0
0.55
OF THE
13
B-3
0.95
0.05
0.93
0.07
0.35
0.40
0.35
0.50
0.15
1.00
7.0
0.53
PRESENT
14
B-4
0.99
0.01
0.85
0.15
0.25
0.45
0.30
0.50
0.20
1.00
2.5
0.56
INVENTION
15
B-5
0.85
0.15
0.88
0.12
0.10
0.45
0.60
0.35
0.05
1.00
8.0
0.50
16
B-6
0.90
0.10
0.92
0.08
0.50
0.55
0.35
0.55
0.10
1.00
2.0
0.59
17
B-2
0.95
0.05
0.90
0.10
0.25
0.48
0.30
0.55
0.15
1.00
4.5
0.51
18
B-3
0.99
0.01
0.99
0.01
0.05
0.39
0.45
0.35
0.20
1.00
3.0
0.44
19
B-4
0.90
0.10
0.88
0.12
0.45
0.49
0.50
0.40
0.10
1.00
4.0
0.56
20
B-6
0.95
0.05
0.85
0.15
0.35
0.44
0.40
0.45
0.15
1.00
2.5
0.49
TABLE 18
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Al, Ti, Si)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Al
Ti
Si
N
(μm)
(degree)
CONVENTIONAL
1
A-1
—
—
—
—
—
—
0.25
0.55
0.20
1.00
8.0
1.20
CUTTING
2
A-2
—
—
—
—
—
—
0.50
0.35
0.15
1.00
2.0
1.00
INSERT
3
A-3
—
—
—
—
—
—
0.40
0.50
0.10
1.00
7.5
0.93
4
A-4
—
—
—
—
—
—
0.45
0.50
0.05
1.00
4.0
1.35
5
A-5
—
—
—
—
—
—
0.45
0.35
0.20
1.00
3.5
0.95
6
A-6
—
—
—
—
—
—
0.30
0.55
0.15
1.00
7.0
1.00
7
A-7
—
—
—
—
—
—
0.40
0.50
0.10
1.00
10.0
1.50
8
A-8
—
—
—
—
—
—
0.60
0.35
0.05
1.00
3.5
1.00
9
A-9
—
—
—
—
—
—
0.45
0.40
0.15
1.00
8.0
1.35
10
A-10
—
—
—
—
—
—
0.45
0.45
0.10
1.00
4.5
0.97
TABLE 19
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Hard Coating Layer ((Al, Ti, Si)N layer)
Carbide
Designated Composition
Designated
FWHM at
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
Al
Ti
Si
N
(μm)
(degree)
CONVENTIONAL
11
B-1
—
—
—
—
—
—
0.40
0.55
0.05
1.00
5.0
0.96
CUTTING
12
B-2
—
—
—
—
—
—
0.55
0.35
0.10
1.00
10.0
0.93
INSERT
13
B-3
—
—
—
—
—
—
0.35
0.50
0.15
1.00
7.0
1.10
14
B-4
—
—
—
—
—
—
0.30
0.50
0.20
1.00
2.5
1.20
15
B-5
—
—
—
—
—
—
0.60
0.35
0.05
1.00
8.0
1.30
16
B-6
—
—
—
—
—
—
0.35
0.55
0.10
1.00
2.0
0.90
17
B-2
—
—
—
—
—
—
0.30
0.50
0.15
1.00
4.5
0.92
18
B-3
—
—
—
—
—
—
0.45
0.35
0.20
1.00
3.0
1.25
19
B-4
—
—
—
—
—
—
0.50
0.40
0.10
1.00
4.0
1.50
20
B-6
—
—
—
—
—
—
0.40
0.45
0.15
1.00
2.5
1.00
TABLE 20
Flank Wear Width (mm)
high-speed,
high-speed,
high-speed,
continuous
interrupted
interrupted
turning of
turning of
turning of
TYPE
alloyed steel
carbon steel
cast iron
CUTTING
1
0.21
0.33
0.31
INSERT
2
0.25
0.26
0.29
OF THE
3
0.19
0.28
0.24
PRESENT
4
0.28
0.25
0.23
INVENTION
5
0.25
0.27
0.23
6
0.22
0.26
0.26
7
0.29
0.23
0.19
8
0.31
0.28
0.22
9
0.25
0.26
0.24
10
0.33
0.25
0.28
11
0.25
0.28
0.21
12
0.20
0.26
0.22
13
0.18
0.19
0.20
14
0.24
0.28
0.26
15
0.29
0.26
0.23
16
0.25
0.19
0.25
17
0.33
0.30
0.23
18
0.21
0.23
0.26
19
0.19
0.29
0.25
20
0.26
0.31
0.24
CONVENTIONAL
1
0.43
0.49
0.51
CUTTING
2
0.39
0.51
0.38
INSERT
3
0.51
0.33
0.41
4
0.40
0.41
0.46
5
0.43
0.45
0.48
6
0.43
0.39
0.45
7
0.49
0.38
0.46
8
0.55
0.35
0.51
9
0.53
0.44
0.58
10
0.48
0.46
0.33
11
0.42
0.51
0.39
12
0.52
0.43
0.45
13
0.40
0.39
0.43
14
0.53
0.48
0.49
15
0.51
0.46
0.49
16
0.49
0.44
0.47
17
0.44
0.47
0.44
18
0.55
0.49
0.51
19
0.45
0.48
0.48
20
0.56
0.51
0.55
EXAMPLE 5
Ingredient powders, i.e., middle coarse grain WC powder having 5.5 μm for the average particle diameter, fine WC powder having 0.8 μm for the average particle diameter, TaC powder having 1.3 μm for the average particle diameter, NbC powder—having 1.2 μm for the average particle diameter, ZrC powder having 1.2 μm for the average particle diameter, Cr 3 C 2 powder having 2.3 μm for the average particle diameter, VC powder having 1.5 μm for the average particle diameter, (Ti, W)C powder having 1.0 μm for the average particle diameter, Co powder having 1.8 μm for the average particle diameter were prepared and mixed in accordance with compounding ratios as presented in TABLE 21. Furthermore, wax was added to the ingredient powders and these were mixed in acetone using a ball mill for 24 hours, dried under a reduced pressure, and were compacted under pressure of 100 MPa so as to form a green compact. The green compact was heated up to a predetermined temperature in a range from 1370 to 1470° C. at a rate of 7° C./min. under a pressure of 6 Pa and held at this temperature for 1 hour so as to be sintered. After that, it was cooled in the condition of a furnace cooling so that a sintered compact was formed. In this way, three types of the sintered compact were made as round bars each having a diameter of 8 mm, 13 mm, and 26 mm, respectively, for making cemented carbide substrate. These three types of sintered compact as round bars were subjected further to a grinding work so that cemented carbide substrates (end mills) from “a” to “h” were made. Here, each substrate has dimensions, i.e., the diameter and the length, of the part of the cutting edge of 6 mm×13 mm, 10 mm×22 mm, and 20 mm×45 mm, were respectively, as presented in TABLE 21.
Next, these cemented carbide substrates (end mills) a-h were subjected to ultrasonic cleaning in an acetone solvent, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) and the hard coating layer ((Al, Ti, Si)N layer) having the designated composition and thickness, which are presented in TABLE 22, were formed on the surface of the cemented carbide substrates by vapor deposition under the same condition as for Example 4, respectively. In this way, end mill made of cemented carbide with surface coating of the present invention 1–8 (hereinafter referred to as a coated cemented carbide end mill of the present invention) having a geometrical configuration as shown in FIG. 7A as a perspective view and in FIG. 7B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional end mills made of cemented carbide with surface coatings 1–8 (hereinafter referred as a conventional coated cemented carbide end mill) as conventional coated cemented carbide tools were made as control samples, as presented in TABLE 23, which are configured as with the end mills of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide end mills of the present invention 1–8 and the conventional coated cemented carbide end mills 1–8 were subjected to a high-speed, dry, slotting operation test. The detailed test conditions were set as follows:
for a test of high-speed, wet, slotting of tool steel using the coated cemented carbide end mills of the present invention 1–3 and the conventional coated cemented carbide end mills 1–3 (wherein water-miscible cutting fluid was applied);
workpiece: JIS-SKD61 plate (hardness: HRC40) having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 120 m/min.; depth of the groove (depth of cutting): 1.3 mm; table-feed: 700 mm/min.;
for a test of high-speed, wet, slottinn of stainless steel using the coated cemented carbide end mills of the present invention 4–6 and the conventional coated cemented carbide end mills 4–6;
workpiece: JIS-SUS304 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 100 m/min.; depth of the groove (depth of cutting): 10 mm; table-feed: 500 mm/min.;
for a test of high-speed, wet, of carbon steel using the coated cemented carbide end mills of the present invention 7 and 8 and the conventional coated cemented carbide end mills 7 and 8 (wherein water-miscible cutting fluid was applied, respectively);
workpiece: JIS-S45C plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 125 m/min.; depth of the groove (depth of cutting): 12 mm; table-feed: 300 mm/min.
In all slotting tests, the cut groove length was measured; when the flank of the peripheral cutting edge is worn away by 0.2 mm, this is a guide for the end of the usual tool life. These results of the measurements are shown in TABLES 22 and 23, respectively.
TABLE 21
diameter × length
COMPOSITION (wt. %)
of the cutting edge
TYPE
Co
(Ti, W)C
TaC
NbC
ZrC
Cr 3 C 2
VC
WC
(mm)
CEMENTED
a
8
5
—
—
—
—
—
middle, coarse
6 × 13
CARBIDE
grain: balance
SUBSTRATE
b
6
—
1
0.5
—
—
—
fine
6 × 13
(END MILL)
grain: balance
c
8
—
1
—
1
0.5
0.5
fine
6 × 13
grain: balance
d
8
—
—
—
—
0.5
0.5
fine
10 × 22
grain: balance
e
9
25
10
1
—
—
—
middle, coarse
10 × 22
grain: balance
f
10
—
—
—
—
1
—
fine
10 × 22
grain: balance
g
12
17
9
1
—
—
—
middle, coarse
20 × 45
grain: balance
h
12
—
10
5
10
—
—
middle, coarse
20 × 45
grain: balance
TABLE 22
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
END MILL
1
a
0.85
0.15
0.99
0.01
0.50
0.40
OF THE
2
b
0.95
0.05
0.88
0.12
0.45
0.36
PRESENT
3
c
0.99
0.01
0.92
0.08
0.05
0.51
INVENTION
4
d
0.90
0.10
0.95
0.05
0.40
0.45
5
e
0.95
0.05
0.85
0.15
0.25
0.48
6
f
0.99
0.01
0.87
0.13
0.35
0.50
7
g
0.85
0.15
0.90
0.10
0.15
0.33
8
h
0.90
0.10
0.85
0.15
0.50
0.42
Hard Coating Layer ((Al, Ti, Si)N layer)
Designated Composition
Designated
FWHM at
cutting
(atomic ratio)
Thickness
(200) plane
length
TYPE
Al
Ti
Si
N
(μm)
(degree)
(m)
END MILL
1
0.25
0.55
0.20
1.00
2.0
0.48
630
OF THE
2
0.50
0.40
0.10
1.00
3.0
0.42
720
PRESENT
3
0.60
0.35
0.05
1.00
5.5
0.58
700
INVENTION
4
0.35
0.50
0.15
1.00
3.0
0.55
690
5
0.45
0.45
0.10
1.00
7.0
0.53
600
6
0.60
0.35
0.05
1.00
4.5
0.57
540
7
0.40
0.50
0.10
1.00
10.0
0.40
530
8
0.45
0.40
0.15
1.00
5.5
0.49
670
TABLE 23
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
CONVENTIONAL
1
a
—
—
—
—
—
—
END MILL
2
b
—
—
—
—
—
—
3
c
—
—
—
—
—
—
4
d
—
—
—
—
—
—
5
e
—
—
—
—
—
—
6
f
—
—
—
—
—
—
7
g
—
—
—
—
—
—
8
h
—
—
—
—
—
—
Hard Coating Layer ((Al, Ti, Si)N layer)
Designated Composition
Designated
FWHM at
cutting
(atomic ratio)
Thickness
(200) plane
length
TYPE
Al
Ti
Si
N
(μm)
(degree)
(m)
CONVENTIONAL
1
0.25
0.55
0.20
1.00
2.0
1.20
270
END MILL
2
0.50
0.40
0.10
1.00
3.0
0.95
250
3
0.60
0.35
0.05
1.00
5.5
1.35
360
4
0.35
0.50
0.15
1.00
3.0
1.50
320
5
0.45
0.45
0.10
1.00
7.0
1.55
300
6
0.60
0.35
0.05
1.00
4.5
1.20
280
7
0.40
0.50
0.10
1.00
10.0
0.90
320
8
0.45
0.40
0.15
1.00
5.5
1.60
250
EXAMPLE 6
The three types of sintered round rod each having a diameter of 8 mm (for cemented carbide substrates a–c), 13 mm (for cemented carbide substrates d–f), and 26 mm (for cemented carbide substrates g, h), respectively, which were made through the process described in Example 5 were used again and further subjected to a grinding work so that cemented carbide substrates (twist drills) from “a′” to “h′” were made in which each substrate has dimensions, i.e., the diameter and the length, of 4 mm×13 mm (cemented carbide substrates a′–c′), 8 mm×22 mm (cemented carbide substrate d′–f′), and 16 mm×45 mm (cemented carbide substrates g′, h′), respectively.
Next, these cemented carbide substrates (twist drills) a′–h′ were subjected to a horning process and ultrasonic cleaning in an acetone solvent for the surface, were dried, and set in an ordinary arc ion plating apparatus as shown in FIG. 5 , respectively. Then, the crystal orientation hysteresis layer (the (Ti, Al)NC layer) and the hard coating layer ((Al, Ti, Si)N layer) having the designated composition and thickness, which are presented in TABLE 24, were formed on the surface of the cemented carbide substrates by vapor deposition under the same condition as for Example 4, respectively. In this way; drills made of cemented carbide with surface coatings of the present invention 1–8 (hereinafter referred to as a coated cemented carbide drill of the present invention) having a geometrical configuration as shown in FIG. 8A as a perspective view and in FIG. 8B as a cross-sectional view were manufactured as coated cemented carbide tools of the present invention.
Moreover, conventional drills made of cemented carbide with surface coatings 1 –8 (hereinafter referred as a conventional coated cemented carbide drill) as conventional coated cemented carbide tools were made as control samples, as presented in TABLE 25, which are configured as with the drills of the present invention excepting that the crystal orientation hysteresis layer ((Ti, Al)NC layer) is not formed.
Next, the coated cemented carbide drills of the present invention 1–8 and the conventional coated cemented carbide drills 1–8 were subjected to a high-speed, wet, drilling operation test in which a blind hole with 2.5 times the diameter of the drill-diameter was drilled. The detailed test conditions were set as follows:
for a test of high-speed, wet, drilling of alloyed steel using the coated cemented carbide drills of the present invention 1–3 and the conventional coated cemented carbide drills 1–3;
workpiece: JIS-SCM440 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 100 m/min.; feed: 0.13 mm/rev.;
for a test of high-speed, wet, boring of carbon steel using the coated cemented carbide drills of the present invention 4–6 and the conventional coated cemented carbide drills 4–6;
workpiece: JIS-S50C plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 120 m/min.; feed: 0.16 mm/rev.;
for a test of high-speed, wet, cutting of stainless steel using the coated cemented carbide drills of the present invention 7 and 8 and the conventional coated cemented carbide drills 7 and 8;
workpiece: JIS-SUS316 plate having plane-size of 100 mm×250 mm and thickness of 50 mm; cutting speed: 80 m/min.; feed: 0.15 mm/rev.;
In all high-speed, wet, drilling tests (wherein water-miscible cutting fluid was used), the numbers of drilled holes were measured when the flank wear width of the cutting edge came down to 0.3 mm. These results of the measurements are shown in TABLES 24 and 25, respectively.
TABLE 24
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
DRILL
1
a′
0.90
0.10
0.85
0.15
0.30
0.43
OF THE
2
b′
0.95
0.05
0.99
0.01
0.35
0.38
PRESENT
3
c′
0.85
0.15
0.95
0.05
0.50
0.45
INVENTION
4
d′
0.99
0.01
0.93
0.07
0.05
0.48
5
e′
0.90
0.10
0.90
0.10
0.25
0.39
6
f′
0.85
0.15
0.91
0.09
0.40
0.45
7
g′
0.95
0.05
0.97
0.03
0.25
0.40
8
h′
0.90
0.10
0.88
0.12
0.45
0.29
Hard Coating Layer ((Al, Ti, Si)N layer)
Designated Composition
Designated
FWHM at
number
(atomic ratio)
Thickness
(200) plane
of
TYPE
Al
Ti
Si
N
(μm)
(degree)
holes
DRILL
1
0.40
0.50
0.10
1.00
6.0
0.55
12500
OF THE
2
0.40
0.45
0.15
1.00
6.5
0.45
13000
PRESENT
3
0.25
0.55
0.20
1.00
5.5
0.50
13500
INVENTION
4
0.60
0.35
0.05
1.00
8.0
0.51
11050
5
0.50
0.35
0.15
1.00
10.0
0.57
15000
6
0.50
0.40
0.10
1.00
5.0
0.51
12500
7
0.40
0.50
0.10
1.00
2.0
0.48
13800
8
0.40
0.45
0.15
1.00
3.0
0.42
15200
TABLE 25
Crystal Orientation Hysteresis Layer
Cemented
((Ti, Al)NC layer)
Carbide
Designated Composition
Designated
FWHM at
Substrate
(atomic ratio)
Thickness
(200) plane
TYPE
No.
Ti
Al
N
C
(μm)
(degree)
CONVENTIONAL
1
a′
—
—
—
—
—
—
DRILL
2
b′
—
—
—
—
—
—
3
c′
—
—
—
—
—
—
4
d′
—
—
—
—
—
—
5
e′
—
—
—
—
—
—
6
f′
—
—
—
—
—
—
7
g′
—
—
—
—
—
—
8
h′
—
—
—
—
—
—
Hard Coating Layer ((Al, Ti, Si)N layer)
Designated Composition
Designated
FWHM at
number
(atomic ratio)
Thickness
(200) plane
of
TYPE
Al
Ti
Si
N
(μm)
(degree)
holes
CONVENTIONAL
1
0.40
0.50
0.10
1.00
6.0
0.92
7500
DRILL
2
0.40
0.45
0.15
1.00
6.5
1.20
9000
3
0.25
0.55
0.20
1.00
5.5
1.10
8500
4
0.60
0.35
0.05
1.00
8.0
0.97
8000
5
0.50
0.35
0.15
1.00
10.0
1.50
5500
6
0.50
0.40
0.10
1.00
5.0
1.30
10000
7
0.40
0.50
0.10
1.00
2.0
1.25
9000
8
0.40
0.45
0.15
1.00
3.0
1.05
8500
Incidentally, the compositions of the above-mentioned layers, i.e., the crystal orientation hysteresis layer ((Ti, Al)NC layer) and the hard coating layer ((Al, Ti, Si)N layer) on the coated cemented carbide inserts of the present invention 1–20, the coated cemented carbide end mills of the present invention 1–8 and the coated cemented carbide drills of the present invention 1–8 as the coated cemented carbide tools of the present invention, as well as the hard coating layer ((Al, Ti, Si)N layer) on the conventional coated cemented carbide inserts 1–20, the conventional coated cemented carbide end mills 1–8, and the conventional coated cemented carbide drills 1–8 as the conventional coated cemented carbide tools, were measured in the thickness direction at the center area by using Auger Electron Spectral analysis equipment. The results of these measurements indicated that the composition of the layers was substantially the same as the designated value.
Also, cross sectional measurements of the thickness of the layers formed on the coated cemented carbide tools of the present invention and the conventional coated cemented carbide tools were done by using a scanning electron microscope. Then, the average thickness (the average of 5 points measurements) was indicated with the same value substantially as the designated thickness.
Moreover, the layers formed on the coated cemented carbide tools of the present invention and the conventional coated cemented carbide tools were inspected at the face and/or the flank of the cutting edge by Cu K a radiation using an X-ray diffractometer. Through these inspections, FWHM of the peak at the (200) plane in the X-ray diffraction pattern was determined (here, when it was difficult to measure the tools itself, the sample pieces for measurement, which were set in the arc ion plating apparatus at the time of manufacturing the tools, were inspected and the X-ray diffraction pattern thereof was used to determine FWHM of the peak). These results are shown in TABLES 16–19 and TABLES 22–25.
The experimental results which are presented in TABLES 16–25 obviously show the following: The coated cemented carbide tool of the present invention on which the hard coating layer having a peak of a narrow FWHM at the (200) plane due to the existence of the crystal orientation hysteresis layer and so having excellent heat resistance (i.e., resistance to oxidation and hardness at high temperature) exhibits an excellent wear resistance even in cutting operations not only of steels but also of cast irons accompanied by high heat generation: This is because both of the increase of the heat resistance and the improvement of the adhesion between the hard coating layer and the cemented carbide substrate surface due to the C component in the crystal orientation hysteresis layer provide a synergetic effect; As opposed to this, with regard to the conventional coated cemented carbide tool in which the degree of crystallinity at the (200) plane of the hard coating layer is low, abrasion proceeds rapidly and the operating life reaches an end in a short time when it is used in high-speed cutting operation accompanied by high heat generation.
As described above, the coated cemented carbide tool according to the second embodiment also has excellent wear resistance even in high-speed cutting operations on various steels and cast irons, and exhibits outstanding ability for cutting so that it sufficiently meets the requirements that cutting apparatus should have high performance, and that cutting operations should be performed with less power, less energy and low cost. | The invention provides a coated cutting tool made of cemented carbide in which a hard coating layer has excellent wear resistance in high-speed cutting operation, wherein (a) a crystal orientation hysteresis layer which consists of a carbonitride compound layer and (b) a hard coating layer which consists of a layer of nitride compound and has a well defined crystal orientation and/or degree of crystallinity are formed on the surface of a cemented carbide substrate, preferably on the surface of a tungsten carbide based cemented carbide or titanium carbonitride based cermet by physical vapor deposition, wherein the crystal orientation hysteresis layer is deposited between the surface of a cemented carbide substrate and the hard coating layer. In one specific example, (a1) the carbonitride compound layer has an average thickness of 0.05 to 0.5 μm and is preferably a Ti—Al carbonitride compound layer expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ), wherein X ranges from 0.05 to 0.20 and Y ranges from 0.01 to 0.15 by atomic ratio and (b1) the nitride compound layer has an average thickness of 2 to 15 μm and is preferably a Ti—Al nitride compound layer expressed by the composition formula as (Ti 1−Z Al Z )N, wherein Z ranges from 0.45 to 0.65 by atomic ratio. In another specific example, (a2) the carbonitride compound layer has an average thickness of 0.05 to 0.5 μm and is preferably a Ti—Al carbonitride compound layer expressed by the composition formula as (Ti 1−X Al X )(N 1−Y C Y ), wherein X ranges from 0.01 to 0.15 and Y ranges from 0.01 to 0.15 by atomic ratio and (b2) the nitride compound layer has an average thickness of 2 to 10 μm and is preferably a Al—Ti—Si nitride compound layer expressed by the composition formula as (Al 1−(A+B) Ti A Si B )N, wherein A ranges from 0.35 to 0.55 and B ranges from 0.05 to 0.20 by atomic ratio. | 2 |
BACKGROUND OF THE INVENTION
This invention was developed at least in part under Contract Number W-7405-Eng-26 with the U.S. Department of Energy. The inventors have been granted a Waiver of the DOE rights to the invention.
TECHNICAL FIELD
The present invention relates generally to circuits for assuring proper connection of wires in complex electrical installations, and more particularly to an interrogator system for passively determining the identity of apparatus connected to lead wires in such electrical installations by using the lead wires themselves and uniquely affecting the impedance of those wires for a specific apparatus.
There are numerous facilities wherein extensive electrical installations involve power or signal sources, electrical equipment and lead wires connecting the sources to the equipment. These include such facilities as electrical generating plants, industrial plants and even various transportation vehicles (particularly aircraft). Such facilities often utilize many thousands of interconnected cables (leads) and miles of wires since the load (the equipment connected to the lead wires) and the source are widely separated.
Quality assurance in these complex facilities must be rigid since improperly connected wires could cause misleading information and/or extensive property damage. For example, in a system having many temperature sensors, it is important that an instrument monitoring those sensors correctly displays the temperature of the proper sensor. A considerable problem would exist if the instrument indicates a satisfactory temperature for a sensor in a critical area when, in fact, it is incorrectly monitoring the sensor in an area that is not critical.
Thus, considerable testing must be conducted during and after installation of wires in the complex wiring systems. This can involve many man-years of time, and thus involve extensive costs. It has been estimated that about fifty percent of the cost of instrument installation in complex system is the cost of the quality assurance of the wiring. Even the replacement of sensitive equipment involves a quality assurance check to determine the correct reinstallation of the replacement.
Various interrogation systems have been considered. All of the known systems, however, have add considerable cost to the installation. Some, for example, require separate wires to provide power to an "identifier" circuit at the ends of electrical wires leading to the "load". Other systems adversely affect signals generated in various sensors; and a common problem is the time involved to properly interrogate all lines of a system.
Accordingly, it is a principal object of the present invention to provide a passive means for generating a signal unique to the apparatus at the end of electrical leads without requiring additional leads.
It is another object of the present invention to provide an interrogation system that does not require a remote power source at the end of electrical leads, but rather such system receives power from an interrogation signal carried on those leads.
It is a further object of the present invention to provide an identifier unit to be installed at the end of electrical leads that will produce an output signal that is unique for that identifier unit, and the format of that output signal can be pre-programmed during installation of the equipment.
It is also an object of the present invention to provide an interrogation system that will supply data to enable a computer to generate a wiring diagram upon completion of the wiring of an installation.
These and other objects of the present invention will become clearer upon a consideration of the following drawings and a complete description thereof.
DISCLOSURE OF THE INVENTION
In accordance with the present invention, there is provided a system for interrogating lead wires of an electrical system to determine the specific electrical equipment connected thereto. Each piece of remote electrical equipment is provided with a passive identifier unit which, when energized, delivers on the lead wires an electrical signal that is unique to that piece of equipment. The identifier unit is powered by an interrogator signal delivered over the leads. The unit is designed to uniquely modify the impedance of the leads such that the interrogator signal is modulated (frequency, phase or amplitude) thereby permitting demodulation at the sending end to identify the specific piece of equipment. The identifier unit is pre-programmed during installation of the electrical equipment within the system, or before installation of a new identifier unit in an established circuit. The results of an interrogation of a complete system can be used to plot the wiring diagram of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an electrical system as incorporating the present invention.
FIG. 2 is a block drawing of one embodiment of a sensor identifier unit.
FIG. 3 is a solid state logic block diagram of the identifier of FIG. 2.
FIG. 4 is a schematic diagram of the identifier unit of FIGS. 1 and 2.
FIG. 5 is a block diagram of an identifier interface for the present invention.
FIG. 6 is a schematic diagram of that portion of the present invention as illustrated in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, shown at 10 therein is a block diagram of the essential components of an interrogator system of the present invention. It is shown as connecting a "source" unit 12 at one location in an electrical system to a "load" unit 14 at the opposite end. Typically, the source unit is connected to the load unit using a pair of leads 16 as indicated at 16A, 16B, 16C. The source unit 12 can be, for example, an instrument to record some type of signal from a sensor at the load 14. Further, this instrument can be connectable through other leads (as at 16B, 16C, etc.) to separate sensors (not shown).
At the source end of leads 16 (A, B, C, etc.) is a signal generator 18 that is connected to a multiplexer unit 20. An isolation unit 22 prevents signals on the leads from feeding back into the signal generator. A second isolation unit 23 prevents an output of the generator 18 from feeding to the source unit 12. The multiplexer 20 provides means for connecting the output of the generator 18 to any selected pair of leads 16. Also in this portion of the circuit of the present invention is a unit 24 identified as a receiver-controller. Details of all these units are given hereinafter.
The "load" end of the circuit of the present invention includes an identifier unit 26 and isolation units 28, 29. The identifier, as described in greater detail hereinafter, utilizes a signal from the signal generator 18 to produce an operating voltage and then to modulate the signal from the generator in a manner that uniquely identifies the particular load 14 connected to the source 12. The isolation unit 28 prevents the passage of the signal from generator 18 to the load 14, and the isolation unit 29 prevents normal signals on leads 16 from feeding into the identifier unit 26.
Although the present invention will have many applications, its use in passive systems will be particularly important. For example, the load 14 is often a sensor of such things as temperature or a sensor monitoring actuation of a particular piece of equipment, such as a valve. It is important to know that the information received by the instrument source is that from the desired sensor. Conversely it is important, for example, to know that a signal to initiate an actuation was received by the correct piece of equipment. For this reason, the operation of the invention will be described relative to such use, using a thermocouple system as an example. Thus, it is assumed for this description that there is a thermocouple attached as a "load" 14 on each lead pair 16A, 16B, 16C, etc. Each of these thermocouples generate a voltage related to its temperature that is conveyed over the lead pairs to a recording instrument 12. Typically, each lead pair is sequentially connected to the instrument using a multiplexer such as that indicated at 20 or by other suitable switching mechanisms.
In the present invention, as intended for this usage, a signal of a selected frequency is generated at the unit 18 which becomes a carrier signal for initiating operation of the specific identifier unit upon command. Depending upon the specific signal levels and type of sensor, the selected frequency can be any value from zero (DC) up to several hundred kilohertz (e.g., 500). This carrier signal is directed by the multiplexer 20 to a particular lead pair (eg., 16A) and thence to the identifier unit 26. As stated above, a portion of the carrier signal is converted to an appropriate operating voltage in the identifier unit 26 which is used to modify the impedance of the lines and modulate the carrier signal. This modulated carrier appears on the lead pairs so as to be monitored by the receiver-controller 24. This modification can be made to produce amplitude modulation, frequency modulation or phase modulation.
Greater detail of the identifier unit 26 is shown in FIGS. 2 through 4. Referring first to FIG. 2, a power supply 30 used to convert the carrier signal into a DC operating voltage is connected across the leads 16. A capacitor 32 (part of isolation unit 29) is used to prevent DC flow of the voltage generated from the sensor 14 in response to temperature. This prevents the identifier from affecting the sensor measurement. The voltage produced by the power supply is used to power the identifier circuit 34 that modulates the carrier to produce a digital code, which output is unique to that particular sensor. This identifier circuit is also capacitively coupled to the leads with a capacitor 36 (part of isolation unit 29). An analog switch 38 utilizes the output of the identifier circuit in digital format to change the effective impedance of the lines and thus cause a modulation of the carrier on the leads 16 such that the receiver at the opposite ends of the leads "credits" the information from the sensor 14 to the proper sensor.
FIG. 3 illustrates a particular construction of the identifier circuit 34 of FIG. 2 when amplitude modulation is to be utilized. The voltage, V, from the power supply 30 is applied to a programmed sixteen bit register 40, for example, and to the counters 42, 44. the output feeds the analog switch whereby a serial "word" is sent back to the receiver via the modulated carrier. The first bit of the serial word is "high", and is used as a timing set-up bit for the receiver. The second bit is "low" and is used to indicate the start of transmission of the identifying information. The other fourteen bits of information are used to determine what kind of sensor is being used and to identify the specific sensor that is responding. After the sixteen bits are transmitted, transmission shift registers 42, 44 are "held off" and reloaded with serial information for the same length of time as taken for the serial word transmission.
In the embodiment illustrated in this FIG. 3 (and FIG. 4), a "dip switch" 41 is utilized to permit setting any code into the identifier. This is particularly useful during testing of a system. Alternatively, an identifier can have a preset code, or the code can be programmed into the identifier using appropriate signals during installation of an identifier unit. It is within the scope of the invention, also, to achieve programing of an identifier with signals transmitted over the lines 16.
A schematic diagram of the identifier unit is shown in FIG. 4. Each of the components are illustrated as integrated circuits, and the components are identified by the numerals used in FIGS. 2 and 3. As indicated, a typical isolation unit 28 is provided with L-C tank circuits 46, 48 in each of the leads of the pair 16. Typical components and typical circuit element values are indicated. The isolation unit 29 is a capacitor for this application. It will be understood by persons versed in the art that components performing the same functions can be substituted for those shown in FIG. 4.
The receiver-controller 24 shown generally in FIG. 1 is shown in greater detail in FIG. 5. More specifically, the circuit components illustrated therein are referred to as an identifier interface as it also includes the oscillator 18. These units are typical of those useful for carrying out the invention, however, persons skilled in the art will recognize that units performing the same function can be substituted in the circuit. As stated, the oscillator 18 generates a carrier excitation voltage which passes through the multiplexer 20 and the isolation unit 22 to leads 16. Demodulation of the serial word appearing on the leads, as produced by the identifier 26, is accomplished in a demodulation unit 50 by receiving the carrier in a half-wave rectifier unit, and low-pass filtering the rectified signal (See FIG. 6). Also within the demodulator is a voltage comparator where the signals are converted to TTL (transistor-to-transistor logic) voltage logic levels.
The serial information in TTL format is entered into a universal asynchronous receiver transmitter 52. A timing or clock signal is derived for this unit from the oscillator via lead 54. The serial word is decoded to determine the specific sensor being identified. Three successive "readings" of the serial word are used; if all agree, the serial word is deemed to be valid. If no start bit is received from the identifier unit 26 at the sensor 14 within a time set by a computer 56, the sensor wire pair is assumed to be defective and a display 58 indicates that there is no line. If, however, there is a valid serial word, the decoded information is displayed.
A schematic diagram of the elements generally shown in FIG. 5 is illustrated in FIG. 6. The particular integrated circuits and circuit elements are typical for accomplishing the desired result. It will be recognized by persons skilled in the art that other specific units and values that accomplish this result can be substituted.
As stated above, the circuit components illustrated in FIGS. 4 and 6 are specific for amplitude modulation of the carrier signal. For such, the analog switch 38 effectively lowers or raises the impedance of the line 16 in an equivalent circuit, as controlled by the identifier circuit, such that the generator impedance and the line impedance remain in a bridge circuit to modify the carrier signal during specific intervals of time, those intervals being unique to a particular identifier unit and sensor. It will be recognized by those skilled in the art that an identifier unit can be introduced into the circuit that will achieve either phase or frequency modulation, rather than amplitude modulation, for applications where such is preferred. The circuits for accomplishing the phase or frequency modulation are well known.
The principle of the present invention was demonstrated relative to lines connected to a thermocouple using the circuits illustrated in FIGS. 4 and 6. A carrier frequency of ten (10) kilohertz was utilized, with an output voltage of fifteen (15) volts peak-to-peak. It will be recognized that other choices of frequency and amplitude can be made for other applications; these were chosen for easy generation. Initial testing was with a one foot long line both "open ended" (no sensor) and shorted. It was found that the identifier responded with the proper identification under both conditions; similar results were obtained with a carrier of four (4) kilohertz.
Similar tests were carried out on a two hundred (200) foot line and a five thousand (5,000) foot line. In both lengths, the identifier unit modulated the excitation voltage correctly, and the decoder displayed the proper identification code. The identification code was varied by changing the position of the dip switch 41 and the identifier system correctly identified each new code. A test of the system at fifty (50) kilohertz was made; however, no amplitude modulation of the excitation voltage was observed. At one (1) kilohertz, the identifier operated normally. (The higher frequencies, however, are useful for phase modulation.)
The present identifier was connected into an existing thermocouple system. The particular system utilized a type K thermocouple, and the readout instrument (Doric Trendicator) had a 0.1 degree Fahrenheit resolution. The thermocouple system without the identifier registered 76.2 degrees F. in ambient air, and 36.3 degrees F. with the thermocouple in an ice-water bath. When the indicator system of the present invention was attached, a reading of 36.2 degrees F. was obtained; the difference is only equal to the resolution of the instrument. The identifier properly modulated the excitation voltage and displayed the correct identifier code. Some fluctuation was observed in the temperature signal during the identification process, but the reading returned to the correct value when identification was discontinued. The incorporation of tank (LC) circuits between the decoder connection to the line and the thermocouples instrumentation will eliminate these fluctuations. These results were obtained using lines of one (1), seventy-five (75) and one hundred fifty (150) feet.
From the foregoing, it will be understood by one skilled in the art that a method and an apparatus have been developed for the proper identification of an unknown "load" at one end of a line pair can be determined at the driving end without seriously affecting a load device. Although an embodiment for amplitude modulation for identification of a sensor such as a thermocouple has been described in detail, such embodiment is not given as a limitation of the present invention. Rather, the present invention is to be limited only by the appended claims and their equivalents when read in combination with the detailed description and the drawings. | A system for interrogating electrical leads to correctly ascertain the identity of equipment attached to remote ends of the leads. The system includes a source of a carrier signal generated in a controller/receiver to be sent over the leads and an identifier unit at the equipment. The identifier is activated by command of the carrier and uses a portion of the carrier to produce a supply voltage. Each identifier is uniquely programmed for a specific piece of equipment, and causes the impedance of the circuit to be modified whereby the carrier signal is modulated according to that program. The modulation can be amplitude, frequency or phase modulation. A demodulator in the controller/receiver analyzes the modulated carrier signal, and if a verified signal is recognized displays and/or records the information. This information can be utilized in a computer system to prepare a wiring diagram of the electrical equipment attached to specific leads. Specific circuit values are given for amplitude modulation, and the system is particularly described for use with thermocouples. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a control apparatus for a sewing machine which moves a fabric pressing device gripping a workpiece to form stitches of a predetermined shape, and also relates a control method for such a sewing machine.
Referring to FIG. 10, the mechanism section of a conventional sewing machine will be described. In FIG. 10, reference numeral 11 is a sewing machine mechanism section which includes a mechanism for forming stitches in a workpiece. This sewing machine mechanism section 11 is mounted on a table 12 and is connected with a needle bar 13 for stitching the workpiece. A needle position detector 13a detects the position of the needle bar 13. A fabric presser 17 grips a workpiece between an upper pressure plate 15 and a lower pressure plate 16. The fabric presser 17 is located above a bed slide 18 and is provided with an X-Y table 19 which moves the workpiece on a plane. There are provided home position detectors 20a, 20b, namely, home position detection means for detecting the mechanical home position of the X-Y table 19.
On the upper surface of a control box 10, there is provided an operating panel 22 on which various switches for setting the sewing machine operation are arranged. The operating panel 22 includes a liquid-crystal display (LCD) 24 for displaying stitching conditions, and a group of switches 27. There is further provided a foot pedal 31 in the lower portion of the control box 10. The foot pedal 31 is provided with a start switch 32, used to issue a stitching start command, and a fabric presser switch 33, which keeps cloth gripped under pressure by the fabric presser 17.
Referring to FIG. 11, the control circuit of the conventional sewing machine will be described as follows. In FIG. 11, reference numeral 2 is a microcomputer. This microcomputer 2 is connected to a read-only-memory ROM 52 in which a control program and other programs are stored, a random access memory RAM 53 in which the sewing data for automatically sewing a workpiece shown in FIG. 12 is stored, a latch circuit 55 for latching the addresses of the ROM 52 and RAM 53, a selection circuit 56 for generating a signal to select a peripheral element, an interface (I/F) 22a to which the operating panel 22 is connected, a needle position detector 13a connected via an I/F 13c, a foot pedal 31 connected via an I/F 31a, a servo motor 21 connected via the drive circuit 21b, home position detectors 20a, 20b connected via an I/F 20c, pulse motors 19a, 19b for driving the X-Y table 19 via the drive circuit 19c, and a programmable controller (PC) 65, which is a computer exclusively used for sequential control. The PC 65 is connected to an actuator 17a for driving the fabric presser 17 via the drive circuit 17b.
In this arrangement, the control unit 10 effects control operations so as to sew pieces of cloth 90, 91. The PC 65 generates an on-signal to remove and set pieces of cloth 90, 91. A completion signal for removing and setting the cloth is applied to the drive circuit 17b of the actuator 17a. The completion of setting or removing of pieces of cloth 90, 91 is detected by a sensor (not shown in the drawing), i.e., a detection means, and this detection signal is received by the PC 65.
After generation of a signal to set the cloth 90 at the sewing machine, the setting signal is turned off in response to the completion signal. After the setting signal of the cloth 90 has been received, the setting signal is turned off in response to the completion signal after the generation of a signal to set the cloth 91 at the sewing machine. Once the setting signal of the cloth 91 has been received, the removing signal is turned off by the completion signal after the generation of the removing signal of the pieces of cloth 90, 91 from the sewing machine. The above sequence of control is carried out by the PC 65. Reference numeral 70 is a reset circuit of the microcomputer 2.
Next, referring to FIG. 13, the operation of the control unit of the above sewing machine will be described below, in which pieces of cloth 90, 91, which are workpieces, are set in the sewing machine so as to be sewn. FIG. 14 is a flow chart indicating how the sewing data shown in FIG. 12 is applied. FIG. 15 is a flow chart relating to the generation of a signal in the case of transfer of the workpiece through each process in FIG. 13.
In this case, the operation is conducted as follows. The X-Y table 19 is located at the home position. The sewing start switch 32 is turned on, so that an operation start signal is applied to the microcomputer 2. When the start signal is detected (step 300), the PC 65 issues a signal to the drive circuit 17b for setting the cloth 90 in the sewing machine (step 301), and the actuator 17a moves the cloth 90 and sets it in the sewing machine.
If operation start signal is not detected in step 300, the signal detection process is continued.
The microcomputer 2 reads a control code "no-load feeding" in the sewing data stored in RAM 53 (step 200). Then the microcomputer 2 reads an argument and moves the needle 13 from the home position to the point "a" shown in FIG. 13 in accordance with the feeding speed and the amounts of movement in the X and Y directions (referred to as a "no-load feeding condition" hereinafter). Next, the control code is advanced by one step (step 201). Since the control code is "sewing", the argument is read, and while the cloth 90 is sewn through three stitches from point "a" to point "b" as shown in FIG. 13, the PC 65 counts the number of output pulses of the needle position detector 13a. When the correct number of output pulses of the needle position detector 13a has been counted, a sewing interruption signal is applied to the microcomputer 2 (step 302), so that the sewing operation is stopped.
The PC 65 issues a signal to the drive circuit 17b for setting the cloth 91 (step 303), and the actuator 17a moves the cloth 91 so that the cloth 91 can be set on the cloth 90. Then, the PC 65 receives a setting completion signal from the sensor, so that the generation of the setting signal is stopped. Next, the control code is advanced by one step (step 201), and then a control word "sewing" of the sewing data is read (step 200), and this argument is read. While the workpiece is sewn by 13 stitches from point "b" to point "d" in accordance with the sewing condition as shown in FIG. 13, the number of output pulses of the needle position detector 13a are counted by the PC 65. When the number of output pulses of the needle position detector 13a are counted up, the sewing machine is stopped (step 202). Then, the PC 65 issues a command signal at the completion of sewing to the microcomputer 2 (step 304), so that the sewing operation is completed. The PC 65 issues a removing signal to the drive circuit 17b for removing the workpieces from the sewing machine (step 305). Therefore, the actuator 17a is driven, and the pieces of cloth 90, 91, which are joined together by sewing, are removed from the sewing machine. The PC 65 receives a removing completion signal from the sensor, and the generation of the removing signal is stopped.
The control code is advanced by one step (step 201), the control word "thread cutting" in the sewing data is read (step 200), and this signal is applied to the PC 65. The PC 65 issues a command signal of thread cutting to a thread cutting mechanism (not shown), so that the thread is cut. The microcomputer 2 reads a control word "completion" in the sewing data stored in RAM 53 (step 200), and the X-Y table 19 of the sewing machine is returned to the home position.
Concerning the above-described operations, if the sewing machine control unit 10 is provided with a function of counting the number of stitches, the software of the control unit 10 becomes complicated. Therefore, the function of counting the number of stitches is performed by the PC 65.
Accordingly, a problem arises in the conventional control apparatus for a sewing machine designed as described above in that it requires a PC 65 for implementing the control system of the sewing machine, and thus the sewing machine is complicated and its cost is relatively high. The reason is that the PC 65 issues a setting and removing signal for the workpiece to the drive circuit 17b of the actuator 17a, and further the PC 65 counts the number of output pulses of the needle position detector 13a so as to count the number of stitches of the workpiece.
A second problem is that the X-Y table cannot be operated at high speed. The reason is described as follows. When the X-Y table 19 is moved while the needle 13 pierces the workpiece, the workpiece is forcibly pulled, and hence the stitches become disordered. Sometimes the needle 13 can be broken. Accordingly, as shown in FIG. 16, pulse generation ranges applied to the pulse motors 19a, 19b are made different according to the distance from the tip of the needle 13 to the surface of the workpiece. In order to simplify the structure, the pulse generation ranges are set in accordance with the maximum thickness of the workpiece.
A third problem is that control of the speed of the pulse motors 19a, 19b cannot be appropriately conducted. The reason is described as follows. Vibration of the X-Y table 19 is changed into variation of the sewing motion of the sewing machine and of the sewing position of the X-Y table 19. Due to the foregoing, the speed of the pulse motors 19a, 19b used to drive the X-Y table 19 is made variable so that it can be appropriately restricted. In order to simplify the structure, the restriction value of the X-Y table 19 is also set.
In this connection, Japanese Unexamined Patent Publication No. 62-112587 discloses a technique in which the sewing area is divided into four portions, and a restriction speed of the sewing machine is set for each area. The area is composed of only four portions, and the restriction value of speed is set in each portion in such a manner that variations in stitching and the like do not occur even under worst-case conditions. Therefore, the problems are not essentially solved by this technique.
SUMMARY OF THE INVENTION
Accordingly, a first object of the present invention is to provide a control apparatus for a sewing machine characterized in that the microcomputer in the control unit of the sewing machine is provided with a sequence control function, and an on-signal for setting and removing a workpiece is incorporated into the sewing data, so that no PC exclusively used for sequence control is required. An object of the present invention is also to provide a control method for controlling the control apparatus for a sewing machine.
A second object of the present invention is to provide a control apparatus for a sewing machine characterized in that the X-Y table can be operated in accordance with the thickness of the workpiece, even when the sewing machine is conducting a sewing operation on a workpiece whose thickness is not uniform.
A third object of the present invention is to provide a control apparatus for a sewing machine characterized in that the sewing position or the sewing condition of a workpiece is judged by the sewing data, and the restriction value of the X-Y table is automatically changed so that vibration of the X-Y table can be suppressed to allow a high speed operation to be conducted.
In fulfillment of the above and other objects of the invention, in accordance with a first embodiment of the invention there is provided a control apparatus for a sewing machine comprising: an actuator for setting a workpiece on the sewing machine or removing it from the sewing machine; a drive means for driving the actuator on and off; a storage element for storing on-data in the sewing data by which a workpiece is automatically sewn, the on-data serving as an on-signal to set the workpiece on the sewing machine or to remove it from the sewing machine; detection means for generating a completion signal of the setting or removing of the workpiece; command means for generating an off-signal in the drive means in accordance with the detection of the completion signal by the detection means; start means for starting to set the workpiece on the sewing machine or to remove it from the sewing machine by operating the actuator when the drive means is turned on in accordance with the on-signal; and stop means for stopping motion of the actuator by turning off the drive means in accordance with the off-signal.
Further, in accordance with a second embodiment of the invention there is provided a control method for controlling a sewing machine comprising the steps of: storing sewing data for automatically sewing a workpiece in a storage element; storing on-data in the sewing data, the workpiece being set or removed in accordance with the on-data; operating an actuator by drive means in accordance with the on-signal so as to start setting the workpiece on the sewing machine or removing it from the sewing machine; detecting the completion of setting or removing of the workpiece after the generation of the on-signal so as to generate a signal to turn off the drive means; and stopping the actuator by turning off the drive means.
In accordance with a third embodiment of the invention there is provided a control apparatus for a sewing machine comprising: an X-Y table on which a workpiece is set, the X-Y table being driven by a motor so that the workpiece can be moved in X and Y directions; and a storage element for storing sewing data for automatically sewing the workpiece, the sewing data including setting data for setting means for setting the thickness of the workpiece at each point where the thickness of the workpiece changes, and motor movement data to be used by motor movement means for changing the range of movement of the motor in accordance with the thickness of the workpiece.
In accordance with a fourth embodiment of the invention there is provided a control apparatus for a sewing machine comprising: a vector detection means for reading sewing data and determining a directional vector for each stitch from the sewing data; a vector computation means for computing an amount of change in the directional vector for each stitch in accordance with a detection value obtained by the vector detection means; and speed restriction means for restricting the moving speed of an X-Y table in accordance with the amount of change in the directional vector computed by the vector computation means.
In accordance with a fifth embodiment of the invention there is provided a control apparatus for a sewing machine comprising: home position detection means for detecting a home position of an X-Y table; a needle movement amount detection means for detecting an amount of movement of a needle; a needle position computation means for computing a needle position on the X-Y table from a detection value detected by the needle movement amount detection means and also from the home position detected by the home position detection means; and speed restriction means for restricting the movement speed of the X-Y table in accordance with a computed value obtained by the needle position computation means.
BRIEF DESCRIPTION OF THE INVENTION
FIG. 1 is a diagram showing the arrangement of a control apparatus for a sewing machine constructed in accordance with a first preferred embodiment of the present invention;
FIG. 2 shows a sewing data composition in accordance with the invention;
FIG. 3 is a timing chart of a sewing module;
FIG. 4 is a flow chart for the module;
FIG. 5 is a view showing a subroutine in FIG. 4;
FIG. 6 is a parameter block diagram of the present invention;
FIG. 7 is a view showing a sewing data composition of the above embodiment;
FIG. 8 is a flow chart for another embodiment of the invention;
FIG. 9 is a flow chart for still another embodiment of the invention;
FIG. 10 is a diagram showing a conventional sewing machine;
FIG. 11 is a diagram showing the control apparatus of the conventional sewing machine;
FIG. 12 depicts the conventional sewing data;
FIG. 13 shows a workpiece to be sewn;
FIG. 14 is a flow chart showing operations in the conventional sewing machine;
FIG. 15 is a flow chart showing operations in the conventional sewing machine; and
FIG. 16 is a view showing the relation between the pulse output range and the cloth thickness.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
FIG. 1 depicts the general arrangement of the control apparatus for a sewing machine constructed in accordance with a first embodiment of the invention. In FIG. 1, like reference characters are used to indicate like parts in the conventional apparatus. Reference numeral 58 is an I/F connected to the microcomputer 2. A completion signal for setting a workpiece on the sewing machine or a completion signal for removing a workpiece from the sewing machine is input to the I/F 58. Reference numeral 153 is a RAM (random-access memory). In this RAM 153, the sewing data shown in FIG. 2, which is used for automatically sewing a workpiece, is stored, and also the program of a module, which will be described later, is stored.
FIG. 3 is a timing chart for a module of sewing data. This module is turned on at the "start of the module" data in the sewing data and turned off by the setting of the workpiece in the sewing machine, or the removing of the workpiece from the sewing machine, or in response to the completion signal for cutting a thread. When the modules are combined with each other, sequence control can be carried out.
In this case, the on-off conditions of the modules 1 to 3 are set as follows. First, as shown in FIG. 2, the on-conditions of the modules 1 to 3 are turned on by the control mode "start of the module" in the sewing data and also by the reading of the argument. By this on-signal, a signal to set the cloth 90, 91 in the sewing machine or a signal to remove the cloth 90, 91 from the sewing machine is generated in the drive circuit.
After the generation of a signal to set the cloth 90 in the sewing machine, the off-condition of the module 1 is set in response to the completion signal. After the reception of the on-signal of the module 1, and after the generation of a signal to set the cloth 91 in the sewing machine, the off-condition of the module 2 is set in response to the completion signal. After the reception of the on-signal of the module 2, and after the generation of a signal to remove the pieces of cloth 90, 91 from the sewing machine, the off-condition of the module 3 is turned off by the completion signal. The off-conditions of the modules 1 to 3 described above are set.
Next, the operation start switch 32 is turned on, and it is checked whether or not an operation command is applied to the microcomputer 2 via I/F 22a (step 400). After the operation command has been applied to the microcomputer 2, the control word "start of module" in the sewing data stored in RAM 153 shown in FIG. 2 is read (step 200 in FIG. 14), and the argument is read. Since the argument is the module 1, the program is transferred to the subroutine 1 (step 401). In the subroutine 1 illustrated in FIG. 5, it is judged whether or not the output of the module 1 has been completed (step 500). Then, it is judged whether or not the output is turned on because this output has not been completed (step 501). Since the output is not turned on, the on-condition is checked (step 502). Since the on-condition is satisfied due to an operation command, the output is turned on (step 504). This on-signal is applied to the drive circuit 17b, and the cloth 90 is moved by the actuator 17c and set on the sewing machine.
The output of the module 1 is turned on, and the off-condition is checked by a signal which indicates whether the setting of the cloth 90 on the sewing machine has been completed (step 503). When this condition is satisfied, the output of the module 1 is turned off (step 505), and a flag indicating completion of sewing is set (step 506). Next, the step of the control word is advanced by one (step 201 in FIG. 14). Since the control word is "no-load feeding" in FIG. 12, the argument is read. As shown in FIG. 2, the cloth 90 is moved from the home position to the point "a" at the no-load feeding speed and by the amount of movement in the directions X and Y (referred to as a no-load feeding condition hereinafter).
Next, the step of the control word is advanced by one (step 201). Next, the microcomputer 2 reads the control word "sewing" in the sewing data stored in RAM 153 as illustrated in FIG. 2 (step 200). The argument is read, and the microcomputer counts the sewing stitches and the number of the output pulses of the needle position detector 13a, so that the cloth is sewn from the point "a" to the point "b" by three stitches, and then the sewing machine is stopped (step 202).
Next, the step of the control word is advanced by one (step 201). Since it is the start of the module and the argument is the module 2, the program is transferred to the subroutine 2 (step 401). It is judged whether or not the output of the module 2 has been completed (step 500). Since the output has not been completed, it is judged whether or not the output 2 is turned on (step 501). Since the output 2 is not turned on, the on-condition of the output 2 is checked (step 502). When the setting condition to set the cloth 91 is satisfied, the output 2 is turned on (step 504). The off-condition is checked by the setting completion signal of the cloth 91 (step 503). When this condition is satisfied, the output of the module 2 is turned off (step 505), and a flag of the completion of sewing is set up (step 506). By this on-signal, a signal by which the cloth 91 is set on the sewing machine is applied to the actuator 17c via the drive circuit 17b, so that the actuator 17c is operated and the cloth 91 is set on the X-Y table 19.
After the completion of the above motion, the next control word of "sewing" is read, and the argument is also read. Then, the cloth is sewn from the point "b" to the point "d" by 13 stitches in accordance with the sewing speed and the amount of movement in the X and Y directions, which will be referred to as a sewing condition hereinafter. The microcomputer counts the number of pulses of the needle position detector 13a. When it has counted up to the number of stitches, the sewing machine is stopped (step 202). The sewing completion command is applied to the control unit. Since the control word is "cutting of thread", the argument is read, and the thread is cut off at the point "d".
When the control word is "start of module", the argument is read. Since it is the module 3, the program is transferred to the subroutine 3 (step 401), and it is judged whether or not the output of the module 3 has been completed (step 500). Since the output is not completed, it is judged whether or not the output 3 is turned on (step 501). When the output 3 is not turned on, the on-condition of the output 3 is checked (step 502). When the removing signals for removing the pieces of cloth 90, 91 coincide with each other, the output is turned on (step 504). The setting condition is checked in response to the removing signals of the pieces of cloth 90, 91 (step 503). When this condition is satisfied, the output of the module 3 is turned off (step 505), and a flag of completion is set up (step 506). A signal to remove the pieces of cloth 90, 91, which have been sewn and integrated into one body by this on-signal, from the sewing machine is output. After the completion of sewing, the next control word of "end" is read, and the X-Y table 19 is moved and returned to the home position, and the home position is detected again, and a control operation to remove the pieces of cloth 90, 91 from the sewing machine is carried out.
As described above, the sewing data shown in FIG. 2 is carried out in order from the above. Even if the PC 65 is not provided, the sewing operation shown in FIG. 2 can be conducted by using the module, and even if the number of stitches is changed in the sewing operation, it is easy to count the changed number.
In this connection, in the above embodiment, steps 501, 503 in FIG. 5 are performed by a command means, steps 502, 503 represent the operation of start means, and step 505 represents operation of stop means. In the above embodiment, the start of the module is designated by the control code in the sewing data, however, the module may be operated by a signal of completion of cutting a thread, a signal of completion of sewing or a signal of returning to the home position irrespective of the sewing data. Start of the module is carried out by the control code in the sewing data, however, the module 2 or 3 may be started by satisfying a predetermined condition after the start of module 1. In this case, the predetermined condition is defined as "after the start of the module" or "after a predetermined period of time".
Embodiment 2
Another embodiment of the present invention will be explained below.
FIG. 6 is a view showing parameter blocks. In this case, the parameter is defined as a setting value for controlling the operation of the sewing machine. Examples of such parameters include the thickness of the workpiece, the changing ratio of the sewing size, the weight of the fabric presser, and the restriction of the torque of the motor. These parameter blocks are stored in RAM 153.
When the thickness of a workpiece is not uniform as shown in FIG. 13, the thickness of the workpiece is set for each point (points "a", "b", "e" and "c") at which the thickness is different. In this way, the operational ranges of the pulse motors 19a, 19b used to drive the X-Y table 19 are changed by the drive circuit 19c, which is a motor operation means, so that the most appropriate control can be carried out. As shown in FIG. 7, the control code "change in the parameter" is inserted into the sewing data for each point at which the thickness of the workpiece is different. The parameter number "00000000" is set in argument 1, and the thickness of the fabric is set in arguments 2 and 3 (setting means).
Referring to FIGS. 7, 13, and 14, the operation of this embodiment will be described below. Here, primarily the differences with respect to the first-described embodiment will be explained. First, the operation command is applied to the control unit. Then, operations in accordance with the sewing data shown in FIG. 7 are successively carried out.
The control word "change in the parameter" is read (step 200). The argument 1 is read. The thickness of the cloth at the point "a" is read. Next, the control word "sewing" is read (step 201). The argument is read. According to the sewing condition that has been read in this way, on the basis of the thickness of the cloth, the main shaft of the sewing machine is rotated in accordance with the distance from the tip of the needle 13 to the surface of the workpiece, and then the X-Y table 19 is operated, whereby the workpiece is sewn from the point "a" to the point "b" by three stitches.
After the sewing operation has been completed to the point "b", the next control word "change in the parameter" is read (step 201), and the argument is read. The thickness of the cloth at the point "b" is read. According to the sewing condition that has been read, on the basis of the thickness, an operation is conducted in the same manner as described above, and the workpiece is sewn from the point "b" to the point "e" by two stitches.
After the sewing operation has been completed to the point "e", the next control word "change in the parameter" is read (step 201), and the argument is read. The thickness of the cloth at the point "e" is read. According to the sewing condition that has been read, and on the basis of the thickness, an operation is conducted in the same manner as described above, and the workpiece is sewn from the point "e" to the point "c" by 11 stitches.
After the above operation has been completed, the next control word "sewing" is read (step 201), and the argument is read. The thickness of the cloth at the point "c" is read. According to the sewing condition that has been read, and on the basis of the thickness, an operation is conducted in the same manner as described above, and the workpiece is sewn from the point "c" to the point "d" by two stitches.
After the workpiece has been sewn to the point "d", the next control word "cutting a thread" is read (step 201), and the operation of cutting the thread is carried out. Then the next control word "end" is read (steps 201 and 202), whereupon the X-Y table 19 is operated to return to the home position.
Since the output range of the drive circuit 19c to drive the pulse motors 19a, 19b differs in accordance with the thickness of the workpiece, the thickness to be used as a parameter is set at each point where the thickness of the workpiece changes. Due to the setting of the thickness described above, it is possible to change the output range of the drive circuit 19c in accordance with the distance from the tip of the needle 13 to the surface of the workpiece. Accordingly, even if the thickness of the workpiece is not uniform, immediately after the needle 13 is drawn out from the workpiece, the X-Y table 19 can be operated.
In this connection, in the above embodiment, the thickness of the workpiece is set at each point where the thickness changes. However, other parameters such as the changing ratio of the size, the weight of the fabric presser or the amount of restriction of the motor torque may be set.
Embodiment 3
Referring to FIG. 8, another embodiment of the present invention will be described below. Sewing data of several stitches is read from the sewing data for the workpiece (step 930). The vector in the sewing direction is detected for each stitch (step 931). The changing ratio of the directional vector for each stitch is computed (step 932). When a change in the vector for each stitch is within a predetermined range, it is judged to be a straight line or a gentle curve (step 933), and the speed restriction value of the X-Y table 19 is maintained at the reference value.
On the other hand, when the amount of change in the vector for each stitch exceeds a predetermined value (step 934), it is judged that the sewing operation is to be conducted at a corner of the workpiece, and the reference speed restriction value is multiplied by a predetermined value, so that the speed restriction value of the X-Y table 19 is lowered. When the amount of change in the vector for each stitch exceeds the predetermined value by a plurality of times (step 935), it is judged that the workpiece is subjected to zigzag-sewing, and the reference speed restriction value is multiplied by a predetermined value, so that the speed restriction value of the X-Y table 19 is greatly lowered. In this connection, the predetermined value to be multiplied with the reference speed restriction value is determined in such a manner that the predetermined value is proportional to a change in the sewing direction angle.
In this connection, in the above embodiment, step 930 in FIG. 8 represents operation of a vector detection means, step 931 represents operation of a vector computation means, and steps 934, 935 represent operation of speed restriction means.
Embodiment 4
Referring to FIG. 9, still another embodiment of the present invention will be described below. The amount of vibration generated differs according to the sewing position of the X-Y table 19. For example, when the center of the frame of the X-Y table 19 is sewn, the cloth absorbs vibration. However, when the edge of the frame of the X-Y table 19 is sewn, the sewing operation is susceptible to vibration. An example will be explained as follows, in which the vibration is suppressed and the maximum speed of the pulse motors 19a, 19b is restricted in accordance with the sewing pitch and other factors.
The home position, which is the center of the X-Y table, is used as a reference point. On the basis of this reference point, the amount of movement of the X-Y table 19 is integrated each time the sewing operation is started at this sewing start position (step 950). While the sewing operation is conducted at the center of the X-Y table 19, the speed of the pulse motors 19a, 19b is determined to be a speed restriction value corresponding to the center of the X-Y table 19 (step 951). While the sewing operation is conducted at a position close to the frame of the X-Y table 19, the speed restriction value of the pulse motors 19a, 19b is decreased. In this connection, the speed restriction value in the case of sewing an intermediate portion between the frame and the center of the X-Y table 19 is computed from the speed restriction values of the center and the frame, and is made proportional to the distance from the center to the intermediate portion.
In the above embodiment, step 950 in FIG. 9 represents a movement amount detection means and needle position computation means, and step 951 represents a speed restriction means.
According to the first and second embodiments, sewing data for automatically sewing a workpiece is provided with on-data which is used as the basis of an on-signal when the workpiece is set or removed, and an off-signal for setting or removing the workpiece can be generated while the sequence control operation is carried out. Accordingly, it is not necessary to provide a separate PC, so that the cost of the system can be reduced.
According to the third embodiment, the moving speed of the X-Y table is changed in accordance with the thickness of a workpiece. Therefore, it is possible to move the X-Y table at high speed without damaging the workpiece by the needle or breaking off the needle. Accordingly, the sewing time of the workpiece can be reduced.
According to the fourth embodiment, the control apparatus comprises vector detection means for reading the sewing data and detecting a sewing direction vector for each stitch from the sewing data, and a vector computation means for computing an amount of change in the directional vector for each stitch in accordance with the detection value detected by the vector detection means. Therefore, the moving speed of the X-Y table is restricted in accordance with the amount of change in the vector computation means. Accordingly, the workpiece can be sewn at the most appropriate moving speed of the X-Y table.
According to the fifth embodiment, the control apparatus comprises home position detection means for detecting the home position of an X-Y table, needle movement amount detection means for detecting the amount of movement of a needle, needle position computation means for computing the needle position on the X-Y table from the detection value obtained by the needle movement amount detection means and the home position detected by the home position detection means, and speed restriction means for restricting the moving speed of the X-Y table in accordance with a computed value obtained by the needle position computation means. Accordingly, the vibration of the X-Y table is reduced, and the apparatus can be operated at high speed. | A control apparatus for a sewing machine in which a microcomputer in the control unit of the sewing machine is provided with a sequence control function, and an on-signal for setting and removing a workpiece is incorporated into the sewing data, whereby no PC exclusively used for sequence control is required. A control apparatus of the invention includes an actuator for setting a workpiece on the sewing machine or removing it from the sewing machine, drive means for driving the actuator on and off, a storage element for storing on-data in the sewing data by which a workpiece is automatically sewn, the on-data serving as an on-signal to set the workpiece on the sewing machine or remove it from the sewing machine, detection means for generating a completion signal of the setting or removing of the workpiece, command means for generating an off-signal in the drive means in accordance with the detection of the completion signal by the detection means, start means for starting to set the workpiece on the sewing machine or remove it from the sewing machine by operating the actuator when the drive means is turned on in accordance with the on-signal, and stop means for stopping motion of the actuator by turning off the drive means in accordance with the off-signal. | 3 |
FIELD OF THE INVENTION
The present invention relates to apparatus and methods for singularizing healds for warp thread drawing-in machines. It is directed particularly to a system for selecting and separating individual healds from a stack of healds and making them available for the drawing-in of the warp threads.
BACKGROUND
In apparatus known hitherto, the selecting member is formed by a needle which sticks into the heald stack directly after the frontmost heald of the stack and then displaces the frontmost heald in the longitudinal direction (that is, in the feed direction) of the heald stack to the drawing-in position. The healds used are either provided with a taper at their narrow edges at the selecting point or they must have a so-called keyhole. This means that healds without tapered narrowed edges or a keyhole could not hitherto be drawn in automatically in such apparatus.
SUMMARY OF THE INVENTION
An aspect of the present invention is the provision of a universally usable device and method for singularizing healds, so as to enable all types of healds to be removed. In accordance with the invention, a selecting member is formed by a piston which can perform a stroke essentially transversely to the heald stack. During the working stroke of this piston, a heald is transported from the heald stack in a positive-locking manner into an intermediate position. In a system according to the invention, the frontmost heald is not, during the selection step, pushed further in the feed direction of the stack, as has been the case heretofore, but is rather moved laterally out of the heald stack. This means an uncoupling between the actual singularizing operation and the following removal, which enables optimally adapted means to be used for the now uncoupled operations. The apparatus is able to select all types of healds from the heald stack so that the healds need not be specially prepared. Since the selection is effected in a positive-locking manner, the healds are always fully under control.
In a preferred form of the invention, transfer means are provided for transferring the respective heald from the said intermediate position to a transport unit for transporting the healds to their drawing-in position.
This transfer means represents an interface between the actual selecting device and the transport unit and opens up the possibility of being able to interrupt the connection between selecting device and transport unit when required, for example in the event of faults.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail below with reference to an exemplary embodiment and the drawings, in which:
FIG. 1 shows a perspective overall representation of a drawing-in machine according to the invention;
FIG. 2 shows a schematic perspective representation of the heald singularizing system in the drawing-in machine of FIG. 1;
FIG. 3 is a view in the direction of arrow III in FIG. 2;
FIG. 4 is a view in the direction of arrow IV in FIG. 3;
FIG. 5 is a somewhat diagrammatic view generally similar to FIG. 4 with some parts omitted and showing on an enlarged scale the relationships between certain parts of the heald singularizing system of the invention;
FIG. 6 is a view similar to FIG. 5 but showing the parts in the positions they occupy after a portion of the endmost heald of the heald stack has been shifted laterally of the stack; and
FIG. 7 is another view similar to FIGS. 5 and 6, but showing the parts in the positions they occupy after a separated heald has been transferred from the intermediate position of FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to FIG. 1, the drawing-in machine includes a mounting stand 1 and various subassemblies arranged in this mounting stand 1. Each of these subassemblies represents a functional module. A warp-beam truck 2 with a warp beam 3 arranged thereon can be recognized in front of the mounting stand 1. In addition, the warp-beam truck 3 contains a so-called lifting device 4 for holding a frame 5, on which the warp threads KF are clamped. This clamping is effected before the actual drawing-in and at a location separate from the drawing-in machine, the frame 5 being positioned at the bottom end of the lifting device 4 directly next to the warp beam 3. For the drawing-in, the warp-beam truck 2 together with warp beam 3 and lifting device 4 is moved to the so-called setting-up side of the drawing-in machine and the frame 5 is lifted upwards by the lifting device 4 so that it then assumes the position shown.
The frame 5 and the warp beam 3 are displaced in the longitudinal direction of the mounting stand 1. During this displacement, the warp threads KF are directed past thread-separating apparatus 6 and as a result are separated and selected. After the selection, the warp threads KF are cut off and presented to a drawing-in needle 7, which forms a component of the so-called drawing-in module. The selecting equipment employed for this operation may be of the type used heretofore in the warp tying machine sold under the designation USTER TOPMATIC by Zellweger Uster AG of Switzerland. USTER is a registered trademark of Zellweger Uster AG.
Next to the drawing-in needle 7, there is a video display unit 8, which belongs to an operating station and serves to display machine functions and machine malfunctions and to input data. The operating station, which forms part of a so-called programming module, also contains an input stage for the manual input of certain functions, such as, for example, creep motion, start-stop, repetition of operations, and the like. The drawing-in machine is controlled by a control module which contains a control computer and is arranged in a control box 9. Apart from the control computer, this control box contains a module computer for every so-called main module, the individual module computers being controlled and monitored by the control computer. The main modules of the drawing-in machine, apart from the modules already mentioned (drawing-in module, yarn module, control module and programming module) are the heald, drop-wire, and reed modules.
The thread-separating apparatus 6 for presenting the warp threads KF to be acted upon by the drawing-in needle 7, and the path of movement of the drawing-in needle 7 transverse to the plane of the clamped warp threads KF, define a plane in the area of a support 10 forming part of the mounting stand 1. This plane separates the setting-up side already mentioned from the so-called taking-down side of the drawing-in machine. The warp threads and the individual elements into which the warp threads are to be drawn-in are fed at the setting-up side, and the so-called harness (healds, drop wires and reed) together with the drawn-in warp threads can be removed at the taking-down side. During the drawing-in, the frame 5 having the warp threads KF and the warp-beam truck 2 for the warp beam 3 are moved to the right past the thread-separating apparatus 6. In the course of this movement, the drawing-in needle 7 successively removes from the frame 5 the warp threads KF clamped on the latter.
When all warp threads KF are drawn in and the frame 5 is empty, the latter, together with the warp-beam truck 2, the warp beam 3 and the lifting device 4, are located on the taking-down side.
Arranged directly behind the plane of the warp threads KF are the warp-stop-motion drop wires LA. Behind the latter are the healds LI and the reed is further to the rear. The drop wires LA are stacked in hand magazines. The full hand magazines are hung in sloping feed rails 11, on which they are transported to the right towards the drawing-in needle 7. At this location they are separated and moved into the drawing-in position. Once drawing-in is complete, the drop wires LA pass on drop-wire supporting rails 12 to the taking-down side.
The healds LI are lined up on rails 13 and shifted manually or automatically on the latter to a separating stage. The healds LI are then moved individually into their drawing-in position and, once drawing-in is complete, they are distributed over the corresponding heald shafts 14 on the taking-down side. The reed is likewise moved step-by-step past the drawing-in needle 7, the corresponding reed gap being opened for the drawing-in. After the drawing-in, the reed is likewise located on the taking-down side. A part of the reed WB can be recognized to the right next to the heald shafts 14. This representation is to be understood as illustrative, since the reed, at the position shown of the frame 5, is of course located on the setting-up side.
A so-called harness truck 15 is provided on the taking-down side. This harness truck 15, together with the drop-wire supporting rails 12 fixed thereon, the heald shafts 14 and a holder for the reed, are pushed into the mounting stand 1 into the position shown. After the drawing-in, the truck 15 carries the harness having the drawn-in warp threads KF. At this moment, the warp-beam truck 2 together with the warp beam 3 is located directly in front of the harness truck 15. By means of the lifting device 4, the harness is now reloaded from the harness truck 15 onto the warp-beam truck 2, which then carries the warp beam 3 and the drawn-in harness and can be moved to the relevant weaving machine or into an intermediate store.
The mode of operation of the individual sub-assemblies is not the subject matter of the invention and is therefore not to be described further here. The functions are distributed over a plurality of modules and these modules represent virtually autonomous machines which are controlled by a common control computer. The cross connections between the individual modules run via this higher-level control computer, and there are no direct cross connections between the individual modules. If the structure of the drawing-in machine described is considered, the drawing-in machine system receives drawing-in data, control data, harness and yarn as well as energy and delivers processed operating data, status information and the drawn-in harness.
The separating stage, designated by SP, for the healds LI is shown in FIGS. 2 to 7. FIG. 2 shows a perspective representation (not true to scale or proportion) which is intended to provide an overview of the separating principle; each of FIGS. 3 and 4 shows a view to the scale of about 1:1.
As already mentioned in the description of FIG. 1, the healds LI are lined up on rails 13 and shifted automatically or manually on the latter to the separating stage SP. The relationship between the upper lug portion of each heald LI and the upper rail 13 is shown in FIG. 2, and it will be understood that a similar relationship exists between a lower lug portion of each heald and a bottom rail which is not shown. The displacement direction of the healds along the rails 13 is designated in FIG. 2 by an arrow A.
The displacement is preferably effected automatically. For this purpose, the heald stack LS bears at one of the narrow edges of the healds LI against a guide rail 16 along which the displacement is effected. A transport means which displaces the heald stack LS in the direction of arrow A is arranged at the other narrow edge (the front edge in the figure) of the healds. According to the representation, this transport means is represented by a brush-like roller 17 which acts on the front narrow edge of the healds LI and has on its circumference a brush-like or plushy or elastic lining for driving the healds. During rotation of the roller 17 in the direction of rotation designated by an arrow B, the healds LI are pushed in the direction of arrow A. Instead of the roller 17 or in combination with the same, a conveying belt can be used. Such a belt would be stretched over two rollers and is provided either with a suitable lining or with individual, preferably brush-like, driving elements.
Directly in front of the separating stage SP, a guide rail 18 is also arranged in the area of the front narrow edge of the healds LI, which guide rail 18 has a sloping, funnel-like entry part so that the healds LI are fed in an ordered manner to the separating stage in a guide channel formed by the two guide rails 16 and 18. In the separating stage, in each case the frontmost heald LI1 of the heald stack LS is separated or selected from the latter and transferred to a transport unit which successively moves the individual healds to the drawing-in position in which the warp threads are drawn in.
Two separating stages SP are provided, of which one acts on the healds LI in their top area and the other acts on the healds LI in their bottom area (see FIG. 3). Both separating stages are driven synchronously.
With the aid of FIG. 2, in which the main parts of the separating stage SP arranged in the area of the top heald end are shown, the operating principle of the heald separation will now be explained. A stop element is arranged directly in front of the removal end of the guide channel formed by the guide rails 16 and 18, which stop element runs transversely to this guide channel and is formed by a rib 20 projecting from an essentially prismatic guide body 19. Its distance from the removal end of the guide channel is selected in such a way that the frontmost heald LI1 bearing against the rib 20 is located completely outside the guide channel. The distance between rib 20 and guide channel is adjustable; the adjustment is preferably made by exchanging the guide body 19, various guide bodies 19 being available in which the stop surface of the ribs 20 is in each case stepped to varying degrees from the corresponding base surface of the guide body 19. In practice, three to four guide bodies 19 of this type are sufficient to cover the entire range of the heald thicknesses which occur.
The frontmost heald LI1 therefore lies in the area of the rib 20 outside the guide channel but is still held with its end lugs on the rails 13. The separation is now effected, that is, the separation of the frontmost heald LI1 from the heald stack LS, for which purpose the center part (i.e., the part lying between the end lugs) of the frontmost heald LI1, is pushed laterally out of the heald stack. This pushing-out is effected by a piston-like selecting member 21 which is mounted in the guide body 19 so as to be adjustable in its stroke transversely to the longitudinal direction of the healds LI and transversely to their guide direction A. During its working stroke in the direction of arrow C (the transverse direction) the selecting member 21 pushes the center part of the frontmost heald LI1 away from the heald stack LS in a positive-locking manner into the intermediate position ZP drawn in broken lines. During this displacement, the said center part slides along a guide plane 22 until it comes to a stop at a stop 23. In the intermediate position ZP, the heald is held at its end lugs by the rails 13 and in the area of its center part between the stop 23 and the front edge of the selecting member 21.
A plunger 24 displaceable in the direction of arrow D is arranged below the guide plane 22, the end face of which plunger 24 is set back slightly relative to the guide plane 22 against the direction of arrow D. The plunger 24 is now moved in arrow direction D and displaces the center part of the heald LI1 from the intermediate position ZP on an inclined path parallel to the inclined end face of the rib 20 into a transfer position UP drawn in chain lines. During this displacement produced by the plunger 24, the heald center part bent during the separation relaxes again and assumes its straight position again in the transfer position UP. If the transfer position UP is compared with the initial position before the separation, only a displacement in the transport direction A has taken place between these two positions indirectly via the intermediate position ZP, the heald being guided in a positive-locking manner during the entire displacement.
In the transfer position UP, the heald is no longer held with its end lugs by the rails 13 but is slipped over needle-like holding means 25 which form part of a transport unit for transporting the heald to the drawing-in position. The plunger 24 is then moved back into its initial position, and the selecting member 21, already moved back into its initial position against the direction of arrow C during the transport stroke of the plunger 24, can perform a further working stroke and as a result separate the next heald LI from the heald stack LS.
Some relationships involved in the heald selection and transfer operations are depicted in FIGS. 5-7. These are a sequence of similar views from above of the heald selecting and transferring components of the lower separating stage SP (FIG. 3).
The front portion of the heald stack LS is shown within the guide channel formed by the rails 16 and 18 and should be understood to be yieldingly urged (as by a brush roller 17) toward a stop surface 20a provided by the guide body/rib unit 19,20. The guide surface 22 is at the removal end of the guide channel for the stack LS and is spaced from the stop surface 20a in a direction parallel to the direction of movement of the stack LS along the channel. This spacing is greater than one heald thickness but less than two heald thicknesses.
The end of piston-like selecting member 21 has a portion (its upper portion in FIG. 5) that extends in the space between the stop surface 20a and the end of the guide channel for the stack LS. The protrusion of the member 21 beyond the stop surface 20a is less than the thickness of one heald. This enables the end face of the selecting member 21 to push against the edge face of the endmost heald LII without contacting any other heald when the member 21 is moved to the left in FIG. 5 over the guide body/rib unit 19, 20.
The movement or stroke of the selecting member 21 is long enough to displace the contacted portion of the endmost heald 21 laterally beyond the nose or tip of the rib 20. This relationship will be evident from a comparison of FIGS. 5 and 6. In its laterally displaced condition, this heald is no longer constrained by the guide body/rib unit 19, 20 from further motion in the direction A of movement of the heald stack LS.
The plunger 24 then is activated to shift this heald forwardly. As the plunger 24 moves in its inclined path, its end face pushes the displaced heald portion forwardly beyond the nose of the rib and then along the inclined side face of the rib. Retraction of the selecting member 21 (as indicated in FIG. 7) frees the displaced heald portion from the biasing force and allows this heald to return to its natural straight condition.
FIG. 3, partly in section, shows a true-to-scale representation of the two separating stages SP and their arrangement. FIG. 4 also is partly in section and shows a true-to-scale representation. Each separating stage SP is fixed to a support 26, of which only the one for the top separating stage is drawn in the figure. The selecting member 21, which is carried by a pneumatically driveable piston 27, will be recognized on the right hand side of the heald LI in FIG. 3. The piston 27 is mounted in a housing 28 provided with compressed-air connections. The selecting member 21 is guided in the guide body 19, and a stop pin 29 passes through it for limiting its stroke. In the area of its front part for separating the heald LI, the selecting member is of U-shaped design and surrounds the rib 20.
Recognizable on the left hand side of the heald LI in FIG. 3 are first and second components 30 and 34, as well as the guide rail 16. The first component 30 includes a basic body 31 fixed to the support 26. A sensor 32 is fixed to this basic body 31 and has a contact spring 33 (see FIG. 4). The second component 34 is likewise fixed to the support 26 and provides the guide plane 22 and the stop 23. The sensor 32 serves to detect the heald separation by the contact spring 33 being pressed against the sensor 32 by the heald LI during its displacement into the intermediate position ZP. In general, it can be said that the movement of the selecting member 21 and the movement of the plunger 24 also are monitored by sensors. If one of these sensors does not respond, the relevant function is repeated.
The plunger 24 also is pneumatically operable. Its arrangement is indicated in FIG. 4, but the plunger 24 has been omitted from FIG. 3 for the sake of clarity. The plunger 24 for each of the separating stages SP is arranged on the inside of the two separating stages, that is, below the top separating stage SP and above the bottom separating stage SP. According to the representation, the longitudinal axis of the essentially prismatic plunger 24 lies at an angle to the feed direction A of the healds LI. Its end face contacting the healds LI runs at an angle to the longitudinal axis, or in other words parallel to the longitudinal axis of the selecting member 21 (arrow C). The plunger 24 has an elongated slot 40 which surrounds a bolt 41 serving to guide it during its stroke movement. A pneumatically driveable piston 43 mounted in a piston housing 42 serves to drive the plunger 24.
Since the selecting members 21 of the upper and lower separating stages SP act on each heald in its top and bottom areas and since the heald eyes LA (FIG. 3) are located in the mid-portions of the lengths of the healds so as to have a relative large distance from the selecting members 21, it can happen that a heald is singularized from the stack at its top and bottom areas but still adheres to the following heald at the heald eye region.
When such a singularized heald is then transferred to the holding means 25 by the plunger 24 (over a distance of approximately 25 millimeters), the two healds adhering together at their eyes will have at their ends a mutual distance of 25 mm. They will look like two convex curves facing each other and being in contact at their vertex.
In order to separate two healds adhering together in this manner, a finger 37 is located to swing in a vertical plane between the front end of the heald stack and the holding means 25. The finger is operated after the transfer of the heald to the holding means 25.
As shown in FIG. 3, suitable means for actuating the finger 37 may be located to cooperate with the other components. A further piston housing 35 is fixed to the support 26. A pneumatically driveable piston 36 is mounted in housing 35. This piston is connected in an articulated manner to the blade-like pivoted lever 37 which is pivoted into the plane of the healds LI when the piston 36 is actuated so that healds possibly adhering to one another at the heald eyes LA can be mechanically detached from one another. The traverse of the pivoted lever 37 is limited by suitable stop means selected in relation to the lengths of the healds being processed. There is a stop 38 whose position is suitable for the maximum length of the healds LI used. Where shorter healds are to be removed, as indicated in FIG. 3, the active stop means may be in the form of an additional stop pin 39 (drawn in chain lines) mounted on the support 26 in order to limit the traverse of the pivoted lever 37 to the upper of the two end positions shown in chain lines.
The arc through which the finger 37 swings amounts according to FIG. 3 (upper of the two end positions drawn in chain lines) to approximately 70°. For longer healds where the lower separating station would be in a lower position than that shown in FIG. 3, the arc would amount to 90° but in both cases the finger 37 would not encounter interference from other structural components.
The described system for singularizing the healds preferably is such that the entire arrangement, that is, the separating stages together with the heald supporting rails and the transport means for feeding the healds, is mounted on a common mounting stand. This mounting stand is of mobile construction and can thus be moved into the warp thread drawing-in machine in a simple manner.
There is a detachable connection in the form of a locking coupling between the device for singularizing the healds and the following transport unit for transporting the healds to their drawing-in position. The various functions of the individual parts, such as selecting member 21, plunger 24 and pivoted lever 37, are separately controlled; and the various functional sequences are synchronized via the module computer of the heald module. | A heald singularizing system includes a selecting member (21) for the healds (LI) fed in the form of a stack (LS). The selecting member (21) separates the front-most heald (LI1) from the stack and makes it available for the drawing-in of the warp threads. The selecting member (21) is formed by a piston which can perform a stroke essentially transversely to the heald stack (LS), during which the heald (LI1) is displaced from the heald stack (LS) into an intermediate position (ZP). Transfer means (24) transfers the respective heald (LI1) from its intermediate position (ZP) to a transport unit (25) for taking it to its drawing-in position. All types of healds can be selected from the heald stack, and neither a special preparation of the healds nor the use of a special type of heald is necessary. The heald separation and the further removal are completely uncoupled, to permit the use of means optimally adapted to the individual functions and also to simplify considerably the rectification of faults. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to both electrochemical and oxygen bleaching or delignification of lignocellulosic materials particularly wood chips and pulp and more particularly to wood pulp prepared by standard pulping methods, especially alkaline pulping methods, and to products prepared thereby and processes for their use.
Chemical pulp is prepared by treating lignocellulosic material with various "pulping chemicals" to render soluble the major portion of the non-carbohydrate portion of the material. The most common chemical pulp is pulp prepared from wood chips by the "kraft" or sulfate process. In this process the wood chips are treated under heat and pressure with sulfide ions in a strongly alkaline aqueous medium. The resulting pulp, while quite strong, is highly colored probably due to a large number of chromophores in the residual lignin. "White" papers are prepared from such pulps and from other chemical pulps by bleaching which principally comprises further delignification. The usual way this is accomplished is by treatment with chlorine-based chemicals such as chlorine, chlorine dioxide, hypochlorite and other oxidative chemicals which oxidize and solubilize the remaining lignin and, thus, remove the chromophoric material.
Recently other oxidative processes employing materials such as oxygen, ozone, peracids and peroxides have been suggested as alternatives to reduce or replace the need for chlorine based chemicals in the bleaching of pulps. For a number of reasons, well known to those in the art, oxygen has proven to be of particular interest and bleaching sequences employing oxygen which are intended to reduce the use of chlorine based chemicals are in commercial operation. However, severe reaction conditions (temperatures greater than 90° and oxygen pressures exceeding 70 psi) are required for standard oxygen-based bleaching sequences as presently practiced.
One convenient means to reduce the severity of oxygen bleaching conditions is to use catalysts which accelerate the reaction between lignin and oxygen. Several such catalysts are known. They are Salcomine (an ethylenediamine-bissalicylaldehyde complex of cobalt), ortho-phenanthroline, and manganese salts. These catalysts are not suitable for practical commercial use because they are relatively expensive due to the fact that they cannot be recovered and regenerated conveniently.
One potential way to generate or regenerate a catalyst for oxygen bleaching is through an electrochemical treatment of the precursor or spent catalyst, respectively.
Electrochemical generation of oxidants or other "electron carriers" in situ or in a closed cycle process in pulp bleaching, and even in some pulping processes for lignocellulosic material, has been experimented with in the past but, as far as is known, with little or no practical success and these processes have never been used commercially.
Electrochemically generated compounds such as hypochlorite, hydrogen peroxide and the like have been shown to react with and solubilize lignin. However, compounds lacking an oxygen function, for example ferricyanide, will react with but not solubilize lignin to any applicable extent unless some oxygen is also present. The prior art has not recognized the importance of the oxygen that was present in providing its reported results and, hence, has not recognized that compounds such as ferricyanide when present in catalytic amounts together with deliberately added quantities of oxygen function as catalysts to solubilize lignin at a very rapid rate under reaction conditions substantially milder than those employed in conventional oxygen bleaching of lignocellulosic pulps. Oxygen bleaching may, therefore, be conducted under milder conditions of temperature and pressure than are presently employed in conventional processes.
Citation of Relevant Art
The most relevant art of which applicants are aware are two Russian papers and a Russian Inventor's Certificate. These are S. B. Stromsky, E. I. Chupka, Wood Chemistry, U.S.S.R, 1978, N4, pp 11 to 14, "Electrochemical Way of Bleaching of Kraft Pulp"; E. I. Chupka et al., Bumazhnaya Promyshlennost (Paper Industry, USSR), 1978, N11, pp 20 to 21, "Chlorine-Free Ways of Electrochemical Bleaching of Pulp"; and Inventor's Certificate 596,687 to Chupka et al.
In these documents electrochemical bleaching of kraft pulp by electrogenerated ferricyanide is taught. Chupka et al. specifically teach that the bleaching is due to the use of ferricyanide as an electron carrier and note that the rate of bleaching is somewhat faster than bleaching under comparable conditions where no ferricyanide is present. Under the high voltage conditions employed by Chupka et al. a small amount of oxygen was concurrently produced with the ferricyanide but Chupka did not recognize the necessity of that oxygen in producing his result. Thus, no teaching or suggestion is provided by these authors that supplying an effective amount of oxygen from outside the system would permit extremely rapid bleaching even at voltages where oxygen is not generated concurrently with ferricyanide.
An additional related USSR Inventor's Certificate is number 535,383 to Chupka et al. The subject matter of this certificate is kraft pulp bleached by oxygen generated electrochemically. This reference is strictly concerned with supplying oxygen from the decomposition of water directly to pulp in situ rather than as a gas collected from the atmosphere. Catalysis of the reaction is not discussed.
Applicants are also aware of the following publication and patents:
"A Study of Some of The Variables in Bleaching Pulp in an Electrolytic Cell" by David R. Gustafson in TAPPI, 42, pp 612 to 616, (1959) which discusses bleaching of sulfite pulp with chlorine generated electrolytically in situ. This reference teaches only that chlorine generated in situ by electrolysis of chloride can be substituted for chlorine generated externally and supplied as an aqueous solution. Bleaching with other than chlorine is not suggested.
U.S. Pat. No. 1,780,750 which discusses the use of in situ electrolytically generated chlorine to bleach bagasse pulp.
U.S. Pat. No. 2,214,845 which discusses brightening of paper pulp and other materials through the use of ferricyanide to generate ferrous ferricyanide (Turnbull's Blue) thereby removing discoloration provided by the iron originally present and in addition adding "blueing" to the materials in question and reducing any inherent grayness due to other trace foreign substances. Electrochemical generation or regeneration of the ferricyanide and its potential use in delignifying bleaching is not mentioned.
U.S. Pat. No. 2,477,631 which deals with hypochlorite bleaching of paper pulp and other materials with the aid of water soluble salts of cobalt, nickel and manganese. Electrochemical delignifying bleaching and the generation and use of ferricyanide therein are not mentioned.
U.S. Pat. No. 2,828,253 which deals with electrochemical generation of chlorine for the pulping of straw, bagasse and the like.
U.S. Pat. No. 3,489,742 which deals with pulping of sisal and similar fibers using chlorine and alkali generated in situ electrochemically.
U.S. Pat. No. 4,141,786 which deals with the use of manganic ions generated in situ in pulp by treatment of precipitated manganous ions on the pulp with oxygen to delignify lignocellulosic pulps.
British Pat. No. 942,958 which deals with delignifying bleaching of lignocellulosic pulps by alkali and chlorine generated electrolytically in situ.
It is readily apparent that of all the above literature and patents, only the above cited Chupka references are really relevant and these do not teach or suggest applicant's invention.
SUMMARY OF THE INVENTION
The invention provides a process for delignification of lignocellulosic material which comprises treating said lignocellulosic material with a bleaching effective amount of oxygen and a catalytically effective amount of electrochemically generated ferricyanide ion in a substantially aqueous solution at alkaline pH.
The tangible embodiments produced by the process aspect of the invention possess the inherent physical characteristics of being relatively bright pulps when tested by standard brightness methods, and of having equal strength properties to comparable pulps bleached by oxygen under the conditions employed in prior art processes.
The tangible embodiments produced by the process aspect of the invention possess the inherent applied use characteristics, particularly when they are derived from wood pulp, of being suitable for the manufacture of paper and paperboard having strength properties equal to those obtained from prior art oxygen bleaching processes, thus, being useable for all standard uses of lignocellulosic pulp based paper and paperboard.
Special mention is made of embodiments of the invention wherein the lignocellulosic material is wood pulp, of embodiments wherein the wood pulp has been at least partly delignified by a conventional alkaline pulping process and of embodiments wherein the alkaline pH is from about pH 10 to about pH 15, preferably from about pH 13 to about pH 14.5.
DESCRIPTION OF THE DRAWING
The drawing FIGURE is a schematic representation of a preferred apparatus configuration for the practice of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The manner of practicing the process of the invention will now be described with reference to the drawing, employing as an illustration a preferred embodiment thereof, namely the bleaching of kraft (alkaline sulfide) softwood pulp 10a in a preferred form of apparatus to be described in detail hereinafter. Referring now to the drawing, to practice the process of the invention, the lignocellulosic material 10, conveniently softwood pulp 10a prepared by a conventional kraft (alkaline sulfide) pulping process to a lignin content and cellulose degree of polymerization typical of wood pulps prepared by such processes, conveniently to a lignin content, which is represented by a kappa number of about 40 and a cellulose viscosity number of about 30 may be suspended in an alkaline, conveniently about 1N in NaOH, ferricyanide solution 11 containing an amount of ferricyanide ion sufficient to provide a catalytically effective amount of ferricyanide, conveniently about 4 millimolar in [Fe(CN) 6 ] -4 , which has been saturated with oxygen gas 12 at normal temperature and pressure, conveniently at about 25° C. and atmospheric pressure. The ferricyanide solution 11 may be obtained by passing a moderate electric current 13, conveniently about 90 m. Ampere, through a ferrocyanide solution of appropriate concentration. The ferricyanide solution 11 will be generated in the anode compartment 15 of an electrochemical cell 16, which may be conveniently separated from the cathode by a semipermeable membrane 17. After saturation with oxygen 12 in standard fashion, the mixture of ferricyanide 11 and oxygen 12 may be continuously circulated though the pulp suspension 10 for a short period of time, conveniently about 3.5 hours, to produce a pulp having a kappa number of about 9 and a viscosity of about 13 cp. The spent solution 18 recovered from the pulp suspension 10 may be recirculated to the anode compartment 15 for reoxidation of ferrocyanide to ferricyanide and subsequent reintroduction of oxygen 12. In the anode compartment 15, in addition to ferricyanide being regenerated, solubilized lignin fragments in the spent solution 18 may be further oxidized. It is thought that this removal of dissolved lignin from the circulating liquor assists in maintaining the extractive power of the liquor for the chromophoric components of the lignocellulosic pulp. The resulting pulp, if desired, may be further bleached by any conventional bleach sequence, or it may be formed directly into paper.
As used herein and in the appended claims the term "a bleaching effective amount of of oxygen" means that the solution is at least saturated with oxygen gas at 25° C. and at normal atmospheric pressure.
The term "a catalytically effective amount of ferricyanide means a concentration of ferricyanide in solution of from about 0.004% to about 0.400% by weight, preferably from about 0.015% at about 0.200% by weight.
The pH of the ferricyanide solution 11 may vary from about 11 to about 15, preferably from about 13 to about 14. The temperature at which the process may be carried out is not particularly critical but conveniently should be less than the 90° to 120° C. at which conventional oxygen bleaching stages are normally carried out. The temperature may range upward from about 0° C. with about 25° to about 65° C. being preferred.
One of skill in the art will understand that the time required for the reaction will also depend upon the type of pulp, and the extent of prior delignification. One of skill in the art will be able to select a desired reaction period to optimize delignification while minimizing cellulose depolymerization employing kappa number and viscosity determinations already standard in the industry.
The concentration of the pulp 10 or other lignocellulosic material in the slurry is also not particularly critical and is largely limited by the difficulty of handling and diffusing reagents through pulp slurries which are too concentrated and the large volume and inordinate residence times involved with too dilute slurries. Normally wood pulp concentrations of from about 1% to about 40%, preferably from about 3% to about 5% and from about 25% to 35% all by weight are preferred because of the ease of handling slurries in these preferred consistency ranges.
The particular configuration of the apparatus employed to practice the invention is not particularly critical and may be any of the prior art described devices. Particularly preferred, however, is a device comprising an electrochemical cell 16 divided by a semipermeable membrane 17, such as a Nafion brand membrane sold by Dupont, into cathodic 14 and anodic 15 compartments employing, conveniently, a carbon electrode 19 in the cathode compartment 14. The anode compartment 15 is conveniently filled with loosely packed nickel shot 20 connected to EMF source 101 by wire 21. Cathode 19 is connected to EMF source 101 by wire 22. Anode compartment 15 is connected to tank 102 by tube 23. Tank 102 is connected to tower 103 by tube 24. Tower 103 is connected to pump 104 by tube 25. Pump 104 is connected to anode compartment 15 by tube 26.
In operation, ferrocyanide solution may be introduced into the system. Passing an electric current 13 from EMF source 101 carried by wires 21 and 22 through electrochemical cell 16 produces ferricyanide solution 11 in anode compartment 15. Ferricyanide solution 11 passes through tube 23 into tank 102 where it is mixed with oxygen 12 introduced, conveniently as air, into tank 102 through tube 27. The mixture of ferricyanide 11 and oxygen 12 passes through tube 24 into tower 103 containing lignocellulosic material 10. After a sufficient residence or dwell time to allow reaction with the lignocellulosic material 10, the now exhausted solution 18 is recirculated through tube 25, pump 104, and tube 26 to anode compartment 15 where it is reoxidized electrically to produce fresh ferricyanide solution 11. Pump 104 provides the hydraulic pressure to produce the fluid circulation of solutions 11 and 18. The electrical potential of nickel anode 20 relative to a standard calomel electrode 28 is measured by voltmeter 105. The flow rate of solutions through the system is adjusted to provide a sufficient dwell time for the reaction to take place in tower 103.
The EMF required for the process of the invention as determined by the potential of the anode with reference to a standard calomel electrode may vary from about +0.2 volts to about +0.6 volts, with about +0.4 volts being preferred. The cell current automatically adjusts to oxidize all species passing through anode compartment 15 which are reactive at the electrical potential selected particularly the ferrocyanide which is completely reactive in this potential range. Thus, the current magnitude is dependent on the concentration of ferrocyanide entering the cell and on the concentration of oxidizable organic species, principally from lignin, extracted from the pulp.
At the anode potentials relative to a standard calomel electrode contemplated by the invention, no oxygen is generated at the anode.
"Kappa" number referred to herein is a measure of residual lignin in a lignocellulosic material and is determined according to TAPPI standard T236 os-76.
Pulp "viscosity" or "viscosity" referred to herein is a measure of the degree of polymerization of cellulose in the pulp. It is determined according to TAPPI standard T230 os-76. Decreasing pulp viscosity reflects an increasing degree of cellulose destruction via depolymerization.
The following examples further illustrate the best mode contemplated by the inventors for the practice of their invention.
EXAMPLE 1
Northern softwood pulp (10 g, kappa 39, viscosity 37) prepared by standard kraft pulping is treated at 25° C. for 3.5 hours by circulating through it 1.5 liters of 1N NaOH solution saturated with oxygen gas and containing ferricyanide ion generated from 1 millimole per liter potassium ferricyanide subjected to a 90 milliAmpere current. At the end of the treatment period, the pulp is separated from the treatment solution, washed and the kappa number and viscosity determined. The kappa number was 9 and the viscosity 13.5.
EXAMPLE 2
The same softwood pulp as in Example 1 is treated with the ferricyanide solution under the conditions described in the Chupka et al references cited above. 21 hours are required to for the pulp reach kappa number 9 and viscosity 13.5.
EXAMPLE 3
Following the method of Example 1 but employing an N 2 purge to remove all but traces of oxygen from the system, the same pulp as used in Example 1 requires 19 hours to reach kappa number 11 and viscosity 19 and over 48 hours to reach kappa 9 and viscosity 13.5.
EXAMPLE 4
Northern hardwood pulp (10 g, kappa number 14.0, viscosity 25 cp) prepared by conventional kraft pulping is treated for 3 hours at 50° C. in 1.0 liter of 1N NaOH-Na 2 CO 3 at pH 12.7 saturated with N 2 at 14 psi containing ferricyanide at an excess concentration of 12.3 millimoles/liter. The pulp after separation and washing has a kappa number 10.9 and a viscosity 24.0 cp demonstrating the relatively small degree of delignification (22%) achieved by ferricyanide alone.
EXAMPLE 5
Following analogous treatment conditions but supplying O 2 at 14 psi to the pulp in the absence of ferricyanide a kappa number of 12.3 and a viscosity of 21.4 is achieved thus demonstrating the small degree of delignification (12%) obtained by oxygen alone at low temperatures (less than 90° C.) and pressures.
EXAMPLE 6
Following analogous treatment conditions but supplying an oxygen purge at 14 psi to the solution containing ferricyanide, the hardwood pulp of Example 5 reaches a kappa 5.9 (delignification of 58%) at a viscosity of 11.4.
EXAMPLE 7
Following the procedure of Example 5 and supplying an overpressure of oxygen gas at 170 psi to the system the pulp reaches a kappa of 4.6 (delignification of 67%) at a viscosity of 7.8. | Delignifying bleaching of lignocellulosic materials, particularly wood pulps already partly delignified by conventional alkaline pulping processes by electrochemically generated ferricyanide in the presence of an effective amount of molecular oxygen is disclosed.
Attainment of low kappa numbers employing milder temperature and pressure conditions than are employed in conventional oxygen bleaching is made possible and the process may be substituted for at least a portion of the conventional chlorine based bleaching processes which are current industry standard practice for bleaching kraft pulps. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to the field of electrical connectors and more specifically to the area of assembly techniques for such connectors.
2. Description of the Prior Art
In multi-pinned shell housing electrical connectors, such as those suitable for use in high moisture environments, the common assembly technique is to first provide the shell housing with a plurality of axially extending apertures and internal compression members for latching subsequently inserted electrical terminals. Electrical terminals, commonly connected to insulated wires, are then inserted, one by one, into the appropriate apertures provided in the shell housing where they are latched in place by the internally formed compression members.
U.S. Pat. Nos. 3,170,752; 3,206,717; 3,430,185; 4,124,264; and 4,128,293 are each representative of prior art assembly techniques in which the electrical pin connectors are individually inserted into the shell housing apertures and latched in place by internal means within the housing.
Commonly assigned U.S. Pat. No. 3,937,545 generally illustrates the above described technique and, in addition, illustrates the use of an elastomeric material containing apertures corresponding to the number of electrical pin connectors in the shell housing, whereby the elastomeric material is compressed within the shell housing. The insulated wires are threaded through the elastomeric apertures and compressibly held to prevent the migration of moisture along that interface and into the electrical contact portion of the connector.
SUMMARY OF THE INVENTION
In contrast to the described prior art assembly technique, the present invention offers an improved method of assembly which eliminates the laborious and time consuming effort of tooling molds with relatively complicated internal latching members and of inserting individual pin connectors into the shell housing apertures.
The present invention allows for the individual pin connectors to be prepositioned and molded into a carrier element. The carrier element is formed to a predetermined shape which matches that of a corresponding aperture in a connector shell housing. The carrier element containing its pin connectors is inserted into the shell housing and bonded thereto to provide a secure and hermetic seal.
It is, therefore, an advantage of the present invention to provide an assembly technique whereby hermetic sealing of an electrical connector is achieved without the use of elastomers and other sealing devices.
It is another object of the present invention to provide an assembly technique whereby a plurality of electrical pin connectors may be simultaneously inserted into the rear of a shell housing in a prearranged distribution on a common carrier element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of an embodiment incorporating the present invention.
FIG. 2 is a cross-sectional view of the first embodiment assembly shown in FIG. 1.
FIG. 3 is a second embodiment incorporating the present invention.
FIG. 4 is a cross-sectional view of the second embodiment taken along lines IV--IV of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate a first embodiment which incorporates the present invention in an assembly 10. The assembly 10 includes a base member 16, a housing 14 and a cover 12. The base member 16 has a raised platform 18 onto which an insulated printed circuit board 40 is located. Printed circuit board 40 has a number of circuit elements 44 (the details of whichare not relevant to this disclosure) and electrical contact pads 42.
The housing 14 has a major aperture 15 into which access may be obtained tothe printed circuit board 40 by removal of the cover 12. The housing 14 further includes an electrical connector shell housing 20 which is preferably formed of an electricaly insulative material with a major opening 22 for receiving a mating electrical connector.
Electrical pin conductors 32 are each formed of an electrically conductive material so as to have an exposed first end portion suitable for contact with a female electrical conductor (female not shown) and for mating therewith. The second end portion of each electrical pin conducor 32 is formed as an electrical terminal 36 that is suitable for being soldered directly to corresponding ones of the conductor pads 42. In other installations, the electrical terminal ends 36 could be of the type suitable for crimping onto wire conductors, as is conventionally known.
In FIGS. 1 and 2, the electrical pin conductors 32 are shown as mounted in an insulated carrier 30 which is sized to conform to the aperture 23 at the base of the shell housing 20. In addition, an insulated support member34 is molded so as to interconnect the terminal ends 36 of the pin conductors 32 and keep them aligned in a common plane for subsequent soldering to the electrical terminal pads 42 on the printed circuit board 40.
The carrier 30 is configured in the described embodiment as having a tapered portion which corresponds to the tapered shape of the aperture 23 in the shell housing 20 and has a flange 31 extending around its periphery. The carrier 30 is a low pressure injection molding which is formed, with a high dielectric insulating material such as a thermosettingplastic. After the pin connectors 32 are temporarily held in a predetermined orientation and spacial relationship, the carrier element 30is formed about the mid-portions 33 of the pin connectors so as to surround, seal and provide a rigid support for each of the pin connectors in the assembly.
In the embodiment shown in FIGS. 1 and 2, the electrical pin connectors 32 are evenly spaced in a linear configuration so as to have their electricalterminal ends 36 disposed in a parallel relationship. It is foreseen, however, that the pin connectors could also be distributed in any other arrangement and a suitable carrier could be molded to conform to the appropriate shell housing aperture.
The support element 34 may be molded to retain terminal ends 36 in their desired orientation prior, during or subsequent to the molding of the carrier element 30.
Upon insertion into the aperture 23 of the shell housing 20, the carrier element 30 is bonded to the shell housing 20 so as to provide a hermetic seal at the aperture 23 and prevent moisture from permeating through that interface. Sonic welding has been found to be suitable for providing a high integrity seal in an automated assembly environment. In that method, an ultrasonic welding transducer is applied to the carrier 30 within the aperture 23 of the shell housing 20. Ultrasonic vibrations produced at thetransducer cause frictional heat to develop between the opposing surfaces and the thermosetting plastic materials of the housing 20 adjacent the aperture 23 and the carrier element 30 will fuse.
A second embodiment incorporating the present invention is shown in FIGS. 3and 4. In that embodiment, a plurality of carriers 130 are bonded to the shell housing 120 of an electrical connector. The shell housing has a major opening 122 and a plurality of apertures 123 which are formed of a predetermined size to accept the carriers 130 containing the plurality of electrical pin connectors 132.
In each of the assembled connector embodiments shown in the figures, it should be appreciated that the assembly technique of utilizing an molded insulator carrier element to support a number of electrical pin connectorsprior to the insertion of those connectors into a shell housing provides for the use of a simplified shell housing structure without internal molded locking structures and provides for hermetic sealing without the use of separate preformed elastomer elements. In addition, the method described eliminates the time consuming process of inserting each pin conductor precisely into a prescribed aperture on a one-at-a-time basis.
It will be apparent that many modifications and variations may be implemented without departing from the scope of the novel concept of this invention. Therefore, it is intended by the appended claims to cover all such modifications and variations which fall within the true spirit and scope of the invention. | A method of assembling an electrical pin connector utilizing a molded carrier element to support and hermetically seal a number of preoriented and spacially disposed electrical pin connectors prior to inserting the carrier into a correspondingly shaped aperture of a shell housing and bonding the carrier to the shell housing to provide a hermetic seal thereto. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus and a method for evaluating laser welds as they are being made, and is particularly suitable for evaluating laser welds made in confined spaces such as within heat exchanger tubing an example of which is the tubing of a PWR steam generator.
2. Background Information
Systems for laser welding are well known. They are particularly suitable for welding in confined spaces, such as inside the tubes of heat exchangers. One such application is welding inside the heat exchanger tubes of a pressurized water reactor (PWR) nuclear power plant. Laser welding is used to directly repair cracks in the tubing or to secure sleeves which bridge damaged sections of the tubes.
The steam generator tubes of a PWR have small inner diameters, typically 3/4 to 7/8 inches (1.9 to 2.2 cm) which are reduced even further if repair sleeves are installed. Access to the tubes through a bifurcated hemispherical chamber at the bottom of the steam generator is restricted. As the steam generator becomes radioactive in use, the welding is performed remotely through the use of robotic manipulators. Specialized laser welding apparatus has been developed for this application. The laser beam is delivered through an optic fiber extending axially through a tool which is inserted into the steam generator tubing. A lens and mirror system is provided in a weld head to focus the beam and deflect it radially outward to the inner surface of the tubing. A mechanism is provided to rotate the mirror for full 360° coverage. Examples of such apparatus for welding inside the tubes of steam generators can be found in U.S. Pat. Nos. 5,182,429; 5,359,172 and 5,371,767.
It is known to monitor radiation generated by the laser welding process, typically downstream of the weld site, to assess the quality of the weld. This is not difficult for an open weld site. U.S. Pat. No. 5,155,329 discloses an arrangement in which a number of monitoring optic fibers arranged around a central optic-fiber, which delivers pulsed laser energy to the weld site, transmit light from the weld site to an analyzer. The analyzer determines the intensity of the beam and the depth of the weld from the minimum intensity, between pulses of the laser beam, of light of a specific wavelength emitted by the weld pool.
The limited space available within the steam generator tubes does not accommodate an arrangement such as that disclosed in U.S. Pat. No. 5,155,329. The current apparatus for laser welding steam generator tubes does have splitters in junction boxes joining sections of the laser beam delivery fiber which divert a small portion of the laser beam to detectors for monitoring the intensity of the delivered beam and the integrity and condition of the delivery system. However, these are all located outside of the tube and there is no arrangement for real time monitoring of reflected or emitted light from the weld site. Instead, after many tubes have been welded, the weld tool is replaced by an inspection tool which is serially inserted into each welded tube. This is not only time consuming, but can allow many bad welds to be made before a problem is detected.
There is a need therefore for an improved method and apparatus for laser beam welding in confined spaces such as the tubes of heat exchangers and particularly the steam generator tubes in PWRs which provides real time monitoring of the weld at the weld site.
There is a more particular need for such an improved method and apparatus which does not require the use of multiple monitoring optic-fibers in addition to the optic-fiber delivering the laser beam.
There is also a need for such a method and apparatus which can monitor the condition of the weld head and permit change-out of a faulty weld head before unacceptable welds are made.
SUMMARY OF THE INVENTION
These needs and others are satisfied by the invention which is directed to a method and apparatus for laser beam welding providing real time monitoring of the weld at the weld site, especially in confined spaces such as the tubes of heat exchangers, and particularly the steam generator tubes in PWRs. In accordance with one aspect of the invention, light from the weld site to which pulses of laser energy are supplied is analyzed during the delivery of the pulses. This analysis comprises comparing the wave shape of the light from the weld site during delivery of the pulses of laser energy to base wave shapes produced under known conditions. This analysis includes determining the heat-up rate of the weld site during each pulse of laser energy. More particularly, this heat-up rate is determined from the time interval after initiation of delivery of the pulse of laser energy to the weld site that light from the weld site exhibits a second substantial upward shift in amplitude. When the pulse is first applied to the weld site, the temperature of the metal begins to rise thereby causing an increase in the amplitude of emitted light. The amplitude of this light from the weld site then levels off as the laser energy is absorbed in the latent heat of the metal. The second substantial increase in the amplitude of light from the weld site occurs as the metal liquifies and its temperature rises. The time interval between the application of the laser pulse and the second substantial increase in amplitude of the light from the weld site is used as a measure of the heat-up rate of the weld site. One of the measures of the quality of the weld is a comparison of the heat-up rate to a standard heat-up rate for the particular material and laser energy.
Another measure of weld quality is the peak temperature of the weld site which is determined from the area under pulses of light emitted from the weld site. The amount of laser energy reaching the weld site can be determined by comparing the waveform of the pulses of light from the weld site to base waveforms developed for the welding conditions. A progressive reduction in the amplitude of the pulses of light from the weld site compared to the base waveforms is an indication of deterioration of the weld head. This can result, from example, from splattering of metal onto the components of the laser beam delivery system such as the mirror that deflects the axially delivered laser beam radially outward to the weld site.
Analysis of the light from the weld site can also be used to detect other weld defects such as blow holes. Blow holes are caused by contamination, usually water at the weld site which is converted to stem. Blowing off of the steam causes splattering of the metal leading to a rough weld surface. It also results in lower temperatures being reached as the energy escapes the weld site. Blow holes and other such contaminate defects can be detected by low, erratic amplitude of the pulses of light from the weld site. In addition to analyzing the individual pulses of light from weld site, displays are generated which present the amplitude of the pulses from the weld site around the entire weld. Blow holes and other contaminates show up as spikes in these composite presentations.
When deterioration of the weld head is detected, the weld head can be changed out before the point is reached that unacceptable welds are being made. As this decision can be made on-line, it provides a great improvement over the prior art where analysis of weld quality can not be made until after removal of the weld head; and hence, many bad welds may be made before the deterioration of the weld head is detected.
As another aspect of the invention, a single optic fiber delivers the beam of laser energy to the weld site and transmits light from the weld site in the opposite direction. A diverter means in the single optic fiber comprises a splitter diverting reflected light and the light emitted from the weld site to an analyzer which provides the above indications of weld quality. This splitter also diverts a portion of the laser beam to an energy monitor. This indication of laser pulse energy is used to differentiate a reduction in the amplitude of light from the weld site due to deterioration of the weld head from a reduction of laser energy delivered to the weld site. The single optic fiber delivering both the pulses of laser energy to the weld site and transmitting the pulses of light from the weld site back to the splitter, makes the invention particularly useful for welding in very confined spaces, such as inside heat exchanger tubes, and particularly the heat exchanger tubes of PWR steam generators. The small profile of the weld head made possible by use of this single optic fiber is even more important in those applications where a sleeve is welded inside the PWR steam generator tubes leaving even less space for the weld head. A weld head inserted within the heat exchanger tubes directs the pulses of laser energy radially outward. By analyzing light from the weld site at different angular positions, the concentricity of the weld head within the tube can be determined.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic view illustrating application of the invention to welding inside the heat exchanger tubes of a PWR steam generator.
FIG. 2 is a schematic view of a diverter in accordance with the invention that includes an energy monitor and a sensor for light emitted from the weld site.
FIG. 3 is a display generated by the analyzer of the invention illustrating detection of a blow hole in a weld from examination of a single pulse.
FIG. 4 is a display illustrating noticeable but acceptable deterioration of the weld head.
FIG. 5 is a display illustrating the average of all the pulses delivered during a low power preheat pass to a weld site.
FIG. 6 is a display showing the average of all of the pulses delivered to the weld site during a high power weld pass.
FIG. 7 is a composite of time of transition to the liquid state for each of the pulses delivered in a low power pass and the high power pass.
FIG. 8 is a display illustrating the composite change in the area under the instantaneous pulse curves for each of the pulses during the low power pass and the, high power pass.
FIG. 9 is a composite display of the variance of the amplitude of the, light received from each of the pulses for both low power and high power welds.
FIG. 10 is a composite display of the value of the first coefficient a third order curve fitting function for pulses delivered during the low power pass and the high power pass.
FIG. 11 is a composite display of the second coefficient of the third order curve fitting function.
FIG. 12 is a composite display of the third coefficient of the third order curve fitting function.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As discussed, the invention is directed to a method and apparatus for real time monitoring of laser welding in confined spaces. It will be described as applied to laser welding of heat exchanger tubes and in particular the heat exchanger tubes in the steam generator of a pressurized water reactor (PWR) nuclear power plant. It will be understood that the invention has application to monitoring of laser welding in other applications, and in some aspects is not limited to monitoring laser welding in confined spaces.
As shown in FIG. 1, the PWR steam generator 1 comprises an upright cylindrical vessel 3 with a hemispherical lower end 5 forming a hemispherical chamber divided into an inlet section 7a and an outlet section 7b by a vertical partition 9. A large number of U-shaped tubes 11 secured at each end in a horizontal tube sheet 13 provide flow paths between the inlet chamber 7a and the outlet chamber 7b. The U-shaped tubes 11 are also supported at various levels above the tube sheet 13 by grids 15. The tubes 11 are typically secured in the tube sheet 13 by expansion.
As is well known, heated coolant from the reactor (not shown) is introduced into the inlet chamber 7a, flows through the U-shaped tubes 11 to the outlet chamber 7b from which it is recirculated through the reactor. Feed water, which is introduced into the upright cylindrical vessel 3 above the tube sheet 13, is converted into steam by the heated coolant circulated through the tubes 11. The steam is then used to drive a turbine generator (not shown).
It is known that after prolonged operation of the steam generator 1, the tubes 11 can become cracked. Typically this occurs at the tube sheet 11 or the grids 15. It is known to repair such cracks in the tubes 11 by welding. Two techniques are used for repairing crack in generator tubes 11 by welding. In one technique, the region of the tube in which the crack is located is welded directly. In the second technique, a sleeve is inserted into the tube 11 and welded above and below the crack. With both techniques, the space in which the weld must be performed is confined, and especially in the case of welding the sleeve to bridge the damaged section of the tube. Laser welding has been found to be uniquely suited to welding in such confined spaces. The present invention utilizes such a laser welding system 17.
The laser welding system 17 includes a laser beam generator 19 located remotely from the tubes 11 in the steam generator. An optic fiber cable 21 delivers the laser beam from the laser beam generator 19 to a tool or weld head 23 which is inserted into the steam generator tube 11 either from the inlet chamber 7a, as shown, or the outlet chamber 7b. The tool 23 may be one of the known types such as disclosed in U.S. Pat. Nos. 5,182,429; 5,359,172 and 5,371,767. A tool handling device 25 is used to insert the tool 23 into and withdraw it from a selected tube 11. In the preferred embodiment of the invention, this tool handling device 25 is a ROSA robotic arm developed and manufactured by Westinghouse Electric Corporation located in Pittsburgh, Pa., and can be such as that described in U.S. Pat. No. 4,538,956. A pusher puller assembly 27 is used to extend and retract the optic fiber cable 21 as the tool 23 is inserted in and withdrawn from the selected heat exchanger tube 11.
The optic fiber cable 21 is made up of a plurality of cable sections 21a, 21b and 21c serially connected by connector units 29. These connector units 29 include lenses which collimate and refocus the light pulses for transmission from one section of the optic fiber cable 21 to the next. The connector 29' which transmits the pulses to the last section 21c of the fiber optic cable which is connected to the weld head or tool 23 is shown schematically in FIG. 2. As shown there, the connector 29' includes within a housing 31 a collimator lens 33 which collimates light in the pulses of laser energy delivered by the optic fiber cable section 21b, and a focusing lens 35 which refocuses the pulses of laser energy in the succeeding section 21c of the optic fiber cable. Between the two lenses 33 and 35 is a splitter 37 set at a 45° angle to the path 39 followed by the pulses. As is well known, the splitter 37 passes most of the light in the laser pulses through to the focusing lens 35. However, a small portion of the light in each pulse is deflected transversely along the path 41 to a power monitoring detector 43 which converts the deflected light into an electrical signal which is delivered to a data acquisition unit 45 (see FIG. 1) over a lead 47.
The pulses delivered to the optic fiber cable Section 21c are delivered to the weld site 49 within the tube 11 by the tool or weld head 23. The tubes 11 can be welded directly, or a repair sleeve 50 can be placed in the tube bridging any crack or other defect and welds 49a and 49b can be made above and below the defect. These pulses heat up the weld site which begins to radiate. The radiated light passes backward through the weld head 23 and the cable section 21c along with a small portion of the laser pulses delivered through the section 21c which is reflected by a mirror in the weld head 23. This light 51 passing in a second direction 53 through the optic fiber section 21c has a portion diverted by the splitter 37 transversely as indicated at 55 to the detector 57. This detector 57 is a well known two wavelength detector having a silicon detector 57a which is sensitive to light of one of the wavelengths and which passes light of the other wavelength through to a second lead sulfide detector 57b. The signals generated by these two detectors and representative of the amplitude of the diverted light 55 at the two wavelengths are transmitted to the analyzer 45 through a cable 59. The tool or weld head 23 directs the pulses of laser energy radially outward toward the wall of the tube 11. By comparing light from the weld site at different angular positions of the weld head 23, the concentricity of the weld head within the tube 11 can be determined.
Returning to FIG. 1, the data acquisition unit 45 stores the pulse information received from the energy monitor and from the analyzer monitor and processes it for presentation on a display device 63 such as on the monitor 65.
In performing welding in accordance with the invention, pulses of laser energy are delivered to the weld head 23 through the optic fiber 21. The weld head 23 contains a mirror which directs the pulses of laser energy radially outward to the inner surface of the steam generator tube 11 or the repair sleeve 50. The weld head 23 is rotated 360° inside the tube or sleeve to effect the weld. A first pass is made at low power to preheat the metal. This is followed by a second weld at a higher energy level which completes the weld. The analysis provided by the data acquisition unit 45 is presented on the display 63. Several types of displays are generated. For each pulse, a display is generated of the energy delivered to the weld site and the response of each of the detectors 57a and 57b. Other displays illustrate the average values of these signals over the full 360° of the weld. Additional displays, illustrate calculated values for each of the pulses of the display.
FIG. 3 illustrates a display of the first type in which the amplitude of the pulse of the laser energy delivered to the weld site as measured by the energy monitor is represented by the trace 67. A base waveform for the delivered pulse is represented by the dotted line 67b. The response of the silicon detector 57a is represented by the trace 69. The base waveform for the silicon detector is represented by the trace 69b. Similarly, the response of the lead sulfide detector 57b to light from the weld site is shown by the trace 71 with the base waveform for this detector represented by the trace 71b. The abscissa of this graphical representation along with that of FIGS. 4-6 represents scans of the analyzer at 35 KHz and is therefore, a measure of time. The ordinate in these figures is an arbitrary measurement of amplitude. As can be seen by the traces 67 and 67b in FIG. 3, the power delivered to the weld site by the illustrated pulse is normal. However, it can be seen that the response of the silicon sensor 69 and the response 71 of the lead sulfide detector both initially follow the associated base waveforms 69b and 71b, respectively, but then level off and become erratic in amplitude. This is an indication of a poor weld, and particularly, a contaminant such as a blow hole. The erratic response of the detectors to the light from the weld site indicates a rough surface which would be the result of the splattering caused by the blow hole.
FIG. 4 illustrates a display generated for an individual pulse by a more normal weld condition. It can be seen here that the delivered pulse 67 is slightly higher in amplitude than the base waveform 67b. Each of the sensor responses 69 and 71 fairly well tracks the respective base waveforms 69b and 71b except that they do not quite reach the same amplitude. This can be an indication of a deterioration of the weld head, but the condition shown in FIG. 4 is within acceptable limits.
FIG. 5 illustrates a composite display for all of the pulses delivered during the 360° low power weld. Again, the power in the delivered pulses is normal as indicated by the close tracking of the base waveform 67b by the response 67 of the energy monitor. This display illustrates that the temperature of the weld sites increases substantially initially in response to the applied pulse of laser energy. This is represented by the initial substantial increase 71b 1 in the base waveform for this detector. The base waveform the begins to level off at 71b 2 as the applied energy goes into the latent heat of the metal. As additional energy is delivered to the weld site, the metal reaches the liquid state and a second substantial increase in the amplitude of the light received from the weld site takes place at 71b 3 .
In the example given in FIG. 5, it can be seen that the time of the second substantial increase 71 3 in the lead sulfide detector response occurs an appreciable interval after the corresponding increase at 71b 3 in the base waveform. This shows that the energy supplied to the weld site is below that for the base waveform. This can be due for instance to a deterioration in the weld head. The time interval from the application of the laser pulse until the metal reaches the liquid state at 71 3 is called the heat-up rate in accordance with the invention and is a measure of the energy delivered to the weld site. FIG. 5 illustrates an abnormally long delay indicating a deterioration in the condition of the weld head.
FIG. 6 is a companion to FIG. 5 illustrating the average power delivered and light received from the weld site for the 360° high power weld made following the low power weld illustrated in FIG. 5. As can be seen here, the responses 69 and 71 of the detectors to light received from the weld site show that the power delivered was considerably below that of the base waveforms indicating a serious deterioration in the condition of the weld head. With such a response, the weld head can be replaced before deterioration reaches the stage where unsatisfactory welds are made. These displays of FIGS. 5 and 6 are of the second type in which average values for all of the pulses in the high power and low power welds are displayed.
FIGS. 7-12 illustrate displays of the third type. These figures all show values calculated for each of the pulses identified by angular position around the weld. In each case, laser energy is initially dumped into an energy dump (not shown) which is located between the connector 29' and the weld head 23. The values calculated for the low power weld begin at about -400° in these figures and the high power weld begins at about -20° so that there is some overlap to assure a complete weld.
FIG. 7 illustrates the heat-up time for each of the pulses during a low energy weld on the left side of the figure and the high energy weld on the right side. As can be seen, the heat-up rate has a higher value for the low power weld as it takes longer to reach the liquid state at lower power. The spike 73' is illustrative of a blow hole where the splattering of the metal and resultant release of energy delays the time that it takes for the liquid state to be reached.
FIG. 8 illustrates the change in area under each instantaneous pulse. In this display also the spike 75' indicates a blow hole.
The data acquisition system 45 also fits a third order polynomial function to the pulses. FIG. 9 illustrates the variance 77 of this third-order curve. This is a measure of the change in amplitude of the response pulses and is thus a measure of the roughness of the weld surface. Again, a blow hole produces a spike 77' in the variance.
FIGS. 10, 11 and 12 illustrate the first, second, and third coefficients 79, 81 and 83 respectively of this third order curve. As can be seen, the blow hole produces spikes 79', 81', and 83' in these functions also.
In general, it can be stated that a bad spot in a weld produces a discontinuity in one or more of the displayed parameters. A slow deterioration in the condition of the weld head can be detected from a steady reduction in the amplitude of the light from the weld site over many pulses or even several welds.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. | Welds made by pulses of laser energy are evaluated on-line by analyzing light emitted from the weld site during application the laser pulses. The pulses of light from the weld site are compared with base pulses generated from a good weld, and are used to calculate parameters such as heat-up rate and peak temperature which in turn, are analyzed to determine weld quality. For use in welding in confined spaces such as heat exchange tubes, and particularly the tubes in a PWR steam generator, a single optic fiber delivers the laser energy pulses to the weld site and transmits light from the weld site back to a splitter which diverts it to detectors for conversion to electrical signals used to generate a graphical display. | 1 |
FIELD OF THE INVENTION
This invention relates to a spectroscopic fluid sample cell for the transmission and detection of radiation.
BACKGROUND OF THE INVENTION
Instruments for measuring the transmission or absorption of radiation through materials contain five key components: a stable source of radiation, a way to restrict the radiation to select wavelengths of interest, a sample interface, a detector to convert radiation to a measurable signal, and a signal indicator. With fluids, a sample cell may be used as the sample interface to contain the fluid during exposure to the radiation. Such a sample cell must be compatible with the fluid, must provide interface surfaces that are transparent to the radiation, and must be in alignment with the radiation. The sample cell may be located directly in the instrument with each sample being automatically or manually inserted, or the sample cell may be located remotely with radiation being conducted to and from the sample cell. Remote sample cells allow for the radiation to be transmitted or absorbed by the fluid at a position at or near the source of the fluid, thus reducing or eliminating sample transportation and time lag problems.
Absorption spectroscopy requires that the sample of fluid contained within the sample cell be free of impurities or contaminants that would interfere with the radiation transmission or absorption measurements. Problems arise since fluid streams to be analyzed frequently contain such contaminants. For example, it is common to find water, particulates, or other emulsified materials in gasoline. These impurities act as scattering agents that reduce the transmission of radiation through the sample and result in high or noisy baselines that degrade the analytical measurement. Therefore, to effectively use current sample cells with fluids containing such contaminants or impurities, a sample conditioning system must be employed. Typical sample conditioning systems include filters, coalescing filters, membrane separators, adsorbents, and the like. Unfortunately, sample conditioning systems require additional investment and maintenance costs and periodically experience failures. Furthermore, sample conditioning systems may severely restrict the flow velocity of the fluid resulting in excessive lag time and rendering real-time analysis and control impossible.
The present invention provides a fluid sample cell that eliminates the need for sample conditioning systems when the base fluid to be measured is distinguishable from the contaminants by a significant difference in density (specific gravity) and is especially useful where the base fluid and the contaminants are in different physical states. The design of the fluid sample cell incorporates centripetal acceleration in order to separate materials of different densities, thus permitting interference-free measurement of the lighter or the heavier component. By forcing the fluid sample to travel in a circular path, the less dense components will be forced toward the center of rotation, due to buoyancy, leaving the more dense components farther from the center of rotation. If the measurement is to be made on the more dense components, the radiation is directed to the outer portion of the sample cell, and if the measurement is to be made on the less dense components, the radiation is directed to the inner portion of the cell.
SUMMARY OF THE INVENTION
One embodiment of the present invention is a spectroscopic fluid sample cell for the transmission and detection of radiation with the key components being a housing; a centripetal acceleration chamber formed by the housing and extending through the housing for circulating a fluid through the housing over a curvilinear flow path about a rotational axis; a pair of windows aligned along a common axis intersecting a portion of the chamber and parallel to the rotational axis; a fluid inlet and a fluid outlet in communication with the centripetal acceleration chamber; and a flow director positioned in the housing to induce centripetal acceleration on fluid passing through the chamber and establish a radial composition gradient across the fluid chamber. A retainer may hold a collimating lens adjacent each window, and an optical fiber may be used to conduct the radiation to the sample cell with a second collimating lens and optical fiber to conduct the sample-altered radiation away from the sample cell. The windows may be coaxial with the cylindrical bore or may be positioned acentrically within the diameter of the cylindrical bore. The axis of alignment of the pair of windows is parallel with the rotational axis of fluid within the centripetal acceleration chamber.
Another embodiment of the invention is to provide a method of measuring the transmission or absorption of radiation by at least one separated or partially separated component of a fluid sample by flowing the fluid sample through the centripetal acceleration chamber at a velocity and a direction to cause centripetal acceleration of the fluid within the chamber to at least partially separate at least one component from at least one other component having a different density, directing the radiation through the chamber so that the radiation passes through the separated or at least partially separated components; and monitoring the change in the radiation after passing though the separated or at least partially separated component.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of a fluid sample cell located between two sets of lenses and optical fibers.
FIG. 2 is a section view of the fluid sample cell taken across line A--A of FIG. 1.
FIG. 3 is a view of a housing defining a helical bore having a fluid entry and a fluid exit.
DETAILED DESCRIPTION OF THE INVENTION
In general terms, the invention is a fluid sample cell designed to separate or partially separate components of different densities within the cell using centrifugal force thereby allowing radiation transmission or absorption measurements to be performed on at least one of the separated components. The details below focus on the hardware of the fluid sample cell and not on the optics required for measurements. For example, to perform remote radiation transmission or absorption measurements, additional apparatus such as collimating lenses and optical fibers may be used in conjunction with the cell, but as many lenses and optical fibers are known in the art, and the selection of a specific lens or optical fiber is not critical to the success of the invention, they will not be described in great detail here. Similarly, the spectrometers used in conjunction with the fluid sample cell will not be discussed. It should be noted, however, that the fluid sample cell of the invention may be located in a variety of positions including in a remote sampling device or within a spectrometer itself.
A fundamental requirement of the invention is a centripetal acceleration chamber that provides a substantially curvilinear path for the circulating sample fluid. Suitable chambers for centripetal acceleration may be provided by a variety of chamber forms. For example, frusto-spherical, frusto-conical, or modified toriodal shapes can all provide a central axis about which the sample fluid may revolve to induce an acceleration that will produce a radial composition gradient through sample components. Cylindrical forms are particularly preferred and include elements defined by continuous curves as well as rectilinear shapes such as polygons having sufficient sides to provide the substantially curvilinear path necessary for inducing the necessary centripetal acceleration. For convenience, this invention is described in the context of the preferred cylindrical bore, which description is not meant to exclude other arrangements for the centripetal acceleration chamber.
The cylindrical bore is defined by a housing. The housing is constructed of material compatible with the fluid sample to be analyzed. Typical examples include stainless steel and other corrosion-resistant steels, as well as polymers, and which material is selected depends on the application. The exterior shape of the housing is not critical. In the preferred case, the housing defines a cylindrical bore having two ends and a circumference. The size of the bore also depends on the application, and will be discussed further below. To facilitate forming the bore, the housing may be formed of at least two pieces. Seals such as o-rings may be used to seal the space between the multiple housing sections.
Adjacent each end of the cylindrical bore is a window. The windows may be composed of any material compatible with the fluid sample and having appropriate radiation transmission such as sapphire, quartz, glass, and polymers. The shape of the window is not critical, and the positioning of the windows across the ends of the cylindrical bore is dependent upon the application, as discussed below. The windows are aligned so that the plane of alignment is parallel to the axis of the cylindrical bore. Seals may be used to prevent fluid leakage around the windows.
A fluid inlet and at least one fluid outlet are in communication with the cylindrical bore to allow fluid sample to pass continuously through the sample cell. In a preferred embodiment, the positioning of the inlet is important to the success of the invention. The fluid inlet is positioned so that the stream of fluid entering the cylindrical bore enters tangentially to the curvilinear flow path of the sample. Similarly, the fluid outlet may be positioned so that the stream of fluid exiting the cylindrical bore exits tangentially to the curvilinear flow path of the sample. However, the positioning of at least one outlet may vary as shown below. The velocity and initial direction of the fluid sample stream along with the cylindrical shape of the bore work to create rotation of the fluid within the bore. Alternately, the fluid inlet may be positioned other than tangentially to the curvilinear flow path of the sample and a flow director such as vanes or grooves may be incorporated into the cylindrical bore to induce the rotation of the fluid within the bore. The rotation creates centrifugal force and the centrifugal force operates to move all the components of the sample stream outward towards the wall of the bore. Differences in density cause the less dense materials to be buoyed radially inward while the denser materials remain along the cylindrical bore. A separation is effected with the more dense components in an outer ring along the circumference of the cylindrical bore and the less dense components in the interior portion of the cylindrical bore. For example, upon entering the sample cell, the flow of a gasoline stream containing particulates and water will be forced to angularly rotate along the circumference of the housing. The denser water and particulates will remain along the outer portion of the cylindrical bore as the gasoline is buoyed inward, now free of contaminants. The windows may be positioned so that radiation is passed through only the inner portion of the sample cell where the contaminant-free gasoline is contained. Note, however, that the exact center of rotation is not usually the preferred location for the radiation transmission or absorption measurements. A vortex, bubbles, or stagnant fluid may be at the center of rotation interfering with accurate measurements. In this gasoline example, positioning the window and directing the radiation slightly off the center of rotation is preferred.
The sample cell of the invention may be used in a variety of applications as long as the components to be separated have sufficiently different densities, i.e., the densities of the components to be separated must be sufficiently different so that the centrifugal forces of the chosen cell design are strong enough to perform the necessary degree of separation. The cell design may be modified to increase the centrifugal forces, but the densities of the components must not be so similar that even maximum centrifugal forces are insufficient to perform the separation. Note that depending upon the application, a partial separation of at least one component may be all that is required. The centrifugal forces may result in only a gradient of components, but such a gradient may be sufficient for the optical measurements being performed. If the denser material is the undesirable impurity, then the desired material can be optically measured near the center of the cell without interference from the impurities such as when measuring gasoline in a stream containing gasoline, particulates, and water. Conversely, lighter impurities may be separated from heavier desired material with the sample measurements being performed near the circumference of the cylindrical bore, such as when separating bubbles from a liquid. The sample cell of the invention is particularly suited for use with low viscosity fluids containing impurities of a different phase. Of course, the sample cell will not operate to effectively separate soluble liquids from each other.
The difference in the densities of the components to be separated and the general nature of the centrifugal-based separation may cause a problem. The lighter components having been buoyed inward may become trapped by the layer of higher density materials and become stagnant and perhaps build up over time. Solutions to this problem depend on the relative flow rates and densities of the components being separated. The most elegant solutions rely on keeping the components apart once they have been separated.
Dual or multiple outlets in fluid communication with the cylindrical bore and equipped to allow independent adjustment of the relative flow rates of each output stream would allow the denser materials to be removed from the circumference of the cylinder while the less dense materials are removed from the central portion of the cylinder. Therefore, one outlet is positioned at a more central position within the cylindrical bore relative to that of another outlet. By adding the centrally located additional outlet, each stream resulting from the separation is allowed to exit the sample cell without re-mixing. The centrally located outlet becomes particularly important when measuring the denser component. With only one outlet, the less dense component must cross the component of greater density and thus contaminate it in order to exit the sample cell, or the less dense component may collect in sufficient volumes to completely displace the denser component resulting in the wrong component being measured. If desired, the two or more separated streams in the outlets could then be recombined outside the sample cell after the transmission or absorption measurement has been made. The modified two- or multiple-outlet designs, while general in nature, would allow the sample cell to be configured for the specific fluid stream under analysis.
Incorporating physical separators such as semi-permeable membranes or filters into the sample cell is another solution. For physical separators to be successful the components to be separated must have a property other than density that differentiates them. The physical separator takes advantage of this additional property to act as a one-way valve, preventing the separated components in the sample cell from recombining. Care must be taken in placing the physical separator such that the buoyancy process used to separate the components is not compromised due to the one-way nature of the device. A common example of such a physical separator is a hydrophobic filter. Modifications such as multiple outlets and physical separators, while not central to the invention, may provide additional capability to separate and analyze streams of similar density.
As mentioned earlier, the size of the cylindrical bore is dependent upon the application. The centripetal acceleration, a, of a rotating object is given by a=v 2 /r where v is the tangential velocity and r is the radius. To maximize the acceleration and hence the separation force, a high velocity and a small radius are most preferred. However, realities such as the viscosity of the sample, the density differences of the components to be separated, turbulence, and the time required to separate the components under the applied stress must be considered in determining the optimum size of the cylindrical bore and the velocity of the fluid sample. Such determinations are readily accomplished using modern fluid dynamic software such as Fluent™ from Fluent Inc. (Lebanon, N.H.), Adina® from Adina R&D Inc. (Watertown Mass.), and CFD Two-Phase™ from CFD Research Corporation (Huntsville, Ala.).
The simplest fluid flow path through the cell is where the sample enters the cylindrical bore tangentially to the diameter of the cylindrical bore and follows a U-shaped path through the sample cell exiting the cylindrical bore on the opposite side, tangentially to the diameter of the cylindrical bore. The flow path would be analogous to the U-shape of a 180 degree tube bend. A modified flow pattern is possible by positioning the inlet and outlets so that the fluid traverses 270 degrees of rotation before exiting.
If the sample to be analyzed is viscous, more time or work in the cell may be required for the sample to separate. A helical or corkscrew-like flow pattern may be used, or the radius of the cylindrical bore may be decreased to increase the separation efficiency through time and force, respectively. Additionally, the cross-section of the flow path could be varied by starting with a square or circular pattern and gradually changing to a rectangular pattern with the long dimension along a radius of the cylindrical bore. Changing the aspect ratio (width of the passageway to height of a passageway in a helical flow path) allows greater differentiation of density as well as a means to accommodate different optical measurement path lengths.
For difficult separations, a second housing defining a helical bore may be placed in fluid communication with the inlet to the cylindrical bore described above. The second housing and helical bore are sized to provide the necessary additional time or work for the separation. The separated or partially separated components exiting the helical bore are immediately introduced to the cylindrical bore via the inlet and the centrifugal motion in the cylindrical bore maintains and perhaps increases the separation of the components while measurements are performed.
Without intending to limit the scope of the invention, and as merely descriptive, the invention is described below in terms of a specific embodiment. Optics such as collimating lenses and optical fibers are discussed merely to illustrate the sample cell as it might be used in one specific device and are not meant to limit the scope of the invention in any way. For ease of understanding, the invention is described with the most simplistic flow pattern, the U-shaped pattern.
FIG. 1 generally shows the fluid sample cell of the invention. The cell has housing 1 defining internal cylindrical bore 2. Inlet 7 and outlet 8 are positioned to help define sample flow path 9. Optional second outlet 22 is shown in fluid communication with the central portion of cylindrical bore 2.
FIG. 2 shows the internal arrangement of the sample cell in more detail. An O-ring seal 16 surrounds bore 2 and seals the space between the two pieces of housing 1, the housing cup 20 and housing cover 21 together when clamped by suitable means (not shown). Cylindrical bore 2 has a cover end 3 and a cup end 4. Cover window 5 is adjacent cover end 3, and cup window 6 is adjacent cup end 4. Windows 5 and 6 are axially aligned across bore 2 parallel to the axis of rotation within bore 2 and having space of the cylindrical bore between them. 0-ring seals 19 and 18 seal space around windows 5 and 6, respectively, from fluid leakage. A cup retainer 10 fixes an optical fiber 14 and collimating lens 11 adjacent to housing cup 20 and in alignment with window S. Similarly, a cup retainer 12 fixes an optical fiber 15 and a collimating lens 13 adjacent housing cover 21 and in alignment with window 6.
Sample separations and measurements are performed by continuously introducing the sample fluid via inlet 7 into cylindrical bore 2 and removing the sample fluid via outlet 8. The velocity of the fluid and the cylindrical shape of the bore establishes a flow path that causes centrifugal motion of the sample. Buoyancy forces drive the less dense material to the inner portions of cylindrical bore 2. More dense material remains along the circumference of cylindrical bore 2. Windows 5 and 6 are positioned to allow radiation to pass through the desired separated material which, in the figures, is the less dense material. Thus, windows 5 and 6 are positioned in optical alignment with each other with one window adjacent each end of the cylindrical bore along a radius of the bore and slightly off the center of rotation of the fluid sample. To make a transmission or absorption measurement, radiation from a spectrometer is conducted via an optical fiber, 14, to the sample cell and directed through a collimating lens, 11, through the separated less dense material of the fluid sample, through a second collimating lens, 13, and into the other optical fiber, 15. The sample altered radiation is conducted back to the spectrometer for interpretation. If the more dense material was to be the subject of the measurements, the windows, lenses and optical fibers would be located near the circumference of the cylindrical bore. If more than one separated component were to be measured, multiple windows and optics could be employed on the same sample cell, or a single set of optics could be moved to multiple positions.
FIG. 3 shows a housing 25 surrounding a helical bore 26 which has a fluid inlet 27 and a fluid outlet 28. Fluid outlet 28 is in fluid communication with inlet 7 of the sample cell. A sample requiring additional separational forces is introduced to helical bore 26 via fluid inlet 27 and flowed through helical bore 26 to induce centrifugal motion of the sample resulting in buoyancy forces driving the less dense material to the inner portions with the more dense material remaining along the outer surface of the helical bore 26. The partially separated sample exits through fluid outlet 28 and is conducted into the sample cell discussed above via inlet 7. Continued separation and measurement of the sample is conducted as described above.
It must be emphasized that the above description is merely illustrative of a preferred embodiment of the invention and is not intended as an undue limitation on the generally broad scope of the invention. Moreover, while the description is narrow in scope, one skilled in the art would understand how to extrapolate to the broader scope of the invention. For example, positioning the windows so that the more dense separated component is exposed to the radiation, sizing the cylindrical bore and positioning the inlet and outlets to form a helical fluid flow path, and retaining the fluid flow cell within a spectrometer can all be readily extrapolated from the foregoing description. | A spectroscopic fluid sample cell for the transmission and detection of radiation with the key components being a housing; a centripetal acceleration chamber formed by the housing and extending through the housing for circulating a fluid through the housing over a curvilinear flow path about a rotational axis; a pair of windows aligned along a common axis intersecting a portion of the chamber and parallel to the rotational axis; a fluid inlet and a fluid outlet in communication with the centripetal acceleration chamber; and a flow director positioned in the housing to induce centripetal acceleration on fluid passing through the chamber and establish a radial composition gradient across the fluid chamber has been developed. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to crop harvesting and threshing machines, more commonly known as combines, and more particularly, to the apparatus used to control the unloading auger by which cleaned grain is unloaded from the grain tank to a receiving vehicle. Specifically, the invention is directed to a mechanical control mechanism which allows the combine operator to activate the unloading auger by momentarily engaging the unloading auger control, permitting the auger to rotate off of the auger switch and then releasing the control, thereby having the unloading auger swing from the fully inboard or storage position to a predetermined outboard position automatically for the unloading of grain. This invention is applicable to all types of combines which utilize some type of grain unloading tube that must move between predetermined positions of non-operation and operation.
Traditionally combines utilize a grain storage system that has the threshed and cleaned grain transported by means of a collection trough and auger to an elevator which carries the cleaned grain upward into a receiving receptacle or grain tank. The grain is continuously fed into the grain tank during the operation of the combine as it harvests and threshes crop material in the field. The continuous field operation of a combine is generally limited by the capacity of the grain tank to store the clean grain. When the grain tank is full, the combine operator must normally cease the harvesting and threshing operation to unload grain from the grain tank to a receiving vehicle. Occasionally, this unloading operation is conducted simultaneously with the continued harvesting and threshing by having a receiving vehicle move alongside the combine as it progresses down the field. The receiving vehicle may either be a wagon towed behind a tractor or a large grain truck. These receiving vehicles haul the unloaded grain to appropriate storage areas generally remote from the field. This procedure is repeated continuously during the harvesting and threshing of the crop material.
Combine operators normally activate the unloading system by engaging a lever or a switch which requires that the operator continue its engagement during the entire time that it takes the unloading tube to swing from its inboard to its outboard position. Should the unloading operation be conducted while the combine continues to harvest and thresh crop material this requires the operator to direct his attention to several functions at one time. The operator must continually monitor the crop material which is being harvested to the front of the combine as it moves across the field, scan the numerous monitors displayed on the combine control panel and observe the movement of the unloading tube from the inboard to the fully outboard position which is utilized for unloading. Since the operator must continue to steer the combine during this time, this means that the operator must remove one of his hands from the steering wheels and simultaneously conduct at least two operations. Obviously this is a difficult and distracting procedure which could inadvertently cause the operator to vary from his desired path across a field. At the least, the continuous engagement of the unloading tube control mechanism is an inconvenience.
Recently, a control system utilizing electromechanical apparatus was designed for a combine which required the operator to momentarily engage a control mechanism which then automatically controls the movement of the unloading auger between the inboard and fully outboard positions. However, this type of a system is relatively complex and costly.
The foregoing problems are solved in the design of the machine comprising the present invention by permitting the combine operator to engage the unloading tube control momentarily, thereby activating a mechanical system which will permit the unloading tube to automatically swing from the full inboard to the fully outboard position without any further operator involvement.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide in a combine an improved mechanical control means for the grain tank unloading means which upon manual activation for a period of time substantially less than that required for the unloading means to move from a first position of non-operation to a second position in which unloading is performed, the control means is effective to automatically move the unloading means from the first position to the second position. Movement of the unloading means is automatically stopped.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when it is taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a side elevational view of a crop harvesting and threshing machine with the improved unloading auger control means shown in phantom lines;
FIG. 2 is a top plan view in enlarged scale taken along the line 2--2 of FIG. 1 showing the mechanical linkages controlling the unloading auger within which is rotatably driven the unloading auger by the hydraulic cylinder;
FIG. 3 is a side elevational view of the unloading auger ring and the hydraulic cylinder control linkage.
FIG. 4 is an enlarged top plan view of the unloading auger control mechanism and the movable contact plate that moves in response to the setting of the unloading auger control;
FIG. 5 is an enlarged side elevational view taken along the lines 5--5 of FIG. 4 showing the relationship between the unloading auger and the movable contact plate;
FIG. 6 is a partially diagrammatic showing of the unloading auger control linkages and the hydraulic circuit utilized to move the unloading auger between the fully inboard and fully outboard positions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a combine indicated generally by the numeral 10 in a side elevational view with the critical portions of the instant invention partially shown in detail in phantom lines. It can be seen that the combine 10 has a mobile frame mounted to a pair of primary driving wheels 11 in the front and a pair of smaller steerable wheels 12 in the rear. It is powered by an engine (not shown) which is usually diesel fuel consuming. The engine is mounted to the upper portion of the combine in suitable fashion and, by means of drive belts or sprocket chains, is drivingly connected to the operational components of the combine.
The combine 10 generally has a header (not shown) and an infeed housing 14 mounted at its front, as seen in FIG. 1. The combine 10 has a main frame or housing indicated generally by the numeral 15, that internally supports threshing and separating means (not shown), as well as the operator's cab 16 and the grain tank 18. The operator's cab 16 extends forwardly over the front of the main frame 15 and overlies the infeed housing 14. The cab 16 has a ladder 19 which provides access for the operator to the cab and extends outwardly and downwardly therefrom. Housings 20 and 21 enclose the engine and the discharge beater and discharge grate assembly (both of which are not shown), respectively.
The structure thus far has been described generally since it is old and well known in the art. This structure and the interrelationships between the various operating components of the combine are described in greater detail in U.S. Pat. Nos. 3,626,472, issued Dec. 7, 1971; 3,742,686, issued July 3, 1973; and 3,995,645, issued Dec. 7, 1976; all to Rowland-Hill, hereinafter specifically incorporated by reference in their entirety, insofar as they are consistent with the instant disclosure.
The grain tank 18 has along its bottommost portion a horizontal grain tank unloading auger 22, best seen in FIG. 2, which is contained within an elongate, open-topped trough 24. As seen in FIGS. 1 and 2, the grain tank 18 has a pivotal unloading auger tube 25 within which is contained a rotatable auger 26, partially shown in FIG. 2. Tube 25 is fastened to the grain tank via an unloading auger ring 28 and a generally conically shaped intermediate connecting section 29, see briefly FIG. 3. This structure is shown and described in greater detail in U.S. Pat. No. 4,093,087, issued June 6, 1978, hereinafter specifically incorporated by reference in pertinent part insofar as it is consistent with the instant disclosure.
A double acting hydraulic cylinder 30, seen in its entirety in FIGS. 1 and 2, is fastened to the connecting section 29 of unloading auger tube 25 at the rod end 31 of the cylinder 30 via a mounting bracket 32 and double arm bracket 34. On its opposing end hydraulic cylinder 30 is fastened via bracket 35 and also via the double arm bracket 34 of FIGS. 2 and 3 to bracket 32, thereby movably connecting the cylinder 30 to brackets 32 and 35. Hydraulic lines 36 and 38 of FIGS. 1 and 3 lead into opposing ends of the piston end of hydraulic cylinder 30. Hydraulic cylinder 30, upon activation, pivotally moves the unloading auger tube 25 with its auger 26 from an inboard storage or transport position illustrated as A in FIGS. 1 and 2 to an outboard unloading position illustrated as B. Tube 25 at its furthermost end has a discharge opening 37 through which crop material passes into a receiving vehicle when the tube is in the outboard position and it is desired to unload the grain tank 18.
FIGS. 3, 4, and 5 best show the interrelationship of the unloading auger control arm 39 and the unloading auger hydraulic cylinder control linkage. Control arm 39 extends from the operator's cab down through the floor 40 of the cab 16 where it is fixedly fastened to contact plate 41. Control arm 39 passes through a hole in plate 41 and into a hub 42 which is welded to the underside of the plate. Pin 44, best shown in FIGS. 4 and 5, fastens the control arm 39 to the hub 42 and contact plate 41. Control arm 39 passes through a suitably shaped opening (not shown) in the floor 40 of cab 16 and is retained for rotational movement by a bearing 43 and a brace member 47. Member 47 is fastened to the support structure of the floor 40. The size of this opening supports the control arm 39 sufficiently to permit the contact plate 41 to pivot about the axis of the control arm 39 when it is rotated by the combine operator.
Contact plate 41 is movably joined via the appropriate fastenings to connecting links 45 and 46, best shown in FIGS. 2 and 4. Connecting link 45 has on its opposing ends double arm brackets 48 and 49, see FIG. 2, through which fastening pin 50 passes to secure the link for movement. Fastener 50 and double arm bracket 48 thus secure the one side of contact plate 41 for rotational movement about the axis of the control arm 39. The opposing side of contact plate 41 similarly has connecting link 46 coupled to it via a second double arm bracket 51 with a bolt and retaining nut indicated generally by the numeral 52.
Connecting link 45 extends forwardly from contact plate 41 where it connects via bracket 49, as seen in FIG. 2, to a T-bar control link indicated generally by the numeral 55. Link 55 is anchored on its one end via a pivotal bracket 56 to a floor support beam 58. The leg of the T-bar control linkage connects to the spool (not shown) of a hydraulic fluid directional control valve 59. Typically the spool works with a detent (also not shown) to maintain the valve in an open position for a predetermined amount of time while the unloading auger tube 25 is moved between positions A and B. The hydraulic fluid directional control valve 59 controls the flow of hydraulic fluid through hydraulic lines 36 and 38 to the double acting hydraulic cylinder 30. Hydraulic fluid is forced to flow by a hydraulic pump 33, seen in FIG. 6, into the directional control valve 59 from the onboard reservoir 37 via infeed line 60 and returns to the reservoir 37 from the control valve 59 via hydraulic line 61. Fluid directional control valve 59 is suitably fastened to the underside of the cab floor 40, such as by bracket 62.
As seen in FIGS. 2, 3 and 6, connecting link 46 extends rearwardly from contact plate 41 where it is fastened to a tab 64 mounted to the auger ring 28 of auger tube 25 by mounting bracket plate 65 so that it pivotally moves about pivot point 66 (see FIG. 3) in response to the pivotal movement of the contact plate 41 about the vertical axis of the control arm 39. A stop plate 68 is affixed to the intermediate connecting section 29 which serves to engage tab 64 when the unloading auger tube 25 returns to the inboard position illustrated as A in FIGS. 1 and 6 to move the T-bar control linkage 55 via connecting linkages 45 and 46 and contact plate 41 to stop the flow of hydraulic fluid to the hydraulic cylinder 30. Another stop plate 69 is fastened via a bracket 70 to the intermediate section 29, best seen in FIGS. 2 and 3, so that stop plate 69 engages tab 64 when the unloading auger tube has reached the fully outboard position indicated by the letter B in FIGS. 1 and 6 to stop the flow of hydraulic fluid to the hydraulic cylinder 30 in a similar fashion. Stop plate 69 may be adjustably fastened to mounting bracket 70 to permit stop plate 69 to engage the tab 64 within a controlled range and to correct minor manufacturing inaccuracies.
In operation, the operator drives the combine 10 across a field harvesting the crop material. When the grain tank 18 is filled with grain, the operator engages the control arm 39 within the operator's cab 16. Control arm 39, when turned in a counter-clockwise direction from its neutral or non-operating position, causes hydraulic fluid to flow through the hydraulic circuit into hydraulic cylinder 30 in such a manner as to cause the rod end to extend and rotate the unloading auger tube 25 and it unloading auger 26 from the inboard position illustrated as A to the outboard position illustrated as B. This counterclockwise pivoting of the control arm 39 causes the contact plate 41 to pivot about the vertical axis of control arm 39 and move the plate so that the link 45 is moved forwardly, causing the T-bar control link 55 to pivot about bracket 56. This causes the spool in the fluid directional control valve 59 to move to permit hydraulic fluid to flow through the circuit driving the hydraulic cylinder 30 rod end 31 to move the unloading auger tube 25 out away from the grain tank 18. When the unloading auger tube 25 has reached its fully outboard position, indicated by the letter B, stop plate 69 engages tab 64 causing it to pivot about pivot point 66 and forcing the spool within the hydraulic fluid directional control valve 59, via connecting linkages 45, 46 and T-bar control linkage 55, to return to the position that terminates the flow of hydraulic fluid through the hydraulic circuit connecting the hydraulic cylinder 30. Should the operator desire to return the unloading auger tube 25 and its unloading auger 26 to the fully inboard position, indicated as A, he merely turns the control arm in a clockwise direction. This returns the unloading auger to the inboard position A in the same general manner by the reversal of the flow of hydraulic fluid through the circuit is indicated immediately above. The flow of hydraulic fluid is terminated by the stop plate 68 engaging the tab 64, thereby causing the same sequence of events described above to occur again.
Thus, a simple, low cost mechanism is provided to automatically move the unloading auger tube 25 from the fully inboard position A to the fully outboard position B with only initial operator input to activate the system. The system functions similarly in moving the unloading auger tube from the outboard position B to the inboard position A. It should also be noted that a neutral safety switch could easily be incorporated with the gear shift mechanism so that the combine cannot be started unless the combine is in neutral.
While the preferred structure in which the principles of the present invention have been incorporated is shown and described above, it is to be understood that the invention is not to be limited to the particular details thus presented, but, in fact, widely different means may be employed in the practice of the broader aspects of this invention. The scope of the appended claims is intended to encompass all obvious changes in the details, materials and arrangements of parts which will occur to one of ordinary skill in the art upon a reading of this disclosure. | A combine has an unloading tube containing an auger, which tube is moveable between a retracted position and an unloading position. Movement is controlled by the operator from the operator's platform by a hydraulic system. The system includes an actuator cooperating with a valve to control a hydraulic cylinder. The cylinder is interconnected to the tube causing movement thereto. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/866,151, filed Jun. 14, 2004, which claims the benefit of U.S. Provisional Application No. 60/477,735, filed Jun. 12, 2003, both of which are herein incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to antenna designs for radio frequency identification (RFID) tags.
[0004] 2. Related Art
[0005] Pick and place techniques are often used to assemble electronic devices. Such techniques involve a manipulator, such as a robot arm, to remove integrated circuit (IC) dies from a wafer and place them into a die carrier. The dies are subsequently mounted onto a substrate with other electronic components, such as antennas, capacitors, resistors, and inductors to form an electronic device.
[0006] Pick and place techniques involve complex robotic components and control systems that handle only one die at a time. This has a drawback of limiting throughput volume. Furthermore, pick and place techniques have limited placement accuracy, and have a minimum die size requirement
[0007] One type of electronic device that may be assembled using pick and place techniques is an RFID “tag.” An RFID tag may be affixed to an item whose presence is to be detected and/or monitored. The presence of an RFID tag, and therefore the presence of the item to which the tag is affixed, may be checked and monitored by devices known as “readers.”
[0008] As market demand increases for products such as RFID tags, and as die sizes shrink, high assembly throughput rates for very small die, and low production costs are crucial in providing commercially-viable products. Accordingly, what is needed is an electronic device, such as an RFID tag, that overcomes these limitations.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to methods, systems, and apparatuses for producing one or more electronic devices, such as RFID tags, that each include a die having one or more electrically conductive contact pads that provide electrical connections to related electronics on a substrate.
[0010] According to the present invention, electronic devices are formed at much greater rates than conventionally possible. In one aspect, large quantities of dies can be transferred directly from a wafer to corresponding substrates of a web of substrates. In another aspect, large quantities of dies can be transferred from a support surface to corresponding substrates of a web of substrates. In another aspect, large quantities of dies can be transferred from a wafer or support surface to an intermediate surface, such as a die plate. The die plate may have cells formed in a surface thereof in which the dies reside. Otherwise, the dies can reside on a surface of the die plate. The dies of the die plate can then be transferred to corresponding substrates of a web of substrates.
[0011] In an aspect, a punch plate, punch roller or cylinder, or expandable material can be used to transfer dies from the die plate to substrates.
[0012] Large quantities of dies can be transferred. For example, 10s, 100s, 1000s, or more dies, or even all dies of a wafer, support surface, or die plate, can be simultaneously transferred to corresponding substrates of a web.
[0013] In one aspect, dies may be transferred between surfaces in a “pads up” orientation. When dies are transferred to a substrate in a “pads up” orientation, related electronics can be printed or otherwise formed to couple contact pads of the die to related electronics of the tag substrate.
[0014] In an alternative aspect, the dies may be transferred between surfaces in a “pads down” orientation. When dies are transferred to a substrate in a “pads down” orientation, related electronics can be pre-printed or otherwise pre-deposited on the tag substrate.
[0015] In an aspect of the present invention, a radio frequency identification (RFID) tag antenna is formed. The antenna includes a first, a second, a third, and a fourth arm. Each of the arms is affixed to a substrate and extends radially from a central location to form a X-shaped structure. The antenna further includes a fifth, a sixth, a seventh, and an eighth arm. The fifth and sixth arms oppositely extend from the third arm. The seventh and eighth arms oppositely extend from the fourth arm. In this way, two smaller X-shaped structures are formed on two legs of the larger X-shaped structure.
[0016] Any number of one or more such antennas may be formed in an array in a web of tags.
[0017] These and other advantages and features will become readily apparent in view of the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0018] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
[0019] FIG. 1 shows a block diagram of an exemplary RFID tag, according to an embodiment of the present invention.
[0020] FIGS. 2A and 2B show plan and side views of an exemplary die, respectively.
[0021] FIGS. 2C and 2D show portions of a substrate with a die attached thereto, according to example embodiments of the present invention.
[0022] FIGS. 3-5 illustrate antenna and web configurations according to exemplary embodiments of the present invention.
[0023] The present invention will now be described with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the reference number.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention provides improved processes and systems for assembling electronic devices, including RFID tags. The present invention provides improvements over current processes. Conventional techniques include vision-based systems that pick and place dies one at a time onto substrates. The present invention can transfer multiple dies simultaneously. Vision-based systems are limited as far as the size of dies that may be handled, such as being limited to dies larger than 600 microns square. The present invention is applicable to dies 100 microns square and even smaller. Furthermore, yield is poor in conventional systems, where two or more dies may be accidentally picked up at a time, causing losses of additional dies. The present invention allows for improved yield values. Badmash
[0025] The present invention provides an advantage of simplicity. Conventional die transfer tape mechanisms may be used by the present invention. Furthermore, much higher fabrication rates are possible. Current techniques process 5-8 thousand units per hour. The present invention can provide improvements in these rates by a factor of N. For example, embodiments of the present invention can process dies 5 times as fast as conventional techniques, at 100 times as fast as conventional techniques, and at even faster rates. Furthermore, because the present invention allows for flip-chip die attachment techniques, wire bonds are not necessary.
[0026] Elements of the embodiments described herein may be combined in any manner. Example RFID tags are described in the section below. Assembly embodiments for RFID tags are described in the next section. Example applications for tags and tag assembly techniques are then described, followed by a description of example substrate webs and antenna layouts.
[0027] The present invention is directed to techniques for producing electronic devices, such as RFID tags. For illustrative purposes, the description herein primarily relates to the production of RFID tags. However, the description is also adaptable to the production of further electronic device types, as would be understood by persons skilled in the relevant art(s) from the teachings herein.
[0028] FIG. 1 shows a block diagram of an exemplary RFID tag 100 , according to an embodiment of the present invention. As shown in FIG. 1 , RFID tag 100 includes a die 104 and related electronics 106 located on a tag substrate 116 . Related electronics 106 includes an antenna 114 in the present example. As is further described elsewhere herein, die 104 may be mounted in either a pads up or pads down orientation.
[0029] RFID tag 100 may be located in an area having a large number, population, or pool of RFID tags present. RFID tag 100 receives interrogation signals transmitted by one or more tag readers. According to interrogation protocols, RFID tag 100 responds to these signals. Each response includes information that identifies the corresponding RFID tag 100 of the potential pool of RFID tags present. Upon reception of a response, the tag reader determines the identity of the responding tag, thereby ascertaining the existence of the tag within a coverage area defined by the tag reader.
[0030] RFID tag 100 may be used in various applications, such as inventory control, airport baggage monitoring, as well as security and surveillance applications. Thus, RFID tag 100 can be affixed to items such as airline baggage, retail inventory, warehouse inventory, automobiles, compact discs (CDs), digital video discs (DVDs), video tapes, and other objects. RFID tag 100 enables location monitoring and real time tracking of such items.
[0031] In the present embodiment, die 104 is an integrated circuit that performs RFID operations, such as communicating with one or more tag readers (not shown) according to various interrogation protocols. Exemplary interrogation protocols are described in U.S. Pat. No. 6,002,344 issued Dec. 14, 1999 to Bandy et aL. entitled System and Method for Electronic Inventory, and U.S. patent application Ser. No. 10/072,885, filed on Feb. 12, 2002, both of which are incorporated by reference herein in its entirety. Die 104 includes a plurality of contact pads that each provide an electrical connection with related electronics 106 .
[0032] Related electronics 106 are connected to die 104 through a plurality of contact pads of IC die 104 . In embodiments, related electronics 106 provide one or more capabilities, including RF reception and transmission capabilities, sensor functionality, power reception and storage functionality, as well as additional capabilities. The components of related electronics 106 can be printed onto a tag substrate 116 with materials, such as conductive inks. Examples of conductive inks include silver conductors 5000, 5021, and 5025, produced by DuPont Electronic Materials of Research Triangle Park, N.C. Other materials or means suitable for printing related electronics 106 onto tag substrate 116 include polymeric dielectric composition 5018 and carbon-based PTC resistor paste 7282, which are also produced by DuPont Electronic Materials of Research Triangle Park, N.C. Other materials or means that may be used to deposit the component material onto the substrate would be apparent to persons skilled in the relevant art(s) from the teachings herein.
[0033] As shown in FIG. 1 , tag substrate 116 has a first surface that accommodates die 104 , related electronics 106 , as well as further components of tag 100 . Tag substrate 116 also has a second surface that is opposite the first surface. An adhesive material or backing can be included on the second surface. When present, the adhesive backing enables tag 100 to be attached to objects, such as books and consumer products. Tag substrate 116 is made from a material, such as polyester, paper, plastic, fabrics such as cloth, and/or other materials such as commercially available Tyvec®.
[0034] In some implementations of tags 100 , tag substrate 116 can include an indentation, “cavity,” or “cell” (not shown in FIG. 1 ) that accommodates die 104 . An example of such an implementation is included in a “pads up” orientation of die 104 .
[0035] FIGS. 2A and 2B show plan and side views of an example die 104 . Die 104 includes four contact pads 204 a - d that provide electrical connections between related electronics 106 and internal circuitry of die 104 . Note that although four contact pads 204 a - d are shown, any number of contact pads may be used, depending on a particular application. Contact pads 204 are made of an electrically conductive material during fabrication of the die. Contact pads 204 can be further built up if required by the assembly process, by the deposition of additional and/or other materials, such as gold and solder flux. Such post processing, or “bumping,” will be known to persons skilled in the relevant art(s).
[0036] FIG. 2C shows a portion of a substrate 116 with die 104 attached thereto, according to an example embodiment of the present invention. As shown in FIG. 2C , contact pads 204 a - d of die 104 are coupled to respective contact areas 210 a - d of substrate 116 . Contact areas 210 a - d provide electrical connections to related electronics 106 . The arrangement of contact pads 204 a - d in a rectangular (e.g., square) shape allows for flexibility in attachment of die 104 to substrate 116 , and good mechanical adherement. This arrangement allows for a range of tolerance for imperfect placement of IC die 104 on substrate 116 , while still achieving acceptable electrical coupling between contact pads 204 a - d and contact areas 210 a - d . For example, FIG. 2D shows an imperfect placement of IC die 104 on substrate 116 . However, even though IC die 104 has been improperly placed, acceptable electrical coupling is achieved between contact pads 204 a - d and contact areas 210 a - d.
[0037] Note that although FIGS. 2A-2D show the layout of four contact pads 204 a - d collectively forming a rectangular shape, greater or lesser numbers of contact pads 204 may be used. Furthermore, contact pads 204 a - d may be laid out in other shapes in embodiments of the present invention.
[0038] FIG. 3 illustrates an antenna array or web 300 that includes a four by five array of antennas 305 a - 305 t , although other sized arrays are also possible. Web 300 may be a complete web sheet, or may be a portion of a larger web. Antennas 305 can be made in any size. For example, a die pitch or spacing of antennas 305 can be 100 mm, or other amounts.
[0039] As shown in FIG. 4 , antenna 305 is disposed on a rectangular substrate portion. Antenna 305 has first and second bar-shaped patterns 402 a and 402 b . The first and second bar-shaped patterns 402 a - b intersect orthogonally to form a first X-shaped structure for antenna 305 . Antenna 305 includes a third bar-shaped pattern 418 . Third bar-shaped pattern 418 intersects first bar-shaped pattern 402 a to form a second X-shaped pattern 408 a . A location where pattern 418 intersects pattern 402 a is at less than half the distance from an end 412 c of pattern 402 a to a central location in a central portion 425 of the first X-shaped structure. Antenna 305 includes a fourth bar-shaped pattern 420 . Fourth bar-shaped pattern 420 intersects second bar-shaped pattern 402 b to form a third X-shaped pattern 408 b . A location where pattern 420 intersects pattern 402 b is at less than half the distance from an end 412 d of pattern 402 b to the central location of the first X-shaped structure.
[0040] From another perspective, antenna 305 can be viewed as having four arms 410 a - d radially extending from a center portion 425 of antenna 305 to form the first X-shaped structure for antenna 305 . Two of the arms that are adjacent to each other each further includes two smaller arms extending therefrom. Specifically, in the example of FIG. 4 , arm 410 c includes an arm 404 a extending from a first side 406 a , and an arm 404 b extending from a second opposing side 406 b to form the third X-shaped pattern 408 b . Arms 404 a and 404 b form third bar-shaped pattern 418 . Similarly, arm 410 d includes an arm 404 c extending from a first side 406 c and an arm 404 d extending from a second opposing side 406 d to form the second X-shaped pattern 408 a . Arms 404 c and 404 d form fourth bar-shaped pattern 420 . In this way, two smaller X-shaped structures 408 a - b are formed in the third and fourth arms 410 c - d of the first X-shaped structure formed by arms 410 a - b.
[0041] As shown in FIG. 4 , arms 410 c and 410 d both include a pair of parallel slots 430 a - b and 432 a - b extending along or portion of their respective lengths. In an embodiment, the pair of slots 430 a - b begin from near a center location of the first X-shaped structure, where arms 410 a - d intersect, and stop approximately at the start of a junction where arms 404 a - b extend from arm 410 c . Similarly, the pair of slots 432 a - b start from near a center location of the first X-shaped structure, where arms 410 a - d intersect, and end approximately at the start of a junction where arms 404 c - d extend from arm 410 d . Any number and length of slots may be present in one or more arms of antenna 305 as desired for a particular application.
[0042] As shown in FIG. 4 , arms 410 a - d have ends 412 a - d , respectively. Ends 412 a - d are shown as squared in FIG. 4 , although they can have other shapes. Arms 404 a - d have ends 416 a - d , respectively. Ends 416 a - d are shown as triangular shaped or pointed, in FIG. 4 , but can have other shapes.
[0043] Arms 410 a - d and 404 a - d are elongated patterns made from an electrically conductive material suitable for use as an antenna material, such as conductive ink, or any other suitable material disclosed elsewhere herein or otherwise known to persons skilled in the relevant art(s).
[0044] FIG. 5 illustrates a detailed view of center portion 425 shown in FIG. 4 . Center portion 425 of antenna 305 has a die mounting position 502 , for a die having four contact pads. When a die is present, each contact pad of the die is coupled to a respective pad coupled to one of arms 410 a - d of antenna 305 . Die mounting position 502 includes a first pad 504 a , a second pad 504 b , a third pad 504 c , and a fourth pad 504 d . As shown in FIG. 5 , first pad 504 a is located most closely to and is coupled to arm 410 a . Second pad 504 b is located most closely to and is coupled to arm 410 b . A slot 506 separates first pad 504 a and second pad 504 b . Third pad 504 c is coupled to a first end of an elongated pattern 506 of arm 410 c located between slots 430 a and 430 b of arm 410 c . Similarly, fourth pad 504 d is coupled to a first end of an elongated pattern 508 of arm 410 d located between slots 432 a and 432 b of arm 410 c . A slot 508 is open between slot 430 a and slot 432 a , and separates first pad 504 a from fourth pad 504 d , and separates second pad 504 b from third pad 504 c . A slot 510 is open between a central location of slot 508 and an intersection of slots 430 b and 432 b.
[0045] As shown in FIG. 5 , one or more of pads 504 a - d may each have one or more openings. The openings allow UV light to pass through the respective pad(s) to cure an adhesive material that is used to attached a die to pads 504 a - d.
CONCLUSION
[0046] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant arts that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | Methods, systems, and apparatuses for antenna designs for radio frequency identification (RFID) tags are described. | 7 |
FIELD OF THE INVENTION
The present invention relates to a recording material, and, more particularly, to a recording material excellent in color developability, shelf life stability, and stability and chemical resistance of the developed color image.
BACKGROUND OF THE INVENTION
Recording materials which utilize electron-donating dye precursors (color former) and electron-accepting compounds (color developer) are well known for use as pressure-sensitive recording paper, heat-sensitive paper, photo- and pressure-sensitive recording paper, electric heat-sensitive recording paper, and the like.
Such recording materials are described in detail, e.g., in British Pat. No. 2,140,449, U.S. Pat. Nos. 4,480,052 and 4,436,920, Japanese Patent Publication No. 23922/85, Japanese Patent Application (OPI) Nos. 179836/82, 123556/85 and 123557/85 (the term "OPI" as used herein refers to "published unexamined Japanese patent application"), and so on.
A recording material should have properties of (1) producing developed color image of sufficiently high density at a satisfactory speed, (2) generating no fog, (3) ensuring sufficient fastness to the developed color image it produces, (4) ensuring an appropriate hue to the developed color image it produces, (5) having an aptitude for copying apparatuses, (6) having a high signal to noise ratio (S/N ratio), (7) ensuring sufficient chemical resistance to the developed color image it produces, and so on. However, recording materials which meet perfectly all of these essential properties have not yet been obtained.
In particular, heat-sensitive recording materials have made remarkable progress in recent years. However, they have defects such as that they generate fog by contact with solvents or the like, and the developed color images they produce cause discoloration or decolorization upon contact with fats and oils, chemicals, finger tips, and so on. Accordingly, color development occurs in white background areas, or discoloration or decoloration occurs in developed color image areas when a conventional heat-sensitive recording material happens to come into contact with stationary writing materials or office supplies, such as a water-base ink pen, an oil-base ink pen, a fluorescent pen, vermilion inkpad, adhesives, paste, a diazo developer, etc., or cosmetics such as hand cream, milky lotion, etc., which can cause significant damage to the commodity value. There has recently been a striking growth in the demand of heat-sensitive recording materials for use as POS labels, and the market demand for heat-sensitive recording materials having chemical resistance is increasing considerably.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a recording material which has satisfactory color developability and shelf life stability, produces a developed color image excellent in fastness and chemical resistance, including water resistance, alcohol resistance and so on, and is made up using constituent materials satisfying other essential properties also.
We have conducted extensive research regarding electron-donating dye precursors and electron-accepting compounds to function as desirable constituent materials of a recording material, and regarding the recording material using such constituents, while taking note of their respective solubilities in oils and in water, partition coefficients and pKa values, polarities and positions of substituent groups they have respectively, crystallinity and solubility changes caused by using them as a mixture, and other characteristics.
As a result, the above-described object has now been attained in accordance with this invention by a recording material comprising an electron-donating colorless dye and a molybdic acid derivative as a color developer.
DETAILED DESCRIPTION OF THE INVENTION
Of the electron-accepting compounds utilized in the present invention, hexavalent molybdenum compounds are preferred over others.
More particularly, complex salts prepared from a hexavalent molybdemum atom and organic ligands containing oxygen atoms, sulfur atoms, or nitrogen atoms, such as β-diketone compounds, β-keto ester compounds, imidazole compounds, antipyridine compounds, dioxy compounds, dimercapto compounds, etc., are advantageous, because colors developed thereby have respective absorption bands which are significantly shifted to longer wavelengths.
Specific examples of such β-diketone compounds and other include acetylacetone, benzoyltrifluoroacetone, dipivaloylmethane, furoyltrifluoroacetone, dibenzoylmethane, hexafluoroacetylacetone, α-acetylacetylacetone, heptafluorobutanoylpivaloylmethane, phenylacetylacetone, naphthoylacetylacetone, p-t-amylphenylacetylacetone, pivaloyltrifluoroacetone, trifluoroacetylacetone, trioctylophosphine oxide, thenoyltrifluoroacetone, thenoylbenzoylmethane, ethyl acetoacetate, butyl methylacetoacetate, antipyrine, dimethylpyridine, and so on.
Compounds which can be particularly preferably used in the present invention are represented by formula (I) ##STR1## wherein R 1 and R 3 each represents a hydogen atom, an alkyl group (preferably C 1 to C 20 , more preferably C 1 to C 10 ), an aromatic ring (preferably C 4 to C 20 , more preferably C 4 to C 12 ), or an alkoxy group; R 2 represents a hydrogen atom, or a lower alkyl group (preferably C 1 to C 8 , more preferably C 1 to C 5 ); R 1 and R 2 , or R 2 and R 3 , together may form a ring.
In formula (I), alkyl groups represented by R 1 and R 3 may be substituted with a halogen atom, an alkyl group, an alkoxy group or so on, and the aromatic ring may contain a hetero atom, and may be substituted with a halogen atom, an alkyl group, an alkoxy group, etc.
Specifically, preferred examples of groups represented by R 1 and R 3 include --H, --CH 3 , --C 2 H 5 , --C 4 H 9 , --C 8 H 17 , --CF 3 , ##STR2##
Solubilities of the electron-accepting compounds used in accordance with the present invention in ethanol at 25° C., are preferably 50 or less, and particularly preferably 15 or less. The term solubility used in the present invention refers to the mass (gram) of a solute dissolved in 100 g of ethanol at 25° C.
Specific examples of electron-accepting compounds in accordance with the present invention are illustrated below. However, the invention is not to be construed as being limited to these compounds. ##STR3##
The molybdic acid derivatives used as a color developer in the present invention can be produced by applying various synthetic method as described, for example, in Inorganic Chemistry, Vol. 5, page 801 (1966) and vol. 7, page 2510 (1968). Typical examples of applicable production processes are given below. ##STR4##
In the above formulae (Ia) and (Ib), X represents Cl and Br.
The electron-accepting compounds in accordance with the present invention may be used alone or may be used as a mixture thereof. Further, the electron-accepting compounds may be used as a mixture with a phenolic compound, a salicyclic acid derivative or a metal salt thereof, a bis-2-hydroxyphenylsulfonic acid derivative, a metal salt thereof, or complex salts of zinc rhodanide.
Examples of phenolic compounds which can be used include 4-phenylphenol, bisphenol sulfone, p-phenylsulfonylphenol, p-tolylsulfonylphenol, bis(3-vinyl-4-hydroxyphenyl)sulfone, 2,2-bis(3-vinyl-4-hydroxyphenyl)-propane, bis-3-allyl-4-hydroxyphenylsulfone, hexyl-4-hydroxybenzoate, 2,2'-dihydroxybiphenyl, 2,2-bis(4-hydroxyphenyl)-propane, 4,4'-isopylidenebis(2-methylphenol), 1,1-bis-(3-chloro-4-hydroxyphenyl)cyclohexane, 1,1-bis(3-chloro-4-hydroxyphenyl)-2-ethylbutane, 4,4'-sec-butylidenediphenol, 4-p-methylphenylphenol, 4,4'-isopentylidenediphenol, 4,4'-methylcyclohexylidenediphenol, 4,4'-dihydroxydiphenylsulfide, 1,4-bis(4'-hydxycumyl)benzene, 1,3-bis(4'-hydroxycumyl)benzene, 4,4'-thiobis(6-tert-butyl-3-methylphenol), 4,4'-dihydroxydiphenylsufone, hydroquinone monobenzyl ether, 4-hydroxybenzophenone, 2,4-dihydroxybenzophenone, polyvinylbenzyloxycarbonylphenol, 2,4,4'-trihydroxybenzophenone, 2,2',4,4'-tetrahydroxybenzophenone, dimethyl 4-hydroxyphthalate, methyl 4-hydroxybenzoate, 2,4,4'-trihydroxydiphenylsulfone, 1,5-bis-p-hydroxyphenylpentane, 1,6-bis-p-hydroxyphenoxyhexane, tolyl 4-hydroxybenzoate, α-phenylbenzyl-4-hydroxybenzoate, phenylpropyl 4-hydroxybenzoate, phenetyl 4-hydroxybenzoate, p-chlorobenzyl 4-hydroxybenzoate, p-methoxybenzyl 4-hydroxybenzoate, benzyl 4-hydroxybenzoate, m-chlorobenzyl 4-hydroxybenzoate, β-phenetyl 4-hydroxybenzoate, 4-hydroxy-2',4'-dimethyldiphenylsulfone, β-phenetylorsellinate, cinnamyl orsellinate, o-chlorphenoxyethyl orsellinate, o-ethylphenoxyethyl orsellinate, o-phenylphenoxyethyl orsellinate, m-phenylphenoxyethyl orsellinate, β-3'-t-butyl-4'-hydroxyphenoxyethyl 2,4-dihydroxybenzoate, 1-t-butyl-4-p-hydroxyphenylsulfonyloxybenzene, 4-N-benzylsulfamoylphenol, p-methylbenzyl 2,4-dihydroxybenzoate, β-phenoxyethyl, 2,4-dihydroxybenzoate, benzyl 2,4-dihydroxy-6-methylbenzoate, methyl bis-4-hydroxyphenylacetate, and so on.
Examples of salicyclic acid derivatives which can be used in the present invention include acids and salts thereof 4-pentadecylsalicylic acid, 3-phenylsalicylic acid, 3-cyclohexylsalicylic acid, 3,5-di-t-butylsalicylic acid, 3,5-di-dodecylsalicylic acid, 3-methyl-5-benzylsalicylic acid, 3-phenyl-5-(α,α-dimethylbenzyl)-salicylic acid, 3,5-di-(α-methylbenzyl)salicylic acid, 3,5-di-t-octylsalicylic acid, 5-tetradecylsalicylic acid, 5-hexadecylsalicylic acid, 5-octadecylsalicylic acid, 5-α-(p-α-methylbenylphenyl)ethylsalicylic acid, 4-dodecyloxysalicylic acid, 4-tetradecyloxysalicylic acid, 4-hexadecyloxysalicylic acid, 4-β-phenoxyethoxysalicylic acid, 4-β-p-tolyloxyethoxysalicylic acid, 4-β-p-ethylphenoxyethoxysalicylic acid, 4-β-p-methoxyphenoxyethoxysalicylic acid, 4-β-p-ethoxyphenoxyethoxysalicylic acid, 4-β-m-tolyloxyethoxysalicylic acid, 4-β-o-tolyloxyethoxysalicylic acid, 4-(8-phenoxyoctyloxy)salicylic acid, and so on. Metals to form the salts of these salicylic acids include zinc, aluminum, magnesium and calcium.
Examples of metal salts of bis(2-hydroxyphenyl)-sulfones which can be used include those prepared from zinc, nickel, magnesium or like metals and bis(2-hydroxy-5-butylphenyl)sulfone, bis(2-hydroxy-5-phenylphenyl)-sulfone, bis(2-hydroxy-5-octylphenyl)sulfone, bis(2-hydroxy-5-chlorophenyl)sulfone, bis(2-hydroxy-3-chloro-5-butylphenyl)sulfone, etc.
Examples of complex salts of zinc rhodanide which can be used include those prepared from zinc rhodanide and imidazole, 2-phenylimidazole, picoline, pyridine, 2-benzylimidazole, benzoimidazole, 2,3-dimethyl-1-phenyl-3-pyrazoline-5-one, 1-phenyl-2-methyl-3-benzyl-3-pyrazoline-5-one, 1-phenyl-2-methyl-3-(2-ethylhexyl)-3-pyrazoline-5-one, 1-phenyl-2-methyl-3-isopropyl-3-pyrazoline-5-one, 1-phenyl-2,3-benzyl-pyrazoline-5-one, 1-phenyl-2-benzyl-3-methyl-pyrazoline-5-one, 4,4'-diantipyrylmethane, and so on.
The electron-accepting compounds in accordance with the present invention are preferably used in an amount of about 0.1 to 2 g/m 2 .
Colorless dyes (color former) used in the present invention have already been well-known. To illustrate by citing several instances from among various kinds of known colorless dyes, specific examples of phthalides are described in U.S. Pat. No. Re. 23,024, U.S. Pat. Nos. 3,491,111, 3,491,112, 3,491,116, and 3,509,174; examples of fluorans are described in U.S. Pat. Nos. 3,624,107, 3,627,787, 3,641,011, 3,462,828, 3,681,390, 3,920,510, and 3,959,571; examples of spirodipyrans as described in U.S. Pat. No. 3,971,808; examples of color forming compounds of pyridine and pyrazine types are described in U.S. Pat. Nos. 3,775,424, 3,853,869, and 4,246,318; examples of fluorene compounds are described in Japanese Patent Application No. 240989/86 filed on Oct. 9, 1986; and so on.
More specifically, examples of triarylmethane compounds include 3,3-bis(p-dimethylaminophenyl)-6-dimethylaminophthalide, 3,3-bis(p-dimethylaminophenyl)-phthalide, 3-(p-dimethylaminophenyl)-3-(1,3-dimethylindole-3-yl)phthalide, 3-(p-dimethylaminophenyl)-3-(2-methylindole-3-yl)phthalide, and the like. As for the diphenylmethane compounds, 4,4'-bis-dimethylaminobenzhydrine benzyl ether, N-halophenyl-leucoauramine, N-2,4,5-trichlorophenyl-leucoauramine and the like.
Examples of xanthene compounds include Rhodamine-B-anilino-lactam, Rhodamine (p-nitroanilino)lactam, Rhodamine B (p-chloroanilino)lactam, 2-dibenzylamino-6-diethylaminofluoran, 2-anilino-6-diethylaminofluoran, 2-anilino-3-methyl-6-diethylaminofluoran, 2-anilino-3-methyl-6-cyclohexylmethylaminofluoran, 2-o-chloroanilino-6-diethylaminofluoran, 2-m-chloroanilino-6-diethylaminofluoran, 2-(3,4-dichloroanilino)-6-diethylaminofluoran, 3-p-anilinoanilino-6-methylfluoran, 3-p,p'-anilinoanilino-6-chloro-7-methylfluoran, 2-octylamino-6-diethylaminofluoran, 2-dihexylamino-6-diethylaminofluoran, 2-m-trifluoromethylanilino-6-diethylaminofluoran, 2-butylamino-3-chloro-6-diethylaminofluoran, 2-ethoxyethylamino-3-chloro-6-diethylaminofluoran, 2-p-chloroanilino-3-methyl-6-dibutylaminofluoran, 2-anilino-3-methyl-6-dioctylaminofluoran, 2-anilino-3-chloro-6-diethylaminofluoran, 2-diphenylamino-6-diethylaminofluoran, 2-anilino-3-methyl-6-diphenylaminofluoran, 2-phenyl-6-diethylaminofluoran, 2-anilino-3-methyl-6-N-ethyl-N-isoamylaminofluoran, 2-anilino-3-methyl-5-chloro-6-diethylaminofluoran, 2-anilino-3-methyl-6-diethylamino-7-methylfluoran, 2-anilino-3-methoxy-6-dibutylaminofluoran, 2-o-chloroanilino-6-dibutylaminofluoran, 2-p-chloroanilino-3-ethoxy-6-N-isoamylaminofluroan, 2-o-chloroanilino-6-p-butylaminolinofluoran, 2-anilino-3-pentadecyl-6-diethylaminofluoran, 2-anilino-3-ethyl-6-dibutylaminofluoran, 2-anilino-3-ethyl-6-N-ethyl-6-N-ethyl-N-isoamylaminofluoran, 2-anilino-3-methyl-6-N-ethyl-N-γ-methoxypropylaminofluoran, 2-anilino-3-chloro-6-N-ethyl-N-isoamylaminofluoran, and the like.
As for the thiazine compounds, examples include benzoyl Leuco Methylene Blue, p-nitrobenzyl Leuco Methylene Blue, and the like.
Examples of spiro compounds include 3-methylspiro-dinaphthopyran, 3-ethyl-spiro-dinaphthopyran, 3,3'-dichloro-spiro-dinaphthopyran, 3-benzyl-spiro-dinaphthopyran, 3-methyl-naphtho-(3-methoxybenzo)spiropyran, 3-propyl-spiro-dibenzopyran and the like.
Examples of fluorene compounds include 3',6'-bisdiethylamino-5-diethylaminospiro(isobenzofuran-1,9'-fluorene)-3'-one, 3',6'-bisdimethylamino-5-dibutylaminospiro(isobenzofuran-1,9'-fluorene)-3'-one, 3',6'-bisdibutylamino-5-diethylaminospiro(isobenzofuran-1,9'-fluorene)-3'-one, 3',6'-bis-N-ethyl-N-isoamylaminospiro)isobenzofuran-1,9'-diphenoxyethylamino-5-fluorene)-3'-one and the like.
Of the foregoing colorless dyes, those capable of showing a black hue when used alone or as a mixture of two thereof are favored over others.
In producing heat-sensitive paper, an electron-donating colorless dye and an electron-accepting compound are used in such a condition that they are ground in a dispersing medium to fine particles generally measuring 10 microns or less, and preferably 3 microns or less, in diameter. As the dispersing medium, an aqueous solution containing a water-soluble high polymer in a concentration of about 0.5 to 10 wt% is generally employed, and the dispersion procedure is performed using a ball mill, a sand mill, a horizontal type sand mill, an attritor, a colloid mill, and so on.
A preferred weight ratio of the electron-donating colorless dye used to the electron-accepting compound used ranges from 1/10 to 1/1, and particularly preferably from 1/5 to 2/3. Independently of the electron-donating colorless dye and the electron-accepting compound, calcium carbonate and/or zinc oxide are typically ground in a dispersing medium to prepare a dispersion. A preferred amount of calcium carbonate used and/or zinc oxide used is 0.5 to 20 times (by weight), particularly 1 to 10 times (by weight), that of the electron-accepting compound used. In addition, the heat-sensitive color developing layer can contain a heat fusible substance in order to enhance its heat-responsiveness.
As suitable examples of a compound which is at least one constituent of a heat fusible substance which can be preferably used, ethers derived from aromatic alcohols are cited.
More specifically, ethers derived from phenols, naphthols, thiophenols or thionaphthols, each of which is substituted with a group containing not more than 8 carbon atoms, e.g., hydrogen atom, an alkyl group, an allyl group, an aryl group, an acyl group, a halogen atom, an alkoxy group, an alkylthio group, a cyano group, an alkoxycarbonyl group, a hydroxy group, or so on, are used to advantage.
Such ethers are represented by formula (II)
Ar--X--R.sub.1 (II)
wherein Ar represents an aromatic ring, X represents --O-- or --S--, and R 1 represents an alkyl group which may be substituted. The aromatic ring represented by Ar may have one or more of the above-cited substitutent groups, and the substituent groups may combine with each other to form a 5- to 7-membered ring which may contain a hetero atom.
Other constituent of the heat fusible substance is selected from among aromatic ethers, esters, acid amides and ureas.
The acid amides and the ureas include compounds derived from aliphatic or aromatic carboxylic acids or sulfonic acids.
Such compounds are represented by the following general formulae (III A) and (III B)
R.sub.2 YNHR.sub.3 (III A)
R.sub.2 YOR.sub.3 (III B)
In the formulae (III A) and (III B), R 2 and R 3 each represents a hydrogen atom, or an alkyl or aryl group which may be substituted with one or more of a substituent selected from halogen atoms, alkoxy groups, alkyl groups, aryl groups, aryloxy groups, hydroxy group, acyl groups, alkoxycarbonyl groups, substituted amino groups, carbamoyl groups, and sulfamoyl groups. Of the foregoing compounds, those containing as at least either R 2 or R 3 a moiety having an aromatic ring or a long-chain alkyl group are favored over others. Y represents --CO-- or --SO 2 --.
As examples of compounds represented by formula (II), (III A) or (III B), mention may be made of phenoxyethyl biphenyl ether, phenetyl biphenyl, benzyloxynaphthalene, benzyl biphenyl, di-m-tolyloxyethane, β-phenoxyethoxyanisole, 1-phenoxy-2-p-ethylphenoxyethane, bis-β-(p-methoxyphenoxy)-ethoxymethane, 1-2'-methylphenoxy-2-4"-ethylphenoxyethane, 1-tolyloxy-2-p-methylphenoxyethane, 1,2-difluorophenoxyethane, 1,4-diphenoxybutane, bis-β-(p-methoxyphenoxy)-ethyl ether, 1-phenoxy-2-p-chlorophenoxyethane, 1-2'-methylphenoxy-2-4"-ethyloxyphenoxyethane, 1-4'-methylphenoxy-2-4"-fluorophenoxyethane, 1-phenoxy-2-p-methoxyphenyl thioether, 1,2-bis-p-methoxyphenyl thioether, 1-tolyloxy-2-p-methoxyphenyl thioether, 1,3-bis-p-tolyloxypropane, 1,3-bis-p-chlorophenoxypropane, 1,1,3-trisphenoxyhexane, 1,4-bis-p-tolyloxybutane, 1,4-bis-p-chlorophenoxybutane, 1,2-bisphenoxyethane, 1,2-bis-p-tolyloxyethane, 1,2-bis-p-chlorophenoxyethane, 1,2-bis-p-methoxyphenoxyethane, 1,4-bis-α-naphthyloxybutane, 1,6-bis-phenoxyhexane, 1,3-bisphenoxy-2-benzyloxypropane, bis-(2-p-tolyloxyethyl) ether, 1,1,3-tris-phenoxybutane, bis-(β-3,5-dimethylphenoxyethyl) ether, bis-(β-4-benzyloxycarbonylphenoxyethyl) ether, 1-phenoxy-2-p-ethylphenoxyethane, bis-(2-β-naphthyloxyethyl) ether, 1,2-bis-[2-(p-tolyloxy)ethoxy]ethane, 1,2-bis[2-(3,5-dimethylphenoxy)ethoxy]ethane, 1-phenoxy-2-p-chloropnenyloxyethane, 1,2-bis(2-β-naphthyloxyethoxy)ethane, bis(2-p-tolyloxyethoxy)methane, bis[2-(2,4,6-trimethylphenoxy)ethoxy]methane, 1-phenoxy-2-β-naphthyloxypropane, bis(2-β-naphthyloxyethoxy)methane, bisphenoxymethyl sulfide, bis(2-phenoxyethyl) sulfide, 1,3-bisphenoxymethylbenzene, 1,2-bisphenoxymethylbenzene, bisphenoxymethyl ether, 1-phenoxy-2-p-ethylthiophenxoyethane, 1,3,5-trisphenoxyethoxybenzene, 1-phenoxy-2-p-tolyloxyethane, 1-phenoxy-2-β-naphthyloxypropane, 1-p-tolyloxy-2-p-chlorophenoxyethane, 1,3-diphenoxy-2-propanol, 4-(2-phenoxyethoxy)-benzoic acid methyl ester, 1,2-bis(phenylthio)ethane, 1,2-bis(4-methoxyphenylthio)ethane, 1,2-bis(3-methoxyphenylthio)ethane, 1,2-bis(4-methylphenylthio)ethane, 1,2-bis-(2-methylphenylthio)ethane, 1,2-bis(4-methylphenylthio)-propane, 1-(4-methylphenylthio)-2-(4-methoxyphenylthio)-ethane, 1,4-bis(4-methoxyphenylthio)butane, 1,6-bis(4-methylphenylthio)hexane, 1,5-bis-β-naphthoxy-3-thioooxapentane, bis[2'-(4-methoxyphenylthio)ethyl] sulfide, bis[2-(4-methylphenylthio)ethyl]ether, 2,2'-bis[2-(phenylthio)-ethyl]-diethyl sulfide, 1,2-bis(2-naphthylthio)-ethane, stearic acid amide, stearic acid anilide, stearic acid p-anisilide, stearic acid o-anisilide, ethylenebisstearoamide, methylolstearoamide, phenylacetic acid amide, phenoxyacetic acid amide, p-methoxyphenoxyacetic acid amide, phenoxypropionic acid amide, phenoxyacetic acid anilide, phenoxybutyric acid amide, phenylpropionic acid amide, phenoxyacetic acid benzylamide, phenoxyacetic acid phenetylamide, 2-ethylhexanoic acid anilide, stearylurea, hexylurea, N-phenylhexylurea, N-stearyl-N'-phenylurea, 2-phenoxy-1-p-methoxyphenylthioethane, 2-p-tolyloxy-1-p-methoxyphenylthioethane, β-naphthylphenoxyacetate, β-naphthoxyacetic acid phenoxyethyl ester, β-phenoxyethylbenzoylpropionate, p-methoxyphenoxyethyl-p'-methoxyphenoxyacetate, phenoxybenzodioxane, phenoxymethylnaphthodioxane, p-phenylphenol glycidyl ether, phenoxyethyl hydroxynaphthoate, phenyl hydroxynaphthoate, 1,4-dibutoxynaphthalene, benzyl benzyloxybenzoate, phenyl benzoate, methoxycarbonylbenzoic acid amide, dihydroxybenzene diglycidyl ether, 2-(3,4-methylenedioxyphenoxy)-1-p-fluorophenoxyethane, diphenyl carbonate, ditolylcarbonate, benzylnaphthyl carbonate, and so on.
The above-described heat fusible substances may be used alone or as a mixture of two or more thereof. In order to impart sufficient heat-responsiveness, such substances are preferably used in a proportion of from 10 to 200% by weight, and particularly preferably from 20 to 150% by weight, with respect to the electron-accepting compound used.
To a coating composition obtained by mixing the thus prepared dispersions in an appropriate ratio, certain additives can further be used in order to satisfy various requirements.
For example, an oil absorbing substance, such as an inorganic pigment, polyurea filler, etc., can be dispersed in advance in a binder for the purpose of preventing a recording head from being stained upon recording. In addition, fatty acids, metallic soaps and the like can be added for the purpose of enhancing the facility in releasing a heat-sensitive paper from a recording head. In general, not only the components responsible for color development, i.e., colorless dyes and electron-accepting compound, but also additives including a pigment, waxes, an antistatic agent, an ultraviolet absorbent, a defoaming agent, a conductive agent, fluorescent dyes, a surface active agent, hindered phenols, benzoic acid derivatives, and so on can be coated on a support to constitue the recording material.
More specifically, pigment added typically has a particle size ranging from 0.1 to 15 microns and is selected from among kaolin, calcined kaolin, talc, diatomaceous earth, aluminium hydroxide, magnesium hydroxide, calcined gypsum, silica, magnesium carbonate, titanium oxide, alumina, barium carbonate, barium sulfate, mica, glass microballoons, urea-formaldehyde filler, polyethylene particles, cellulose filler, and so on.
Examples of the waxes include paraffin wax, carboxy-denatured paraffin wax, carnauba wax, microcrystalline wax, polyethylene wax, higher fatty acid esters, and so on.
Examples of the metallic soaps include polyvalent metal salts of higher fatty acids such as zinc stearate, aluminum stearate, calcium stearate, zinc oleate, and so on.
Examples of favored hindered phenols include phenol derivatives having a branched alkyl substituent at least at the 2-position or the 6-position.
For example, 1,1-bis(2-methyl-4-hydroxy-5-t-butylphenyl)butane, 1,1,3-tris(3-methyl-4-hydroxy-5-t-butylphenylbutane, bis(2-hydroxy-3-t-butyl-5-methylphenyl)-methane, bis(2-methyl-4-hydroxy-5-t-butylphenyl)sulfide, and so on can be cited.
These additives are dispersed into a binder, and coated.
Examples of favored benzoic acid derivatives include metal salts of benzoic acids containing one or more of an electron-attracting group. Specific examples of such salts include zinc, aluminum, cadmium, magnesium calcium and like salts of halogen-substituted benzoic acids, nitrobenzoic acid, cyanobenzoic acid, substituted sulfonyl benzoic acids, acylbenzoic acid, substituted carbamoyl benzoic acids, alkoxycarbonylbenzoic acids, substituted sulfamoyl benzoic acids and the like. Of these salts, the zinc salts are preferred over others. These salts can also be used a an electron-accepting compound. These are dispersed together with or independently of another electron-accepting compound, and coated.
As for the binder, water-soluble binders are generally used. Specific examples thereof include polyvinyl alcohol, hydroxyethyl cellulose, hydroxypropyl cellulose, epichlorohydrin-denatured polyamide, ethylenemaleic anhydride copolymers, styrene-maleic anhydride copolymers, isobutylene-maleic anhydride copolymers, polyacrylic acid, polyacrylamide, methylol-denatured polyacrylamide, starch derivatives, casein, gelatin and so on. To these binders can be added a gelling agent or a cross-linking agent, and an emulsion of a hydrophobic polymer, such as styrene-butadiene rubber latex, aryl resin emulsion, etc., in order to impart water resisting property.
The coating composition is coated on base paper, wood free paper, synthetic paper, plastic sheet or neutralized paper at a coverage of 2 to 10 g/m 2 .
Further, a protective layer comprising a water-soluble or water-dispersible high polymer, such as polyvinyl alcohol, hydroxyethyl starch or epoxy-denatured polyacrylamide, and a cross-linking agent, and having a thickness of about 0.2 to 24 microns may be provided on the coated layer surface, thereby enhancing resisting properties.
In case of heat-sensitive paper, various embodiments described in German Patent Application (OLS) Nos. 2,228,581 and 2,110,854, Japanese Patent Publication No. 20142/77, and so on can be employed. On the other hand, heat-sensitive paper may be subjected to procedures like preheating, moisture control, stretching of coated paper, and so on.
The present invention is illustrated in greater detail by reference to the following examples. However, the invention is not to be construed as being limited to these examples.
EXAMPLE 1
(1) Preparation of Sample 1:
Two gram of 2-anilino-3-methyl-6-N-ethyl-N-propylaminofluoran and 2 g of 2-anilino-3-chloro-6-diethylaminofluoran were dispersed into separate 25 g portions of a 3.5% aqueous solution of polyvinyl alcohol (saponification degree: 99%, polymerization degree: 1,000) using a sand mill until their respective mean particle size became 2 microns.
Separately, 10 g of 4-β-p-methoxyphenoxyethoxysalicylic acid and 8 g of β-benzyloxynaphthalene were dispersed together with a 50 g portion of a 3% aqueous solution of polyvinyl alcohol using a ball mill over a 24-hour period. Further, 8 g of Mo-Compound (1), 10 g of zinc oxide and 15 g of phenylacetylbenzylamide were dispersed together with a 50 g portion of a 3% aqueous solution of polyvinyl alcohol using a ball mill over a 24-hour period. Furthermore, 0.1 g of 1,1,3-tris-2'-methyl-4'-hydroxy-5'-t-butylphenylbutane was dispersed together with a 20 g portion of a 5% aqueous solution of polyvinyl alcohol over a 24-hour period.
The thus prepared dispersions were thoroughly mixed, and thereto was added 15 g of Georgia kaolin and 6 g of finely divided silica, followed by the dispersion procedure. To the resulting dispersion was further added 4 g of a 50 g dispersion of a parafin wax emulsion (Cellosole #428, produced by Chukyo Yushi Co., Ltd.) to prepare a coating composition.
The coating composition was coated on neutralized paper having a basis weight of 45 g/m 2 at a coverage of 5.2 g/m 2 on a solids basis, dried at 60° C. for one minute, and subjected to a supercalendering process under a linear pressure of 60 Kg W/cm to produce coated paper.
To the coated paper was applied thermal energy of 35 mJ/mm 2 using a facsimile machine (FF-2000, produced by Fujitsu Ltd.) to develop a color. A density of the developed color was 0.92 upon measurement with a Macbeth densitometer.
The recording material prepared in the above-described manner did not have fog resulting from storage prior to recording, that is, it had excellent keeping stability. In addition, the developed color image assumed pure black hue, and exhibited excellent resistances to chemicals, water, and sunlight.
EXAMPLE 2
A coating composition was prepared in the same manner as in Example 1, except that Mo-Compound (4) was used in place of Mo-Compound (1). The coating composition was coated on calcium carbonate-coated neutralized paper at a coverage of 6 g/m 2 , and dried under the same condition as in Example 1. Color development was performed using the same procedure as in Example 1, and thereby was obtained a pure black image with a reflection density of 0.90 or above.
This pure black image caused little discoloration or fading even when touchned with oils and fats, or exposed to sunlight.
EXAMPLE 3
An electron-donating colorless dye constituted with 6 g or 2-N-po-diethylaminophenylanilino-6-N-ethyl-N-isoamylaminofluoran, 8 g of 2-anilino-3-chloro-6-diethylaminofluoran and 2 g of 3',6'-bisdiethylamino-5-diethylaminospiro(isobenzofuran-1,9'-fluorene)-3'-one, 20 g of Mo-Compound (1) as an electron-accepting compound, and a mixture of 10 g of 2-benzyloxynaphthalene and 15 g of stearic acid amide as a heat fusible substance were dispersed together with separate 100 g portions of a 5% aqueous solution of polyvinyl alcohol (PVA 105, produced by Kuraray Co., Ltd.) using a ball mill over a period of one day and night, whereby achieving the volume average particle size of 3 microns. Separately, 80 g of calcium carbonate-zinc oxide 1:1 (by weight) mixture was dispersed together with 160 g of a 0.5% solution of sodium hexametaphosphate using a homogenizer.
The thus prepared dispersions were mixed in such a proportion that the dispersion of the electron-donating colorless dye was used in an amount of 5 g, that of the electron-accepting compound in an amount of 10 g, that of the heat fusible substance in an amount of 5 g, and that of the calcium carbonate-zinc oxide mixture in an amount of 22 g. To the resulting mixture were further added 4 g of an emulsion of zinc stearate and 5 g of a 2% aqueous solution of sodium (2-ethylhexyl)sulfosuccinate to prepare a coating composition.
The coating composition was coated on wood free paper, which had a basis weight of 50 g/m 2 , at a dry coverage of 6 g/m 2 using a wire bar, dried for 5 minutes in a 50° C. oven, and subjected to a calendering procedure to prepare coated paper.
Color-development processing was performed using a high speed facsimile machine (FF-2000, produced by Fujitsu Ltd.) to produce a black image on the coated paper. This developed-color image had a light absorption band in the near infrared region. In addition, when two sheets of filter paper were impregnated with ethanol and caster oil, respectively, and superposed on the color-developed side of the recording paper obtained in the above-described manner, fog in the white area and decoloring (discoloration and fading) in the developed-color area were hardly perceived.
Furthermore, the coated paper was kept for 24 hours under a high temperature condition (60° C., 30% RH), or a high humidity condition (40° C., 90% RH). However, fog was hardly generated by such storage procedures.
EXAMPLE 4
Coated paper was prepared in the same manner as in example 3, except that a mixture of 10 g of Compound (1) and 10 g of 2,3-dimethyl-1-phenyl-3-pyrazoline-5-one complex of zinc rhodanide were used in place of 20 g of Compound (1).
The developed color images each showed the absorption of light in the near infrared region, and fog was hardly generated.
EXAMPLE 5
The efficiencies of the pressure-sensitive recording microcapsule sheet as one embodiment of the present invention were checked using the following developer sheet. All parts are by weight.
Preparation of a developer sheet:
Into 70 parts of water, 2 parts of zinc oxide, 18 parts of calcium carbonate and 4 parts of Mo-Compound (6) were added and mixed, and the mixture was dispersed for 30 minutes by an attritor. Then, 2.5 parts by weight (solids content) of carboxyl modified SBR latex and 12 parts of 10 wt% aqueous solution of polyvinyl alcohol (saponification degree: 99%, polymerization degree: 1000) were added to the dispersion and were homogeneously stirred to obtain a coating solution. The coating solution was coated by an air knife coating device on a base paper of 50 g/m 2 so that the coating amount was 4 g/m 2 (solids content), and was dried to obtain a developer sheet.
Preparation of a microcapsule sheet
Four parts of 3-(2-ethoxy-4-diethylaminophenol)-3-(1-octyl-2-methylindole-3-yl)phthalide 2 parts of the nickel compound were dissolved in 100 parts of 1-phenyl-1-xylylethane and the resulting color former-containing oil solution was dispersed in 100 parts of 4.4 wt% aqueous solution of partially sodium salt of polyvinylbenzene sulfonic acid (average molecular weight: 500,000) which has a pH value of 6 to obtain o/w (oil-in-water) type emulsion having an average particle size of 4.5 μm.
Separately, 6 parts of melamine, 11 parts of 37 wt% aqueous solution of formaldehyde and 83 parts of water were heated and stirred at 60° C. for 30 minutes to prepare a transparent aqueous solution of a mixture of melamine, formaldehyde, and initially condensed product of melamine and formaldehyde.
The thus prepared aqueous solution was added to the above-described emulsion, and, with stirring, a 20 wt% aqueous solution of acetic acid was added thereto to adjust pH to 6.0. After raising the temperature of the mixture to 65° C., the mixture was allowed to stand for 30 minutes to carry out encapsulation.
Into the microcapsule solution, 200 parts of 20 wt% of aqueous solution of etherified starch, 47 parts of starch particles (an average particle size: 40 μm) and 10 parts of talc were added, and water was further added thereto to adjust the solid concentration to 20 wt% to prepare a coating soluton of microcapsule.
The thus prepared microcapsule solution was coated by an air knife coating device on a base paper (weighing capacity: 40 g/m 2 ) so that dry coating amount was 5 g/m 2 , and dried to provide a microcapsule sheet.
The obtained microcapsule sheet was superposed on the above developer sheet under a pressure of 300 kg/cm 2 to form a coloration. As a result, blue color image was obtained.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A recording material is described comprising an electron-donating colorless dye and a molybdic acid derivative as a color developer; the material has excellent color developability and shelf life stability, and enables the production of a developed color image with excellent fastness and chemical resistance. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a method and apparatus for analyzing and verifying the operation of a cardiac pacer prior to implantation, and more particularly to a system for verifying pacer operation which prior to implantation is interposed between the pacer and implanted pacer leads, and which can be readily removed to establish a direct connection between the pacer and the pacer leads when required.
To assist physicians in treating cardiac disorders of the type for which the use of implantable cardiac pacers is indicated, pacer system analyzers (PSA's) have been developed. These devices are used immediately prior to the time of pacer implantation to efficiently measure the parameters of the pacer system, which includes the patient's heart, the pacer to be implanted, and the previously implanted pacer leads, without the need to perform separate procedures requiring multiple interconnections and an undesirably long time to complete. Pacer System Analyzers test the pacer to be implanted for proper programming and operation, not only while connected in a simulated pacing system environment, but also while operating in the actual system in which they are to be used. Moreover, pacer system analyzers are preferably equipped to generate pacing pulses as required to support the patient during the pacer implantation process, independently of the pacer to be implanted.
By using a pacer system analyzer, a physician is able to adjust the operating parameters of a pacer and the implanted pacer leads to suit the specific needs of an individual patient before the pacer has been fully implanted and the implantation surgery completed. This minimizes the need for inconvenient and potentially injurious post-implantation adjustment of the pacer or the pacer leads.
Typically, when utilized to measure and analyze cardiac system parameters, pacer system analyzers have been connected between the implanted cardiac leads and the pacer terminals. Separate sets of connecting terminals have been provided, and individual sets of leads have been required between the exposed ends of the cardiac leads and the analyzer, and between the pacer terminals and the analyzer.
In the event it was necessary to remove the analyzer from the system, as when required in treating another patient, or in the event of a malfunction in the analyzer, there was no efficient way in prior pacer system analyzers of connecting the pacer to the cardiac leads so that the pacer could pace the heart directly. Instead, it was necessary for the operator to first disconnect the connecting leads from the pacer and from the cardiac leads, so that the exposed ends of the pacer leads could be connected directly to the pacer.
The present invention provides a pacer system analyzer which includes a patient lead connector and a pacer connnector which are electrically and mechanically compatible, and connecting cables for establishing electrical connection between these connectors and the pacer leads and the pacer, whereby the connecting cables can be readily disconnected from the analyzer and connected to each other to provide direct pacing by the pacer. This obviates the need for adding or removing cables from the system, or for making direct interconnections between the components. Consequently, a rapid changeover between pacing sources is possible to minimize trauma to the heart.
Accordingly, it is a general object of the present invention to provide a new and improved pacer system analyzer.
It is a more specific object of the present invention to provide a pacer system analyzer which can be readily removed from the pacing system with minimal interruption of a patient's pacing regimen.
SUMMARY OF THE INVENTION
The invention is directed to a pacer system analyzer for verifying and analyzing the operation of a cardiac pacing system comprising a patient heart, implanted patient pacer leads, and a pacer to be implanted. The analyzer includes a first connector for establishing electrical communication with the pacing leads, and a second connector for establishing electrical communication with the pacer. A first cable assembly is connected between the pacer leads and the first connector. A second cable assembly is connected between the pacer and the second converter. The first and second connectors and the first and second cable assemblies connecting therewith are electrically and mechanically compatible and of opposite gender, whereby the cable assemblies upon removal from the analyzer are directly connectable to establish electrical communication between the cardiac lead and the pacer.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements, and in which:
FIG. 1 is a perspective view of a pacer system analyzer incorporating an alternative direct connection between pacer and patient lead construction in accordance with the invention.
FIG. 2 is a simplified functional block diagram showing the principal components of the pacer system analyzer of FIG. 1.
FIG. 3 is an enlarged perspective view of the patient lead connector of the pacer system analyzer.
FIG. 4 is a cross-sectional view of the patient lead connector taken along line 4--4 of FIG. 3.
FIG. 5 is an enlarged perspective view of the pacer connector provided in the pacer system analyzer showing an implantable cardiac pacer positioned for insertion in the connector.
FIG. 6 is a cross-sectional view of the connector taken along line 6--6 of FIG. 5.
FIG. 7 is a cross-sectional view of the pacer connector taken along line 7--7 of FIG. 6.
FIG. 8 is a perspective view of the pacer system analyzer system of FIG. 1 in an alternative operating mode showing the implantable pacer connected directly to the patient lead.
FIG. 9 is an enlarged cross-sectional view of the interconnection of the patient lead and the pacer taken along line 9--9 of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, and particularly to FIG. 1, a pacer system analyzer (PSA) 10 is shown which incorporates a patient lead and pacer interconnection system constructed in accordance with the invention. As illustrated, the pacer system analyzer is connected to the heart 11 of a patient 12 by means of an implantable cardiac lead 13, which may be conventional in construction and operation. The cardiac lead is electrically connected to the analyzer 10 by means of a patient connecting lead 14 and a multicontact connector assembly 15.
The pacer system analyzer 10 is contained within a generally rectangular housing 16 formed of a durable insulating plastic or like material and includes a sloping, generally flat control panel 17. A portion of the housing is formed to provide a receptacle 18 for receiving a sealed package 19 containing a sterile implantable cardiac pacer 20. A pacer receptacle 21 in recess 18 engages a pacer connector assembly 22 comprising a plurality of electrical contacts 23 formed on package 19 to provide electrical communication between the analyzer and pacer 20.
Panel 17 includes a plurality of pressure sensitive user-actuable push button controls 24 and a liquid crystal display (LCD) 25. The analyzer operates in one of several user-selected modes in accordance with entered key stroke commands. To assist the user in selecting the appropriate operating mode, a series of internally generated instructions and a plurality of measured pacer system operating parameters are displayed on LCD 25. A plotter mechanism 26 provides a display of sensed EKG signals, as well as a printed record of measured pacer system operating parmeters and measured patient parameters. Two sets of IECG electrodes 27 and 28 provide isolated atrial and ventricular cardiac signals for connection to external instrumentation. Atrial and ventricular pacing lights 30 and 31, located along the top edge of control panel 17, provide an indication of pacer operation.
The patient's heart 11, implanted cardiac lead 13, and pacer 20 together form a pacer system. Analyzer 10 functions to measure various parameters of this system and to thereby assist a physician in selecting, implanting and adjusting the pacer leads and pacer for maximum effectiveness. Additionally, proper operation of the system can be verified before final implantation, and pacing pulses for supporting the patient during pacer system implantation can be generated.
Referring to the simplified pacer system analyzer functional block diagram of FIG. 2, analyzer 10 includes a sense amplifier 40 for amplifying sensed cardiac signals, a data processor 41 for processing the sensed signals, a pace processor 42 for genrating atrial and/or ventricular pacing signals, an interface circuit 43 for coupling the patient's heart 11 and implantable pacer 20 to the pacer system analyzer, and a control processor 44 for controlling the operation of the analyzer components.
Control processor 44 is preferably microprocessor based and is programmed to generate system control voltages in response to user-entered keystroke commands from control panel 17 (FIG. 1). Additionally, the control processor may generate a series of user instructions for display on LCD 25.
With the pacer system analyzer 10 interposed between the pacer leads and the pacer as shown in FIG. 1, pace processor 42 generates pacing pulses for application to heart 11 to facilitate measurement of patient parameters and to provide basic patient life support. Atrial and ventricular pacing pulses of predetermined amplitude, duration and rate are generated in accordance with applied pace control signals from control processor 44. The pacing pulses are transferred from the pace processor through interface circuit 43 for application to the heart 11 through cardiac lead 13 and patient lead 14.
As further illustrated in FIG. 2, pacer 20 is connected by pacer receptacle 21 and connector assembly 22 to interface circuit 43. Upon application of an appropriate control signal from control processor 44, interface circuit 43 couples cardiac lead 13 to pacer 20 whereupon the heart is paced by the pacer. Thus, by producing appropriate control signals, the control processor can cause the heart to be paced by either pace processor 42 or by implantable pacer 20.
Atrial and/or ventricular intracardiac signals detected by cardiac lead 13 are applied to respective inputs of sense amplifier 40. The sense amplifier generates atrial and/or ventricular strobe signals for application to control processor 44 upon the occurrence of atrial or ventricular intracardiac signals above a predetermined threshold. Additionally, the sense amplifier provides amplified atrial and ventricular signals for application to data processor 41 and for application to IECG terminals 27 and 28 through an isolation circuit 45, as well as signals indicative of the peak atrial and ventricular R-waves sensed by cardiac lead 13. Data processor 41 performs the mathematical operations required to calculate various patient or pacer system operating parameters for display on LCD 25 or for printing by printer 26.
Referring to FIG. 3, pacer system analyzer 10 is seen to include a patient receptacle 50 for receiving the patient connector assembly 15 associated with the pacer lead interconnect cable 14. As shown in FIG. 4, connector 15 includes a housing 51 having a slot-shaped recess 52 within which a plurality of electrical contacts 53 are provided in spaced side-by-side relationship. Cable 14 is received within a recess 54 within housing 51. The cable contains ten individual conductors which connect with respective ones of the ten spring contacts 53 as shown in FIG. 4. Each of the contacts 53 is generally U shaped with the ends thereof inwardly biased so as to receive a mating contact therebetween.
Within receptacle 50 the pacer system analyzer 10 includes a male contact assembly comprising ten individual strip-like contacts 55 arranged on an electrically non-conducting insulator board 56 so as to engage respective ones of female contacts 53 when connector assembly 15 is inserted into receptacle 50. The individual contacts 55 are connected to respective conductors of a cable 57 associated with circuitry within analyzer 10. In practice, contacts 55 may extend to both opposing surfaces of insulator board 56 so as to provide a positive low resistance electrical contact with spring contacts 53 when connector 15 is seated in receptacle 50, as shown in FIG. 4.
Referring to FIGS. 5-7, the pacer 20 to be implanted is seen to be contained within a semi-rigid electrically-insulating transparent housing 19 formed of plastic or similar material. The construction and function of this pacer housing is described in U.S. Pat. No. 4,423,732, which is assigned to the same assignee as the present invention. As shown in FIG. 5, the pacer 20, while hermetically sealed within housing 19, is received within receptacle 21 of analyzer 10 by insertion into the receptacle. A raised rib 60 may be provided on the top surface of housing 16 to guide the pacer package 19 into the receptacle.
Alternatively, the pacer to be implanted may be connected unpackaged within the sterile, field, with a short connecting cable similar to conductors 65 having a plug for insertion into the pacer connector port 66 at one end, as shown in FIG. 9, and a connector similar to connector assembly 22 for connection with the pacer system analyzer at its other end, as shown in FIG. 6. This cable would be subsequently removed prior to implantation of the pacer, the cardiac lead 13 then being connected directly to the pacer in a conventional manner.
As best shown in FIG. 6, the pacer package basically comprises a rigid electrically non-conductive base member 61 on which the pacer 20 is mounted. A housing 62 formed of a transparent semi-rigid plastic material is attached to the surface of base member 61 by means of adhesive and is so formed as to provide an enclosed sterile compartment 63 within which the pacer 20 is contained. Extending on the upper surface (as viewed in FIG. 6) of base member 61 is a narrow strip of electrically conductive foil 64 which extends from a location within compartment 63 to a location adjacent the end of the base member. The exposed portion of foil 64 forms an electrical contact surface 23. In practice ten such contacts are provided on the top surface of carrier member 61 to form the pacer connector 22.
Depending on the type of pacer 20 provided, and hence the number of connections associated with the pacer, certain of the contacts 23 are connected by individual conductors 65 to terminals of pacer 20 at the pacer connector port 66, which may be conventional in construction. As shown in FIG. 7, in practice ten foil strips 64 may be provided extending in parallel equi-spaced relationship across the base member 61. Each of these strips may in addition extend around the edge of the base member to provide an additional contact surface 23 on the bottom of the carrier member, as shown in FIG. 6.
Within receptacle 21 there is provided a slot-shaped recess 67 for receiving the contact end of pacer housing 19. Within this recess is provided a plurality of U-shaped contacts 68 arranged side-by-side for engaging respective ones of contacts 23. Electrical connections to contacts 68 are provided by individual conductors within a cable 70 received within a recess 71 in the housing of pacer receptacle 21.
When the pacer package 19 is inserted in receptacle 21 as shown in FIG. 6, individual contacts 23 associated with pacer 20 engage individual contacts 68 to establish electrical communication between pacer 20 and the circuitry of pacer system analyzer 10. By reason of the double wiping action of the U-shaped contacts 68, positive low-resistance electrical connections are established. This is particularly important in the present application because of the criticality of maintaining pacing pulses to the heart. Since electrical connections are established without breaking the hermetic seal within which pacer 20 is packaged, the pacer remains in a sterile condition ready for implantation in the patient when the verification and analysis procedure undertaken by the pacer system analyzer 10 has been completed.
Upon completion of the procedure, or in the event of a malfunction of pacer system analyzer 10, or in the event that the analyzer 10 is suddenly needed for another procedure, there is provided, in accordance with the invention, a means by which the pacer system analyzer 10 can be bypassed and the pacer 20 can be quickly and easily connected directly to cardiac leads 13, without the necessity of disconnecting and reconnecting individual connections, and without disconnecting the cardiac leads from patient cable 14 or breaking the hermetic seal of pacer package 19. To this end, patient lead connector assembly 15 is constructed to be compatible with the pacer connector assembly 22 of pacer housing 19 such that the contacts 23 associated with pacer 20 engage respective contacts 53 of plug assembly 15.
To establish the by-pass connection, it is merely necessary to remove connector assembly 15 from patient lead receptacle 50 and remove pacer package 19 from pacer receptacle 21. The pacer connector assembly 22 of housing 19 is then inserted into recess 52 of connector assembly 15, causing the necessary connections to be established. The non-conductive base 56 of connector assembly 15 is constructed to correspond in thickness to the base 61 of pacer package 19. Furthermore, contacts 23 are positioned on base 61 so as to conform in position and spacing to contacts 55 on base 56. In practice, connection may be established by the ten contacts to unipolar (UNIP), bipolar (BIP) lead configurations in either the atrial or ventricle, or both, of the patient heart 11. By reason of the double contact area provided for each connection, the connections are mechanically secure and of low electrical resistance, thereby providing the desired reliability for pacing applications.
As a final step after the pacer has been disconnected from the pacer system analyzer 10 and reconnected directly to pacer lead 13, as shown in FIG. 8, the pacer 20 may be removed from its package 19 and implanted in the patient. At this time, the connections between the patient lead 14 and the cardiac lead, collectively identified as 72 in FIG. 8, are disconnected. At the same time, the connections to pacer 20 established by conductors 65 are broken. The pacer is then quickly reconnected, the ends of cardiac lead 13 being connected to appropriate terminals in the pacer. The pacer is then implanted in the patient.
By reason of the compatibility of connector assembly 15 and pacer connector assembly 22 of pacer package 19, the pacer system analyzer 10 can be quickly bypassed when required for other purposes, or in the event of a malfunction, or upon completion of the analysis and verification procedure. Because of the unique complementary construction of receptacles 50 and 21 of the pacer system analyzer 10, and the connector assemblies 15 and 22, the electrical connections are established with a high degree of mechanical and electrical continuity.
While a particular embodiment of the invention has been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made therein without departing from the invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A pacing system analyzer for analyzing and verifying the performance of a pacer system which includes an implanted pacer lead and a pacer to be implanted. A patient cable includes a first plug member for connecting the implanted cardiac lead to a first connector on the analyzer. The pacer includes a second plug member for connecting the pacer to a second connector on the analyzer. The first and second plug connections are of opposite gender and complementary to enable the pacer to be connected directly to the patient cable in an alternative, operating mode of the analyzer. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of applicant's co-pending application Ser. No. 891,657, filed Mar. 20, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the invention
The invention relates to transmission of signals in a borehole, and more particularly to transmission of acoustical signals through a drill pipe.
2. Technical considerations
The desirability of telemetering information to the surface from a borehole while drilling has long been recognized. The best method presently in use is to cease drilling and lower an electronic instrument package into the borehole by means of a conductor cable to measure temperature, pressure, inclination, direction, etc. Borehole conditions of interest are measured and transmitted electrically up the cable to the surface where they are interpreted and displayed on surface instruments. After use the instrument and cable must be removed from the borehole before recommencing drilling in rotary drilling is used. Use can be left in place until another section of drill pipe must be added to the drill string, however, if a downhole mud motor is used to drive the drill bit. Insertion and removal of such instruments require a considerable amount of time during which drilling cannot occur. It has been estimated that elimination of such costly drilling rig down-time by means of while-drilling telemetry systems could eliminate 5% to 6% of direct production platform drilling costs in offshore platforms.
The applicant has disclosed in previous patents, e.g., U.S. Pat. No. 4,019,148, utilization of an acoustical transmission system in which an acoustical signal is inserted into a drill string at one location at a "nominal" frequency and is detected at a second location. The signal is then repeated and retransmitted at a second nominal frequency to a second detector, where it is in turn repeated and retransmitted to a third detector located at a third position in the drill string. After the third repeater the sequence of frequencies is repeated in subsequent repeaters until the signal reaches the surface and is detected and read out. It was disclosed in U.S. application Ser. No. 644,686 now U.S. Pat. No. 4,019,148 that these nominal frequencies are in fact two frequencies that are separated by only a very small frequency difference (e.g., 20 Hz.). In that application it was disclosed that information is encoded into an intelligible form for acoustical transmission along the drill string into binary coded data according to the frequency-shift-keyed modulation (FSK) system. The information concerning borehole parameters is converted from analog or other form to digitally coded words which are used to modulate the FSK system. The FSK system represents digital data by shifting between the aforementioned two nominal frequencies. One frequency is used to represent a binary "zero" and the other to represent a binary "one," and by shifting between the two frequencies in the proper sequence binary words can be represented. The encoded FSK signals can then be used to drive an electro-acoustical transducer, or other suitable device, which induces the desired signals into the drill string in the form of acoustical signals.
It has been found that several problems are associated with this type of modulation system. It was found to be a characteristic of drill pipe that signals once induced tend to continue to oscillate or "ring" long after the driving signal has been removed. This is a fact that was not recognized previous to the present invention by either the applicant or by others. It was assumed that drill pipe would act like other acoustical conductors and would dampen out any ringing by the well known process of attenuation. It has been discovered, however, by the applicant that for unknown reasons, whether it be the tubular shape of the drill pipe, the length of the drill pipe, the manner in which drill pipes are conventionally interconnected, or other reasons, the assumptions extant in the prior art are erroneous. It was also found that the problems are compounded by the use of two frequencies that are close together. Phase delays and ringing found by the applicant to be inherent in the transmission of acoustical signals in a drill pipe cause interference and intermodulation between the two different signals, thereby destroying the coherency and thus the informational value of the signals.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to transmit acoustical information signals in a drill string in a coherent manner. This is accomplished by transmitting a signal for a predetermined length of time and ceasing such transmission for a second predetermined length of time and combining such transmission and cessation in predetermined time frames in a manner to impart informational significance to such transmission and cessation.
It is another object of the invention to transmit acoustical information signals through a drill string in a manner such that retransmission of such signals does not interfere with the reception of such signals. This is accomplished by transmitting a signal for a portion of a time frame and ceasing transmission of such signal for a second portion of a time frame to represent a first binary state and ceasing transmission of such signal for all of a time frame to represent a second binary state. Retransmission of the signal occurs only during the second portion of the time frame, and during such retransmission reception of the signal is blanked.
It is a further object of the invention to provide a telemetry system through a drill string of great length. This is accomplished by transmitting a signal by the method previously described at a first frequency from a first location and receiving it at a second location at the same frequency retransmitting the signal to and receiving it at a third location at a second frequency, retransmitting the signal to and receiving it at a fourth location at a third frequency and repeating the reception and retransmission in the same frequency sequence until the signal reaches a desired location.
DESCRIPTION OF THE DRAWINGS
The invention may be more fully understood by reading the following description of a preferred embodiment in conjunction with the appended drawings, wherein:
FIG. 1 is a graph illustrating the prior art and the theory of the invention;
FIG. 2 is a block diagram of a drill string acoustical signal transmission system in which the invention may be utilized;
FIG. 3 is a block diagram of the reception and retransmission apparatus utilized by the invention; and
FIG. 4 is a graph illustrating the method of the invention.
THEORY OF THE INVENTION
Referring to FIG. 1 a diagram illustrating the transmission characteristics of a drill pipe is shown. Signal 100 is a typical FSK modulated signal having a portion 102 at a frequency F 1 representing a digital "one" and a portion 104 at a frequency F 2 representing a digital "zero". Signal 106 represents a DC analog of signal 100 and has a pulse portion 108 representing the digital "one" and a zero level portion 110 representing the digital "zero". Signal 106 is shown in two different states. State 112 shows the signal response in a nonresonant condition in the drill pipe. The signal has a relatively low level and is accompanied by a following edge 114 having a sharp drop off. Signal 116 represents the same signal in a resonant condition in a drill pipe. This signal has a relatively higher amplitude, but in this case is accompanied by a slowly decaying following edge 118. It is well known that an excitation in a resonant system will resonate while the system is being excited and will continue to resonate, although decreasing with time, long after the excitation has ceased to be applied. Following edge 118, therefore, represents the decaying portion of signal 106 in a resonant drill pipe condition. It can readily be seen that in portion 110 the signal representing the digital "one" is still present when in fact it is desired that the signal level be at zero in order to represent a digital "zero".
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 2, an acoustical information telemetry system in which the present invention may be used is shown. The telemetry system is incorporated into a conventional drilling apparatus that includes a drill bit 200 and a drill stem 202, which are used to drill a borehole 204 from the surface 206 through earth formations 208.
Information concerning parameters in a borehole is often desirable during drilling to plan further progression of the hole. This can be secured by a sensor 210, or a similar device, secured in the drill string. Sensors 210 can, for example, be an orientation sensing device, such as a steering tool, that provides information necessary for directional drilling. This type of device would normally be placed in the drill string very near bit 200 as shown in FIG. 2.
Information generated by sensor 210 is usually sent to the surface 206 where it can be evaluated and utilized. One transmission system useful for such purposes is an acoustical telemetry system that uses the drill string 202 as a transmission medium. The information is sent along drill string 202 by an acoustical transmitter 212, which receives the information from nearby sensor 210 through an electrical conductor 214, or by other suitable means and method of transmission.
The information is then encoded into an intelligible form that is compatible with the particular form of transmission chosen. The manner of such encoding and transmission is the subject of the present invention. Acoustical waves suffer attenuation with increasing distance from their source at a rate dependent upon the composition characteristics of the transmission medium. Many boreholes are so deep that signals sent by transmitter 212 will not reach the surface before they are attenuated to a level at which they are indistinguishable from noise present in the drill string.
In order that the signals reach the surface, they may have to be amplified several times. However, since some waves travel in both directions along the drill string, some method is desirable that will ensure that the information signals will be propogated in only one direction. Otherwise an amplifier would amplify signals coming from both above and below itself, thereby causing oscillations and rendering the system ineffective. One method that has been found suitable for producing directional isolation uses frequency shifts among three or more frequencies. Transmitter 212 starts the transmission process by transmitting the signal at a frequency F 1 . A repeater 216 capable of receiving frequency F 1 is positioned in the drill string above transmitter 212. Repeater 216 alters the signal from frequency F 1 to frequency F 2 .
The signal at frequency F 2 is sent along drill string 202 and is received by repeater 218 which will receive only signals of frequency F 2 . Repeater 218 then transforms its signal to a frequency F 3 and retransmits it. The signal of frequency F 3 travels in both directions along drill string 202, but it can be received only by a repeater 220, which receives at F 3 and retransmits at F 1 . The signal cannot be received by repeater 216 since it will receive only F 1 . In this manner, directionality is assured using three frequencies if alternate repeaters capable of receiving the same frequency are further apart than the distance necessary for the signal to attenuate to an undetectable level.
A sufficient number of repeaters to transmit the signal to the surface is used, repeating the sequence established by repeaters 216, 218, and 220 until the surface is reached. In FIG. 2 only three repeaters are shown, although a larger number may be used. In the system of FIG. 2, repeater 220 performs the final transmission to the surface at F 1 . At the surface a pickoff 222, which includes a receiver similar to that used in the repeaters, detects the signal in drill string 202. The pickoff sends a signal to a processor and readout device 224, which decodes the signal and places it in a useable form.
Referring to FIG. 3, a block diagram of a repeater is shown. The repeater comprises a detector 300, a transmitter 302 and a disable network 304. It should be recognized that while the components shown in FIG. 3 comprise a repeater, transmitter 302 may be used separately and in substantially the same configuration as transmitter 212. In addition, detector 300 may be similarly used as pickoff 222. Although repeater 216 is utilized for explanatory purposes, its operation and construction is exactly the same as that for repeaters 218 and 220 with changes only to alter the receive and transmit frequencies. Referring to repeater 216 for illustrative purposes, detector 300 receives a signal at F 1 and reconstructs the original wave form, compensating for losses and distortion occurring during transmission through the drill pipe. Detection can be accomplished, for example, by means of a transducer such as a magnetostrictive or electrostrictive device. The reconstructed signal then enters transmitter 302 where it is again applied to a transducer of the type discussed in connection with detector 300. In order to prevent chatter, which is analogous to oscillation in an analog network, transmitter 302 is operative only during times that detector 300 is certain not to receive a signal, as will be discussed in more detail in connection with FIG. 4. In addition operation of transmitter 302 actuates a disable network 304 which prevents detector 300 from receiving a signal while transmitter 302 is transmitting.
Referring to FIG. 4, the method of reception and transmission of an acoustical signal in a drill pipe is illustrated by means of a signal diagram. Signal 400, which consists of a sequence of DC pulses 402 interspersed with segments of zero voltage 404, is divided into a number of time frames 406, 408, 410, etc. Each of these time frames represents a single bit of digital information. For example, time frame 406 represents a "one" and time frame 408 represents a "zero." The time frames are referenced, i.e., sink is achieved, by transmitting a predetermined number of one's. As will be noted from the figure a one consists of a portion of a time frame, 406 for example, in which a DC pulse 402 is generated and a portion 404 in which a zero signal is generated. The pulse and zero signal portions of time frame 406 may be in any order and of any relative duration. It is preferable that portion 402 be smaller than portion 404 to provide extra time for the tuned circuit effects discussed in connection with FIG. 1 to subside. A zero is represented by a time frame in which there is an absence of a signal, as in 408 for example.
FIG. 4 also illustrates the manner in which the detector 300 and transmitter 302 operate in coordination. The letter R represents the portion of a time frame during which detector 300 is operative and the letter T the time during which transmitter 302 is operative. From this it may be seen that the transmitter never operates while the detector, or receiver, is operative, and vice versa. In this way possible feedback from the transmitter of a particular repeater to the receiver portion of the same repeater is prevented. Further isolation is provided, as outlined in connection with FIG. 3, by the disabling of detector 300 whenever transmitter 302 is in operation.
While particular embodiments of the present invention have been shown and described, it is apparent from the foregoing description that changes and alterations may be made without departing from the true scope and spirit of the invention. It is the intention in the appended claims to cover all such changes and modifications. | Data is transmitted through a drill string by means of acoustical energy by transmitting an acoustical signal for a first predetermined interval and ceasing transmission of the signal for a second predetermined interval to represent a first binary state; ceasing transmission of the signal for a third predetermined interval to represent a second binary state; and combining transmission and cessation of transmission of the signal in binary sequences representative of borehole data. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a laser medium and more particularly to a laser medium for use in a slab laser (hereunder referred to simply as a slab laser medium) which can weaken amplified spontaneous emission (hereinafter abbreviated as ASE) and suppress parasitic oscillation to thereby increase an oscillation efficiency or an amplification efficiency.
2. Description of the Related Art
As a conventional solid state laser medium, is publicly known a slab laser medium which has a slab structure provided with two parallel planes facing each other as reflecting inner surfaces (hereunder referred to simply as reflecting surfaces) as disclosed in, for example, Japanese Patent Application Publication No. 48-15599 Official Gazette. This conventional slab laser medium is used to perform laser oscillation or optical amplification by extracting a laser beam therefrom. Further, in this conventional slab laser medium, the laser beam follows a zigzag path undergoing internal reflection at the alternate reflecting surfaces. Therefore, even if the distance between the reflecting surfaces is short, the optical path followed by the laser beam can be sufficiently long. In other words, even if the laser medium is made thin, a desired path length can be obtained. Thereby, the laser medium can be efficiently cooled. Thus, large pump energy can be supplied to the laser medium. This realizes laser oscillation providing a large laser output.
Further, in general, where a thermal gradient is presented within a laser medium, thermal lensing and thermal birefringence occurring due to thermally induced distortion and stress cause phase differences among laser beams to be extracted. This results in degradation of beam quality. However, in case of this conventional slab laser medium, the laser beam goes along the zigzag path between the reflecting surfaces as described above. Thus, the laser beam equally and repeatedly travels obliquely to a transverse direction, in which the thermal gradient is presented, perpendicular to the two reflecting surfaces. Consequently, the phase difference due to unevenness of refractive index in the laser medium, which is caused by the thermal lensing and the thermal birefringence, is substantially cancelled, and further a laser beam with relatively good beam quality can be obtained.
As a conventional laser medium obtained by making better use of the characteristic of this slab laser medium to improve beam quality, is publicly known what is called a composite slab type laser medium proposed by J. L. Emmett et al (see The Potential of High-Average-Power Solid State Lasers UCRL-53571, Lawrence Livermore National Laboratory, California, 1984). This composite slab type laser medium includes a laser activating material only in a specific region between the reflecting surfaces to decrease the thermal gradient. Generally, in a slab laser medium, temperature is high in a central portion in the transverse direction between the two reflecting surfaces. Further, the closer to end portions (i.e., to the reflecting surfaces) a portion, the lower temperature. Thus, by removing the laser activating material from the central portion, generation of heat therein is prevented. Moreover, by making laser pumping regions of the end portions extremely thin, the thermal gradient in the transverse direction is made to be very small.
This slab laser medium, however, has encountered problems of the ASE and a parasitic oscillation caused in the inside thereof, which are obstacles to obtain a larger laser output. Incidentally, the ASE is an emitted light, which is stimulated and amplified by fluorescence in a laser medium and attenuates energy stored prior to normal laser oscillation and optical amplification. Further, the parasitic oscillation is a phenomenon that in a laser medium, a part of laser beams do not go along a normal optical path to be followed by a laser beam which resonates in the laser medium (hereunder sometimes referred to as a resonant optical path) but perform a harmful oscillation by, for instance, going back and forth many times between the reflecting surfaces in the transverse direction. Further, if the parasitic oscillation frequently occurs, the efficiency of effective laser oscillation and the efficiency of the amplification are decreased and as a result a large laser output cannot be obtained.
A known technique of suppressing this parasitic oscillation is what is called a segmented spacer (see "New Slab and Solid-State Laser Technology and Application", SPIE., Vol. 736, p. 38, 1987). According to this technique, a gasket member made of rubber and so on is put into contact with an outer surface of each of parts, at which a laser beam is not reflected, of the parallel planes in order to prevent conditions of total internal reflection from holding. As described above, in the slab laser medium, a laser beam to be extracted therefrom (hereunder sometimes referred to simply as an extraction beam) goes along a zigzag path undergoing reflection at the alternate reflecting surfaces. As a consequence, each reflecting surface is scattered with parts of a region (hereinafter referred to as a non-path region), through which the extraction beam does not pass. Therefore, the efficiency of oscillation is not decreased in case where the conditions of total reflection of the laser beam are made not to hold for parts of the non-path region. Moreover, by preventing the conditions of total reflection from holding for parts of the non-path region, reflection of light generated by the ASE or the parasitic oscillation having reached the parts of the non-path region can be prevented, Furthermore, attenuation of the stored energy can be suppressed.
The segmented spacer is developed on the basis of an idea that reflection of a laser beam at parts of the non-path region is restrained by making the conditions of total reflection from holding for the parts of the non-path region. Thus, the gasket member is used as a member for making the conditions of total reflection from holding.
However, the results of the experiments made by inventors of the present invention reveals that the gasket member is very easily deteriorated by iteration of the laser oscillation and optical amplification. From an investigation, it is found that the cause of this is a phenomenon that the gasket member is not also heated by heat conducted from the laser medium but also absorbs pumping light and light emitted due to parasitic oscillation (hereinafter referred to as parasitic oscillation light) and generates heat and thus temperature of the gasket member is liable to rise to a permissible temperature and higher. Especially, this phenomenon is conspicuously presented in case that an air-cooling method with low cooling efficiency is employed for cooling the laser medium.
The present invention is intended to obviate the above described drawbacks of the conventional slab laser.
It is accordingly an object of the present invention to provide a slab laser which can effectively suppress parasitic oscillation and stably perform laser oscillation and light amplification for a long period of time.
SUMMARY OF THE INVENTION
To achieve the foregoing object and in accordance with a first aspect of the present invention, there is provided a slab laser medium having a slab structure provided with two parallel planes facing each other as reflecting surfaces and being used to perform laser oscillation or optical amplification by extracting a laser beam, which follows a zigzag path undergoing internal reflection at the alternate reflecting surfaces therein, therefrom, wherein at least a part of a region, which is deviated from the zigzag path and the laser beam to be extracted therefrom does not pass through, is made up of a light absorbing member.
Thus, the light absorbing member absorbs ASE, parasitic oscillation light or fluorescence. Thereby, the parasitic oscillation and so forth can be effectively suppressed.
Further, in accordance with a second aspect of the present invention, there is provided a slab laser medium having a slab structure provided with two parallel planes facing each other as reflecting surfaces and being used to perform laser oscillation or optical amplification by extracting a laser beam, which follows a zigzag path undergoing internal reflection at the alternate reflecting surfaces therein, therefrom, wherein a light absorbing member is fixedly mounted on an outer surface of at least a part of a region which is deviated from the zigzag path and the laser beam to be extracted therefrom does not pass through, of each of the two parallel planes, and wherein the light absorbing member is made of materials having an optical property that conditions of total internal reflection at a part of an inner surface of each of the two parallel planes corresponding to a part of the outer surface thereof, on which the light absorbing member is fixedly mounted, become unsatisfied when the light absorbing member is put into contact with the part of the outer surface and thermal properties similar to thermal properties of materials composing the slab laser medium other than the light absorbing member.
Thus, the conditions of total reflection of the laser beam to be extracted are not satisfied at the part of the inner surface of each of the two parallel planes corresponding to the part of the outer surface thereof, on which the light absorbing member is fixedly mounted. Consequently, ASE, parasitic oscillation light or fluorescence, which reach this part of the inner surface of each of the two parallel planes corresponding to the part of the outer surface thereof, on which the light absorbing member is fixedly mounted, are not reflected thereat but absorbed by the light absorbing member. Thereby, the parasitic oscillation and so forth can be effectively suppressed. Moreover, because the light absorbing member has the thermal properties similar to those of materials composing the slab laser medium other than the light absorbing member, the light absorbing member has a good thermal-resisting property. Thus, there is substantially no possibility of occurring thermal distortion due to the difference in thermal expansion among parts of the laser medium.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features, objects and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the drawings in which like reference characters designate like or corresponding parts throughout several views, and in which:
FIG. 1 is a sectional view of a first embodiment of the present invention;
FIG. 2 is an enlarged sectional view of a part A of FIG. 1;
FIG. 3 is a graph for illustrating characteristics of the first embodiment of FIG. 1;
FIG. 4 is a partially cutaway view of a second embodiment of the present invention;
FIG. 5 is a partially cutaway view of a third embodiment of the present invention;
FIG. 6 is an enlarged sectional view of a part B of FIG. 5;
FIG. 7 is a graph for illustrating characteristics of the second and third embodiments of FIGS. 5 and 6;
FIG. 8 is a sectional view of a fourth embodiment of the present invention; and
FIG. 9 is an exploded perspective view of the fourth embodiment of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described in detail by referring to the accompanying drawings.
First, by referring to FIGS. 1 and 2, a first embodiment of the present invention will be described in detail hereinbelow. FIG. 1 is a sectional view of a first embodiment (i.e., a first slab laser medium) of the present invention. Further, FIG. 2 is an enlarged sectional view of a part A indicated by a dashed circle in FIG. 1. Incidentally, this embodiment is an example of application of the first aspect of the present invention to what is called a composite slab type laser medium.
In these figures, reference numeral 10 designates a laser medium; 11 a substrate portion; 12 and 13 glass substrate portions made of glass (hereunder referred to as laser glass plate portions); 14 a non-path region portion; and 15 a light absorbing member.
The substrate portion 11 is a plate-like portion made of transparent phosphate glass, which contains no laser activating material, and is approximately 6 millimeters (mm) in thickness, 25 mm in width and 80 mm in length. Further, a refractive index n d and a thermal expansion coefficient α of the glass composing the substrate portion 11 are 1.549 and 99×10 -7 /°C., respectively.
As illustrated in FIG. 1, the laser glass plate portions 12, . . ., 12 and 13, . . . , 13 and the light absorbing members 15, . . . , 15 are fixed to surfaces 11a and 11b of the substrate portions 11, respectively.
Further, the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 are plate-like portions each made of phosphate glass containing Nd 3+ ions of 1×10 21 /c.c. as laser activating material, and is 1 mm or so in thickness. Furthermore, a refractive index n d and a thermal expansion coefficient α of the glass composing the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 are 1.549 and 100×10 -7 /°C., respectively.
When irradiated with predetermined pump light L, these laser glass plate portions 12, . . . , 12 and 13, . . . , 13 perform stimulated emission of light of the wavelength is 1.06 micrometer (μm). Further, when the laser glass plate portions are positioned in a predetermined resonant optical path, laser oscillation occurs at wavelength of 1.06 μm. Moreover, when a laser beam passes through the laser glass plate portion, light amplification is effected.
Furthermore, the light absorbing members 15, . . . , 15 are band-like portions each made of phosphate glass including 1% Fe 2+ ions which absorb light having wavelength of 1.06 μm, and is 1 mm or so in thickness. Incidentally, the light absorbing member 15 is obtained by first adding 2.3% Fe 3 O 4 to phosphate glass and next dissolving the phosphate glass in a reducing atmosphere. In passing, the width of each of the light absorbing members 15, . . . , 15 is suitably determined corresponding to the non-path region portions 14, . . . , 14.
Moreover, surfaces of the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 and light absorbing members 15, . . . , 15 are abraded like a mirror. Further, the abraded surfaces of the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 and the light absorbing members 15, . . . , 15 are alternately arranged and are pushed and welded to the surfaces 11a and 11b of the substrate portion 11 as illustrated in FIG. 1. Namely, the entire surfaces 11a and 11b facing each other in the transverse direction are covered by the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 and the light absorbing members 15, . . . , 15. In this case, the light absorbing members 15, . . . 15 are placed at the positions of the non-path region portions 14, . . . , 14.
Incidentally, the laser glass plate portions 12, . . . , 12 and 13, . . . , 13 and the light absorbing members 15, . . . , 15 are made of the phosphate glass material of which the refractive index is different from that of the phosphate glass material of the substrate portion 11 by a quantity equal to or less than 0.03 and the thermal expansion coefficient is different from that of the phosphate glass material of the substrate portion 11 by a quantity having an absolute value equal to or less than 5×10 -7 /°C. in such a manner to prevent occurrence of Fresnel reflection and thermal distortion as far as possible.
In addition, each of an incident end surface 10a and an exit end surface 10b, which faces each other in a longitudinal direction, of the laser medium 10 is formed to be inclined at a predetermined angle away from the longitudinal direction and is further abraded like a mirror. Incidentally, the angle is set such that a laser beam l 1 , which enters and exits from the laser medium in the longitudinal direction, meets Brewster's condition. Thereby, total reflection of only polarized light can be effected at the alternate reflecting surfaces 10c and 10d.
Hereunder, will be considered effects obtained in case where the laser having the above described arrangement is Q-switched. When mirrors for effecting laser resonance are placed at the both ends of the laser medium 10 in the longitudinal direction and further the laser medium 10 is irradiated with pump light L from a pump source (not shown), a laser beam which resonates in the laser medium (hereunder sometimes referrred to as laser resonance light) l 1 is generated between the mirror and the laser medium. The laser resonance light l 1 follows a zigzag path undergoing total reflection at the alternate reflecting surfaces 10c and 10d facing each other in the transverse direction. In this case, a region portion 14 deviated from the zigzag path (i.e., a non-path region portion) is formed in the laser medium 10. Namely, the non-path region portion 14 is a portion through which the laser resonance light l 1 does not pass. As above described, the light reflecting member 15 is placed in the non-path region portion 14. Thus, ASE or parasitic oscillation light generated in the laser glass plate portions 12 and 13 and traveling from left to right, and vice versa, as viewed in FIG. 1, can be effectively absorbed by the light absorbing member 15. Thereby, ASE can be weakened and parasitic oscillation can be suppressed, and oscillation with good efficiency can be achieved. In passing, where the laser medium 10 is used as a light amplifier, ASE can be weakened and parasitic oscillation can be suppressed, and light amplification with good efficiency can be achieved.
Referring next to FIG. 3, there is illustrated a graph showing results of measurement of a single pass gain (=optical path length×a gain) of the laser medium 10 of this embodiment and of a single pass gain of a prior art composite slab type laser medium which has the same structure as the laser medium of this embodiment does except being provided with no light absorbing members. In FIG. 3, the vertical axis represents single pass gains expressed by relative values; the horizontal axis electrical input energy (i.e., input pump energy) expressed in kilojoule (kJ).
Next, a second embodiment of the present invention will be described in detail hereinbelow. FIG. 4 is a partially cutaway view of the second embodiment (i.e., a second slab laser medium) of the present invention. Incidentally, this embodiment is an example of application of the second aspect of the present invention to what is called a composite slab type laser medium.
In this embodiment, the laser medium 20 is constructed by replacing the light absorbing members 15 of the laser medium 10 of the first embodiment with the laser glass plate portions 12 and 13 and further welding the light absorbing members 15 to the outer surfaces 24, . . . , 24 of the non-path region portions 14, . . . , 14. The other composing elements of this embodiment are the same as the corresponding elements of the first embodiment. Therefore, composing elements of the second embodiment, which are the same as the corresponding elements of the first embodiment, are designated by the same reference numerals as used to the corresponding elements of the first embodiment. Further, detailed descriptions of the composing elements of the second embodiment, which are the same as the corresponding elements of the first embodiment are omitted herein for brevity of description. Incidentally, reference character 20a designates an incident end surface of the laser medium 20; 20b an exit end surface thereof; and 20c and 20d reflecting surfaces thereof. Further, in the second embodiment, doped phosphate glass containing approximately 5 to 10% Sm 3+ ions, which are added thereto by doping and absorbs light having wavelength of 1.06 μm, is employed as the light absorbing member 15. In passing, a refractive index n d and a thermal expansion coefficient α of the glass composing the light absorbing member 15, . . . are 1.542 and 100×10 -7 /°C., respectively. Thus, the difference in refractive index of the composing glass material between the light absorbing members 15 and the laser glass plate portions 12 and 13 is very small, i.e., equal to or less than approximately 0.01. In addition, the laser medium 20 is 10 mm in thickness and 30 mm in width. Further, the substrate portion 11 is 6 mm in thickness. Moreover, the number of times of total reflection which an extraction beam undergoes in the laser medium, is 6.
As described above, in the laser medium 20 of the second embodiment, the light absorbing members 15, which are made of the phosphate glass having the refractive index very slightly different in magnitude from that of the phosphate glass composing the laser glass plate portions, are welded onto the outer surfaces 24 of the non-path region portions 14. Therefore, at parts of the surface to which the light absorbing members are welded, the conditions of total reflection is not satisfied. Accordingly, parasitic oscillation light l 2 , which is generated in the laser glass plate portions 12 and 13 and has wavelength of 1.06 μm and reaches the parts of the welded surface, is not reflected by the outer surface 24 and is incident on the light reflecting member 15 and further is absorbed therein. Thereby, can be obtained technical advantage which is similar to the technical advantage of the first embodiment. Moreover, the difference in thermal expansion coefficient of the composing glass material between the light absorbing members and the laser glass plate portions is extremely small. Therefore, there is substantially no possibility of occurrence of thermal distortion owing to the difference in thermal expansion coefficient of the composing glass material between the light absorbing members and the laser glass plate portions. Additionally, this embodiment excels in thermal resistance.
In passing, as described above, this embodiment is an example of application of the second aspect of the present invention to what is called a composite slab type laser medium. It is, however, apparent that the second aspect of the present invention can be applied to an ordinary slab laser medium.
Hereinafter, a third embodiment of the present invention will be described in detail. FIG. 5 is a partially cutaway view of the third embodiment of the present invention. Further, FIG. 6 is an enlarged sectional view of a part B of FIG. 5. Incidentally, this embodiment is an example of application of the first aspect of the present invention to what is called a composite slab type laser medium.
In this embodiment, the laser medium 30 is constructed by welding water-resisting glass plates 36, . . . , 36 and 37, . . . , 37 to portions other than the portions, to which the light absorbing members 15 are fixed, of the reflecting surfaces 20c and 20d of the laser medium 20 of the second embodiment. With such an arrangement of the water-resisting glass plates 36, . . . , 36 and 37, . . . , 37, laser glass plate portions 12, . . . , 12 and 13, . . . , 13 made of phosphate glass (containing Nd ions), which is poor in water resisting property, can be protected from cooling water. Consequently, water-cooling can be performed. Incidentally, in FIG. 5, reference character 30a designates an incident end surface of the laser medium 30; 30b an exit end surface thereof; and 30c and 30d reflecting surfaces thereof. Further, in the third embodiment, the water-resisting glass plates 36 and 37 are made of silicate glass of which the refractive index n d and the thermal expansion coefficient α are 1.555 and 101×10 -7 /°C., respectively. Moreover, water-resisting glass obtained by making the silicate glass contain 10% Cu 2+ ions which absorb parasitic oscillation light having wavelength of 1.06 μm is employed as the light absorbing members 15. Incidentally, the refractive index n d and the thermal expansion coefficient α of this water-resist glass are 1.555 and 101×10 -7 /°C., respectively. Furthermore, the water resistance of the water-resisting glass of the composing elements 15, 36 and 37 is measured by effecting what is called a powder method by using H 2 O at 100° C. for one hour. As the result of the measurement, 0.03% of the weight of water is reduced. Further, fine abrasion is performed on the surfaces of the water-resisting glass of the composing elements 15, 36 and 37 with the result that the water-resisting glass is formed in such a manner to be 0.2 mm or so in thickness. In addition, the laser medium 30 is 10 mm in thickness and 30 mm in width. Furthermore, the substrate portion 11 is 5.6 mm in thickness and 165 mm in length. Moreover, the number of times of total reflection which an extraction beam undergoes in the laser medium, is 6.
By this embodiment, can be obtained technical advantage which is similar to the technical advantage of the first and second embodiments. Moreover, dissolution of the laser glass plate portions due to cooling water can be suppressed. Thereby, laser oscillation providing a higher laser output can be effected, or higher optical amplification can be achieved.
Referring further to FIG. 7, there is illustrated a graph showing results of measurement of single pass gains of the laser medium 20 and 30 of the second and third embodiments and of a single pass gain of a prior art composite slab type laser medium which has the same structure as the laser medium of the second embodiment does except being provided with no light absorbing members. In FIG. 7, the vertical axis represents single pass gains expressed by relative values; the horizontal axis electrical input energy (i.e., input pump energy) expressed in kJ.
Next, a fourth embodiment of the present invention will be described in detail hereinbelow. FIG. 8 is a sectional view of the fourth embodiment of the present invention and FIG. 9 is an exploded perspective view of the fourth embodiment of FIG. 8. Incidentally, this embodiment is an example of application of the first aspect of the present invention to an ordinary slab laser medium. Namely, in this embodiment, portions corresponding to the non-path region portions 14 of each of the first to third embodiments are comprised of light absorbing members, and the other portions thereof are made up of glass members containing laser activating materials.
In FIGS. 8 and 9, reference numeral 40 designates a laser medium; 41 a substrate portion; 42 and 43 reflecting plate portions; and 45 a light absorbing member.
The substrate portion 41 has a shape which is substantially the same as the shape of the substrate portions 11 of each of the first to third embodiments but different in composing materials from the substrate 11. Namely, the substrate portion 41 is made up of phosphate glass members, which contain Nd +3 ions as laser activating material.
Further, the light absorbing member 45 is substantially shaped like a triangular prism similarly as in cases of the non-path region portions of the first to third embodiments. Furthermore, the light absorbing member 45 is made of phosphate glass including ions which absorb light having wavelength of 1.06 μm. In addition, surfaces of the light absorbing member 45 is abraded like a mirror.
Moreover, as is seen from FIG. 8, each of the reflecting plate portions 42 and 43 has inclined surfaces to be used as contact surfaces when the portions 42 and 43 and the light absorbing member 45 are alternately combined with each other on the same plane in such a fashion to make a plate-like body. In passing, the surface of the inclined plane is abraded like a mirror. Additionally, the substrate portion 41 and the reflecting plate portions 42 and 43 are made of the same glass material.
As illustrated in FIG. 9, the reflecting plate portions 42 and 43 are welded onto the two surfaces of the substrate portion 41 facing each other in the transverse direction, respectively. Subsequently, the light absorbing member 45 are fitted and further are welded onto adjacent two of the reflecting plate portions 42, . . . , 42 and 43, . . . , 43. Thus, is obtained the laser medium 40 in which the non-path region portions deviated from the zigzag path are made up of the light absorbing members 45.
Thereby, in case of the fourth embodiment, parasitic oscillation can be suppressed by actions similar to the actions in case of the first to third embodiments. Moreover, laser oscillation providing a higher laser output can be effected, or higher optical amplification can be achieved.
While preferred embodiments of the present invention have been described above, it is to be understood that the present invention is not limited thereto. For example, Pr 3+ , Dy 3+ and V 3+ ions may be employed as ions contained in the light absorbing member for absorbing parasitic oscillation light. Further, the above described embodiments can be used for effecting laser oscillation or optical amplification of laser light having wavelength other than 1.06 μm. In addition, the composing elements of the laser medium may be made of a crystalline material instead of a glass material.
Further, it is to be understood that other modifications will be apparent to those skilled in the art without departing from the spirit of the invention.
The scope of the present invention, therefore, is to be determined solely by the appended claims. | A laser medium for use in a slab laser having a light absorbing member provided in a region, wich is deviated from a zigzag path to be followed by a laser beam to be extracted therefrom and thus the laser beam does not pass through. Thereby, parasitic oscillation can be effectively suppressed, and laser oscillation and light amplification can be performed for a long period of time. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending application Ser. No. 132,504, filed Mar. 21, 1980, now abandoned, for Non-Nitrocellulose Non-Formaldehyde Or Formaldehyde Resin Nail Polish Employing An Acrylate Resin As The Film Former.
BACKGROUND OF THE INVENTION
1. Field of the Invention
A nail polish in which the conventional film former, nitrocellulose, and the conventional hardener, formaldehyle or a formaldehyde resin, are omitted and, in lieu thereof, ethyl methacrylate polymer of a low molecular weight is employed as the film former.
2. Description of the Prior Art
It has been conventional for many decades to commercially use nitrocellulose as the film former for nail polish. Many other film formers have been proposed but none has come into widespread commercial use. Nitrocellulose as a film former in nail polish has various drawbacks which have been overlooked because of the low cost of nitrocellulose. Nail polishes employing this film former have been generally accepted by the public. Such polishes have many desirable attributes such as a reasonably long life, a high gloss, and an acceptable moisture vapor transmission rate. However, unmodified nitrocellulose nail polishes tend to lift off the nail and are subject to yellowing with age in the bottle.
Furthermore, nitrocellulose is basically an explosive, namely, gun cotton, so that its manufacture and transfer prior to incorporation in the nail polish represents a hazard. There are many states in the United States which do not permit the manufacture of nitrocellulose. It would be quite advantageous to provide a nail polish that does not require nitrocellulose, thereby to limit the problems created by this potential explosive.
The incorporation of formaldehyde or formaldehyde resin in a nitrocellulose nail polish also is frowned upon because they dry the nails and make the nails brittle.
Furthermore, nitrocellulose nail polishes create allergenic problems for some of their users, and nitrocellulose tends to yellow in the bottle because of its chemical instability.
It has been proposed to use other film formers in addition to or in replacement of the nitrocellulose, but none of these suggested modifications has found its way into widespread public acceptance.
By way of example, reference is made to U.S. Pat. No. 2,173,755 which suggests the substitution of non-flammable esters of cellulose for nitrocellulose, mentioning cellulose aceto butyrate and ethyl cellulose.
U.S. Pat. No. 3,483,289 mentions the addition to nitrocellulose nail polishes of material such as cellulose acetate, methyl and ethyl cellulose, benzyl cellulose, cellulose aceto propionate, cellulose aceto butyrate, alkyds, urea formaldehyde resins, melamine, casein, zein, phenol-formaldehyde and phenol-furfural resins, vinyl-polyvinyl acetate, polyvinyl chloride, polyvinyl butyrate, vinylidine chloride, copolymers of vinyl and polyvinyl acetates and butyrates, polymethyl methacrylate, polyethylacrylate, sulfonamide-formaldehyde, maleic and maleic anhydride, and linseed oil type resins.
U.S. Pat. No. 3,927,203 discloses nail polishes containing a copolymer of at least one alkoxy alkyl acrylate or methacrylate with at least one different alkoxy alkyl acrylate or methacrylate or at least one hydroxy alkyl acrylate or methacrylate and, optionally, a minor amount of a further monomer.
U.S. Pat. No. 4,097,589 discloses a nail polish whose basic film former is nitrocellulose but which also includes a copolyamide.
U.S. Pat. No. 4,126,675 discloses a nail polish whose basic film former is nitrocellulose but which also may include acrylate copolymers of methyl methacrylate and hexyl methacrylate.
U.S. Pat. No. 4,158,053 discloses a nail polish of the water-base type in which the film former is an aqueous emulsion polymer of acrylates and methacrylates and, optionally, styrenes.
U.S. Pat. No. 4,179,304 discloses a nail polish containing nitrocellulose as the film former, formaldehyde resin as the hardener, and a mixture of sucrose esters as modifiers. Other film forming resins whose use is mentioned are cellulose propionate, cellulose acetate butyrate, ethyl cellulose, and acrylic resins which are homopolymers and copolymers of alkyl acrylates and methacrylates.
Finally, Australian Pat. No. 64,458 of 1965 discloses a nail polish which employs as the film former one or a combination of resins selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, polyamide resins, acrylic resins, cyclic ketones, nitrocellulose, ethyl cellulose, methyl cellulose, and modified resin derivatives, all characterized by their solubility in alcohol, water, or low odor aliphatic or aromatic hydrocarbon solvents or blends thereof.
SUMMARY OF THE INVENTION
1. Purposes of the Invention
It is the primary object of this invention to provide a nail polish which is free of nitrocellulose and free of formaldehyde and formaldehyde resins, and which essentially consists of ethyl methacrylate having a molecular weight of approximately 25,000 as the film-forming ingredient, including as necessary modifiers certain additives which improve the physical characteristics of the nail polish film and, as optional additives, further modifiers such as are conventionally employed in nail polishes.
It is another object of the invention to provide a nail polish of the character described in which the necessary modifiers include cellulose acetate propionate of a viscosity of approximately 20 seconds (ASTM method D-1343), acetyl tributyl citrate and a mixture of sucrose esters, with camphor as an optional modifier.
It is another object of the invention to provide a nail polish of the character described in which the conventional modifiers that may be included in the formulation are ingredients such as polyamide resins, thickeners, pearlescents, pigments, U.V. absorbers and fragrances.
It is another object of the invention to provide a nail polish of the character described which, despite the substitution of a new chemical ingredient for the film former in place of nitrocellulose and despite the provision of hardening ingredients other than formaldehyde and formaldehyde resins, has a life as long as that of a conventional nitrocellulose nail polish, dries as quickly, applies as easily, has as good a gloss, is just as hard, adheres as well to the nail, is as easily removed by solvents, is as flexible, has a comparable viscosity, and has a vapor moisture transmission that is at least as good.
It is another object of the invention to provide a nail polish of the character described employing a film former which is less dangerous to manufacture and yet is not unduly expensive.
It is another object of the invention to provide a nail polish of the character described which can be formulated to provide a clear film or can be modified to provide a colored transparent or a colored opaque film or a pearlescent film, as desired.
It is another object of the invention to provide a nail polish of the character described which is essentially nonallergenic, does not tend to unduly harden or crack the nails, and which does not yellow the nails.
Other objects of the invention in part will be obvious and in part will be pointed out hereinafter.
2. Brief Description of the Invention
The new nail polish is a viscous liquid with a high solids content dissolved in an organic volatile solvent which will dry sufficiently rapidly for practical use to leave a hard, glossy, detergent-resistant film that is smooth and has an excellent sheen, and is uninterrupted by cracks or crazing. For the film former there is employed an ethyl methacrylate homopolymer made by the Commercial Resins Division of Dupont Plastic Products and Resins Department under the trademark Elvacite 2043, this being a plastic of low molecular weight in the order of 25,000. The physical fingerprints of this resin are furnished at a later portion of the present specification. The amount of ethyl methacrylate polymer ranges from 10% to 25% by weight of the nail polish.
For necessary modifiers there are employed cellulose acetate propionate of a viscosity of approximately 20 seconds (ASTM method D-1343), acetyl tributyl citrate, and a mixture of sucrose esters sold by cellofilm Corp. of Wood-Ridge, New Jersey under the trademark CV-170. An optional modifier is camphor. The cellulose acetate propionate is present in an amount of about 0.5% to about 6% by weight of the nail polish, the acetyl tributyl citrate is present in an amount of from about 2% to 6% by weight of the nail polish, and the mixture of sucrose esters is present in an amount of from about 2% to about 6% by weight of the nail polish. The camphor varies from about 0% to about 3% by weight of the nail polish.
A mixture of solvents is employed which are organic and volatile and are essentially anhydrous. Typical solvents are isopropyl alcohol (95%+, essentially anhydrous), ethyl acetate, butyl acetate and methyl ethyl ketone; these total approximately 70% by weight of the nail polish. Other suitable solvents are acetone, amyl acetate, methyl acetate, ethanol (95%+, essentially anhydrous), Cellosolve, toluene, xylene and mixtures thereof.
There are no acceptable substitutes for the cellulose acetate propionate of the specified viscosity, nor for the acetyl tributyl citrate, nor for the mixture of sucrose esters.
There also may be present in the nail polish the conventional modifiers to adapt the nail polish to any particular marketing requirements. These include polyamide resins, thickeners, pearlescents, pigments, dyes, U.V. absorbers and fragrances.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Set forth below are the active ingredients which have been referred to above, together with their maximum range by weight in the nail polish and their ideal range by weight.
______________________________________ MaximumActive Range Ideal RangeIngredients by Weight by Weight______________________________________Ethyl, methyl, butyl, or isobutyl 10-25% 13-16%methacrylate homopolymersCellulose acetate propionate 0.5-6.0% 3-5%(viscosity approximately 20seconds) [ASTM method D-1343]Acetyl tributyl citrate 2-6% 4-5%Mixture of sucrose esters 2-6% 4-5%(CV-170)Camphor 0-3% 0-2%Ethyl methacrylate 0-15% 5-10%methylacrylate copolymer(for use as a luster en-hancing agent)______________________________________
The methacrylate homopolymers are fast-dissolving, low-viscosity resins with alcohol solubility. They have excellent pigment-wetting ability and have a broad solubility. Their molecular weights are approximately 25,000. Their density in kilograms of the resin per cubic meter is 1140 (in lbs. per gallon 9.51). They have a bulking value of 0.1051 gallons per lb. The test employed for density and bulking value is ASTM D-1475, the density calculation being that of 20% solutions of the resin in methyl ethyl ketone. Their specific gravity at 25°/25° C. is 1.14 calculated from a water density equal to 997 kilograms per cubic meter. Their glass transition temperature is 65° measured by differential thermal analysis as described in ASTM D-3418. Their Tukon hardness has a value of Knoop #11 measured at 23° C. and 50% RH on the Tukon tester at 25-g load using a 1.6 mm. thick disc prepared by compression molding the polymer in bead form. It is noted that this hardness reading on the molded specimen reflects inherent hardness with the resin without the reinforcing effect of a rigid substrate. Such readings are consistently lower than corresponding hardness readings for thin coatings on glass or metal substrates. They have an acid number of 8 measured as milligrams of potassium hydroxide per gram of polymer. Their tensile strength at 23° C., 50%RH, has an MPa value of 7 and a psi of 1000, being determined with the use of compression molded samples. Their elongation at break using a sample at 23° C., 50% RH, has a percentage value of less than 1. Their typical viscosity in toluene, mPa.s (cP) at 25° is 300. Their percentage of solids as furnished by Dupont is 37.5. They are insoluble in methyl alcohol, cyclohexanol, ethylene glycol, glycerol, formamide, diisopropyl ether, trichlorotrifluoroethane, n-hexane, cyclohexane, VM & P naphtha, mineral spirits, turpentine, castor oil, and alkali refined linseed oil. They are soluble in ethyl alcohol, n-propyl alcohol, isoamyl alcohol, dimethyl formamide, methylene chloride, ethylene dichloride, perchlorethylene, methyl formate, isopropyl acetate, butyl lactate, ethylene glycol monoethyl ether acetate, diethyl ether, tetrahydrofuran, methyl isobutyl ketone, diisobutyl ketone, cyclohexanone, isophorone, "Pentoxone" solvent, diacetone alcohol and acetonitrile, as well as the solvents mentioned previously in connection with the formulation of the nail polish. They form a cloudy solution with trichlorofluoromethane, "Freon" TMC solvent which is an azeotrope of trichlorotrifluoroethane and methylene chloride, nitromethane and nitroethane.
The cellulose acetate propionate employed is one having a viscosity of about 20 seconds as determined by ASTM method D-1343 in the solution described as Formula A ASTM method D-817. It is made by Eastman Chemical Products, Inc. and has the following physical fingerprints:
______________________________________Acetyl content in weight percentage 2.5on the averagePropionyl content in weight percentage 46.3on the averageHydroxyl content in weight percentage 2.07on the averageColor in particles per million; 300haze is 50, both color and hazedeterminations being made on thesame solution used for viscositydetermination using Pt-Co colorstandards and Johns-Manville Celite(diatomaceous silica products)haze standardsMelting point range 200-210° C.Free acidity as acetic acid, 0.02weight percentageAsh, weight percentage 0.017Refractive index, n.sub.D.sup.25° C. 1.475Specific gravity, 25° C./25° C. 1.23Weight/volume, 20° C. lb./U.S. gal. 10.2______________________________________
The product is sold by Eastman Chemical Products under the trademark CAP-482-20.
The acetyl tributyl citrate employed is sold by the Special Chemicals Department of Pfizer, Inc. under the trademark Citroflex A-4 and has the following physical fingerprints:
______________________________________Boiling point at 1 mm. of mercury 173° C.Vapor pressure at 1 mm. of mercury 0.8at 170° C.Vapor density compared to air 14.1It is insoluble in water.Specific gravity at 25° C. 1.045-1.055______________________________________
Its toxicology is documented in the magazine "Toxicology and Applied Pharmacology", Vol. 1, No. 3, May 1959, pp. 283-298
______________________________________Molecular weight 402.5Refractive index, 25° C. 1.441Weight per gallon, 25° C. 8.74 lb.Pour point -75° F.Viscosity, 25° C. 42.6 cps.Flash point (Cleveland open cup) 204° C.Free acidity (as citric acid) 0.10% max.after 1 hr., 150° C.Assay, minimum 99.0%Acidity (as citric acid), maximum 0.02%Color, maximum 50 APHAWater (Karl Fischer), maximum 0.25%Odor Odorless______________________________________
The mixture of sucrose esters is sold by Cellofilm Corporation under the trademark CV-170, which is a composition including sucrose benzoate, sucrose acetate isobutyrate, toluene or butyl acetate, dibutyl phthalate, and methyl methacrylate copolymer. CV-170 is embraced by the additives to the nitrocellulose formulation disclosed in U.S. Pat. No. 4,179,304.
Conventional camphor is employed, this being a ketone derived from the wood of the camphor tree in its natural form, Cinnamomum camphora, a synthetic camphor having the formula ##STR1## It is also known as 2-bornanone and gum camphor.
It is preferred also to employ a luster enhancing agent for which the desired formulation utilizes Acryloid B-72 made by ROHM and HAAS COMPANY of Philadelphia, Pa., which constitutes a copolymer of 75% ethyl methacrylate and 25% methacrylate.
The solvents mentioned above are conventional and need not be detailed.
Typical thixotropic agents which could be used are diatomaceous earths, colloidal silica, and quaternerized Montmorillonite clays such as stearylkonium hectorite.
Typical pearlescents are guanine (natural pearl), bismuth oxychloride and titanium dioxide-coated mica.
For a pigment or dye, conventional materials can be employed. Suitable ones are listed in "The Chemistry and Manufacture of Cosmetics" by Madison G. DeNavarre, Vol. 2, Second Edition, pp. 996-998.
Ultra-violet absorbers typically are utilized to inhibit the action of U.V. radiation from deteriorating the various chemicals employed for the film and to prevent fading of the pigment or dye. Those which may be usefully employed in the instant nail polish formulation are listed in Encyclopedia of Chemical Technology under the heading "U.V. Absorbers", Vol. 21, 1969, pp. 115-122.
Any suitable fragrances can be added.
An example of a typical formulation embodying the present invention is as follows:
EXAMPLE
______________________________________Ingredients % W/W______________________________________Isopropyl alcohol (95%+, essentially 5.90anhydrous)Ethyl acetate 9.90Butyl acetate 31.60Methyl ethyl ketone 25.00CV-170 3.8Citroflex A-4 (acetyl tributyl citrate) 2.94Camphor 1.05Elvacite 2043 (ethyl methacrylate 10.36homopolymer)CAP 482-20 (cellulose acetate 3.01propionate)Acryloid B-72 7.0______________________________________
The total percentage of active ingredients (aside from the organic volatile solvents) is about 30.
The aforesaid formulation is an excellent nail polish. It has an excellent ease of application when brushed on the nail. Its drying time is as follows:
______________________________________Sufficiently set to touch 3 minutesTack free 6 minutesDried through 9 minutesDried hard 20 minutes______________________________________
These times are for a single film application 3 mils thick, using as the testing procedure ASTM D-1640.
The gloss of the dried film at a 60° angle of incidence is about 100%. Its gloss at a 20° angle of incidence is about 81%. Its Sward hardness is 30 oscillations. Its adhesion to the nail using the cross-cut method is about 90%. Its Taber abrasion is 49 milligrams lost. It can be removed from the nail very easily and quickly with acetone. Its flexibility is excellent--it passed the 1/8" rod test. Its vapor moisture transmission is unusually good, being about 6×10 -3 grams/24 hours/cm 2 , in this respect being better than most nitrocellulose nail polishes. Its viscosity measured on a Brookfield viscosimeter using a #2 spindle at speed 6 for 1 minute is 384 cps, and when given an accelerated life test at 40° C. for 6 weeks, it did not yellow in the bottle.
When compared with a standard high-quality prior art nail polish employing a nitrocellulose film former and a formaldehyde hardener, the new nail polish was as easy to apply and was equal in appearance. Its wear rating at the end of 24 hours and 48 hours was essentially the same. Thus, despite the fact that an entirely new formulation has been employed for the film-forming ingredients, the net result is absence of degradation in the polish as applied.
It thus will be seen that there is provided a nail polish which achieves the various objects of the invention and which is well adapted to meet the conditions of practical use.
As various possible embodiments might be made of the above invention, and as various changes might be made in the embodiments above set forth, it is to be understood that all matter herein described is to be interpreted as illustrative and not in a limiting sense. | A nail polish that does not contain as a film-forming ingredient a potentially explosive nitrocellulose film former, and furthermore it does not contain formaldehyde or formaldehyde resin as a hardener which embrittles and dries the nails, and is non-allergenic and non-yellowing.
The new nail polish contains ethyl methacrylate homopolymer of a molecular weight of approximately 25,000 as the film-forming ingredient, and includes as necessary modifiers cellulose acetate propionate of a viscosity of approximately 20 seconds (ASTM method D-1343), acetyl tributyl citrate, a mixture of sucrose esters and, optionally, camphor. In addition, the new nail polish contains organic volatile solvents and is essentially water free. It also may contain other additives commonly employed in nail polishes such as polyamide resins, thickeners, pearlescents, pigments, U.V. absorbers and fragrances. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a waterless urinal for use in a residential bathroom or non bathroom area.
OBJECTS AND ADVANTAGES
[0002] The object and advantage of the invention is to provide a waterless urinal in a residential non bathroom area which eliminates the need for flushing with water, which is easy to manufacture, and which is easy to install or retrofit in any room of a dwelling.
[0003] Other objects are to provide a urinal that blends with the wall and is odorless.
[0004] Further objects and advantages will become apparent from a study of the following description and accompanying drawings.
SUMMARY OF THE INVENTION
[0005] In accordance with one embodiment of the present invention, a urinal housing is provided for installation in a residence as described. The housing is accessed by a door, which is adapted to open and close against the frame to permit urine transfer into the housing as required. A U-shaped trough is provided on the interior of the door for channelling urine into the housing. An integral drain assembly is provided underneath the housing which fluidly communicates with the housing by means of a drain opening in the housing. The drain assembly comprises a urine trap reservoir and a removable urine trap insert. The urine trap reservoir is a container having a bottom, an inlet opening at the top fluidly communicating directly with the drain opening, and an elevated outlet opening within the container above the bottom thereof. The urine trap insert is a vertically elongated closure with a cover. The urine trap insert circumscribes the elevated outlet in the urine trap reservoir and is aligned within the drain. The urine trap insert is retained in place above the bottom of the reservoir container by means of engagement of the cover with the floor of the housing.
[0006] In accordance with another embodiment of the invention, the framed opening has a bottom ledge which cooperates with the underside of the door trough to enable the door to pivot outwardly from a closed position against the frame to an open position.
[0007] In accordance with yet another embodiment of the invention, a protective layer of liquid is provided inside the drain assembly as described. The liquid has a density lower than that of urine and functions to form an overlying seal on the urine in the reservoir.
DESCRIPTION OF THE DRAWINGS
[0008] In order that the invention may be more clearly understood, a preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
[0009] FIG. 1 is a plan view of an installed urinal assembly showing the door in the closed position against a vertical wall.
[0010] FIG. 2 is a perspective view of the installed waterless urinal illustrating the opening of the door.
[0011] FIG. 3 is a perspective view of the waterless urinal housing.
[0012] FIG. 4 is a perspective view of the door of the waterless urinal.
[0013] FIG. 5 is a perspective view of the urine trap insert.
[0014] FIG. 6 is a perspective view of the urine trap reservoir.
[0015] FIG. 7 is a partially sectional view of the cover of the urine trap insert illustrated the spacer means.
[0016] FIG. 8 is a cross sectional view of the drain assembly.
[0017] FIG. 9 is a cross sectional view of the drain assembly illustrating the fluid level.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The waterless urinal according to this invention is intended for easy installation and use in a bathroom or non bathroom area of the home such as, for example, the bedroom. As shown in FIGS. 1 and 2 , the urinal is installed flush against the wall 21 and is accessed by means of a door 7 which pivots outwardly for use and otherwise functions to close the urinal as will hereinafter be described. The door 7 has grips 8 on the top corners of the door for the user to grasp to operate the door 7 . The door of the urinal is the only visible part of the urinal in the room.
[0019] Referring to FIG. 3 , the urinal further comprises a urinal housing 1 and a specialized waterless drain assembly 2 underneath the housing below the drain opening. A circular drain opening 4 communicates with the drain assembly wherein the urine is conveyed therethrough to the house drain pipe (not shown). The urinal installation may be OEM or a retrofit requiring only a connection to a conventional drain pipe. A drain pipe fitting 3 at the bottom of the drain assembly is provided for attachment to the drain pipe.
[0020] The urinal housing is prefabricated and its width D is sized to be installed between the 2×4 wall studs by means of integral attachment tabs 5 which are adapted to receive a fastener therethrough. The housing portions can be fabricated by means of, for example, injection molding using a suitable plastic material such as ABS. In one embodiment the housing is manufactured in two pairs 1 a and 1 b and joined together by conventional means. The door accessed opening to the housing is provided with an outwardly extending flange like border 6 to allow for the flush installation of wall board around the opening.
[0021] Referring to FIGS. 2 and 3 , the housing is provided with a front door accessed opening having an upright ledge 17 along the bottom on which the door 7 is seated and on which the door pivots between the open and closed positions.
[0022] Referring to FIG. 4 , the interior of the door is configured with a U-shaped trough having sides 9 with lower edges and bottom for channeling the urine into the housing. Referring to FIG. 3 , the lower edges of the door engage the ledge between the alignment guides 19 which center the door on the housing. Referring to FIGS. 2 , 3 and 4 , the door 7 pivots outwardly on the ledge 17 which motion is limited by the lugs 20 provided on each side. The lugs 20 engage the inside of the housing opening at the point of maximum door opening. In the open position, the interior door surface and sides 9 function as a trough to channel the urine into the housing for discharge into the housing and drain opening 4 . The drain assembly 2 is installed directly underneath the drain opening 4 of the housing as shown in FIG. 3 .
[0023] Referring to FIGS. 2 , 3 and 4 , the vertical sides 9 of the door opening are tapered upwardly and inwardly from the centre point 18 so as to present a greater width at the centre line than the operative width of the door 7 . This allows for the easy insertion of the removable door 7 through the greater center width whereupon the door may be lowered into position. The retaining lugs 20 at the sides are dimensioned to fit through the centre of the opening to be thereby secured behind the door opening edge when the door 7 is lowered into its pivoting position. The door 7 accordingly easily lifts out for periodic cleaning and sanitizing.
[0024] Referring to FIGS. 5 , 6 and 7 , the drain assembly 2 consists of a urine trap reservoir 10 to collect the urine and a urine trap insert 11 which functionally co-operates with the urine trap reservoir 10 to discharge an added volume of urine into the drain opening 4 as will be hereinafter described.
[0025] The urine trap reservoir 10 is concentrically shaped and has an elevated drain outlet port 12 . The removable urine trap insert 11 has an inverted pipe 13 having a closure 14 at the top end thereof. The diameter of the urine trap insert pipe 13 is greater than the diameter of the drain outlet port 12 and circumscribes the elevated drain outlet port 12 of the urine trap reservoir 10 and is retained in place by resting over the drain opening 4 . Referring to FIGS. 8 and 9 , the operative length L of the trap insert pipe 13 is selected to ensure that it remains above the floor of the reservoir in order to provide passage for the urine 23 thereunder. The urine trap insert 11 is seated and retained in position above the drain by suitable spacer means 15 provided on the underside periphery of the closure 14 maintaining said cover in spaced apart relationship to the floor 22 . The closure 14 resting on the spacer means 15 is thus above the floor 22 of the housing to permit the flow of urine 23 from the housing into the trap reservoir 10 . The urine trap insert 11 is removable to permit cleaning of the urine trap reservoir 10 .
[0026] The drain assembly 2 may be initially primed using water as the urine liquid whose density is functionally equivalent to urine. As such a volume of water is poured into the reservoir to a first height A which is below the elevated drain. Next, the trap insert is installed. Following, the Blue Seal® liquid is added in overlying sealing relationship to the water or urine shown as the “dark layer 16 in FIG. 9 . The density of the Blue Seal® liquid is less than water or urine enabling it to float on the urine. Once the volume of urine in the container rises above the height of the elevated drain outlet, it naturally overflows under the action of gravity into the drain outlet and is thereby discharged. In this way, the urine in the container will automatically drain into the elevated outlet. The Blue Seal® liquid readily available on the open market is a mixture of aliphatic alcohol and surfactants. A material data safety sheet is attached as FIG. 8 by way of example of a suitable liquid.
[0027] In operation, a volume of urine 23 is added to the urinal and flows through the drain opening 4 into the trap reservoir 10 . Since the urine is denser than the Blue Seal® liquid, the urine flows through the Blue Seal® layer to comingle with the urine in the urine trap reservoir. The added volume of the urine in the reservoir creates a dynamic head above the elevated drain outlet 12 which operates to discharge the added volume of urine into the elevated drain outlet for discharge into the house sewer. It is expected that approximately 3 ounces of blue seal will last for a minimum of 1500 uses.
[0028] Other advantages which are inherent to the structure are obvious to one skilled in the art. The embodiments are described herein illustratively and are not meant to limit the scope of the invention as claimed. Variations of the foregoing embodiments will be evident to a person of ordinary skill and are intended by the inventor to be encompassed by the following claims. | A waterless urinal for easy installation in bathroom and non bathroom areas of a residence. The waterless urinal includes a urinal housing with an integral drain assembly and removable door. The waterless urinal enables the discharge of urine without the need for flushing with water. A protective layer of specialized liquid is used to mask the urine in the urinal and prevent odors. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure is related to the disclosures provided in the following U.S. applications filed concurrently herewith: "A Machine And A Method For Driving Inserts Into Pieces Of Sheet Metal Device", filed in the names of K. ITO et al. U.S. Ser. No. 08/613,167; and "A Machine And A Method For Driving Inserts Into Pieces Of Sheet Metal", filed in the name of K. ITO U.S. Ser. No 08/613,171; and the disclosures of the aforementioned applications are hereby expressly incorporated by reference herein in their entireties.
The present invention is related to the manufacture of pieces of sheet metal such as casings for electronic devices and the like, furniture elements, etc. More specifically, the present invention relates to the driving of inserts into holes previously formed in the metal sheets.
2. Description of Background Information
Inserts for driving into preformed holes in metal sheets, may be of various shapes and sizes according to the function they are to perform. The most common inserts have holes or shanks, which are generally threaded and form anchorage points for equipment, components and the like.
A press is normally used to drive inserts into the holes in the metal sheets. Generally, the press includes a punch and a die which cooperate with one another. The inserts are anchored to the sheet when they are force-fitted into the respective holes in the sheet so as to bring about plastic deformation of the portion of the metal sheet adjacent the hole in which the insert is inserted. Some existing presses have devices for automatically supplying the insert from a store of inserts to a position in front of a thrust surface of the punch to position the same for insertion.
An automatic supply system is disclosed in U.S. Pat. No. 3,465,410, in which a retractable arm places the inserts on an axis of the punch. The punch includes means for holding an insert in axially alignment on its end. Once the insert is positively held on the end of the punch, the retractable arm withdraws from the operating area of the punch before the driving of the punch is enabled.
The supply system of the device disclosed in U.S. Pat. No. 3,465,410 is slow, owing to the fact that the retractable arm occupies the field of action of the punch, and has to be retracted before the punch can be operated. This solution also requires the insert to be transferred from the arm to the punch, and this action can cause jamming and other forms of malfunctioning.
Another type of insert-driving press with automatic supply has been produced by the company Haeger. In particular, this press, known as HP6-C has a punch associated with a blank holder which is coaxial with and slidable relative to the punch. The blank holder is connected to a pipe through which the inserts are supplied.
It is very complicated to replace the punch or other driving tool of the HPC-6 device, particularly when the replacement has to be carried out automatically. The replacement process requires that the system for supplying the inserts be disconnected from the old tool and then connected to the new tool.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a device for driving inserts comprising a punch for cooperating with an automatic supply system which supplies the inserts into a position in front of the thrust surface of the punch.
Another object is to provide an insert-driving tool which can be rapidly connected to and disconnected from an automatic insert-supply system, and which can work in conjunction with an insert-supply device which does not obstruct the working area.
In particular, the present invention relates to a device comprising a punch with a body having an axis of symmetry and having a hole extending along the axis and constituting the insert-supply duct. The insert-supply duct extends through a surface of the punch which applies the thrust force to the insert in use.
A punch thus formed is particularly suitable for cooperating with sources for supplying inserts of various types.
According to the present invention, these objects are achieved by providing a device for driving inserts into pieces of sheet metal. The device includes a punch having a body extending along a longitudinal axis of symmetry, a thrust surface formed by a distal end of the punch, for applying a driving force to the inserts; and a through hole extending within the body and through the punch along the longitudinal axis for moving the inserts through the punch and placing the inserts in front of the thrust surface. The through hole extends through the thrust surface.
The punch further preferably includes flexible elements extending integrally from the body along the axis of symmetry. The flexible elements include blades which extend from the body towards a distal end of the punch. Each of the blades has a head at a distal end thereof, and the distal ends of the blades form a thrust surface.
The device is further disclosed to include a blank holder coaxial with and coupled slidingly on an external surface of the body of the punch, and resilient means for urging the blank holder toward a distal end of the body such that the blank holder forms an extension of the body. An internal wall of the blank holder cooperates with the heads of the blades so that axial sliding of the blank holder relative to the punch causes the blades to bend towards the axis of symmetry of the punch.
The internal wall of the blank holder is tapered towards the axis of symmetry of the punch in a direction from a proximal end of the punch towards the distal end.
Preferably, the punch further includes a thrust member coaxial with the body. The thrust member is coupled with the body for sliding on an external surface thereof. The blades have external surfaces for cooperating with the thrust member so that sliding of the thrust member relative to the body causes the blades to bend towards the axis of symmetry of the punch.
Each of the heads of the blades preferably includes an abutment element, and the blank holder includes an abutment element which cooperates with the abutment elements of the heads to prevent the blank holder from sliding off the punch. Preferably, each of the heads of the blades includes a portion having two abutment surfaces which are fitted in a cavity in the blank holder to prevent the blank holder from sliding axially relative to the punch.
Sliding of the thrust member relative to the body to cause the blades to bend towards the axis of symmetry, cause a release of the portions of the heads from the cavity in the blank holder, to allow the blank holder to slide axially relative to the punch.
A distal end of the thrust member forms a free surface which contacts one of the two abutment surfaces of each of the heads of the blades during driving of the thrust member to transmit a thrust force from the thrust member to the heads.
The blank holder further preferably includes guide elements for guiding the inserts, and through holes along walls of the blank holder. The guide elements are preferably flat springs which converge through the through holes of the blank holder toward the axis of symmetry of the punch so as to guide the inserts along the axis.
Still further, the device preferably includes a rod which urges the inserts through the through hole in the punch to supply the inserts for insertion.
As will become clear from the following description, the device according to the invention can easily be replaced automatically and does not involve obstructions due to the insert-supply means in the operating area since the inserts come from the rear end of the punch and perform the last portion of the supply travel which places them in front of the thrust surface in a duct formed inside the punch.
The present disclosure relates to subject matter contained in Italian patent application No. T095 A 000182 (filed on Mar. 10, 1995) which is expressly incorporated by reference herein in its entirety.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become clear in the course of the detailed description which follows, given purely by way of non-limiting example, with reference to the appended drawings, in which:
FIG. 1 is a sectional view taken on the longitudinal axis of a punch according to the present invention;
FIGS. 2a-2c are sectional views of the device according to the invention during an approach, a centering of a hole in, and a clamping of a piece of sheet metal;
FIGS. 3a-3c show the device of FIG. 1 during a supply, insertion and driving of an insert;
FIG. 4 is a sectional view of an alternative embodiment of a punch according to the present invention;
FIGS. 5a-5c are sectional views of an approach, a centering of a hole and a clamping of a piece of sheet metal using the device shown in FIG. 4;
FIGS. 6a and 6b show a supply and insertion of an insert and an initial stage of the advance of the thrust element using the device shown in FIG. 4; and
FIGS. 7a-7c show various stages of advance of the thrust element of the punch using the device shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a punch includes a body 2 which has a tubular, essentially cylindrical shape, for reasons of structural practicality. The body 2 may, however, be of any shape, for example, polygonal, and is generally elongate along an axis of symmetry 5.
The body 2 includes a through-hole 6, which extends along the axis of symmetry 5, which functions as a supply-duct for the inserts to travel through.
The body further includes an end portion 7 which functions as a shank for connection of the body to an element 45 forming part of a press for driving the inserts. The element 45 includes means for the quick coupling and release of the shank 7. In use, the duct 6 in the punch 1 is aligned with a duct 46 in the element 45 through which the inserts are fed into the duct 6 in the punch 1. The inserts come from automatic loaders (not shown) which guide the inserts to the mouth of the punch in succession. The element 45 of the press is movable along the axis of symmetry 5 of the punch and is connected to an actuator (not shown) which generates the force necessary for driving the inserts.
The body 2 has a plurality of blades 8 which extend parallel to the axis of symmetry 5. The blades 8 are formed by a series of slits 13 through the body 2, only one of which can be seen in FIG. 1. Blades 8 are integral with the rest of the body 2, but can bend resiliently under the action of an external force and return to the undeformed position shown in FIG. 1 when the external force ceases to act. The frontal surfaces of the individual blades 8 define an annular thrust surface 9 which applies the driving force to the inserts. The dimensions of the thrust surface 9 of the punch (particularly its internal diameter) vary as a result of the resilient deformation of the blades 8. As noted above, the supply duct 6 extends the length of the punch 2, and thus through the thrust surface 9.
Heads 10 at the distal ends of the blades 8 define the thrust surface 9 of the punch 1 on one side. The opposite sides of the heads 10 define stop abutments 11, against which the blades 8 are fixed.
A blank holder 3 is configured to slide against the outer surfaces of the blades 8. The blank holder 3 has an internal cavity 14 having a frusto-conical intermediate portion and an end portion which has an internal diameter that is smaller than the outside diameter of the heads 10 of the blades 8 in the undeformed condition. The blank holder 3 further includes windows 15 formed through the walls thereof. Flat springs 16 are anchored to the element 17 and project therefrom. Springs 16 abut the ends of the internal cavity 14 and project into the internal space of the blank holder through windows 15. The springs function to guide the insert and/or restrain it in front of the thrust surface 9.
The element 17 of blank holder 3 is urged against the stop abutments 11 of the blades 8 by a helical compression spring 4 which reacts against an annular shoulder 12 of the body 2. Sliding of the blank holder 3 relative to the body 2 of the punch 1 in the direction indicated by the arrow A in FIG. 1 brings about interference and relative sliding between the internal surface 14 of the blank holder and the heads 10 of the blades 8. This relative sliding forces the heads 10 to follow the contour of the internal surface 14 and thereby deforms the blades 8 toward the axis of symmetry 5. The deformation of the blades 8 causes a reduction in the internal diameter of the opening formed by the thrust surface 9.
FIGS. 2a-2c and 3a-3c show various steps in the driving of an insert. A piece of sheet metal 30 includes a hole 31 into which an insert is to be driven. A die 20 includes a locating pin 21 which is slidable through hole 22. Locating pin 21 is resiliently biased outwardly from the hole 22 by a helical compression spring 23.
In FIG. 2a, the sheet 30 is first roughly positioned in the assembly between the punch 1 and the die 20, with the hole 31 in the general vicinity of the axis of symmetry 5. Unlike in conventional presses, the piece of sheet metal 30 is suspended in a vertical plane whereas the punch and the die are aligned along a horizontal axis. Vertical suspension of the sheet metal piece prevents problems connected with deformations caused by gravitational effects on a sheet that are apt to occur when a sheet is held horizontally, particularly when the sheet lacks stiffening bends. The axis of the hole 31 in the piece of sheet metal 30 is then aligned with the axis 5 of the punch using the locating pin 21, which is also aligned along the same axis.
In FIG. 2b, the punch 1 is moved towards the sheet metal piece 30 until the blank holder 3 makes contact with the surface of the sheet 30. In FIG. 2c, the die 20 is moved towards the sheet metal piece 30 until the end of the die 20 makes contact with the sheet 30. During this movement, the locating pin 21 inserted through the hole 31, thereby finely adjusts the alignment of the components. This step completes the gripping of the sheet between the punch and the die. At this time, the sheet is securely clamped between the distal end of the die 20 and the distal end of the blank holder 3.
Next, as shown in FIG. 3a, a thrust rod 50 is driven by an actuator (not shown) included in the press, to advance an insert 40 through the duct 6, to position the insert 40 in front of the thrust surface 9. As shown in FIG. 3a, the insert 40 is advanced to a position where it is restrained between the thrust rod 50 and the locating pin 21. At this position, the insert 40 is also laterally guided by the flat springs 16 of the blank holder 3.
The thrust rod 50 continues to advance the insert, as shown in FIG. 3b, and drives a shank portion of the insert 40 through the hole 31. At the same time, the punch 1 starts to advance towards the die 20. The advancement of the punch causes the heads 10 of the blades 8 to slide relative to the frusto-conical portion 14 of the blank holder 3. Thus, the heads 10 are pushed towards the axis of symmetry 5 by the frusto-conical portion 14 of the blank holder 3, as described above causing deformation of the blades 8. As the heads 10 are pushed towards the axis of symmetry 5, the inside diameter of the thrust surface 9 reduces until it becomes smaller than an outside diameter of the head 42 of the insert 40. Thus, the thrust surface 9 forms a bearing surface for the head 42.
The punch 1 is further advanced to generate a driving force which is transmitted to the insert 40 by means of the blades 8 and the thrust surface 9. This driving force causes plastic deformation of the region of the sheet in the immediate vicinity of the hole 31, as the head of the insert is driven into the sheet.
FIG. 3c shows the configuration of the device upon completion of the driving of the insert. The punch 1 is next brought back to its starting position, thereby allowing the spring 4 to return the blank holder 3 to the distal end of the punch 1, as the spring 4 returns to its least compressed position. When the blank holder has reached its starting position (i.e., at the distal end of the punch 1), the heads 10 of the blades 8 disengage from the frusto-conical surface, thereby allowing the blades 8 to return to their original, undeformed positions as shown in FIG. 1. Thus, the unrestricted, opening of the duct 6 is reestablished to permit the passage of a new insert therethrough.
FIG. 4 shows an alternative embodiment of the punch according to the present invention. The punch 100 includes a blank holder 103 which cooperates with a spring 104, in the same manner that the above-described blank holder 3 cooperates with spring 4. The punch 100 includes an insert-supply duct 106, which corresponds to the supply duct 6 of the first embodiment.
The body 102 of the punch 100 includes a tubular member 122 in which the blades 108 are formed, and a thrust member 123 mounted for sliding coaxially on the outer surface of the tubular member 122. The flexible blades 108 are formed by slits 113 made in the wall of the tubular member 122. The distal ends of the blades 108 include heads 110 which form the thrust surface 109, and which are fitted in an annular cavity 111 of the blank holder 103. The heads 110 further include abutment surfaces 117 and 118, which abut against opposite walls of the annular cavity 111.
The heads further include inclined surfaces 119. The thrust member 123 is axially movable such that the distal end 126 thereof contacts the inclined surfaces 119 and slides with respect thereto. The walls of the thrust member are relatively unyielding and thus cause the blades 108 to bend towards the axis 105 of the device upon sliding movement of the distal end along the inclined surfaces 119. As the thrust member advances, the blades 108 are bent sufficiently to release the heads 110 from the annular cavity 111. The distal end 123 slides along the inclined surfaces until it contacts the abutment surfaces 118 so as to transmit the thrust force thereof to the thrust surface 109.
The spring 104 is located between an abutment element 127 of the blank holder 103 and an annular shoulder 112 formed on the thrust element 123. The thrust element 123 further includes an oblong groove 124 in which pins 125, fixed to the blank holder 103, are engaged. As in the previous embodiment, the blank holder 103 has windows 115 through which flat springs 116 extend. Springs are fixed to the abutment element 217 and function to laterally guide and restrain the inserts.
FIGS. 5a-5c, 6a, 6b and 7a-7c show the operating sequence of the embodiment shown in FIG. 4. In FIG. 5a, the sheet 130 is first roughly positioned in the assembly between the punch 100 and the die 120, with the hole 131 in the general vicinity of the axis of symmetry 105. Unlike in conventional presses, the piece of sheet metal 130 is suspended in a vertical plane whereas the punch and the die are aligned along a horizontal axis. The axis of the hole 131 in the piece of sheet metal 130 is then aligned with the axis 105 of the punch and the locating pin 121 is also aligned along the same axis.
In FIG. 5b, the punch 100 is moved towards the sheet metal piece 130 until the blank holder makes contact with the surface of the sheet 130. In FIG. 5c, the die 120 is moved towards the sheet metal piece 130 until the end of the die 120 makes contact with the sheet 130. During this movement, the locating pin 121 inserted through the hole 131, thereby finely adjusts the alignment of the components. This step completes the gripping of sheet between the punch and the die. At this time, the sheet is securely clamped between the distal end of the die 120 and the distal end of the blank holder. In the next step shown in FIG. 6a, a thrust rod 150 is driven by an actuator (not shown) included in the press, to advance an insert 140 through the duct 106, to urge the shaft of the insert 140 through the hole 131, at the same time forcing the retraction of the locating pin 121 from the hole 131.
Next, as shown in FIG. 6b, the thrust member 123 is advanced, so that the distal end 126 slides against the inclined surfaces 119 of the heads 110 and causes bending of the blades 108 and the reduction in the inner diameter of the thrust surface 109. As the thrust member 123 advances still further, the distal end 126 slides off the inclined surfaces 119 and comes into contact with the abutment surface 118 of the heads 110. Accordingly, the thrust member 123 entrains the tubular member 122, and drives the tubular member, through the contact between the distal end 126 and abutment surfaces 118, towards the head 142 of the insert 140.
FIGS. 7a and 7b show that upon placement of the shank 140 of the insert through the hole 131, the tubular member 122 is advanced towards the die 120. The advancement of the tubular member 122 continues so that thrust surfaces 109 make contact with the head 142 of the insert as shown in FIG. 7b. Continued driving of the tubular member 122 and thus the thrust surfaces against the head 142 causes plastic deformation of the region of the sheet in the immediate vicinity of the hole 131, as the head 142 of the insert is driven into the sheet, and the movement of the tubular member is discontinued when abutment surfaces 117 make contact with the sheet 130.
FIG. 7c shows the configuration of the device upon completion of the driving of the insert. After completion of the driving operation, the thrust member 123 is retracted. At the same time, an actuator, not shown, urges the tubular member 122 towards the distal end of the thrust member 123. The heads 110 of the blades 108 thus return to their original positions inside the cavity 111 of the blank holder 103 and the device is ready for a new cycle.
The second embodiment of the punch is particularly advantageous owing to the fact that it avoids axial compression stresses on the blades 108.
Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed and extends to all equivalents within the scope of the claims. | A device for driving inserts into pieces of sheet metal includes a punch having a longitudinal axis of symmetry, a thrust surface and a through hole extending along its longitudinal axis which constitutes a supply duct for the inserts. The through hole extends through the thrust surface. A thrust rod applies a driving force to the inserts to move them into position in front of the thrust surface of the punch. The thrust surface drives the head of the insert into a piece of sheet metal through a hole while plastically deforming the periphery of the hole which interfaces with the head. | 1 |
This application is a national phase entry based on International Patent Application PCT/CA2005/001178, which is entitled to the benefit of and claims priority to U.S. provisional patent application Ser. No. 60/591,626, filed Jul. 28, 2004, which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to salmon vaccines. More particularly, the present invention relates to vaccines against parasitic caligid copepods (sea lice) and antigen sequences thereof.
BACKGROUND OF THE INVENTION
A number of closely related species of parasitic copepods in the family Caligidae (caligid copepods) infect and cause disease in cultured fish. Collectively, these species are referred to as sea lice. There are three major genera of sea lice: Pseudocaligus, Caligus and Lepeophtheirus . With respect to salmonid production throughout the northern hemisphere, one species, the salmon louse ( Lepeophtheirus salmonis ), is responsible for most disease outbreaks on farmed salmonids. This parasite is responsible for indirect and direct losses in aquaculture in excess of US $100 million annually (Johnson, S. C., et al., Zool Studies 43: 8-19, 2004). All developmental stages of sea lice, which are attached to the host, feed on host mucus, skin and blood. The attachment and feeding activities of sea lice result in lesions that vary in their nature and severity depending upon: the species of sea lice, their abundance, the developmental stages present and the species of the host (Johnson, S. C. et al., “Interactions between sea lice and their hosts”. In: Host - Parasite Interactions . Editors: G. Wiegertjes and G. Flik, Garland Science/Bios Science Publications, 2004, pp. 131-160). In the southern hemisphere, Caligus rogercresseyi , is the primary caligid affecting the salmon farming industry in Chile (González, L. and Carvajal, J. Aquaculture 220: 101-117, 2003).
Caligid copepods have direct life cycles consisting of two free-living planktonic nauplius stages, one free-swimming infectious copepodid stage, four to six attached chalimus stages, one or two preadult stages, and one adult stage (Kabata, Z., Book 1: Crustacea as enemies of fishes. In: Diseases of Fishes ., Editors: Snieszko, S. F. and Axelrod, H. R.; New York, T.F.H. Publications, 1970, p. 171). Each of these developmental stages is separated by a moult. Once the adult stage is reached caligid copepods do not undergo additional moults. In the case of L. salmonis , eggs hatch into the free-swimming first nauplius stage, which is followed by a second nauplius stage, and then the infectious copepodid stage. Once the copepodid locates a suitable host fish it continues its development through four chalimus stages, first and second preadult stages, and then a final adult stage (Schram, T. A. “Supplemental descriptions of the developmental stages of Lepeophtheirus salmonis (Krøyer, 1837) (Copepoda: Caligidae)”. In: Pathogens of Wild and Farmed Fish : Sea Lice. Editors: Boxshall, G. A. and Defaye, D., 1993, pp. 30-50). The moults are characterized by gradual changes as the animal grows and undertakes physical modifications that enable it to live as a free-roaming parasite, feeding and breeding on the surface of the fish.
Caligid copepods (sea lice) feed on the mucus, skin and blood of their hosts leading to lesions that vary in severity based on the developmental stage(s) of the copepods present, the number of copepods present, their site(s) of attachment and the species of host. In situations of severe disease, such as is seen in Atlantic salmon ( Salmo salar ) when infected by high numbers of L. salmonis , extensive areas of skin erosion and hemorrhaging on the head and back, and a distinct area of erosion and sub-epidermal hemorrhage in the perianal region can be seen (Grimnes, A. et al. J Fish Biol 48: 1179-1194, 1996). Sea lice can cause physiological changes in their hosts including the development of a stress response, reduced immune function, osmoregulatory failure and death if untreated (Johnson et al., supra).
There are several management strategies that have been used for reducing the intensity of caligid copepod (sea lice) infestations. These include: fallowing of sites prior to restocking, year class separation and selection of farm sites to avoid areas where there are high densities of wild hosts or other environmental conditions suitable for sea lice establishment (Pike, A. W. et al. Adv Parasitol 44: 233-337, 1999). Although the use of these strategies can in some cases lessen sea lice infection rates, their use individually or in combination has not been effective in eliminating infection.
A variety of chemicals and drugs have been used to control sea lice. These chemicals were designed for the control of terrestrial pests and parasites of plants and domestic animals. They include compounds such as hydrogen peroxide, organophosphates (e.g., dichlorvos and azamethiphos), ivermectin (and related compounds such as emamectin benzoate), insect molting regulators and pyrethrins (MacKinnon, B. M., World Aquaculture 28: 5-10, 1997; Stone J., et al., J Fish Dis 22: 261-270, 1999). Sea lice treatments can be classified into those that are administered by bath (e.g. organophosphates, pyrethrins) and those administered orally (e.g. ivermectin). Bath treatments for sea lice control are difficult, expensive to apply and can have significant effects of fish growth following treatments (MacKinnon, supra). Chemicals used in bath treatments are not necessarily effective against all of the stages of sea lice found on fish. At present the use of oral treatments such as SLICE® (emamectin benzoate) is predominant in the salmonid industry. Unlike chemicals administered as bath treatments SLICE® does provide short-term protection against re-infection. This treatment although easier to apply than bath treatments is still expensive and, like bath treatments, requires a withdrawal period before animals can be slaughtered for human consumption (Stone, supra). As seen in terrestrial pest and parasites there is evidence for the development of resistance in L. salmonis to some of these treatments, especially in frequently-treated populations (Denholm, I., Pest Manag Sci 58: 528-536, 2002). To reduce the costs associated with sea lice treatments and to eliminate environmental risks associated with these treatments new methods of sea lice control such as vaccines are needed.
A characteristic feature of attachment and feeding sites of caligid copepods on many of their hosts is a lack of a host immune response (Johnson et al., supra; Jones, M. W., et al., J Fish Dis 13: 303-310, 1990; Jónsdóttir, H., et al., J Fish Dis 15: 521-527, 1992). This lack of an immune response is similar to that reported for other arthropod parasites such as ticks on terrestrial animals. In those instances suppression of the host immune response is due to the production of immunomodulatory substances by the parasite (Wikel, S. K., et al., “Arthropod modulation of host immune responses”. In The Immunology of Host - Ectoparasitic Arthropod Relationships . Editors: Wikel, S. K., CAB Int., 1996, pp. 107-130). These substances are being investigated for use as vaccine antigens to control these parasites. Sea lice, such as L. salmonis , like other arthropod ectoparasites, produce biologically active substances at the site of attachment and feeding that limits the host immune response. As these substances have potential for use in a vaccine against sea lice we have identified a number of these substances from L. salmonis and have examined their effects of host immune function in vitro.
Potential antigens have been identified using a combination of molecular biological, proteomic, biochemical and immunological techniques. For example, an increase in protease activity has been observed in the mucus of L. salmonis infected Atlantic salmon, compared to non-infected fish (Ross, N. W., et al., Dis Aquat Org 41: 43-51, 2000; Fast, M. D., et al., Dis Aquat Org 52: 57-68, 2002). This increased activity is primarily due to the appearance of a series of low molecular weight (18-24 kDa) proteins, that are produced by L. salmonis and were identified as trypsins based on activity, inhibition studies and size. Trypsin activity was identified in infected salmon mucus using aminobenzamidine affinity adsorption and protease zymography (Firth, K. J., et al., J Parasitol 86: 1199-1205, 2000). Several genes encoding for trypsin have been characterized from L. salmonis and the site of trypsin expression determined (Johnson, S. C., et al., Parasitol Res 88: 789-796, 2002; Kvamme, B. O., et al., Int. J. Parasitol. 34, 823-832, 2004; Kvamme, B. O. et al., Gene 352:63-72, 2005).
Several cDNA libraries have been developed from the copepodid, preadult and adult stages of L. salmonis . An expressed sequence tag (EST) study of the preadult library resulted in the identification of a number of genes encoding trypsin and related proteases (including chymotrypsin and others in the peptidase S1 family), heat shock proteins, cuticle proteins and metabolic enzymes. Some of these genes as described herein have utility as antigens in a sea lice vaccine.
Trypsin-like activity is secreted by L. salmonis onto the salmon skin and is believed to be used by the sea lice to feed on the salmon mucus, skin and blood and to protect the sea lice from the salmon immune response (Firth, et al. supra). Trypsin was discovered in the secretion products (SPs) of sea lice, following stimulation with dopamine, by amino acid sequencing using mass-spectrometry. Table 1 shows the peptide sequences of L. salmonis secreted trypsin. Protection against sea lice trypsin may reduce the feeding of the lice and reduce the suppression of the immune response.
TABLE 1
Summary of L. salmonis secreted trypsin identified from LC/MS/MS
Assoc.
Sea Lice
Fraction
Parent
protein
(pool#-
Ion
Error
Peptide sequence
matches
fraction#)
(m/z)
Mr (Da)
(ppm) a
Score b
(Start-end) c
Sea Lice
1-2
579.80
1157.77
27
46
215 FIDWIAEHQ 223
Trypsin
(SEQ ID NO: 25)
(types 1-
1-1
638.35
1274.69
38
72
71 IAVSDITYHEK 81
4)
(SEQ ID NO: 26)
3-6
920.18
1840.28
13
25
115 DQEFIGDVVVSGWGTI
SSSGPPSPVLK 141
(SEQ ID NO: 27)
SL-0903
1-1
580.28
1158.48
46
27
NQYDEFESK
vitellogenin-
(SEQ ID NO: 28)
like
SL-1469
1-1
724.85
1447.66
17
24
LSFEHETTEEAR
SEP protein 3
(SEQ ID NO: 29)
1-2
879.98
1757.91
29
72
IILGHEFTPGYIENR
(SEQ ID NO: 30)
SL-0547
1-1
604.31
1204.67
19
25
IVILKELSSGM
SEP protein 1
(SEQ ID NO: 31) +
M oxidation d
SL-0858
1-2
1248.71
2495.33
65
35
AGQYGGEISGIVLPNIP
SEP Protein 2
PSISNLAK
(SEQ ID NO: 32)
a Difference (in parts-per-million) between measured mass and mass predicted from the DNA sequence.
b Score from MASCOT ™ search, scores above 21 indicate identity or extensive homology (p < 0.05)
c Cyanogen bromide/tryptic peptide sequence predicted from the DNA sequence.
d +M oxidation means that the MASCOT match was for a peptide containing an oxidized methionine residue.
Vitellogenin-like protein was discovered in the secretion products (SPs) of sea lice following stimulation with dopamine. Vitellogenin has previously been reported as an effective antigen in a tick vaccine (Tellam, R. I., et al., Vet Parasitol 103: 141-156, 2002). Inclusion of vitellogenin in a sea lice vaccine may interfere with the fecundity of sea lice and reduce the number of offspring and hence reduce future numbers of sea lice. In addition, vitellogenin-like proteins have been implicated in the synthesis of melanin in invertebrates (Lee, K. M. et al., Eur J Biochem 267:3695-3703, 2000). Melanin is an important defence molecule of invertebrates.
Mussel adhesion-like genes express proteins similar to those found in the mussel byssus threads that mussels use to attach themselves to solid surfaces. How these genes relate to sea lice infestation is not currently understood, but they may be involved in the production of frontal filaments. The frontal filament is used by chalimus stages to physically attach themselves to the host (Gonzalez-Alanis, P., et al., J Parasitol 87: 561-574, 2001).
BCS-1 genes are expressed by barnacles when they switch from a planktonic form to an attached form (Okazaki, Y., et al., Gene 250 (1-2): 127-135, 2000). There is currently evidence to suggest that these are cuticle-binding proteins. Disruption of these proteins by antibodies may interfere with moulting, integrity of the sea lice cuticle and normal growth of the lice.
Secretory proteins produced by the sea lice may act as immunomodulatory agents or assist in the feeding activities on the host (Fast, M. D., et al., Exp Parasitol. 107:5-13, 2004; Fast, M. D., et al., J Parasitol 89: 7-13, 2003). Neutralization of these activities by host-derived antibodies may impair sea lice growth and survival on salmon.
Vaccines are generally safer than chemical treatments, both to the fish and to the environment. However, no commercial vaccines against sea lice have been developed to date. Vaccine development has been hindered by a lack of knowledge of the host-pathogen interactions between sea lice and their hosts. There appears to be very limited antibody response in naturally infected hosts. Experimental vaccines, particularly through whole-animal extracts, have been produced against L. salmonis . Investigations in the development of sea lice vaccines have targeted immunogenic proteins from sea lice and, in particular, targeting gut antigens. These vaccines, based on whole animal extracts, have not been shown to be protective though their administration did result in minor changes in L. salmonis fecundity (Grayson T. H., et al., J Fish Biol 47: 85-94, 1995). This particular study, however, was a one-time trial and no further results have been reported from this group. Liposome-based fish vaccines in certain species of fin-fish have also been explored (Keough, PCT Application WO 03/101482) but not in combination with sea lice antigens.
A more recent discussion of possible vaccine targets in the gut was put forth by Raynard et al.; however, their studies have been met with limited success (Raynard, R. S., et al., Pest Manag Sci 58: 569-575, 2002).
Promiscuous T-Cell Epitopes
Promiscuous T-cell epitopes (or “PTC epitopes”) are highly immunogenic peptides that can be characterized in part by their capacity to bind several isotypic and allotypic forms of human MHC class II molecules. By helping to bypass MHC restriction, they can induce T-cell and antibody responses in members of a genetically diverse population expressing diverse MHC haplotypes. The PTC epitopes can therefore be combined with antigens that, by themselves, are poorly immunogenic, to generate potent peptide immunogens. In the present invention, these epitopes are incorporated into the composition to enhance the immunogenicity of the antigen, and the composition overall, in a broad range of species.
Promiscuous T-cell epitopes can be derived from naturally occurring immunogens of viral and bacterial origin. Naturally occurring PTC epitopes can also be conservatively modified by single- or multiple-amino acid additions, deletions or substitutions (e.g. within classes of charged, hydrophilic/hydrophobic, steric amino acids) to obtain candidate sequences that can be screened for their ability to enhance immunogenicity.
Non-naturally occurring PTC epitopes can be artificially synthesized to obtain sequences that have comparable or better immunogenicity. Artificial PTC epitopes can range in size from about 15 to about 50 amino acid residues in length and can have structural features such as amphipathic helices, which are alpha-helical structures with hydrophobic amino acid residues dominating one face of the helix and charged or polar residues dominating the surrounding faces. The PTC epitopes may also contain additional primary amino acid patterns, such as a Gly or a charged residue followed by two to three hydrophobic residues, followed in turn by a charged or polar residue (a Rothbard sequence). In addition, PTC epitopes often obey the 1, 4, 5, 8 rule, where a positively charged residue is followed by hydrophobic residues at the fourth, fifth, and eighth positions after the charged residue.
These features may be incorporated into the designs of artificial PTC epitopes. Variable positions and preferred amino acids are available for MHC-binding motifs (Meister et al., Vaccine, 1995; 13:581-591). For example, the degenerate PTC epitope described in WO 95/11998 as SSAL1TH1 has the degenerate sequence (Asp/Glu)-(Leu/Ile/Val/Phe)-Ser-(Asp/Gly)-(Leu/Ile/Val/Phe)-(Lys/Arg)-Gly-(Leu/Ile/Val/Phe)-(Leu/Ile/Val/Phe)-(Leu/Ile/Val/Phe)-His-(Lys/Arg)-Leu/Ile/Val/Phe)-(Asp/Glu)-Gly-(Leu/Ile/Val/Phe)-.
Specific Examples of PTC Epitopes
Particularly useful promiscuous T-cell epitopes are measles virus protein F LSEIKGVIVHRLEGV (SEQ ID NO: 33); or tetanus sequence QYIKANSKFIGITEL (SEQ ID NO: 34).
Examples of particularly useful promiscuous T-cell epitopes are listed in Table 2:
TABLE 2
Examples of Promiscuous T-cell Epitopes
SEQ ID
description
amino acid sequence
NO:
measles 289-302
LSEIKGVIVHRLEGV
33
tetanus toxin 830-844
QYIKANSKFIGITEL
34
Because of a lack of understanding of the mechanisms and pathology surrounding sea lice infestation of salmon, identification of suitable targets to treat the disease has not been successful. This has hampered the progress of vaccine research and as such, despite the promise and success of vaccine-based therapies in other areas of infection, a suitable sea lice vaccine has yet to be developed. Consequently, there is a need to provide effective suitable molecular targets (antigens) and a vaccine against sea lice infection.
SUMMARY OF THE INVENTION
It is an object of the present invention to obviate or mitigate at least one disadvantage of previous treatments against sea lice infection in fish.
In a first aspect, the present invention provides a vaccine against caligid copepod infection in fish, the vaccine comprising an immunologically effective amount of antigen. Particularly, the caligid copepod is Lepeophtheirus salmonis , although any copepod infection may be treated. In one embodiment, the vaccine comprises a nucleotide or peptide fragment of L. salmonis trypsin and a pharmaceutically-acceptable adjuvant, diluent or carrier.
In another aspect of the present invention there are provided DNA and amino acid sequences encoding antigens for use in the preparation of vaccine formulations for the treatment of caligid copepod infection in fish. Embodiments of these sequences include secretory products (SEPs) 1, 2 and 3, vitellogenin-like protein, melanization-related protein, adhesion protein 1 and 2, and cuticle binding protein 1.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIG. 1 shows the a) nucleic acid sequence and b) amino acid sequence of vitellogenin-like protein (SEQ ID NO: 1, 2).
FIG. 2 shows the a) nucleic acid sequence and b) amino acid sequence of SEP protein 1 (SEQ ID NO: 3, 4).
FIG. 3 shows the a) nucleic acid sequence and b) amino acid sequence of SEP protein 2 (SEQ ID NO: 5, 6).
FIG. 4 shows the a) nucleic acid sequence and b) amino acid sequence of SEP protein 3 (SEQ ID NO: 7, 8).
FIG. 5 shows the a) nucleic acid sequence and b) amino acid sequence of adhesion protein 2, homologous to mussel adhesive plaque matrix protein 2 precursor (SEQ ID NO: 9, 10).
FIG. 6 shows the a) nucleic acid sequence and b) amino acid sequence of adhesion protein 1, homologous to mussel adhesive plaque matrix protein precursor (foot protein 1) (SEQ ID NO: 11, 12)
FIG. 7 shows the a) nucleic acid sequence and b) amino acid sequence of cuticle binding protein 1, homologous to BSC-1 like protein (moran 9-15) (SEQ ID NO: 13, 14).
FIG. 8 is a graph of lice per cm of fish over duration of time post-infection, using vaccines (A/B=expressed sea lice trypsin gene with T-cell epitope; Y/Z=expressed sea lice trypsin gene; C=control) of the present invention.
FIG. 9 is a graph of lice per gram of fish over duration of time post-infection, using vaccines (A/B=expressed sea lice trypsin gene with T-cell epitope; Y/Z=expressed sea lice trypsin gene; C=control) of the present invention.
FIG. 10 shows a stacked data graph showing the percentages of different stages of sea lice present in fish immunized with L. salmonis trypsin vaccine as compared to control fish at each sampling time.
FIG. 11 shows a partial nucleic acid sequence (SEQ ID NO: 15) of vitellogenin-like protein SL-903 similar to but longer than the one in FIG. 1 . Bolded, underlined and italicized TGA, TAA or TAG are predicted stop codons.
FIG. 12 shows the full-length nucleic acid sequence of SEP protein 1 SL-0547 (SEQ ID NO: 16). Bolded and underlined ATG are presumed starting codons. Bolded, underlined and italicized TGA, TAA or TAG are predicted stop codons.
FIG. 13 shows the putative full-length nucleic acid sequence of SEP protein 2 SL-0858 (SEQ ID NO: 17). Bolded and underlined ATG are presumed starting codons for protein. Bolded, underlined and italicized TGA, TAA or TAG are predicted stop codons.
FIG. 14 shows the putative full-length sequence of SEP protein 3 SL-1469 (SEQ ID NO: 18). Bolded and underlined ATG are presumed starting codons for protein. Bolded, underlined and italicized TGA, TAA or TAG are predicted stop codons.
FIG. 15 shows the putative full-length sequence of mussel adhesive protein SL-0927 (SEQ ID NO: 19). Bolded and underlined ATG are presumed starting codons for protein. Bolded, underlined and italicized TGA, TAA or TAG are predicted stop codons.
FIG. 16 shows a partial amino acid sequence of vitellogenin-like protein SL-903 (SEQ ID NO: 20), together with BLAST™ hits of the sequence. Underlined amino acids are the peptide fragments from Proteomics Mass Spectrometry data.
FIG. 17 shows the putative full-length amino acid sequence of SEP protein 1 SL-0547 (SEQ ID NO: 21), together with BLAST hits of the sequence. Underlined amino acids are the peptide fragments from Proteomics Mass Spectrometry data.
FIG. 18 shows the putative full-length amino acid sequence of SEP protein 2 SL-0858 (SEQ ID NO: 22), together with BLAST hits of the sequence. Underlined amino acids are the peptide fragments from Proteomics Mass Spectrometry data.
FIG. 19 shows the putative full-length amino acid sequence of SEP protein 3 SL-1469 (SEQ ID NO: 23), together with BLAST hits of the sequence. Underlined amino acids are the peptide fragments from Proteomics Mass Spectrometry data.
FIG. 20 shows the putative full-length amino acid sequence of mussel adhesive protein SL-0927 (SEQ ID NO: 24), together with BLAST hits of the sequence. Underlined amino acids are the peptide fragments from Proteomics Mass Spectrometry data.
FIG. 21 shows mean (±SEM) expression of interleukin-1β, gene, relative to β-actin, in SHK-1 cells incubated with and without lipopolysaccharide (LPS), pooled L. salmonis secretory/excretory product fraction 1, pooled L. salmonis secretory/excretory product fraction 2, and pooled L. salmonis secretory/excretory product fraction 3. * indicates significant differences from control; † indicates significant differences from LPS+control.
FIG. 22 shows mean (±SEM) expression of interleukin-1β gene, relative to β-actin, in SHK-1 cells incubated with and without lipopolysaccharide (LPS), LPS and lyophilized liquid chromatography solvent (LC), L. salmonis secretory/excretory product fraction 1, L. salmonis secretory/excretory product fraction 2, and L. salmonis unfractionated secretory/excretory products. * indicates significant differences from control; † indicates significant differences from LPS+control.
DETAILED DESCRIPTION
Generally, the present invention provides a vaccine for treating sea lice infection in fish, particularly infection from L. salmonis . It also relates to the DNA and amino acid sequence of molecular targets for use in the preparation of these vaccines.
The vaccines of the present invention were generated based on studies performed by our group and others on gene expression in sea lice. Several genes in sea lice that have the potential as producers of antigens in vaccine formulations designed to protect salmon against sea lice, especially L. salmonis . The genes include: 1) a gene for sea lice trypsin; 2) a gene having high similarity to a vitellogenin-like protein that is found in secretory products; 3) a gene having high sequence similarity to the mussel adhesion protein-1 gene; 4) a gene having high sequence similarity to the mussel adhesion protein-2 gene; 5) a number of genes having high sequence similarity to the gene coding for Balanus amphrite stage specific protein BCS-1; and, 6) genes coding for three secretory products (SP) proteins in sea lice that, at present, have no significant similarity with known proteins in public databases.
As used herein, an “antigen” refers to a molecule containing one or more epitopes that will stimulate a host's immune system to make a humoral and/or cellular antigen-specific response. The term is also used herein interchangeably with “immunogen.”
As used herein, the term “epitope” refers to the site on an antigen or hapten to which a specific antibody molecule binds. The term is also used herein interchangeably with “antigenic determinant” or “antigenicdeterminant site.”
FIGS. 1 through 6 show the sequences of the genes of the present invention described above and sequenced in our laboratory, with the exception of trypsin, of which the nucleic acid sequence has been published (Johnson, 2002, supra). We have identified trypsin gene product in the sea lice secretions by amino acid sequencing using mass spectrometry. These genes were selected and investigated based on a prior understanding of their putative function.
FIGS. 11 through 20 show longer or putative full-length nucleotide and amino acid sequences of the genes and proteins as described herein.
Antigens derived from L. salmonis should provide protection for fish against other sea lice species as they are likely to use highly conserved methods to attach themselves to enable them to successfully feed on the host.
Adjuvants which can be used in the context of the present invention include Montanide™ ISA and IMS Adjuvants (Seppic, Paris, France), other oil-in-water, water-in-oil, and water-in-oil-in-water adjuvants, Ribi's Adjuvants (Ribi ImmunoChem Research, Inc., Hamilton, Mont.), Hunter's TiterMax (CytRx Corp., Norcross, Ga.), aluminum salt adjuvants, nitrocellulose-adsorbed proteins, encapsulated antigens, nanoparticle containing adjuvants. Preferred adjuvants include Seppic Montanide 720, Montanide IMS111x, Montanide IMS131x, Montanide IMS221x, Montanide IMS301x, Montanide ISA206, Montanide ISA 207, Montanide ISA25, Montanide ISA27, Montanide ISA28, Montanide ISA35, Montanide ISA50A, Montanide ISA563, Montanide ISA70, Montanide ISA51, Montanide ISA720, Montanide ISA264. Particularly preferred adjuvants include, Montanide ISA740, Montanide ISA773, Montanide ISA 708, Montanide ISA266. The recommended adjuvant is Montanide ISA763.
Data from studies using the vaccines of the present invention for the treatment of sea lice infection are provided herein by way of the following examples.
Example 1
Salmon were challenged with L. salmonis trypsin as the antigen. The fish were immunized with two formulation groups of trypsin vaccine: A/B (recombinant sea lice trypsin with a T-cell epitope) and Y/Z (recombinant sea lice trypsin only). Certain fish were administered with a control vaccine, C, containing adjuvant only. Protection of the fish is apparent at days 6, 11 and 20 ( FIGS. 8 and 9 ). The number of sea lice per cm and per gram of fish is reduced in the vaccinated fish as compared to controls. The A/B vaccine formulation resulted in lower lice numbers than the Y/Z formulation showing that the inclusion of T-cell epitopes with sea lice antigens provide further protection against sea lice.
FIG. 10 shows stacked data results of the challenge and vaccination experiments. The A/B (recombinant sea lice trypsin with a T-cell epitope) vaccine formulation appeared to slow the development of L. salmonis , as at days 6, 11 and 20, there were lower percentages of lice that had moulted to a more advanced stage compared to control fish
Example 2
Size Exclusion Chromatography and Protein Determination
Lyophilized secretory excretory products (SEPs) were reconstituted with 1.0 M ammonium acetate (AMA) (pH 6.0). An Agilent 1100 HPLC equipped with a diode array detector (monitoring at 230 and 256 nm) and a Taso Haas (G3000PWX2, 6 μm d p (7.8 mm×300 mm)) column were used to separate proteins/peptides in the secretions. These samples were then fractionated using a Waters Fraction collector according to time intervals. The fractions as shown in Table 1 were collected for 6 separate HPLC runs and pooled for each time interval. These samples were then freeze dried (−80° C.) prior to protein determination. The column was kept at room temperature and eluted isocratically with 98:2 AMA: acetonitrile (ACN) for 30 minutes at 0.2 ml min −1 . Standard solutions of bovine serum albumin (BSA) (20 μg, 2.0 μg, and 0.2 μg), SW+DA, and bovine trypsin (40 μg) were all run as controls for peak comparison with SEPs.
Protein concentrations of L. salmonis secretory fractions were determined using a dye binding method (Bradford, M. M. Anal Biochem 72: 248-254, 1976). All assays were run on a Thermomax™ Microplate Reader (Molecular Devices). Samples were reconstituted in ddH 2 O and then, following protein determination, were split equally between cell-based functional assays and proteomic analysis.
SHK Cell Culture
SHK-1 cells were cultured at 18° C. in 75 cm 2 tissue-culture-treated flasks (Costar), in L-15 medium (with 300 mg/L L-glutamine) supplemented with 500 μl gentamicin sulphate (50 mg/mL distilled in water), 365 μl 2-mercaptoethanol (55 mM in D-PBS) and 5% fetal bovine serum (FBS), as described by Fast et al. 2004 supra. All media components were purchased from Gibco. Confluent flasks were passaged weekly by dividing cells and medium evenly between two flasks and adding an equal volume of new media to each flask. Cells used in this study were passaged between 64 and 68 times.
SHK-1 cells were seeded at approximately 4×10 6 cells/flask in L-15 medium supplemented as described above. Cell stimulation followed the same procedure as in Fast, M. D. et al. Dev. Comp. Immunol. 29: 951-963, 2005. Briefly, following a 48 h period, to allow any manipulation-induced gene expression to return to constitutive levels, media was removed and 20 ml fresh media was added. Lipopolysaccharide (LPS) was added to all flasks, except the controls, to obtain a final concentration of 5 μg/mL.
In the first trial, SEP fractions were pooled into 3 groups (Table 1), each containing equal time ranges (10 min) and volumes from the size exclusion chromatography. This resulted in 13 μg protein (pooled fraction 1), 8.0 μg protein (pooled fraction 2) and <0.1 μg protein (pooled fraction 3) being added to each flask. These incubations were carried out for 4 h at 18° C. before media was removed and cells stored in RNA later at −80° C. until RNA extraction. This trial was repeated twice with triplicate flasks for each condition.
In the second trial, SEP fractions 1 and 2 from pooled fraction 1 (Table 1) were added at 1.0 and 1.4 μg per flask, respectively. These concentrations were attained after concentrating 4 size exclusion runs for each fraction. To test any affect of residual solvent on the cell-based assay, 4 blank runs of AMA underwent the same treatment and were included in the experiment as controls. Finally, the non-fractionated SEPs used in the macrophage incubations were incubated here at the same concentration (660 ηg). These incubations were carried out in triplicate and followed the same procedure as the first trial.
Real-Time PCR on Atlantic Salmon Genes
Total RNA was isolated from SHK-1 cells stored in RNAlater™ with the Nucleospin™ RNA II kit (Clontech) and concentration measured by spectrophotometer. RNA samples underwent PCR to verify the lack of DNA contamination. Sequences for Real-time PCR primers were designed, tested and products sequenced as previously described by Fast et al., supra (2004; 2005). Real-time quantitative PCR was performed using an iCycler iQ™ Real-Time detection system and SYBR green kits (Bio-Rad) also previously described by Fast et al., supra (2004; 2005). To ensure no genomic DNA contamination added to the quantified cDNA, non-RT controls for each RNA isolation were run under PCR and observed by 2.5% agarose gel electrophoresis.
The PCR profile was as follows: an initial 3 min denaturation step at 95° C., followed by 40 cycles of denaturation (30 s at 95° C.), annealing (30 s at 58° C.) and extension (30 s at 72° C.), and finishing with a final extension step of 72° C. for 5 min. The sensitivity of reactions and amplification of contaminant products such as primer dimers, indiscriminately detected by SYBR green (ie. SYBR green binds to all double stranded DNA), were evaluated by amplifying 10 fold dilutions of the clones (10 −2 to 10 −8 ng) and duplicate samples as well as by performing a blank without cDNA with each run. The relationship between the threshold cycle (Ct) and the log (RNA) was linear (−3.5<slope<−3.2) for all reactions. Copy numbers were estimated based on the molecular weight of clones and OD 260.
Immunomodulatory Activity of SEP Proteins
The SEPs were fractionated based on size and fractions were collected. In the first trial ( FIG. 21 ), pooled fractions (PF1, PF2, PF3) were incubated with SHK-1 cells (a salmon macrophage-like cell line) in combination with lipopolysaccharide (LPS) and the expression of the interleukin-1β gene was monitored in order to determine the immunomodulatory effect of the fractionated SEP proteins on immune gene expression. Interleukin-1β gene was reduced in expression by all three pooled fractions in comparison to cells stimulated with LPS alone ( FIG. 21 ). When individual fractions containing proteins were tested, interleukin-1β gene expression was reduced by fraction 2. LC-MS analysis showed that Fraction 2 of pool 1 contained the SEP protein 1, SEP Protein 2 and trypsin. Evidence for immunomodulatory activity of SEP, which contains all described proteins, is presented in FIG. 22 where there is a significant decrease in LPS-induced expression of interleukin-1β in the presence of total SEPs.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto. | Molecular targets and vaccines against them in the treatment of sea lice infection of fish are provided, particularly caligid copepods. Vaccines targeted to L. salmonis trypsin are shown to reduce the quantity of sea lice present in challenged salmon from day 14 p.i. onward. Additional and novel molecular targets for vaccines are also provided. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to freeze protection devices and more particularly to a valve assembly which is automatically responsive to ambient temperatures at the freezing point of water, whereby damage to aqueous systems caused by freezing of water in pipes can be automatically prevented without reliance upon external sources of power.
2. Review of the Prior Art
Power failures during blizzards in northerly climates can cause severe freezing damage to pipes and water damage to the interiors of unoccupied homes during a subsequent thaw. Such freezing can occur in both water supply systems and hot water and steam heating systems. In addition, freezing of water in pipes, causing rupture of the pipes and subsequent damage to buildings by melted water, is a common difficulty in areas of the world where severe freezing is sufficiently infrequent that plumbing design does not include complete thermal protection. Such freezing is by no means limited to exposed faucets and can occur in any unprotected water pipe when ambient temperatures drop to 32° F. and below. Manually opening an exposed valve, to allow steady dripping from a water supply system at the onset of potentially freezing weather, is commonly done to prevent such damage. However, it is necessary that a householder be aware of an oncoming freezing period and remember to open and close the valve. Moreover, if the householder is away from home when the freezing occurs, or if the home is a vacation home in an area where freezing is normally unexpected, such manual opening for freeze protection may be unavailable.
Many freeze protection devices have been developed, but they generally require an external power source, use complicated springs or bellows devices, or rely upon o-rings or other sealing means which are susceptible to undisclosed failure.
U.S. Pat. No. 3,369,556 of Allderdice describes a freeze protection valve for water supply systems. The valve has a single bellows filled with water which expands when it freezes to move a valve element off its seat against the water pressure within a water line. This valve must be mounted vertically so that bypass water passes upwardly through the device to be discharged. This freeze device requires a loss motion adjustment for its bellows system to permit free expansion and contraction of the water contained therein.
U.S. Pat. No. 3,380,464 of Arterbury, et al describes a temperature-responsive valve adapted to be installed in a water line to protect it against freezing by opening a bleed actuator which comprises an elongated housing surrounding an annular expansion chamber and an axially disposed valve member which is hollowed to allow bypass water to flow through and be discharged from the valve member while heating the inner wall of the expansion chamber. To enhance such heat transfer, a portion of the valve member extends into the water line. After the valve has been opened to bleed water from the water line, it thereafter closes because of such heat transfer and is again in position to operate responsively to freezing ambient temperatures. The valve thereby utilizes the concept of heat balance between heat supplied by the flowing water and heat lost to the atmosphere.
U.S. Pat. No. 3,618,625 of Walters is directed to preventing freezing of water within a watering tank for animals which is connected to a pressurized source of warmer water. The tank has an inflow inlet conduit and a valve device which regulates outflow. This valve device comprises a sensing bulb connected to one end of a tubular conduit which is connected at its other end to a bellows and an outflow tube having a valve heat surface. When freezing temperatures are sensed by the bulb, there is an outflow of water from the valve device and an inflow of water from the inlet conduit, thereby preventing freezing of water within the tank.
U.S. Pat. No. 4,638,828 of Barrineau, Sr., et al. discloses an automatically operated valve to prevent freezing of water lines. The water faucet has female threads to accommodate a drip valve which is threaded into a standard "tee" type plumbing fitting. The drip valve includes an elongated housing having a temperature monitoring device within its upper end and a moveable tip at its lower end. When water temperature falls to freezing levels, a wax-like substance in the upper portion of the device contracts, causing the tip to reflex and allow water to flow through an opening at the bottom of the device.
The TL ambient sensing control valve for steam tracing systems and the Type F and Type AF valves for water systems, both sold by the Ogontz Controls Co., 141 Terwood Road, P.O. Box 479, Willow Grove, Pa. 19090, utilize an operating spring and an overtemperature spring. An externally disposed thermal actuator, filled with a solid-liquid phase wax, is on one end of the valve yoke which is connected to these springs and has a silicone plug on its other end for engaging the valve seat. These devices can be set for operation at a selected temperature.
None of the prior art devices can be considered safe from mechanical failure before onset of freezing weather. Devices requiring adjustment to set the temperature of actuation are subject to wrong settings or to change of settings caused by movement in the mechanism. Other devices containing an actuation chamber filled with water or another expansible substance can be subject to undetected leakage through o-rings, seals, or threads, and consequently will fail to open during sub-freezing conditions. If such failure occurs, the condition will not be visible in these devices until after the freeze has been followed by a thaw.
Still other devices depend upon an outside source of power for actuation. If there is a power failure, the device will fail to operate, and freeze damage will occur.
Moreover, industrial factories and chemical plants in many parts of the world have numerous pipelines and equipment containing water that are protected from freezing by heating with steam. The steam is used to heat the water by direct injection of steam into the water or by indirect heating of the water by using coils containing steam in direct contact with water, such as a coil of tubing or a plate coil submerged in a water tank, or by using coils containing steam in contact with the wall of the system containing the water. Examples of such indirect contact are: tubing (usually copper) containing steam strapped to a water pipeline, tubing containing steam wrapped around a tank, and a steam-plate coil containing steam strapped to a tank containing water.
In most instances, the system containing the steam and the system containing water are both wrapped with insulation. Systems containing water may include water lines, return steam lines, and aqueous solution lines. Such lines may be hundreds of feet long, and rupture thereof during freezing weather, as can occur during a power failure, can cause shutdown of an entire plant.
Thus, there is a need for a completely failure-safe freeze prevention valve that is useful under industrial conditions, automatically responsive to freezing temperatures and to thawing temperatures, completely reliable as a standby device, entirely independent of outside power sources, incapable of leaking, and operable without periodic maintenance.
Furthermore, in those parts of the country in which pipelines and equipment are subjected to sub-freezing conditions, the steam used for protecting water systems in most industrial plants is turned on manually in the fall of the year, before a freeze occurs, and is turned off manually in the spring, after the last freeze. This practice is particularly prevalent for water lines that are steam traced and insulated. It results in a loss of steam energy while the steam system is on during ambient temperatures that are above freezing.
There is, accordingly, a need for a failure-safe freeze prevention valve for industrial plants that is automatically operable during freezing weather and is automatically inoperable under other weather conditions without manual or electrical operation thereof.
SUMMARY OF THE INVENTION
It is accordingly an object of this invention to provide a device which furnishes completely dependable protection against freezing and consequent damage to water systems and the interiors of homes and other buildings.
It is another object to provide a water freeze prevention device which is automatically responsive to ambient temperatures that are at and near the freezing temperature of water.
It is still another object to provide a water freeze prevention device that is sensitive both to the ambient temperature and to the temperature of the water system in order to minimize the amount of water that must be wasted to prevent freezing of the water system.
It is an additional object to provide a water freeze prevention device that does not require venting of air during operation thereof.
It is a further object to provide a water freeze prevention device that derives its motive force entirely from the freezing of water within the device.
It is a still further object to provide a water freeze prevention device that is not subject to failure because of failure of o-rings, seals, or threaded connections.
It is still another object to provide a steam-actuating freeze prevention valve that is automatically operable during freezing weather and inoperable during above-freezing weather.
In accordance with these objects and the principles of this invention, it has surprisingly been discovered that the freezing of water can be utilized as the sole source of power for opening a relief valve which is connected to a water or steam system, such as a water supply system, a closed water tank, or steam tracer lines, thereby respectively bleeding or draining water therefrom or admitting steam to the tracer lines and thereby preventing damage to the system and subsequent water damage during a thaw. It has also been discovered that the freezing of water can be utilized to provide an internal sealing means that requires no additional sealing device, such as an o-ring. It has additionally been found that the freezing of water can be utilized to bleed water lines and to operate steam tracer lines for protection of aqueous systems during freezing weather but not during thaws.
This invention utilizes the volumetric expansion of water while it freezes in a water-filled actuation chamber that is elongated and operably connected to a linkage means for transmitting expansion of the freezing water to a valve poppet controlling a discharge port which is connected to (a) a water system, which is herein defined as a water or aqueous solution supply system of pipes, valves, and the like, a water or aqueous solution storage system of one or more tanks, or a water heating system comprising a water heating device, circulating pumps, pipes, valves, and the like, and/or (b) a steam system for tracer lines protecting industrial pipelines and the like.
The invention more specifically comprises an actuator for a temperature-responsive valve, having a valve poppet and a valve seat, which is connected to a water or steam system that is exposed to a freezing ambient environment, comprising:
A. a housing which encloses an elongated chamber having a closed end, an open end, and a central axis, this chamber being filled with water and in flow communication with the water or steam;
B. at least one segment of an expansion sensing means which is disposed within the chamber; and
C. a linkage means for axially transmitting movement of the segment to the valve poppet when freezing of the water within the chamber initially forms a seal between the housing and the segment and then causes the distance between the segment and the closed end to increase.
These segments are preferably balls which fit closely and are freely movable within the chamber which is preferably cylindrical in cross section. The segments may also be shaped as truncated double cones and be aligned within the chamber so that ends of the cones are in abutting relationship and substantially coincide with the central axis of the chamber. As another embodiment, each segment may comprise a disk and an axially aligned rod.
Broadly defined, the sensing means comprises at least one segment, and preferably two or more, such as four to eight segments, each comprising a transverse portion having a periphery which is approximately adjacent to the inner surface of the wall of the chamber and a longitudinal portion which spaces the segments apart and provides expansion space beneath the periphery. Most preferably, the chamber is cylindrical, and the segments are balls which fit closely but moveably within the chamber.
Both the segments and the chamber are preferably formed from the same material in order to minimize corrosion. Suitable materials include non-corrosive alloys, such as copper alloys and stainless steels, preferably the 300 series of stainless steel. Copper alloys include bronze, brass, and industrial copper.
The linkage means comprises an actuation rod which is axially aligned with the housing and in firm contact at one end with the surface of the uppermost segment and in contact with a valve poppet at the other end. Expansion of the water to form ice within the chamber causes axial movement of the rod, without destroying the ice seal between the periphery and the wall. This rod movement separates the valve poppet from the valve seat and allows a selected amount of water to be discharged from the water system or a selected amount of steam to enter the steam heating system.
The actuator may be disposed in any position from vertical to approximately 45° from vertical, provided that air escaping from the water within the chamber is always able to leave the chamber at its upper end. Such positioning is referred to herein as being substantially vertical.
The invention may further be described as a device for: (a) bleeding water from water and steam systems, and/or (b) admitting steam to steam heating coils, steam tracing lines, and the like when ambient air temperatures are approximately at freezing temperatures, comprising:
A. a temperature-responsive actuator, comprising:
(1) a housing which encloses an actuation chamber containing control water and having an open end,
(2) a means for sensing expansion of at least a portion of the control water toward the open end at the freezing temperatures, and
(3) an actuation rod which is disposed within the chamber and is operably in contact with the expansion sensing means;
B. a relief valve which comprises a valve body having:
(1) an inlet end which is sealably connected to the system,
(2) an outlet end,
(b 3) a control opening at which the housing is sealably connected at its open end, whereby the chamber is in flow communication with the inlet end,
(4) a valve seat,
(5) a valve port which is interposed between the inlet and outlet ends for conducting water and/or steam therebetween and which passes through the valve seat, and
(6) a valve poppet for opening and closing the port when the control water freezes within the chamber and the linkage rod transmits the expansion from the expansion sensing means to the valve poppet, the valve poppet being in contact with the actuation rod, operably disposed within the valve, and adapted for fitting against the valve seat when the water is at temperatures above freezing temperatures; and
C. a biasing means for pressing the poppet against the valve seat.
The expansion sensing means preferably comprises a plurality of segments which incrementally form a plurality of ice seals and sense the expansion of the water at the freezing temperatures. Heat from the valve selectively moves toward the closed end of the actuator through the wall of the housing, the actuation rod, the segments, and the water within the chamber while heat is moving outwardly through the wall and the bottom end of the housing. Freezing conditions are consequently maintained within the chamber up to a heat balance zone where heat inflow balances heat outflow. If this zone is below the periphery of the lowest segment, the actuator will not operate because an ice seal cannot form. If always above the lowest segment, the actuator will operate with only one segment. However, a plurality of segments provides flexibility for the actuator, i.e., a variable quantity of water may be selectively bled from the valve in accordance with the height of this zone above the bottom of the chamber. The valve body additionally comprises:
A. a valve cap, having a bore which is in alignment with the actuation rod;
B. a stem, which is attached to the poppet and is guided within the bore as the poppet opens and closes the port; and
C. as the biasing means, a spring which is compressed between the cap and the poppet to maintain the poppet seated against the valve seat when ambient temperatures are above freezing temperatures.
The actuator also comprises a shaft cap screw which provides a means for bleeding air from the chamber after initial installation. The selectively extended shaft of the cap screw also provides an additional reservoir of water at the closed end of the chamber, beneath the bottom segment. A wear compensation spring may be disposed around this extended shaft in order to compensate for slight wear of the segments. Its force is always less than the force of the biasing means for pressing the poppet against the valve seat.
The segments of the expansion sensing means also function as an incremental sealing means because formation of ice initially occurs at the bottom of the chamber and along the interior surface of the housing (i.e., the wall of the chamber) and then between the wall and the periphery of each segment before freezing of water and resultant expansion occurs within the interior of the chamber, progressively moving between the segments from the closed end of the chamber toward the valve.
The flow rate of a fluid at a stated pressure can be selectively varied by changing the size of the opening created by lifting the valve poppet from the valve seat. This opening can be selectively altered by changing the length of the actuator or by changing its diameter, for the amount of axially disposed ice that is available for creating linear expansion is a function of the number of inter-segment spaces. The more balls, for example, that are within the chamber, the more spaces are available, and the greater the expansion that can be sensed.
Although the housing can be thermally isolated from the relief valve and the water contained therein, it is preferred that a thermally conductive path be provided so that heat transfer by conduction is available from the relief valve and into the chamber. Such heat conduction occurs: (a) along the wall of the chamber toward its bottom, and (b) through the actuation rod into the topmost segment and thence to the underlying water and/or ice and to the lower segments. However, when the ambient temperature is below freezing, this heat is removed laterally and rapidly from the housing to the surrounding air. Where the incoming and outgoing heat transfers are equal, a heat balance zone is established. Its distance from the bottom of the chamber directly controls the amount of expansion that occurs and the quantity of water that is bled from the system.
The method of this invention, for incrementally and cumulatively sensing the expansion of a liquid while freezing, comprises:
A. providing an actuator having an elongated housing which is disposed substantially vertically and has a wall, an open end, and a closed end to define an elongated actuation chamber which is filled with the liquid;
B. providing a plurality of segments of a sensing means which is disposed within the chamber, each segment having an uninterrupted peripheral portion extending substantially to the wall and an axial portion extending toward the closed end, these segments being biased toward the closed end;
C. providing a linkage means that is in contact with the topmost segment and is aligned substantially axially with the housing;
D. exposing the actuator to freezing temperatures;
E. forming an ice seal between each peripheral portion and the wall when freezing of the liquid initially occurs near the closed end and along the wall; and
F. moving each segment sequentially upwardly without destroying the seal when freezing of the liquid occurs above the closed end and beneath each segment, whereby the linkage means is pushed upwardly.
In addition, the incrementally and cumulatively sensed expansion is transmitted by the linkage means to the poppet of a valve controlling flow of a fluid that is to be protected from freezing or that is to be used to protect another liquid from freezing. The fluid may be the liquid in the chamber or may condense to form this liquid.
The freeze prevention device of this invention comprises a fluid control valve and an actuator, the valve comprising a poppet and a valve seat which is adapted to be closed by the poppet and which controls a valve port between a valve inlet and a valve outlet and the actuator comprising a housing which is disposed substantially vertically, is open at its upper end where it is connected to the valve, is closed at its lower end, and forms an actuation chamber which contains a liquid and is in fluid communication with the port. The method of operating this device comprises:
A. providing a means for sensing the expansion of the liquid while it freezes; and
B. providing a means for transmitting the sensed expansion to the poppet, whereby the poppet is lifted from the valve seat and the fluid flows through the valve port.
Both the fluid and the liquid may be water or the fluid may be steam. The liquid may also be any other liquid which expands when changing from its liquid state to its solid state.
Valves made by the Lunkenheimer Co., P.O. Box 145487,Cincinnati, Ohio 45214 and by the S.C. Kingston Co., 1007 N. Main St., Los Angeles, Calif. 90012, are suitable for both water and steam control in the devices of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevation of an experimental device of this invention, assembled from brass pipe and fittings.
FIG. 2 is a diagrammatic sketch showing an experimental test arrangement.
FIG. 3 is a schematic sectional elevation of an actuator, having no segments therein, in which the water is partially frozen.
FIG. 4 is a schematic sectional elevation of the same actuator in which the water is entirely frozen.
FIG. 5 is a schematic sectional elevation of the actuator shown in FIGS. 3 and 4 which is filled with water and many small balls.
FIG. 6 is a schematic sectional elevation of the same actuator containing water and a circular, tapered pin.
FIG. 7 is a schematic sectional elevation of the same actuator containing water, a floating tapered chamber, and the tapered pin of FIG. 6.
FIG. 8 is a schematic sectional elevation of the same actuator containing a centrally disposed rod and a plurality of spacers and washers as segments of the sensing means.
FIG. 9 is a partial schematic sectional elevation of the same actuator containing a plurality of plastic washers and steel sections as alternative segments.
FIG. 10 is a schematic sectional elevation of the freeze prevention device of this invention, containing water and a plurality of axially aligned balls as such segments, in closed position.
FIG. 11 is a schematic sectional elevation of the device as in FIG. 10 in which the water has begun to freeze.
FIG. 12 is a schematic sectional elevation, like FIGS. 10 and 11, in which the water has partially frozen and the relief valve has partially opened.
FIG. 13 is a schematic sectional elevation of the device of FIGS. 10-12 in which the water has completely frozen and the valve has completely opened.
FIG. 14 is a sectional elevation of the valve of FIGS. 10-13 in which the valve has begun to close at the onset of a thaw.
FIG. 15 is a sectional elevation of the valve of FIGS. 10-14 in which the valve has not yet closed but which shows more complete melting of ice within the actuator chamber with the exception of a small amount of ice between the lower three balls.
FIG. 16 is a sectional elevation of a commercially useful embodiment of the invention for a water system, containing a plurality of balls therein as preferred segments, in which the angled valve is in open position.
FIG. 17 is a sectional elevation of another commercially useful embodiment of the invention for a water system, also containing balls, in which the straight-through valve is in closed position.
FIG. 18 is a sectional elevation of an experimental freeze prevention device in which the valve controls the flow of steam.
FIG. 19 is a sectional elevation of the extended actuation rod between the actuator and the valve of FIG. 18.
FIG. 20 is a diagrammatic sketch showing an experimental test arrangement for the devices of FIGS. 18 and 19.
FIG. 21 is a schematic sectional elevation of a portion of an actuation chamber having three balls therein.
FIG. 22 is a schematic sectional elevation of the same chamber portion and balls as FIG. 21 in which the balls are separated by ice formed therebetween.
FIG. 23 is a schematic sectional elevation of the bottom of the actuation chamber of FIGS. 21 and 22, showing the bottom ball and a cap screw providing linear adjustment.
FIG. 24 is a schematic sectional elevation of a portion of an experimental actuator, as shown in FIG. 1, having a single piston-shaped (T-shaped in profile) segment.
FIG. 25 is a schematic sectional elevation of the actuator portion of FIG. 24 which contains two piston-shaped segments, each having half the length of the segment of FIG. 24.
FIG. 26 shows, as schematic representations of an actuator in sectional elevation, eight usable shapes of solid segments that provide incremental sensing of the expansion of water into ice within the actuation chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Experimental models of the water freeze prevention device of this invention were made of brass and tested under actual or simulated freeze conditions which are described hereinafter in the examples. Operational principles, as presently understood, are discussed thereafter.
The experimental prototype that is shown in FIG. 1 was made mostly of brass in order to avoid corrosion problems. It comprises an actuator 40 and a relief valve 50.
Actuator 40 comprises a housing formed from a 3/8-inch schedule 40 brass pipe nipple 41 which had been reamed on its inside to 0.505 inch, a 3/8-inch brass cap 42 which had been drilled and tapped to 1/4-inch UNC, a 1/4-inch plated steel bleed cap screw 44, a plurality of 1/2-inch diameter brass balls 45 as segments of its sensing means, and an adjustable actuation rod made of plated steel, consisting of a 1/4-inch cap screw 46, two 1/4-inch nuts 47, a 1/4-inch long nut 48, and a 1/4-inch threaded rod 49.
Valve 50 is a 1/2-inch adjustable in-line relief valve, model B-8CPA2-150 of the Nupro Company, 4800 E. 345th St., Willoughby, Ohio 44094. This valve comprises a 1/2-inch housing 51, which has NPT threads at both ends, a poppet 52, a compression spring 53, internal bushings 54, and a valve seat 56.
The valve had a soft seat with a metal stop, but only a metal-to-metal stop is needed for this invention. However, even if a soft seat is used and it eventually leaks, it will not affect the openability of the device.
Actuator 40 is threadably attached to a 1/2-inch x 3/8-inch brass bushing 61 which is in turn threaded into a 1/2-inch brass tee 62. Valve 50 is threadably attached to the other end of this tee, and a 1/2-inch brass ell 63 is threadably attached to the other end of valve 50.
Because nipple 41 was readily changed, this device was found to be very convenient for experimental work with a variety of segments replacing balls 45 as the means for sealing the actuation chamber and for sensing the linear expansion of water therewithin during its phase change into ice.
Experimental usage of the device shown in FIG. 1 is illustrated in FIG. 2 in which a 3/4-inch hose, having a length of 15 feet, was attached to an outdoor faucet 66 protruding from a building 65. The freeze prevention device of the invention, comprising a relief valve 68 and an actuation chamber 70, was attached at its inlet end to the discharge end of hose 67, and a 3/4-inch drain hose 69 was attached to its outlet end. With faucet 66 open, the bleed screw at the bottom of actuation chamber 70 was opened until all air was purged from the system.
Tests were then run by exposing the valve to ambient sub-freezing conditions for a period of up to about 20 minutes, depending upon the ambient temperature, when the water would freeze in the actuation chamber and the valve would open to permit water to run to waste through hose 69. To simulate warming up of the ambient air, the experimenter would clasp actuation chamber 70 in one hand and observe the discharge of water from hose 69. Generally within 5-10 minutes, valve 68 closed. This operation was repeated several times to verify that valve 68 opened an closed.
Other tests were run indoors by immersing actuation chamber 70, detached from relief valve 68, in a mixture of ice and brine and observing discharge of water, shortly after immersion, indicating upward movement of the actuation linkage, and cessation of discharge after removal from the cold brine, indicating downward movement of the linkage.
During additional test for controlling the flow of either water or steam, the actuator was placed in a chest-type home freezer in order to simulate freezing conditions in still air.
These experiments are described in more detail in the following examples by means of which the invention may be more thoroughly understood.
EXAMPLE 1
Actuator 70, having cylindrical wall 71 and bottom 72 and filled with water 73, was observed under ambient conditions at a temperature of 25° F. Actuator 70 was made from a brass pipe having a length of 5 inches and an inside diameter of 0.505 inch after reaming. As water 73 progressively froze close to wall 71 and bottom 72 to form ice 74, a central cone-shaped hump or elevation 79 was formed, as shown in FIG. 3. When water 73 had completely frozen to form ice 74, central elevation 79 was noticeably larger, as shown in FIG. 4. This experiment showed that progressive freezing of water is from the outside wall of chamber 71 and bottom 72 into its central core.
EXAMPLE 2
Chamber 70 was filled with water and 166 small balls 75 having a diameter of 0.1742-inch, made of zinc-plated steel, as shown in FIG. 5. Ball-filled chamber 70 was then placed in the freezer portion of a refrigerator at a temperature of about 25° F. As freezing occurred and ice expanded, balls 75 did not move. Water was pushed up between balls 75 until all freezing was completed. Accordingly, this experiment failed because expansion of water between balls 75 could not actuate a relief valve, such as valve 50.
EXAMPLE 3
An experiment was made with an actuation chamber 80, similar to chambers 40 and 70, and comprising side or wall 81, bottom 82, and a tapered pin 85 having a cylindrical portion 86 and a circular tapered portion 87 with truncated bottom 88 resting on bottom 82, as shown in FIG. 6.
When tested in a freezing environment, the actuation device operated successfully and provided re-actuation when the initial freeze was followed by a complete thaw, melting of all ice, and then by re-freezing. However, the device did not re-actuate the attached relief valve when the thaw was a partial thaw that was followed by a second freeze. The device operated successfully during the first freeze because water 83 expanded inwardly as it turned into ice and caused taper pin 85 to be wedged upwardly. However, after a partial thaw, the ice around the top of tapered portion 87 and adjacent to chamber wall 81 melted and water escaped from the chamber as pin 85 settled downwardly under pressure of the compression spring. When re-freezing began, there was still ice in the space between lower parts of tapered portion 87 and wall 81 so that there was little water available for further freezing and expansion.
EXAMPLE 4
Further experiments were conducted with actuator 80 containing tapered pin 85, comprising cylindrical portion 86 and conical portion 87, within a floating tapered chamber 89, comprising tapered walls 89a and bottom 89b resting on pin 84, as shown in FIG. 7. Water 83 was within the chamber of actuator 80 and within tapered chamber 89.
During freezing conditions, both tapered pin 85 and floating chamber 89 moved upwardly. It was anticipated that during a partial thaw that either the space between pin 85 and chamber 89 or the space between chamber 89 and wall 81 of actuator 80 would thaw to 100% water and then re-freeze. This did not occur, so that the experiment failed.
EXAMPLE 5
As shown in FIG. 8, an actuator 90, similar to actuators 70 and 80 and containing water 93, was fitted with a central rod 94 extending to bottom 92, a nut 95, a small collar 96, and a plurality of spacing collars 97 and washers 98 which extended substantially to cylindrical side 91.
A test was run under freezing conditions using this embodiment. The test failed; rod 94 did not move up during freezing of water 93. It is believed that water 93 froze from wall 91 inwardly and then, as expansion occurred, water escaped upwardly through the spaces between rod 94 and washers 98 before the central portion of water 93 froze.
It was concluded that segments of the sealing means would have to be solid in their centers in order to trap the water as it froze.
EXAMPLE 6
As shown in FIG. 9, an actuator 100, constructed similarly to actuators 70, 80, 90, was provided with T-shaped expansion-sensing segments of its sealing means, each comprising a plastic sealing disk 105 having a thickness of 3/32-inch and a diameter of 1/2-inch, a plastic spacer disk 106 having a thickness of 3/32-inch and a diameter of 3/8-inch and a short steel rod 107, having a thickness of 5/16-inch and a diameter of 1/4-inch. Disk 105, disk 106, and rod 107 were glued together to form each segment. The segments were stacked within cylindrical wall 101 of the chamber which was filled with water 103.
This assembly was tested by immersing actuator 100 and its contents in a container of brine and ice at 15° F. Freezing of the water and opening of the valve occurred within about two minutes, as indicated by discharge of water. After removing actuator 100 and warming it by hand, the valve closed, as indicated by cessation of the discharge. When re-immersed in the brine, it opened again and then closed again when warmed a second time.
EXAMPLE 7
Actuator 40, as shown in FIG. 1, was immersed in a container of brine and ice at 15° F. Within 5 minutes, valve 50 opened and water ran from drain hose 69. Actuator 40 was then removed from the brine container, and valve 50 closed within 10 minutes. These steps ere repeated several times. Valve 50 opened and closed in the same way as in the initial test.
EXAMPLE 8
Another test of actuator 40 was made out of doors while it was connected to a water supply system as shown in FIG. 2. The ambient temperature was 22° F. on a windy day. In 20 minutes, water 43 froze within the chamber of actuator 40, valve 50 opened, and the water ran to waste from drain hole 69. To simulate a warm, ambient atmosphere, actuator 40 was grasped in one hand. Within one minute, valve 50 closed. These steps were repeated several times. Valve 50 opened and closed in the same way.
EXAMPLE 9
A home freezer having an inside temperature of 8° F. was used for a series of experiments to determine the minimum number of segments that could used in the actuator. The freezer lid was shimmed with foam rubber so that the valve and actuator could be placed within the freezer and the inlet water hose and the waste water hose could be run through the foam. The freezer was used because it more closely approximated actual conditions, i.e., air-to-metal heat transfer on a quiet winter day, as compared to immersion of the actuator in a brine/ice mixture.
The prototype actuator 40 and valve 50 shown in FIG. 1 were used for these experiments. However, actuator 100 contained T-shaped segments as shown in FIG. 9 and as used in Example 6, except that the length of the rods 107 was varied as shown in FIGS. 24 and 25 which represent the lower portion of actuator 40 containing segments as shown in FIG. 9 rather than schematic actuators 70, 80, 90, 100.
The experiment was made by connecting inlet hose 67 to water-filled actuator 40 and opening and then closing bleed screw 44 at its bottom. The valve and actuator, comprising the experimental freeze prevention device, was then placed within the freezer. Discharge of water from waste water hose 69 was noted when it occurred, and the time elapsed was recorded. The freezer was opened when required, and the device was disassembled, when necessary, to determine the extent of freezing that had occurred.
As shown in FIG. 24, actuator 40 was fitted with a supplemental actuation rod 232 to compensate for the segments not being used, a plastic sealing disk 235, a plastic spacing disk 236, a steel rod 237 having a length of exactly 2 inches, and a bottom disk 239 having the same dimensions as disk 236. Disk 235, disk 236, and rod 237 were glued together to form the single segment. The actuator was attached to globe valve 50 which was connected to the inlet and discharge hoses.
After 11/2 hours within the freezer, there was no discharge of water from the discharge hose. The freezer lid was raised, and the device was removed from the freezer and disassembled. It was found that all water was frozen within the chamber and within the inlet water hose. It is believed that the reason for failure was that the freeze occurred so slowly that the heat leaving wall 41, cap 42, and screw 44 was replaced by heat moving downwardly from relief valve 50, whereby the heat balance zone was somewhere below sealing disk 235, such as at position 238. Water 43 consequently escaped between wall 41 of the chamber and the periphery of disk 235.
EXAMPLE 10
The same actuator, containing the single T-shaped segment tested in Example 9, was immersed in a mixture of brine and ice. The device performed successfully, as in Example 7, because the quick freeze caused an ice seal to form between the periphery of disk 235 and chamber wall 41.
EXAMPLE 11
As shown in FIG. 25, actuator 40 was fitted with two T-shaped segments, comprising the same supplemental actuation rod 232, two plastic sealing disks 235, two plastic spacing disks 236, two steel rods 237 having a length of exactly one inch, and the same bottom disk 239 that was used for Examples 9 and 10. Disk 235, disk 236, and rod 237 were glued together to form each segment. The actuator was then attached to globe valve 50 which was connected to the inlet and discharge hoses, as shown in FIG. 2.
The device was placed within the same home freezer at 8° F. Within 40 minutes, a small trickle of water (approximately 1/4 gallon per minute) was observed to be running out of the discharge hose. The temperature of the water supply was 52° F. Fifteen minutes later, the water continued to trickle from the hose. After another 25 minutes, the trickle stopped.
The valve, hoses, and actuator were removed from the freezer. The valve was disassembled. It was found that only a small amount of ice was in the actuation chamber. Five minutes after removal from the freezer, the reassembled actuator was again connected to the globe valve and hoses and was replaced in the freezer. Within 40 minutes, the trickle of discharge water began again. Thirty minutes later, the trickle was observed to be continuing. After another 10 minutes, the trickle stopped.
At this point in the experiment, it appeared that the trickle was enough to melt the ice within the actuation chamber and that the actuator was alternately freezing and thawing. It was believed that the heat balance zone was initially above at least the lower disk 235, such as at position 238. Then when warmer water from inlet hose 67 began to flow through globe valve 50 and heat from this water transferred to tee 62, long nut 48, and screw 46 and then to wall 41 and rod 232, the heat balance zone moved downwardly to position 238a. The ice seal between the periphery of lower disk 235 and wall 41 and the ice therebelow then melted, causing poppet 52 to be lowered onto valve seat 56.
EXAMPLE 12
In order to be sure that the device would work with two segments when subjected to a higher heat loss, the valve, actuator, and hoses were removed from the freezer, and the actuator was placed in a container of brine and ice. Within about 5 minutes, the valve was running wide open, discharging about 31/2 gallons of water per minute. After removal from the brine-ice mixture and exposure to ambient conditions (about 70° F.), the flow stopped within 10 minutes. The device was replaced in the brine, and within about five minutes, it ran wide open again.
EXAMPLE 13
In many industrial situations, steam tracer lines are used for tracing a large number of liquid lines that are subject 1 to freezing. These lines may be many feet in length and may contain various solutions, slurries, or pure water.
A suitable valve, for bleeding steam into such steam tracer lines when a freeze is beginning to occur and for shutting off such tracing steam when a thaw begins, is shown in FIG. 18.
Using a steam valve 210 connected to an actuator 190 as shown in FIG. 18, a test set-up was assembled as shown in FIG. 20. It consisted of an electric stove 221 and a 4-quart pressure cooker 222 within a house, approximately 30 feet of 3/8-inch plastic tubing 223 which was connected at one end to cooker 222, a copper tube (two feet in length) 224 which was connected to the other end of tubing 223, a steam temperature gage 225, a steam pressure gage 226, a home freezer 227 which was disposed in a garage, a freezer temperature gage 227a, insulation 227b of 1/2-inch thick foam insulation between the lid and body of freezer 227, a copper tube 228 (about 3 feet in length), and a brine/ice cooler 229, having a temperature of about 15° F. Valve 210 and actuator 190 were connected to inlet tube 224 and outlet tube 228.
The experimental device shown in FIG. 18, as a prototype water freeze prevention valve utilizing steam to heat the system, comprises valve 210 and actuator 190 which comprises a 3/8-inch brass pipe 191 having threaded ends and forming the housing wall for the actuation chamber, bottom end cap 192, water 193, bleed screw 194, balls 195 as segments of its sensing means, galvanized steel pipe coupling 196, and wear compensation spring 197. Actuation rod 200, functioning as the linkage means between balls 195 and valve 210, comprises 1/4-inch lower long nut 201, threaded rod 202, and 1/4-inch upper long nut 204. Steam valve 210 comprises valve body 211, valve seat 212, valve poppet 213, vacant o-ring slot 215, equalizing port 216, o-ring 217, valve cap 218, and compression spring 219.
The test was begun by turning on hot plate 221. While valve 210 was outside of freezer 227, pressure within cooker 222 rose to 20 psig. Bleed screw 194 was opened for 3 minutes to purge air from the system and was closed when steam flowed freely from cap 194.
Valve 210 and actuator 190 were then placed in freezer 227 when temperature gage 227a indicated 12° F. It was expected that condensed steam within the chamber would fill it with water. Steam pressure, as shown by pressure gage 226, was maintained between 15 psig and 20 psig for 65 minutes by turning hot plate 221 on and off; valve 210 did not open.
Valve 210 and actuator 190 were then removed from freezer 227 and placed in brine/ice container 229. Steam was discharged in 3 minutes from line 228.
Valve 210 and actuator 190 were immediately replaced in freezer 227. Valve 210 remained open for 4 minutes while steam pressure, as indicated by gage 226, was about 0 psig and steam temperature, as indicated by gage 225, was about 212° F. The flow of steam through line 228 apparently ceased because of heat transfer from flowing steam in valve 210 to actuator 190.
The test procedure was repeated by removing valve/actuator 210/190 from freezer 227 and immersing actuator 190 in container 229. Valve 210 opened in about 6 minutes.
Valve/actuator 210/190 were immediately replaced in freezer 227. Steam continued to run for about 3 minutes.
It was concluded that heat transfer from valve 210 to actuator chamber 190 was too rapid. Specifically, heat conducting conditions were too favorable and/or the distance from valve 210 to the lowest ball 195 was too short, so that heat from the heated metal of valve 210 melted the ice too rapidly.
EXAMPLE 14
Actuator 190 was separated further from valve 210 by inserting a 3/8-inch galvanized steel pipe 205, 6 inches long and threaded at both ends, between housing wall 191 and valve body 211, as shown in FIG. 19. Actuation rod 200 was then lengthened by replacing threaded rod 202 with a 1/4-inch adjustable extension rod 203 of galvanized steel which was similarly threaded into long nuts 201, 204. Coupling 196 was used to attach the lower end of pipe 205 to wall 191, and another coupling 206 was added to attach the upper end of pipe 205 to valve body 211. Steel was selected for rod 203 and pipe 205 because its heat conductivity is less than that of brass.
This lengthened test device was connected to copper tubes 224, 228, as shown in FIG. 20, for tests in which brine container 229 was not used. Hot plate 221 was turned on while the device was outside freezer 227, and the pressure was raised to 20 psig. Bleed screw 194 was opened to fill the chamber with steam.
Valve 210 opened and closed three times during the duration of the test (3 hours, 34 minutes). The time and freezer temperature, as measured by gage 227a, were noted at each change.
The device was placed within freezer 227 which was at 10° F. and which rose in temperature to 16° F. in 30 minutes. The device was kept within freezer 227 for the duration of the test.
The test results for the lengthened test device are summarized in the following table.
______________________________________TIME REQUIRED, FINAL TEMPERATURE INTest MINUTES FREEZER, °F.No. To Open To Close Valve Open Valve Closed______________________________________1 79 25 16 202 91 28 15 183 95 26 14 20______________________________________
This test was considered to be successful because valve 210 was open for approximately 30 minutes and was shut for approximately 90 minutes while at ambient temperatures of 15°-20° F. in still air. In a practical situation, an insulated and steam-traced line would probably be heated to over 100° F. in 30 minutes but would require several hours to cool to 32° F. in ambient temperatures of 15°-20° F.
During colder ambient temperatures, the water system will cool faster and need more protection, but this will be offset by the valve off-cycle being reduced so that the valve stays open for a longer time.
It is also pertinent that these freezer tests were performed in still air, whereas under field conditions, there will usually be air movement that could increase heat conductance from 3 to 5 times, thereby causing the valve to remain open for a longer time. An additional factor is that the tests were performed with steam at 250°-257° F. and 15-20 psig. Under field conditions, the steam temperature could be 75 psig, causing the valve temperature to approach 320° F. Using a base temperature of 30° F., this higher temperature would increase heat flow to the actuation chamber as follows: (320-30)/(212-30)=1.6, or a 60% increase in heat flow, causing the valve to close more quickly. However, the higher temperature would heat the traced line more rapidly.
The length of extension rod 203 should be directly proportional to the heat conductance of its material of construction. Galvanized steel was used for this test, but Ryton® and other high-temperature plastic materials of low conductivity, such as Kevlar®, are also suitable.
DISCUSSION OF OPERATIONAL PRINCIPLES
The test conducted as described in Examples 7 and 8 with balls 45 in actuator 40 may be understood more clearly by reference to FIGS. 10-15 which are schematic drawings in sectional elevation of the valve shown in FIG. 1 and of actuators 70, 80, 90, 100. Actuator 110 comprises cylindrical side 111, bottom 112, adjustment screw 114, a plurality of balls 115 fitting closely but moveably within cylindrical side 111, actuation rod 116 in contact with topmost ball 115, actuation pin 117 which is connected and attached to rod 116, valve poppet 118, and compression spring 119 which forces poppet 118 against valve seat 121.
Actuator 110 contains water 113 when the ambient temperature is above 32° F., as shown in FIG. 10. When the ambient temperature drops below 32° F., freezing of water 113 starts at wall 111 and at bottom 112, below ball 115a, forming a seal between balls 115a and 115b, and between ball 115c and wall 111, as shown in FIG. 11. As the temperature continues to be below 32° F., freezing becomes complete around lower balls 115a, 115b, 115c, to form ice 113a, forcing ball 115a from its seat on adjustment screw 114 to form a first space and forcing ball 115b upwardly to form a second space between it and ball 115a. Ice has not completely solidified, however, between ball 115b and ball 115c, as shown in FIG. 12. Expansion within these two spaces, transmitted upwardly to actuation rod 116, has lifted poppet 118 from valve seat 121 so that inlet water 124, entering inlet opening 122, flows as bleed water 125 from the partially opened relief valve.
As the ambient temperature continues to be below 32° F., the freeze becomes complete within the chamber of actuator 110 around all balls 115 therewithin. There is a space between adjustment screw 114 and lowermost ball 115a and additional spaces between each of the succeeding three balls, as shown in FIG. 13. These four spaces provide additional lift to valve poppet 118 so that flow 125' is noticeably greater than flow 125. At this flow rate, bleeding continues to provide maximum protection during the lowest temperature of the freeze.
FIGS. 14 and 15 schematically depict the onset of a thaw. Heat flowing downwardly from inlet piping connected to inlet 122 and flowing water 124 therewithin through wall 111 has melted ice to form water 123 below topmost ball 115d in FIG. 14 and has melted ice to form water 123 below second ball 115c in FIG. 15, in combination with incoming heat from the surrounding air through wall 111 which has formed additional water 129 at the bottom of the chamber. Residue ice 128 remains below the three lowest balls. The heat balance zone is approximately at top 126 of the ice during the coldest temperature, as seen in FIG. 13 but has advanced to ice level 126' in FIG. 14 during the thaw.
Preferred Embodiments
Practical relief valve devices of this invention for water are shown in FIGS. 16 and 17. FIG. 16 shows an angle embodiment in open position, and FIG. 17 shows a straight-through embodiment in closed position.
The angle valve shown in FIG. 16 comprises a unitary actuator 130, a valve body 150, and a valve cap 160. Unitary actuator 130 comprises a cylindrical wall 131, a bottom end 132, an adjustment and bleed screw 134, a plurality of balls 135 which move freely within the chamber formed by wall 131, an actuation or linkage rod 136 which is in close contact with topmost ball 135, and an actuation pin 137 which is attached to rod 136 and axially aligned therewith.
Rod 136 and pin 137 can be of unitary construction. Unitary actuator 130 further comprises actuator body 141, threaded inlet 142, and threaded outlet 146.
Rod 136 forms a close fit with wall 131 in order to minimize downward circulation of inlet water and consequent melting of ice within the actuation chamber.
Valve 150 comprises valve body 151, valve seat 152, threaded inlet 153, threaded cap opening 154, outlet 156, valve poppet 158 which is axially aligned with pin 137 and attached thereto, compression spring 159, and guide pin 157 which is axially aligned with poppet 158 and attached thereto and around which spring 159 is disposed.
Valve cap 160 comprises bore 161, which is axially aligned with pin 157, poppet 158, actuation pin 137, and actuation rod 136, and threads 163 for attaching to body 151.
When ice 138 has replaced water 133 within the actuation chamber, lower balls 135 are spaced apart, as shown in FIG. 16, to displace poppet 158 from valve seat 152 so that water entering through inlet 142 can pass through the port around actuation pin 137 and between valve poppet 158 and valve seat 152 to be discharged through outlet 156.
FIG. 17 shows a highly preferred embodiment comprising an actuator 170 and a globe valve 180. Actuator 170 comprises a housing formed by cylindrical wall 171 and a bottom end 172 in which is fitted a bleed screw 174. The housing surrounds an actuation chamber within which are balls 175 as segments of its expansion sensing means, a wear compensation spring 177, and water 173.
Compression spring 177 is useful in order to compensate for slight wear in balls 175. Its force is always less than compression spring 189 and is merely enough to keep balls 175 in contact with each other and to localize the total linear wear within the volume beneath the bottom ball.
Globe valve 180 comprises valve body 181, valve seat 182, valve poppet 183, poppet guide 184, actuation rod 186, adjustment nut 187, cap 188, and compression spring 189. This globe valve is a major portion of a quick-opening, self-closing globe valve Model 305B made by the S.C. Kingston Co., 1007 N. Main St., Los Angeles, Calif. 90012. Valves formerly made by the Walworth Co., P.O. Box 873, Valley Forge, Pa. 19481, would also be useful for the device of this invention.
Mass
Pertinent mass considerations are as follows:
(1) In the actuator, the ratio of the mass of the metal (chamber wall, chamber bottom, and balls) to the mass of the water is approximately 40:1.
(2) In the inlet piping, the ratio of the mass of the metal to the mass of the water is approximately 3:1.
(3) The ratio of the mass of the metal in the inlet piping and relief valve to the mass of metal in the actuator is approximately 1:0.
(4) The ratio of the mass of the water in the relief valve to the mass of the water in the chamber is approximately 50:1.
Heat
Pertinent data are as follows:
______________________________________ Specific Thermal Conductivity SpecificMaterial Heat BTU/Hour-Ft.sup.3 -°F.-Ft Gravity______________________________________Water 1.00 0.33 1.0Ice 0.50 1.26 0.9Copper, 99% 0.09 224 8.9Brass 0.09 56-81 8.5-8.7Bronze 0.09 15-108 8.6-8.8Cr--Ni Steel 0.11 9.70 8.0______________________________________
The heat of fusion of water to ice is 143 BTU/pound.
Heat Transfer During Freeze
Assuming that the ambient temperature has dropped below 32° F., heat flows out of the chamber wall to the air while heat flows into the actuator by flowing down the chamber wall from the inlet piping, the relief valve, and the water contained therein. Consequently, the temperature of the water of the lower part of the chamber tends to drop faster than the water in the upper part thereof. Within the chamber, the mass of the metal to the mass of water is approximately 40:1. Since the specific heat of the metal is approximately 0.1, it requires about four times as much heat loss from the metal as it does from the water to lower the temperature to 32° F.
However, the amount of heat loss required to lower the temperature of the water to 32° F. is insignificant compared to the heat loss required to transform the water to ice at 143 BTU/pound of water. The result is that the temperature of the water and the balls tends to remain at 32° F. until the water is frozen because the temperature necessarily remains constant during a phase transition period. At that time, the temperature of the outside chamber wall drops below 32° F. and the water starts to freeze along the interior of the wall. This process begins at the bottom of the chamber and moves upwardly therefrom. As the heat loss continues, the ice forms a seal between each ball and its surrounding wall, thereby trapping the water located between the lower portion of the ball and the next lowermost ball. As the water continues to freeze, the ice forms a wedge which forces the balls apart. Because the lowermost balls have already formed a solid frozen mass, the ball above the wedge being formed moves upwardly against the compression spring. This process continues as each ball successively moves upwardly until a balance zone is reached. This balance zone occurs when heat loss through the wall of the chamber equals the heat gained through the metal from the inlet piping, the relief valve, and water contained therein. The balance zone may move up or down, depending upon the balance of heat flow along and through the wall of the actuation chamber.
Heat Transfer During Thaw
Assuming that the ambient temperature increases above 32° F. after a freeze, heat is gained through the chamber wall from the ambient air, causing progressive melting of the ice from the outside of the wall toward the center of the chamber. Heat continues to be gained from the valve body and the water therewithin to cause melting of the ice from the top of the chamber downwardly. The balance zone consequently moves far down the chamber wall. The last ice to melt is that between the balls; therefore, the balls will not move together and the valve will not close until all of the ice has melted. It is critical that only water remain between the balls and that the balls come back into contact with each other, because if a re-freeze occurs, expansion of the freezing water will be necessary for re-actuation of the relief valve.
Assuming that the ambient temperature remains below 32° F., that the valve is actuated, and that the heat gained from the valve body and the water therewithin because of water flow far exceeds the heat loss, this incoming heat will flow downwardly through the balls and through the water between the balls. Because the chamber wall is below 32° F., the seal between the balls and the water tends to be the last ice to melt and occurs from the interior outwardly until all ice has melted. In other words, the balance zone remains at a relatively high level. Because this seal remains until after the interior ice has melted, a re-freeze can occur.
Linear Expansion Within Chamber Above Bottom Ball
Referring to FIGS. 21 and 22, the shaded area in FIG. 21 represents a portion of the chamber volume having a length d. The linear expansion per ball in this chamber, having an inside diameter of d, may be calculated as follows when water freezes into ice and expands approximately 10% by volume:
Volume of Balls (1/2 of 2 balls=1 ball)
Vb=πd.sup.3 /6
Volume of Empty Chamber Per "d" Length
Ve=π(d/2)×d=πd.sup.3 /4
Volume of Water in "d" Length
Vw=Ve-Vb
Vw=πd.sup.3 /4-πd.sup.3 /6
Vw=πd.sup.3 /12
Volume of Expansion (ΔV)
ΔV=πd.sup.3 /l2×10%=πd.sup.3 /120
Length of Expansion (Δd)
ΔV=(d/2).sup.2 π×Δd
πd.sup.3 /120=πd.sup.2 /4×Δd
Δd=d/30
The linear expansion is therefore directly proportional to the diameter of the chamber and the number of spaces between the balls, i.e., the total expansion=d/30×(number of balls-1).
LINEAR EXPANSION IN BOTTOM OF CHAMBER BENEATH BOTTOM BALL
Referring to FIG. 23, the adjustment screw or pin at the bottom of the chamber may be of any reasonably desired 1 length and, in general, provides a selective increase in the linear expansion that is available. For a ball d in a chamber having a diameter d and a pin of 3/16-inch diameter, the calculation of the expansion in the bottom of the chamber, beneath the bottom ball, is as follows:
Volume (V 1 ) of Water in Length of (d/2)
V.sub.1 =Volume w/o Ball-Volume of 1/2 Ball
V.sub.1 =π/4×d.sup.2 ×d/2-1/2×πd.sup.3 /6
V.sub.1 =πd.sup.3 /8-πd.sup.3 /12
V.sub.1 =πd.sup.3 /24
Volume (V 2 ) of Water in Length of 1/2 inch
V.sub.2 =Volume w/o Pin-Volume Pin
V.sub.2 =π/4×d.sup.2 ×1/2-π/4×(3/16).sup.2 ×1/2
V.sub.2 =π/8)d.sup.2 -9/256)
Total Volume of Water (V t )
V.sub.t -V.sub.1 +V.sub.2
V.sub.t =πd.sup.3 /24+π/8(d.sup.2 -9/256)
V.sub.t =π/8(d.sup.3 /3+d.sup.2 -9/256)
Volume of Expansion (ΔV)
ΔV=Vt×10%
ΔV=0.10 ×π/8(d.sup.3 /3+d.sup.2 -9/256)
ΔV=π/80(d.sup.3 /3+d.sup.2 -9/256)
Length of Expansion (Δd) ##EQU1##
Δd=π/80(d.sup.3 /3+d.sup.2 -9/256)÷πd.sup.2 /4
Δd=1/20(d/3+1-9/256d.sup.2)
Δd=d/60+1/20-9/5120d.sup.2
The expansion due to water freezing within the actuation chamber is directly proportional to the amount of water in the chamber, the number of segments, shape of segments, the diameter of the chamber, and the size of the bottom of the chamber. For a single ball, only the expansion in the bottom of the chamber is relevant. Calculated expansions for three sizes of balls in similarly sized actuation chambers are given in the following table.
______________________________________TOTAL LINEAR EXPANSION, INCHESDiameterof Chamber Number of Balls in ChamberInches 1 2 3 4 5 6 7 8______________________________________1/2 0.051 .068 .085 .101 .118 .135 .151 .1683/4 0.059 .084 .109 .134 .159 .184 .209 .2341 0.064 .098 .132 .165 .198 .232 .265 .298______________________________________
If the freeze prevention device of this invention is designed (1) with a large bottom chamber and (2) so that the balance zone never reaches any segment, it is possible to use a single segment. In other words, having a single segment that can never have its seal melted by incoming heat from the inlet piping, valve body, and water therein means that its seal can always be reformed before water beneath the segment can escape because of expansion therein. Maintaining the balance zone always above such a single segment is possible by use of insulation between the actuator and the relief valve or by having a sufficiently elongated actuator and particularly one having a sufficiently high length-to-diameter ratio.
However, it is preferred that the number of segments be at least two. It is highly preferred that a larger plurality of segments, such as six, be used. Such a larger number imparts greater versatility to the device and enables the incoming heat from the inlet piping, the relief valve, and the flowing water therein to be utilized for faster thawing and generally more precise responses to temperature changes.
Because it will be readily apparent to those skilled in the art of freeze prevention that innumerable variations, modifications, applications, and extensions of the examples and principles hereinbefore set forth can be made without departing from the spirit and the scope of the invention, what is hereby defined as such scope and is desired to be protected should be measured, and the invention should be limited, only by the following claims. | A freeze prevention device for water systems includes a relief valve and an actuator having an elongated chamber which contains water and segments that sequentially sense the incremental expansion caused by ice formation therebetween. The segments are axially aligned within the chamber. The segments may be balls, truncated pyramids, and the like that have a sealing portion and an axial portion with a foot which is adapted to engage an adjusting screw or a wear compensating spring at the bottom of the chamber or the top of the adjacent segment. An actuation linkage transmits linear meovement of one or more segments to a poppet in a valve seat, thereby opening a valve port connecting water, from a water supply system or a tank, to a discharge port, whereby water may be bled from the water system to prevent freezing thereof, or steam from a steam system for admission to tracer lines. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an endoscope for medical use and, more particularly, to a bending control mechanism which is built in the endoscope.
[0002] In general, the endoscope is composed of two main portions, of which one is a control portion and the other is a flexible insertion portion connected with the control portion and is inserted in the somatic cavity. The insertion portion includes a flexible soft portion connected with the control portion, a bent-free bending portion connected with the soft portion on the tip side of it, and a hard tip distal end portion which includes an objective window (lens) and others, is connected with the tip of the bending portion.
[0003] The endoscope is provided with a bending control mechanism for controlling the bending of the bending portion. This bending control mechanism includes a bending control lever, a pulley of which the rotational motion is controlled by the control lever, and a driving wire wound round the pulley, all of the above lever, pulley, and driving wire being provided inside the control portion of the endoscope. The driving wire is connected with the bending wires through a connection member and functions as a control wire for controlling the bending portion.
[0004] The above pulley includes two juxtaposed independent grooves capable of winding up an independent driving wire by one each (referred to as “driving wire winding groove” hereinafter). Here, if these two driving wires are wound round these driving wire winding grooves by one each in the opposite winding direction and then, the pulley is turned in one direction, one of two driving wires extending out from the pulley is taken up or wound up while the other is paid out or wound off from the pulley. Accordingly, two control wires connected with driving wires are controlled such that one advances and the other retreats, thus the bending control of the bending portion being carried out.
[0005] In the endoscope, however, in order to improve the observational performance, specifically to expand the observable area by the endoscope, it is desired to make a bending angle of the bending portion as large as possible. To meet the above desirable requirement, there is needed for the driving wire to have a large wire stroke.
[0006] Because of this, in order to make the wire stroke large, there is proposed a prior art endoscope which increases the winding diameter of the pulley, round which the driving wire is wound. However, if the winding diameter of the pulley is made large, the turning torque of the pulley becomes large, which causes such inconvenience that the bending control lever requires larger force for controlling it.
[0007] On the other hand, in order to decrease the turning torque of the pulley, there is another prior art endoscope which makes the size of the pulley smaller by shortening the winding diameter of it. In case of such a small pulley, however, as the winding diameter of the pulley is made shorter, the bending control lever has to be turned much more in order to obtain the same bending angle as obtained by the large pulley. Because of this, controllability of the bending portion is reduced.
[0008] Furthermore, in the pulley of which the winding diameter is made smaller, the more it is tried to make the stroke of the driving wire large, the more the excess driving wire has to be wound round the driving wire winding groove, for instance 2 turns or more. Because of this, the turning torque of the pulley gradually becomes larger corresponding to the winding number of the driving wire, thus the bending control at a uniform turning torque becoming impossible. Still further, as the overlapped driving wires caused by double or more turned driving wires interfere with each, for instance rub one with the other, thus the durability of the driving wire being reduced.
[0009] The invention has been made in view of such problems as described above. Accordingly, an object of the invention is to provide a bending control mechanism for the endoscope with high controllability, which can improve the durability of the driving wire wound round the pulley of the bending control mechanism and also enables the bending portion to be controlled with a smaller force.
SUMMARY OF THE INVENTION
[0010] In order to solve the problems as described above, according to the invention, there is provided a bending control mechanism for an endoscope, which is characterized in that the bending control mechanism includes a bending portion provided in an insertion portion of the endoscope; a bending wire extended out from the bending portion in order to control the bending portion; a pulley linked to a bending control lever through the shaft portion of the pulley, the bending control lever being provided in the control portion of the endoscope; a driving wire winding groove as spirally formed on the outer peripheral surface of the pulley as well as in the peripheral direction of the pulley; a driving wire wound round the driving wire winding groove of the pulley; a connection member connecting the driving wire with the bending wire; and a guide member provided in the control portion and including a connection member slidably mounted thereon, wherein in the state where the most driving wire is wound round the pulley, a relative position between the pulley and the guide member is determined such that the extending direction of the driving wire is substantially in parallel with the guide surface of the guide member.
[0011] According to the invention like this, in the state where the tension applied to the driving wire wound round the pulley connected with the bending control lever is maximized while the bending portion control is carried out, as the extending direction of the driving wire is substantially in parallel with the guide surface of the guide member guiding the driving wire, there is no need for any excess force to be used for winding up the driving wire round the pulley by using the bending control lever, and the bending portion can be controlled with smaller force, thus the controllability of the endoscope is improved.
[0012] Furthermore, in the state where the tension applied to the driving wire wound round the pulley is maximized while the bending portion control is carried out, as the driving wire is substantially in parallel with the guide surface of the guide member, it becomes possible to prevent the consumption or frictional wear of the driving wire caused by the rubbing motion between the driving wire and the wall face of the driving wire winding groove, which take place when winding the driving wire round the pulley. Consequently, there is improved the durability of the driving wire wound round the pulley of the bending control mechanism. With this, durability of the driving wire can be improved.
[0013] Furthermore, in the state where the most driving wire is wound round the pulley, the direction of spiral turn of the driving wire winding groove may be such a spiral turning direction that the extending direction of the driving wire becomes substantially parallel to the guide surface of the guide member. Like this, as the position in the axial direction of the driving wire extended out from the pulley can be changed by changing the direction of spiral turn of the driving wire winding groove, it becomes possible to make the extending direction of the driving wire be substantially in parallel with the guide surface of the guide member. Therefore, there is no need for the guide member to change its arrangement position and it is enough only to change the direction of spiral turn of the driving wire winding groove.
[0014] Still further, in the state where the most driving wire is wound round the pulley, the guide member may be arranged to be in such a position that the extending direction of the driving wire becomes substantially parallel to the guide surface of the guide member. With this, as the arrangement position of the guide member can be arranged to meet the position in the axial direction of the driving wire extended out from the pulley, it is possible to arrange the driving wire and the guide member such that the extending direction of the driving wire becomes substantially parallel to the guide face of the guide member. Therefore, there is no need for the driving wire winding groove to change the direction of spiral turn of it and it is enough for the guide member only to change the arrangement position of it.
[0015] Still further, there may be provided a pulley displacement mechanism which displaces the pulley in the axial direction of it such that the extending direction of the driving wire becomes substantially parallel to the guide surface of the guide member, in correspondence with the height in the axial direction of the pulley of the driving wire wound round the pulley. As this pulley displacement mechanism makes it possible to produce such a state that the driving wire and the guide face of the guide member become always substantially parallel to each other, there is no need for any excess force to be used for winding up the driving wire round the pulley by using the bending control lever, and the bending portion can be controlled with smaller force. Also, it becomes possible to effectively prevent the consumption or frictional. wear of the driving wire, which is caused by the rubbing motion between the driving wire and the wall face of the driving wire winding groove.
[0016] Still further, the pulley displacement mechanism may be provided with a cam groove formed on the shaft portion of the pulley as well as a cam pin formed on the pulley support member for supporting the pulley so as to fit to the cam groove. Also, the pulley displacement mechanism may be provided with a cam formed on the pulley support member for supporting the pulley as well as a cam pin formed on the shaft portion of the pulley so as to be fitted the cam.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will now be described in detail by way of some preferred embodiments with reference to the accompanying drawings. In the following description and drawing, a constituent of the invention having substantially like function and constitution is designated by a like reference numeral or sign.
[0018] In the drawing:
[0019] [0019]FIG. 1 is a perspective view showing a whole constitution of an endoscope according to the first embodiment of the invention.
[0020] [0020]FIG. 2 is a sectional view showing the peripheral portion of a bending control lever in the endoscope control portion according to the first embodiment of the invention.
[0021] [0021]FIG. 3 is an exploded perspective view showing a pulley and a support member of the pulley in the endoscope control portion.
[0022] [0022]FIG. 4 is a perspective view showing a complete assembly of the pulley and the support member of the pulley as shown in FIG. 3.
[0023] [0023]FIGS. 5A and 5B are diagrams showing the constitution of the pulley provided in a prior art endoscope. FIG. 5A is an illustration showing an external appearance of the pulley and FIG. 5B is a sectional side view of the pulley.
[0024] [0024]FIGS. 6A and 6B are diagrams schematically showing the constitution and the operation of the bending control mechanism of the prior art endoscope.
[0025] [0025]FIG. 7A is an illustration showing an external appearance of the pulley according to the first embodiment of the invention and FIG. 7B is a sectional side elevation of the pulley according to the first embodiment of the invention.
[0026] [0026]FIGS. 8A and 8B are diagrams schematically showing the constitution and the operation of the bending control mechanism of the endoscope according to the first embodiment of the invention.
[0027] [0027]FIGS. 9A and 9B are diagrams schematically showing the constitution and the operation of the bending control mechanism of the endoscope according to the second embodiment of the invention.
[0028] [0028]FIGS. 10A and 10B are diagrams schematically showing the constitution and the operation of the bending control mechanism of the endoscope according to the third embodiment of the invention.
[0029] [0029]FIGS. 11A and 11B are diagrams schematically showing the constitution and the operation of the bending control mechanism of the endoscope according to the fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] (First Embodiment)
[0031] First of all, there will be described an endoscope according to the first embodiment of the invention with reference to FIG. 1, which indicates the whole constitution of an endoscope according to the first embodiment of the invention. As shown in this figure, an endoscope 100 is composed of two principal portions, of which one is a control portion 102 and the other is a flexible insertion portion 104 connected with the control portion 102 and is inserted in the somatic cavity. The insertion portion 104 includes a flexible soft portion 106 connected with the control portion 102 , a bend-free bending portion 108 connected with at the tip side of the soft portion 106 , and a hard tip distal end portion 110 which is provided with an objective window (lens) and is connected with the tip of the bending portion 108 .
[0032] In the control portion 102 of the endoscope 100 , there is provided a bending control mechanism for controlling the bending of the above bending portion 108 . This bending control mechanism is made up of a bending control lever 112 , a pulley 114 rotated by the bending control lever 112 , and a pair of driving wires 116 a , 116 b wound round the pulley 114 , which are all provided in the control portion 102 of the endoscope 100 . Driving wires 116 a , 116 b are connected with the bending wires 120 a , 120 b through connection members 118 a , 118 b slidably mounted on guide members 130 a , 130 b which are provided in the control portion 102 . Consequently, driving wires 116 a , 116 b come to function as control wires 122 a , 122 b of the bending portion 108 .
[0033] [0033]FIG. 2 is a vertical sectional view schematically showing the state of connection between the bending control lever 112 and the pulley 114 which are provided in the control portion 102 . FIG. 3 is an exploded perspective view showing the pulley 114 and a support member 124 of the pulley while FIG. 4 is a perspective view showing a complete assembly of the pulley 114 and the support member 124 of the pulley as shown in FIG. 3. Here, an expression “bending control lever 112 ” represents a bending control lever 112 a for right-left (RL) bending control (referred to as “RL bending control lever 112 a ” hereinafter) and a. bending control lever 112 b for up-down (UD) control (referred to as “UD bending control lever 112 b ” hereinafter). Also, an expression “pulley 114 ” represents a pulley 114 a for RL control (referred to as “RL control pulley 14 a ” hereinafter) and a pulley 114 b UD control (referred to as “UD pulley control 114 b ” hereinafter). Furthermore, an expression “pulley shaft portion 115 ” represents a pulley shaft portion 115 a for RL control (referred to as “RL control pulley 115 a ” hereinafter) and a pulley shaft portion 115 b for UD control (referred to as “UD control pulley shaft portion 115 b ” hereinafter) control. Still further, an expression “pulley support member 124 ” represents a pulley support member 124 a for RL control (referred to as “RL pulley support member 124 a ” hereinafter) and a pulley support member 124 b for UD control (referred to as “UD pulley support member 124 b ” hereinafter).
[0034] As shown in FIG. 3, a plate 125 for fixing a shaft (referred to as “shaft-fixing plate 125 ” hereinafter) arranged inside the above control portion 102 is immovably fitted with a fixed shaft 126 , by means of screws or the like. Also, a ring shaped pulley support member 127 is firmly fixed on the shaft-fixing plate 125 by means of screws or the like, and the RL control pulley 114 a is inserted along the fixed shaft 126 so as to be accepted inside the ring shaped pulley support member 127 .
[0035] The RL control pulley support member 124 a is inserted along the shaft portion 115 a of the RL control pulley 114 a while the UD control pulley 114 b is inserted along the RL control pulley support member 124 a . The UD pulley support member 124 b is inserted along the shaft portion 115 b of the UD control pulley 114 b . The UD control pulley support member 124 b is fixed on the shaft-fixing plate 125 by means of screws or the like through the RL control pulley support member 124 a and the ring shaped pulley support member 127 .
[0036] Driving wires 116 a , 116 b are wound round the RL control pulley 114 a while driving wires 116 c , 116 d are wound round the UD control pulley 114 b.
[0037] Furthermore, driving wires 116 a , 116 b , 116 c and 116 d are respectively connected with bending wirers 120 a , 120 b , 120 c and 120 d through connection members 118 a , 118 b , 118 c and 118 d , which are slidably arranged on a guide member 30 as shown in FIG. 8. The guide member 30 is arranged inside of the control portion 102 .
[0038] As shown in FIG. 2, the shaft portion 115 a of the RL control pulley 114 a is connected with the RL bending control lever 112 a while the shaft portion of the UD control pulley 114 b is connected with the UD bending control lever 112 b.
[0039] With the constitution as described above, if the bending control lever 112 is turned, the pulley 14 is turned through the pulley shaft portion 115 . Therefore, the pulley 114 is turned by an angle corresponding to the angle of rotation of the bending control lever 112 . For instance, if the RL bending control lever 112 a is turned, the pulley shaft portion 115 a is turned and then, the RL control pulley 114 a is turned by an angle corresponding to the angle of rotation of RL bending control lever 112 a . With this, the control wire 122 comes to go back and forth, thereby the bending portion 108 being made to move in the right or left direction.
[0040] In the next, the pulley of the bending control mechanism according to the invention will be described in detail especially about the concrete constitution of the pulley as well as about the positional relation between the pulley and a guide member. First of all, let us start from comparing the pulley 114 of the bending control mechanism according to the invention with a prior art pulley with reference to the drawings. FIGS. 5A and 5B indicate the constitution of a prior art pulley 10 and FIGS. 6A and 6B show the positional relation between the pulley 10 and a prior art guide member 20 . Here, as the RL control pulley and the UD control pulley have the substantially same constitution and also, the RL control pulley shaft portion and the UD control pulley shaft portion have the substantially same constitution. Therefore, both of these pulleys and both of pulley shaft portions will be collectively referred to as the pulley 10 and the pulley shaft portion 9 in the following description.
[0041] As shown in FIGS. 5A and 5B, the pulley 10 is provided at one end portion of the pulley shaft portion 9 . A groove 12 round which a driving wire 14 is wound (referred to as “driving wire winding groove” hereinafter) is formed on the peripheral surface of the pulley 10 . As shown in FIG. 5A, the driving wire winding groove 12 is formed in the shape of a spiral which continuously extends in the peripheral direction of the pulley 10 . The driving wire winding groove 12 is formed such that a plurality of step grooves are formed in the axial direction of the shaft portion 9 from the end face of the pulley 10 toward the pulley shaft portion 9 . The end portion of one driving wire is fixedly connected with the one end portion of the driving wire winding groove 12 while the end portion of the other driving wire is fixedly connected with the other end portion of the driving wire groove 12 . FIGS. 6A and 6B indicates a state attained when winding the driving wire 14 round the driving wire winding groove 12 as described above. In these figures, however, only one driving wire is shown and the other one is omitted.
[0042] The driving wire 14 extending out from the pulley 10 is connected with a bending wire 16 through a connection member 18 , which is slidably mounted on a guide member 20 .
[0043] Consequently, if the pulley 10 like the above is rotated in one direction, one driving wire is taken up or wound up while the other one is paid out or wound off. Contrary to this, if the pulley 10 is rotated in the direction opposite to the above, the other driving wire is taken up (wound up) while one driving wire is paid out or wound off.
[0044] Accordingly, it can be avoided to wind the driving wire round the same driving wire winding groove 12 twice or more times, that is, the so-called double winding can be avoided. This prevents the same driving wires from interfering with each other, which contributes to improvement of the durability of the driving wire.
[0045] Furthermore, as the driving wire winging groove 12 is formed in the shape of a spiral, it becomes possible to wind a longer driving wire 14 . Thus, the winding diameter of the pulley 10 can be made larger, by which the rotational torque of the pulley 10 can be reduced. These effects of the spiral shaped driving wire winging groove 12 make it possible to provide a bending control mechanism with excellent controllability.
[0046] As described above, even the pulley 10 having a structure like the above can take sufficiently useful effects, but if the pulley 10 is able to overcome the following points, it will is able to assure more excellent controllability and more improved durability of the driving wire.
[0047] For example, in case of the pulley 10 , as the driving wire winding groove 12 is formed in the shape of a two-step spiral extending along the outer peripheral surface of the pulley 10 as well as in the axis direction of the shaft of the pulley 10 , the extending direction of the driving wire 14 becomes different depending on two states, one is the state where the bending portion is not bend, the so-called a neutral state as shown in FIG. 6A, and the other is the state where the bending portion is bent as shown in FIG. 6B. Because of this, there happens the case that the driving wire 14 as paid out from the driving wire winding groove 12 is not in substantially parallel with the guide surface of the guide member 20 . For instance, as shown in FIG. 6A, even if the driving wire 14 paid out from the inner step groove (groove near the pulley shaft) of the driving wire winding groove 12 is set to be substantially in parallel with the guide surface of the guide member 20 in the neutral state, the substantial parallelism as set above between the guide surface of the guide member 20 and the driving wire 14 paid out from the outer step groove (groove near the pulley end surface) of the driving wire winding groove 12 is lost due to the displacement of the pulley 10 in the axial direction of its shaft as shown in FIG. 6B when the maximum tension (caused by the most wire winding) is applied to the driving wire. Accordingly, in case of FIG. 6B, as the angle θ of inclination is caused between the driving wire 14 and the guide member 20 , the pulley 10 has to be rotated with an ordinary force plus 1/cos 2 θ of the wire tension.
[0048] ( 11 )
[0049] Furthermore, the larger the angle of inclination between the driving wire 14 and the guide surface of the guide member 20 becomes, the more the driving wire 14 comes to strongly rub against the wall face of the driving wire winding groove 12 of the pulley 10 , thus the durability of the driving wire 14 being damaged.
[0050] Therefore, in the invention, in the state where the most driving wire 116 is wound round the pulley 114 , the extending direction of the driving wire 116 paid out from the pulley 114 is determined taking account of the position of the guide member 130 such that the extending direction of the driving wire 116 becomes substantially parallel to the guide surface of the guide member 130 .
[0051] A pulley 114 of the bending control mechanism according to the invention as described above will now be described with reference to the accompanying drawings. FIGS. 7A and 7B are diagrams showing the constitution of the pulley 114 of the bending control mechanism according to the first embodiment of the invention in which FIG. 7A is an external view of the pulley 114 and FIG. 7B is a vertical sectional view of the pulley 114 . Here, in this embodiment, as the RL control pulley and the UD control pulley have the substantially same constitution while the RL control pulley shaft portion and the UD control pulley shaft portion also have the substantially same constitution. Therefore, both of these pulleys and both of these pulley shaft portions will be collectively referred to as the pulley 114 and the pulley shaft portion 115 in the following description.
[0052] As shown in FIGS. 7A and 7B, the pulley 114 according to this embodiment is provided at the one end of the pulley shaft portion 115 , which is formed in the substantially cylindrical shape. The other end (with which no pulley is fitted) of the pulley shaft portion 115 is fitted with the bending control lever 112 .
[0053] As shown in FIG. 7A, the driving wire winding groove 128 for winding the driving wire 116 round itself is formed on the outer periphery of the pulley 114 . The driving wire winding groove 128 is in the shape of a spiral continuously extending in the peripheral direction of the pulley 114 . The driving wire winding groove 128 in this embodiment is also in the shape of a spiral continuously extending in the peripheral direction of the pulley 114 , but the turning direction of this spiral is made opposite (anti-clockwise to the peripheral direction of the pulley 114 ) to that of the spiral of the driving wire winding groove 12 of the pulley 10 as shown in FIG. 5A. To put it concretely, the spiral groove of the driving wire winding groove 128 is formed such that a plurality of step grooves are formed in the direction from the pulley shaft portion 115 of the pulley 114 toward the end surface of the pulley 114 .
[0054] One end portion 128 a of the driving wire winding groove 128 is fixedly connected with the end portion of one driving wire while the other end portion 128 b of the driving wire winding groove 128 is fixedly connected with the end portion of the other driving wire. The driving wire winding groove 128 and the driving wire winding groove 12 of the pulley 10 as shown in FIGS. 5A an 5 B differ from each other in the point from which the winding of the driving wire 116 starts. In FIGS. 7A and 7B, the other driving wire is omitted.
[0055] The above driving wire 116 is wound round the pulley 114 which is provided so as to act in link with the bending control lever 112 provided in the control portion 102 . If the bending control lever 112 is turned, the pulley shaft portion 115 is turned, thereby the pulley 114 being turned by an angle equal to the angle of rotation of the bending control lever 112 . With this, the driving wire 116 is wound round the pulley 114 and the bending wire 120 connected with the driving wire 116 through the connection member 118 is pulled back in the direction toward the pulley 114 , thereby the bending portion 108 being bent. Like this, the driving wire 116 is connected with the bending wire 120 through the connection member 118 , and it functions as the control wire 122 of the bending portion 108 .
[0056] As described above, the driving wire 116 is connected with the bending wire 120 through the connection member 118 . The connection member 118 is slidably mounted on the guide member 130 . The guide member 130 is provided between the pulley 114 and the insertion portion 104 of control portion 102 . In this embodiment, the guide member 130 is arranged in advance such that, in the neutral state, the extending direction of the driving wire 116 is slanted to the guide face of the guide member 130 . With this arrangement, when the most driving wire 116 is wound round the pulley 114 , in other words, when the most force is applied to the driving wire 116 in the bending control operation, it becomes possible to make the extending direction of the driving wire 116 be substantially in parallel with the guide face of the guide member 130 .
[0057] Here, there will be described the operation of the bending control mechanism of the endoscope according to the first embodiment of the invention with reference to FIGS. 8A and 8B, in which FIG. 8A indicate the state of the bending control mechanism where the bending portion 108 is in the neutral state and FIG. 8B indicates the state of the bending control mechanism where the most driving wire 116 is wound round the pulley 114 .
[0058] In the first embodiment, there is provided the driving wire winding groove 128 in the shape of a anti-clockwise spiral formed along the peripheral surface of the pulley 114 , and the end portion 117 of the driving wire 116 is connected with the end portion 128 a of the driving wire winding groove 128 , the end portion 128 a being located on the end surface side of the pulley 114 . Here, in the following description, an expression “pulley surface side” stands for the side where no pulley shaft portion is provided in the axial direction of the pulley while an expression “pulley shaft provision side” means the side where a pulley shaft portion is provided in the axial direction of the pulley.
[0059] Furthermore, in this embodiment, the spiral shaped driving wire winding groove 128 provided in he pulley 114 is made to turn anti-clockwise along the peripheral direction of the pulley 128 as shown in FIGS. 8A and 8B. The driving wire 116 is connected with the end portion 128 a of the driving wire winding groove 128 , the end portion 128 a being located on the end surface side of the pulley 114 . The guide member 130 is located such that in the neutral state, the extending direction of the driving wire 116 is slanted to the guide surface of the guide member 130 .
[0060] Because of this arrangement, in the neutral state, the extending direction of the driving wire 116 can not be in parallel with the guide surface of the guide member 130 as shown in FIG. 8A. To the contrary, when the most driving wire 116 is wound round the pulley 114 as shown in FIG. 8B, the position of the pulley 114 in the axial direction of itself, at which the driving wire 116 is paid out through the driving wire winding groove 128 , is substantially in the same height of the position of the connection member 118 on the guide member 130 . Therefore, the extending direction of the driving wire 116 becomes substantially parallel to the guide surface of the guide member 130 .
[0061] As described above, according to the first embodiment of the invention, in the state where the tension applied to the driving wire 116 is maximized, in other words, when the most driving wire is wound round the pulley 114 , the relative position between the driving wire 116 and the guide member 130 is determined such that they becomes substantially parallel to each other. With the constitution like the above, it becomes possible for the bending control lever 112 to rotate the pulley 114 for winding up the control wire 122 round it without using any extra force but with the smaller force, comparing with the pulley 10 of the bending control mechanism as shown in FIG. 5. Consequently, as the bending portion 108 can be controlled with smaller force, controllability of the endoscope is improved.
[0062] Furthermore, in the state where the tension applied to the driving wire 116 is maximized, in other words, when the most driving wire is wound round the pulley 114 , as the driving wire 116 and the guide member 130 are held substantially in parallel with each other, it becomes possible to prevent the consumption or frictional wear of the driving wire which is caused by the rubbing motion between the driving wire 116 and the wall face of the driving wire winding groove 128 , which takes place when winding the driving wire 116 round the pulley 114 . Thus, there can be improved the durability of the driving wire 116 wound round the pulley of the bending control mechanism.
[0063] (Second Embodiment)
[0064] In the next, there will be described the bending control mechanism of the endoscope according to the second embodiment of the invention with reference to the accompanying drawings. FIGS. 9A and 9B are diagrams schematically showing the constitution and the operation of the bending control mechanism for the endoscope according to the second embodiment of the invention, in which FIG. 9A indicates the bending control mechanism staying in the neutral state (non-bending control) while FIG. 9B indicates the bending control mechanism staying in the state where the most driving wire 116 is wound round the pulley 214 . Besides, the endoscope to which the bending control mechanism of this embodiment is applied is the same as the one described in the first embodiment, thus, the detailed explanation thereabout being omitted. This omission will be applied to the other embodiments as will be described later.
[0065] As shown in FIG. 9B, in the state where the most driving wire 116 is wound round the pulley 214 , the bending control mechanism of the second embodiment differs from that of the first embodiment in the constitution of the pulley 214 as well as in the arrangement position of the guide member 230 .
[0066] To put it more concretely, the pulley 214 of the second embodiment is provided with a driving wire winding groove 228 in the similar way as the pulley 10 provided with the driving wire winding groove 12 as shown in FIG. 5. That is, both of driving wire winding grooves 228 and 12 are similarly formed along the peripheral direction of respective pulley and in the shape of a clockwise spiral, respectively. Also, as shown in FIG. 9B, the end portion 117 of the driving wire 116 is connected with the end portion 228 a of the driving wire winding groove 228 on the shaft-provision side of the pulley 214 and extends therefrom.
[0067] Furthermore, as shown in FIG. 9A, in the neutral state before the driving wire is wound up by the pulley 214 , the connection member 118 , which is slidably mounted round the guide member 230 provided inside the control portion, stays in the position that is deviated in the axial direction of the pulley 214 from the position out of which the driving wire 116 extends. At this time, the driving wire 116 makes an angle θ′ with regard to the direction vertical to the axial direction of the pulley 214 .
[0068] With the constitution like this, when the most driving wire 116 is wound, the position of the guide member 230 is determined such that the extending direction of the driving wire 116 and the guide face of the guide member 230 are substantially in parallel with each other. Like this, relative position between the pulley 214 and the guide member 230 is determined such that the extending direction of the driving wire 116 becomes parallel to the guide face of the guide member 230 .
[0069] In the neutral state, because the guide member 230 is arranged as shown in FIG. 9A, the driving wire 116 can not be in parallel with the guide face of the guide member 230 in the neutral state but slopes up directing to the extending point of the driving wire 116 from the pulley 214 as shown in FIG. 9A. In contrast with this, in the state where the most driving wire 116 is wound round pulley 214 as shown in FIG. 9B, as the driving wire 116 is wound round the spiral-shaped driving wire winding groove 228 provided on the shaft-provision side of the pulley 214 , the extending point of the driving wire from the driving wire winding groove 228 comes down until the same height level as that of the connecting member 118 mounted on the guide member 230 provided inside the control portion.
[0070] Because of this, when the most driving wire 116 is wound round the pulley 214 , the extending direction of the driving wire 116 and the guide face of the guide member 230 become in parallel with each other and at this time, the positional relation between the driving wire 116 and the guide member 230 is relatively determined. With this, when the tension applied to the driving wire 116 is maximized, in other word, when the most driving wire 116 is wound round the pulley 214 , the driving wire 116 becomes substantially parallel to the guide member 230 . Accordingly, comparing to the pulley 10 of the bending control mechanism as shown in FIG. 5, there is no need for any excess force to be used for winding up the driving wire 116 round the pulley 214 , and it becomes possible to turn the bending control lever 112 with smaller force.
[0071] Besides, when the tension applied to the driving wire 116 is maximized, that is, when the most driving wire 116 is wound round the pulley 214 , as the driving wire 116 and the guide member become substantially parallel to each other, it becomes possible to prevent the consumption or frictional wear of the driving wire caused by the rubbing motion between the driving wire 116 and the wall face of the driving wire winding groove 228 , which takes place when winding the driving wire 116 round the pulley 214 .
[0072] Furthermore, as there is no chance that the driving wire 116 is in contact with the guide member 230 even in the neutral state, it becomes possible to prevent the consumption or frictional wear of the driving wire 116 caused by the rubbing motion between the driving wire 116 and the guide member 230 .
[0073] (Third Embodiment)
[0074] In the next, there will be described the bending control mechanism for the endoscope according to the third embodiment of the invention with reference to the accompanying drawings. FIGS. 10A and 10B are diagrams schematically showing the constitution and the operation of the bending control mechanism for the endoscope according to the third embodiment of the invention, in which FIG. 10A indicates the bending control mechanism when it stays in the neutral state, and FIG. 10B indicates the state of the bending control mechanism when the most driving wire 116 is wound round the pulley 314 .
[0075] Besides, in the bending control mechanism according to the third embodiment as shown in FIGS. 10A and 10B, there is provided a pulley displacement mechanism, which enables a pulley 314 to move up and down in the axial direction thereof such that the extending direction of the driving wire 116 becomes substantially parallel to the guide face of the guide member 130 in correspondence with the height of the driving wire 116 wound round the pulley 314 in the axial direction thereof.
[0076] With provision of the pulley displacement mechanism like the above, it becomes possible to produce such a state that the driving wire 116 and the guide face of the guide member 130 mounting a connection member thereon become always substantially parallel to each other, the connection member being connected with the driving wire 116 with a bending wire 120 . Because of this, there is no need for any excess force to be used for winding up the driving wire 116 round the pulley 314 by using the bending control lever 112 and the bending portion 108 can be controlled with smaller force. Furthermore, it becomes possible to prevent the consumption or frictional wear of the driving wire, which is caused by the rubbing motion between the driving wire 116 and the wall face of the driving wire winding groove 328 .
[0077] Here, there will be described in detail the concrete constitution of the pulley displacement mechanism according to the third embodiment, referring to the accompanying drawings. As shown in FIGS. 10A and 10B, the pulley displacement mechanism includes a cam of the cylinder type 330 which is provided on a pulley shaft portion 315 and a cam pin 325 which is provided on a support member 324 supporting the pulley 314 in the control portion such that the cam pin 325 fits to the cam groove 332 of the cylinder type cam 330 . The cylinder type cam 330 may be arranged in a region, for instance the region between the pulley 314 and the bending control lever 112 .
[0078] Similar to the pulley 10 as shown in FIGS. 5A and 5B, the pulley 314 according to this embodiment includes the driving wire winding groove 328 in the shape of a clockwise spiral, which is formed on the peripheral surface of the pulley 314 so as to extend in the peripheral direction of the pulley 314 . The driving wire winding groove 328 is formed such that a plurality of stepped grooves are formed in the shape of a spiral along the axial direction of the shaft portion 315 from the end face side of the pulley 314 toward the side of the pulley shaft portion 315 . Besides, as shown in FIG. 10B, the one end portion 328 a of the driving wire winding groove 328 is fixedly connected with the end portion of one driving wire while the other end portion of the driving wire winding groove 328 b is fixedly connected with the end portion of the other driving wire. In FIGS. 10A and 10B, the other driving wire is omitted.
[0079] As shown in FIGS. 10A and 10B, the above cylinder type cam 330 is constituted to have the same diameter as the pulley 314 , and the cam groove 332 is formed in the shape of a spiral extending in the peripheral direction similar to the driving wire winging groove 328 of the pulley 314 . Besides, the cam pin 325 fitting to the cam 332 is provided in the inner peripheral surface of the pulley support member 324 inserted in the shaft portion 315 of the pulley 314 .
[0080] According to the bending control mechanism of the third embodiment, if the pulley 314 is rotated by means of the bending control lever 112 , the cylinder type cam 330 is turned linking with rotation of the pulley 314 If the cylinder type cam 330 is rotated, the cam pin 325 fixed through the pulley support member 324 is guided along the cam groove 332 , thereby the cylinder cam 330 sliding in the axial direction, in link with which the pulley 314 also slides also in the axial direction. As a result, as shown in FIG. 10B, the pulley 314 is displaced in the axial direction by a distance of X.
[0081] As shown in FIG. 10B, in the state where the most driving wire 116 is wound round the pulley 314 , the arrangement position of the cam pin 325 is determined such that the height in the axial direction of the driving wire 116 extending out from the driving wire winding groove 328 becomes the same as that of guide face (i.e. arrangement position of the connection member 118 ) of the guide member 130 . Because of this, the extending direction of the driving wire 116 as extended out from the pulley 314 becomes always substantially parallel to the guide surface of the guide member 130 .
[0082] In the way like this, when the most driving wire 116 is wound round the pulley 314 and the tension applied to the driving wire 116 is maximized, as the driving wire 116 and the guide face of the guide member 130 become substantially parallel to each other, the bending control lever 112 can be rotated without using any excess force.
[0083] Furthermore, according to the displacement mechanism of the third embodiment, the extending direction of the driving wire 116 can always be made substantially parallel to the guide face of the guide member 130 , not limited to only when the tension applied to the driving wire 116 is maximized. Consequently, it becomes possible to more effectively prevent the consumption or frictional wear of the driving wire 116 which is caused by the rubbing motion between the driving wire 116 and the wall face of the driving wire winding groove 328 , when winding the driving wire 116 round the pulley 314 .
[0084] (Fourth Embodiment)
[0085] In the next, there will be described a bending control mechanism for the endoscope according to the fourth embodiment of the invention with reference to the accompanying drawings. FIGS. 11A and 11B are diagrams schematically showing the constitution and the operation of the bending control mechanism for the endoscope according to the fourth embodiment of the invention, in which FIG. 11A indicates the bending control mechanism when it is in the neutral state, and FIG. 11B indicates the bending control mechanism when the most driving wire 116 is wound round a pulley 414 at the time of executing the bending control.
[0086] The constitution of the pulley 414 according to the fourth embodiment is similar to that of the pulley 314 according to the third embodiment. A driving wire winding groove 428 , an end portion 428 a and an end portion 428 b in the fourth embodiment correspond to the driving wire winding groove 328 , the end portion 328 a and the end portion 328 b in the third embodiment as described in the above, respectively.
[0087] The pulley 414 of the fourth embodiment is also provided with a pulley displacement mechanism capable of displacing the pulley 414 in the axial direction thereof in the same way as the pulley 314 of the third embodiment. However, the former differs from the latter in that in the pulley displacement mechanism of the fourth embodiment, a cam pin 425 is provided on the pulley shaft portion 415 while a cam groove 426 is provided on the pulley support member 424 .
[0088] To put it more concretely, as shown in FIGS. 11A and 11B, a cam groove 426 is provided along the inner face of the pulley support member 424 inserted in the shaft portion 415 of the pulley 414 , the cam groove 426 being in the shape of a spiral extending in the peripheral direction of the above inner face of the pulley support member 424 . Besides, the cam pin 425 fitting to the cam groove 426 is provided on the shaft portion 415 within a region between the pulley 414 and the bending control lever 112 .
[0089] According to the bending control mechanism of the fourth embodiment, if the pulley 414 is rotated by the bending control lever 112 , the cam pin 425 is turned linking with the rotation of the bending control lever 112 . At this time, the cam pin 425 is guided along the cam groove 426 of the pulley support member 424 , thereby the pulley 414 sliding in the axial direction. As a result, as shown in FIG. 11B, the pulley 414 is displaced in the axial direction by a distance of X.
[0090] As shown in FIG. 11B, the formation position of the cam groove 426 is determined such that, in the state where the most driving wire 116 is wound round the pulley 414 , the height in the axial direction of the driving wire 116 extending out from the driving wire winding groove 428 becomes the same as that of the guide face (i.e. arrangement position of the connection member 118 ) of the guide member 130 . As a result, the extending direction of the driving wire 116 as extended out from the pulley 414 becomes always substantially parallel to the guide surface of the guide member 130 .
[0091] In this way, when the most driving wire 116 is wound round the pulley 414 and the tension applied to the driving wire 116 is maximized, as the driving wire 116 and the guide face of the guide member 130 become substantially parallel to each other, the bending control lever 112 can be rotated without using any excess force.
[0092] Furthermore, according to the displacement mechanism of the fourth embodiment, the extending direction of the driving wire 116 can be always substantially parallel to the guide face of the guide member 130 , not limited to only when the tension applied to the driving wire 116 is maximized. As the result of this, it becomes possible to more effectively prevent the consumption or frictional wear of the driving wire 116 which is caused by the rubbing motion between the driving wire 116 and the wall face of the driving wire winding groove 428 , when winding the driving wire round the pulley 414 .
[0093] While several preferred embodiments of the invention have been shown and described with reference to the accompanying drawings, it is needless to say that the invention is not always limited to such embodiments. It will be apparent that one who is skilled in the art can make various changes and modifications without departing from the principle and spirit of the invention, the scope of which is defined in the appended claims, and it is understood that those changes and modifications naturally belong to the technical scope of the invention.
[0094] For instance, in the first embodiment, there is described on an example wherein a driving wire winding groove in the shape of an anti-clockwise spiral is formed on the external peripheral surface of the pulley along the peripheral direction thereof. However, the invention is not always limited to this embodiment. If the driving wire is fixedly connected with the end portion of the driving wire winding groove on the end surface side of the pulley, the driving wire winding groove in the shape of clockwise spiral formed along the peripheral surface of the pulley can bring the same effect as the first embodiment.
[0095] Besides, in the second, third and fourth embodiments, there are described examples wherein each driving wire winding groove in the shape of a anti-clockwise spiral is formed on the external peripheral surface of the pulley along the peripheral direction thereof. However, the invention is not always limited to this example. If the driving wire is fixedly connected with the end portion of the driving wire winding groove on the shaft side of the pulley, even the driving wire winding groove in the shape of anti-clockwise spiral formed on peripheral surface of the pulley can bring the same effect.
[0096] As has been discussed so far, according to the bending control mechanism for the endoscope, when the tension applied to the driving wire is maximized, as the extending direction of the driving wire becomes substantially parallel to the guide face of the guide member, the control of the bending portion can be carried out by winding up the driving wire wound round the pulley with smaller force. Accordingly, there is provided an endoscope with the improved controllability.
[0097] Besides, when the tension applied to the driving wire is maximized, as the extending direction of the driving wire becomes substantially parallel to the guide face of the guide member, it becomes possible to prevent the consumption or frictional wear of the driving wire which is caused by the rubbing motion between the driving wire wound round the pulley and the wall face of the driving wire winding groove provided along the peripheral surface of the pulley. Because of this, the durability of the driving wire can be improved.
[0098] Furthermore, as there is provided a pulley displacement mechanism capable of moving up and down the pulley in the axial direction thereof in correspondence with the height in the axial direction of the driving wire wound round the pulley such that the extending direction of the driving wire becomes substantially parallel to the guide face of the guide member, it become possible to make the extending direction of the driving wire be always substantially parallel to the guide face of the guide member. Because of this, it becomes possible to more effectively prevent the consumption or frictional wear of the driving wire which is caused by the rubbing motion between the driving wire and the wall face of the driving wire winding groove, when the driving wire is wound round the pulley. | A bending control mechanism for an endoscope includes a bending portion in an insertion portion of the endoscope. The bending portion is controlled by a bending wire extending therefrom. A pulley operates in linkage with a bending control lever through a shaft portion of the pulley. The lever is in a control portion of the endoscope. A driving wire winding groove spirals along the pulley's outer peripheral surface and extends in its peripheral direction. A driving wire winds along the groove. A connection member connects the driving wire with the bending wire. A guide member in the control portion has a slidably mounted connection member. With the most driving wire wound around the pulley, a relative position between the pulley and the guide member is such that the driving wire extends substantially in parallel to a guide surface of the guide member. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical disk apparatus, and more particularly to an optical disk apparatus capable of discriminating a loaded optical disk from a plurality of optical disks having different thicknesses and selecting a pickup lens most suitable for the discriminated optical disk.
2. Description of the Related Art
A conventional optical disk apparatus for data recording, reproducing and erasing has: an optical focussing system in which a laser beam is focussed via a pickup lens to a loaded optical disk, and light reflected from the optical disk is detected with a photodetector; and a focus pull-in control system having an actuator for converging the laser beam to the optical disk.
FIG. 7 is a block diagram showing the structure of such a conventional optical disk apparatus. This optical disk apparatus has: a photodetector 31 having a total of four unit elements A, B, C and D; amplifiers 32, 33, 34 and 35 for amplifying respective signals detected with the unit elements A, B, C and D; an RF amplifier 36 for amplifying a sum of all the outputs of the amplifiers 32, 33, 34 and 35; a focus error (hereinafter abbreviated as FE) amplifier 37 for amplifying a sum of the outputs of the amplifiers 33 and 35 subtracted by a sum of the outputs of the amplifiers 32 and 34; a signal processing circuit 50 for processing an RF signal 38 output from the RF amplifier 36 to obtain a necessary signal such as an audio signal; a D/A converter 51 for converting a digital signal output from the signal processing circuit 50 into an analog signal; an amplifier 52 for amplifying an output of the D/A converter 51, and a speaker 53 for receiving an output of the amplifier 52 and producing sounds. The optical disk apparatus further includes: an RF comparator 40 for receiving an RF signal 38 generally called a sum signal as its non-inverting input (+) and a voltage divided by a variable resistor 42 as its inverting input (-) and outputting a focus-ok (FOK) signal 55; an FZC comparator 41 for receiving an FE signal 39 from the FE amplifier 37 as its non-inverting input (+) and a voltage divided by resistors 43 and 44 as its inverting input (-) and outputting a focus zero cross (FZC) signal 56; a servo ON/OFF switch 46, a resistor 45 connected between one end of the switch 46 and an output of the FE amplifier 37; a servo circuit 47 for receiving a signal at the one end of the switch 46 and a signal from a controller 54; a driver 48 for power amplifying a signal output from the servo circuit 47; an actuator 49 connected to an output of the driver 48 and made of a focus coil; and the controller 54 made of a microcomputer for receiving the FOK signal 55 and the FZC signal 56 and controlling the servo system including the switch 46, servo circuit 47, and the like. A combination of the FOK signal and FZC signal is called a focus signal.
The variable resistor 42 is connected between a power source voltage +V and the ground, and is used for controlling an FOK level so that the focus point of a reflection film of the optical disk is detected without detecting the surface of the optical disk. The resistors 43 and 44 are serially connected between the power source voltage +V and the ground, and is used for presetting the bias of the inverting input (-) to a predetermined voltage value so that the zero cross point of the FE signal 39 is correctly detected. The block diagram of FIG. 7 described above is mainly pertains to a focus pull-in control system.
The operation of the optical disk apparatus shown in FIG. 7 will be described with reference to the flow chart of FIG. 8 illustrating the control procedure for the optical disk and with reference to the timing chart of FIG. 9 showing the waveforms of signals at various circuit portions. First, at Step S1 a laser power source is turned on and a laser beam is applied to a loaded optical disk. Next, at Step S2 the focus servo system starts moving up a pickup lens toward the optical disk at a constant speed. Therefore, the in-focus position gradually moves toward the inner region of the optical disk.
In this case, a small peak appears on the RF signal 38 at a position P1 and at a timing t1 when the in-focus position reaches the surface of the optical disk. This small peak waveform has a level of the FOK level or lower set to the RF comparator 40 so that the FOK signal 55 does not change. An S-character or inverted S-character curve appears on the FE signal 39 so that the FZC signal 56 of a negative pulse having a falling edge at the focus zero cross point is output. The two signals, FOK and FZC signals 55 and 56, are collectively called a focus signal as described earlier. This position P1 corresponds to the in-focus position of the optical disk surface. Since it is not meaningless to stop the servo system and fix the focus at this timing, the switch 46 maintains an OFF state so that the servo system continues its operation without advancing to Step S5.
A position P2 at a timing t2 when the FOK signal 55 is detected at Step S3 corresponds to the in-focus position at the reflection layer in the inner region of the optical disk. In this case, since the RF signal 38 has a level higher than the FOK level, an FOK signal 55 is output which is a positive pulse having a width corresponding to the period while the RF signal 38 takes a level higher than the FOK level. In this case, the FE signal 39 has a large S-character impulse which is shaped by the FZC comparator 41 and output as the FZC signal 56 having a falling edge at the zero cross point.
Since the FZC signal 56 takes an L (low) level at Step S4 and the FOK signal 55 takes an H (high) level at Step S3, the flow advances to Step S5 whereat the focus servo loop is closed so that motion of the pickup lens is stopped and the position P2 is established as the focus-on-point which is the in-focus point at the reflection layer.
As the lens is moved at a constant speed, there is a point at which the in-focus is obtained instantaneously. This in-focus point corresponds to the zero cross point while the RF signal 38 is higher than the FOK level and while the amplitude of the focus error signal is lower than a threshold value E. It is known that if the objective lens is positioned in the area corresponding to this period, the focus pull-in can be performed always stably.
In the structure described above, the FOK level is set by the RF comparator 40. There is a case wherein there is only a small difference between the peak values of the RF signals 38 reflected from the surface of an optical disk and from the reflection layer in the inner region of the optical disk. In such a case, the pulse of the FOK signal 55 is generated for both the peak signals of the RF signals. Therefore, the disk surface may be erroneously judged to be the reflection layer surface. Alternatively, the pulse of the FOK signal 55 may not generated for both the peak signals so that the unload state of an optical disk may be erroneously judged. As above, inability of setting a sufficient voltage margin of the FOK level may result in focus pull-in control with less reliability.
Also in the above structure, the focus control is performed by a pickup lens used in common for optical disks of one kind having generally the same focus-on-point. If an optical disk of another kind having a thickness greatly different from the one kind is loaded, it is impossible to use the same lens for the focus control in excess of a refraction limit because of the spherical aberration.
FIGS. 10A to 10C are cross sectional views of optical disks of three kinds. The optical disk shown in FIG. 10A is called a CD (compact disk) having a thickness of about 1.2 mm and an aluminum reflection film 60 formed on the main surface of a polycarbonate substrate 61. An optical disk shown in FIG. 10B is called a DVD (digital versatile disk) having a thickness of about 0.6 mm and an aluminum reflection film 64 formed on the main surface of a second polycarbonate substrate 63 and a first substrate 62 stacked on the surface of the reflection film 64. The optical disk shown in FIG. 10C is called a two-layer DVD having a thickness of about 0.6 mm and a reflection film 67, an intermediate layer (transparent material) and a semi-transparent film 68 interposed between first and second substrates 65 and 66. It is desired to use the same optical disk apparatus for the reproduction and recording of optical disks of three different kinds.
A conventional optical disk apparatus having a function of discriminating between optical disks of a plurality of different kinds is disclosed in Japanese Patent Laid-open HEI 5-54406. This optical disk can discriminate between different kinds of optical disks without using a specific detector, by measuring a disk substrate thickness with measuring means which measures the time interval of two S-character waves on the focus error signal while focus position control means moves the objective lens near to the disk surface.
With this structure, however, the time interval depends on the motion speed of the objective lens. Therefore, if the motion speed fluctuates, the time interval changes even if the disk thickness is the same so that correct measurement of the disk thickness is difficult.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an optical disk apparatus capable of solving the following issues:
(1) realizing a considerably increased detection voltage margin, without using means for discriminating between a disk surface and a reflection layer by setting the FOK level;
(2) enabling focus control with high reliability;
(3) enabling to load disks having a large thickness difference of the substrate on the same optical disk apparatus for data recording and reproducing;
(4) enabling to load disks including a CD, a DVD and a two-layer DVD on the same optical disk apparatus for data recording and reproducing;
(5) eliminating influence of a lens motion speed change upon thickness measurement; and
(6) enabling to quickly discriminate between disk thicknesses even if the substrate thickness is greatly different.
According to one aspect of the present invention solving the above issues, an optical disk apparatus for data recording, reproducing and erasing is provided which has an optical focussing system in which an optional optical disk is selected from a plurality of optical disks of different kinds having different thicknesses and loaded in the optical disk apparatus, a laser beam is focussed via a pickup lens to the loaded optical disk, and light reflected from the loaded optical disk is detected with a photodetector, and having a control system with an actuator for converging the laser beam to the optical disk, the optical disk apparatus comprising: means for detecting a focus signal from the photodetector while the pickup lens is moved by the control system; temporary storage means for storing, as first and second measured values, drive currents or voltages of the actuator representative of the in-focus positions at the surface of the optical disk and at a reflection film of the optical disk, in accordance with the focus signal; subtraction means for calculating a difference of the second measured value from the first measured value; and identifying means for identifying the kind of the optical disk by comparing the calculated difference with a reference value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of an optical disk apparatus according to an embodiment of the invention.
FIG. 2 is a timing chart showing signal waveforms at various circuit portions of the optical disk apparatus of the embodiment, in which focus search is performed for an optical disk of 0.6 mm thick.
FIG. 3 is a timing chart showing signal waveforms at various circuit portions of the optical disk apparatus of the embodiment, in which focus search is performed for an optical disk of 1.2 mm thick.
FIG. 4 is a flow chart illustrating the first half portion of the control procedure according to an embodiment of the invention.
FIG. 5 is a flow chart illustrating the second half portion of the control procedure of the embodiment.
FIG. 6 is a perspective view showing the structure of a pickup used by the embodiment optical disk apparatus.
FIG. 7 is a block diagram showing the structure of a conventional optical disk apparatus.
FIG. 8 is a flow chart illustrating a conventional control procedure.
FIG. 9 is a timing chart showing signal waveforms at various circuit portions of the conventional optical disk apparatus performing focus search.
FIGS. 10A to 10C are cross sectional views showing optical disks of different kinds.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An optical disk apparatus according to an embodiment of this invention shown in the block diagram of FIG. 1 is different from the conventional optical disk apparatus shown in the block diagram of FIG. 7, in that the servo system is provided with a current detector circuit 31, that a controller 16 discriminates between optical disks by detecting current or voltage of an actuator of the servo system, and that an FOK level set to an FOK amplifier 10 is low. The other structures are the same as those shown in the block diagram of FIG. 7.
A pickup 1 has the structure, for example, same as that of the photodetector 31 and amplifiers 32, 33, 34 and 35 shown in FIG. 7. RF and FE amplifiers 2 and 3 may be the same as the RF and FE amplifiers 36 and 37. An FOK amplifier 10 for inputting an RF signal 12 and outputting an FOK signal 14 may have the same structure as the RF comparator 40, however, with a different setting value of the variable resistor 42. In this embodiment, in particular, the bias of a variable resistor (not shown) is set so that pulses detecting both the surface and reflection film of an optical disk can be generated as will be described later.
A FZC amplifier 11 for inputting an FE signal 13 and outputting a FZC signal 15 may have the same structure as the FZC comparator 41 and have bias resistors (not shown) same as the bias resistors 43 and 44. The servo system including a phase compensator circuit 9 receiving the RF signal 12, a switch 18 and an adder 19 is controlled by a controller 16. The adder 19 is controlled via a D/A converter 17 for converting a digital value into an analog value. An amplification factor of a power amplifier driver 22 is set by resistors 20 and 21. An output of the driver 22 is supplied via a resistor 24 to an actuator 23 made of a focus coil.
The current detector circuit 31 detects a voltage across the resistor 24 having a predetermined value in order to detect current flowing through the actuator 23. Resistors 25 and 27 are serially connected to an inverting input terminal (-) of a comparator 30, and resistors 26 and 28 are serially connected to a non-inverting input terminal (+) thereof also connected to which is a resistor 33. In order not to amplifier high frequency components such as noises, a capacitor 29 is connected between the common connection point of the resistors 25 and 27 and the common connection point of the resistors 26 and 28.
An analog value output of the comparator 30 is converted by an A/D converter 32 into a digital value which is supplied to the controller 16. The controller 16 is made of a microcomputer and stores therein control programs which are executed in a predetermined order to be described later. The RF signal 12 is supplied to a signal processing circuit 34 which supplies a video signal to a D/A converter 4 and to a display unit 6 and supplies an audio signal to a D/A converter 5 and via a driver 7 to a speaker 8.
The circuit shown in FIG. 1 mainly shows the focus pull-in control system of the optical disk apparatus in which any one of optical disks of different kinds shown in FIGS. 10A to 10C can be loaded.
Reference is made to the timing chart of FIG. 2 illustrating the focus search of an optical disk of 0.6 mm thickness and the flow charts of FIGS. 4 and 5 illustrating the procedure of the controller 16. First, at Step S6 a power is turned on to apply a laser beam to an optical disk. Next, at Step S7 the pickup lens is gradually moved up toward the surface of the optical disk.
If an in-focus is obtained at the surface of the optical disk, the RF signal 12 takes a level higher than a preset FOK level so that an FOK signal 14 is obtained which has a pulse width corresponding to the period while the RF signal 12 takes a level higher than the preset FOK level. It is to be noted that the bias of the FOK amplifier 10 is set so that the FOK signal 14 is output also when the in-focus at the optical disk surface is obtained.
The focus error (FE) signal 13 has an S-character impulse (in this case, inverted S-character impulse) which is shaped by the FZC amplifier 11 to obtain an FZC signal 15 having a predetermined pulse width and a falling edge at the zero cross point. These pulse signals satisfy the condition of Step S8 that the FOK signal 14 takes an H (high) level and the condition of Step S9 that the FZC signal takes an L (low) level. At the next Step S10, coil current of the actuator 23 is sampled and held and then A/D converted. At Step S11, this coil current i1 is stored in a memory of the controller 16. It is judged at Step S12 whether the stored current which satisfied the conditions of Steps S8 and S9 is either for the first time (in-focus at the surface of the optical disk) or for the second time (in-focus at the reflection film). If it is judged to be the first time, the flow returns to Step S8.
Next, as the lens is further moved, the RF signal 12 having a larger impulse is obtained when the in-focus at the reflection film of the optical disk is obtained. This RF signal 12 is compared with the FOK level to obtain the FOK signal 14 having a pulse width corresponding to the period while the RF signal 12 takes a level higher than the FOK level. In this case, the FE signal 13 has a larger S-character impulse and an FZC signal 15 is obtained which has a predetermined pulse width and a falling edge at the zero cross point. These pulse signals satisfy the conditions of Steps S8 and S9, and after Step S10, coil current i2 is stored in the memory of the controller 16 at Step S11.
Since the coil current i2 is for the second in-focus at Step S12, the flow advances to Step S13 whereat a current value (i2-i1), i.e., a current difference, is calculated. This current difference is compared at Step S14 with a preset reference value (in this embodiment, a current value corresponding to a thickness of 0.9 mm is used as the reference value). If the current difference is smaller than the reference value, it is judged at Step S15 that the optical disk is an 0.6 mm thick optical disk. If the current difference is lager than the reference value (corresponding to the thickness of 0.9 mm), it is judged at Step S16 that the optical disk is an 1.2 mm thick optical disk. After Step S15, the pickup lens is changed to a DVD (high NA) type to thereafter terminate the procedure.
Reference is made to the timing chart of FIG. 3 illustrating the focus search of an optical disk of 1.2 mm thickness. Also in this case, the coil current i1 for the in-focus at the surface of the optical disk is detected at time t1, and another coil current i3 for the in-focus at the reflection film is detected. A current difference (i3-i1) is calculated. Since this current difference is larger than the reference value (corresponding to the thickness of 0.9 mm), the flow advances to Steps S16 and S18 to change the pickup lens to the CD (low NA) type to thereafter terminate the procedure.
Although the coil current i3 is smaller than twice the coil current i2, the current difference (i3-i1) is about twice the current difference (i2-i1). Therefore, it is more advantageous to compare the current difference with the reference value and the reliability of the comparison at Step S14 becomes better, because of a lager difference between the two current differences. Furthermore, if an absolute value is used for the comparison therebetween instead of the current difference, this absolute value changes with the mount position of the turntable. In this connection, if the current difference is used, a variation of coil current to be caused by the variation of the mount state of an optical disk can be eliminated.
For selecting a pickup lens at Steps S17 and S18, a plurality of lenses having different numerical apertures NA are prepared for realizing in-focus without any spherical aberration. A plurality of lenses are disposed in plane and controlled to be rotated about one axis to thereby select a suitable one.
A pickup of such a twin-lens type is shown in FIG. 6. The pickup shown in FIG. 6 has a lens holder 70 mounted on which are a CD objective lens 78, a DVD objective lens 79, iron pieces 71, 72 and 75, and tracking coils 73, 74 and 76. A focussing magnet 80 is also mounted between a support 81 and the lens holder 70, and tracking magnets 77 and 83 are fixed to the support 81 spaced apart from each other so that the lens holder 70 can rotate freely about a rotary shaft 82. Another iron piece and another tracking coil are also mounted although they are not shown in FIG. 6 because they are at the back of the tracking magnet 77.
While no current flows through the tracking coils 73, 74 and 76 and the like, the iron piece 72 and tracking magnet 81 for example are structured to be attracted each other. Namely, even if no control voltage is applied, one of the lenses 78 and 79 is set to a normal stage. With this structure, in order to switch between the lenses, a kick pulse is applied to the tracking coil 74 in a short time to generate a repulsion force larger than the attraction force between the magnet 81 and iron piece 72. The lens holder 70 therefore receives a rotation torque and rotates the lens holder 70. After some rotation, the iron piece 71 is attracted to the magnet 81 and fixed to the normal stage. In this manner, the lenses 78 and 79 fixed to the lens holder 70 are selectively switched. In order to recover the position of the original lens, a kick pulse of an opposite polarity is applied to perform a similar control.
At Steps S17 and S18, the switching control only is executed. In this case, means for visually displaying which optical disk was selected may be provided.
In the current detector circuit 31 of this embodiment, the resistor 24 is connected serially to be actuator 23 to measure the current flowing through the actuator 23 by detecting the voltage across the resistor 24 having a presumably constant resistance. This voltage value is supplied via the A/D converter 32 to the controller 16 which converts the voltage value into the current value. Since the voltage value is proportional to the current value, the voltage value itself may be used for comparison. The current detector circuit 31 shown in FIG. 1 is only illustrative and may use known means for directly detecting a current.
As above, since it becomes possible to discriminate between optical disks during the focus search, the lens can be replaced immediately so that the time required for reading actual data can be shortened.
According to the optical disk apparatus of this invention described above, a current difference obtained during the in-focus at the surface and reflection film of an optical disk is used for the discrimination between optical disks. Therefore, discrimination reliability is very high and all the previously described issues can be solved. | An optical disk apparatus capable of automatically setting a pickup lens suitable for an optional optical disk selected from a plurality of optical disks having different thicknesses. Current flowing through an actuator is detected with a detector circuit, A/D converted, and supplied to a controller. The controller detects the in-focus positions at the surface and reflection film of an optical disk in accordance with an FOK signal and an FZC signal, calculates the current values flowing through the actuator at the in-focus positions, and judges the thickness of the optical disk in accordance with a difference between the current values. | 6 |
RELATED APPLICATION
[0001] This patent document claims priority under 35 U.S.C. §119 and all other benefits from PCT Application No. PCT/US2014/022339, filed Mar. 10, 2014, the content of which is hereby incorporated by reference to the extent permitted by law.
FIELD
[0002] The present invention relates generally to methods and systems for integrating backup audio routing and supervisory circuitry into a voice control panel in an alarm system.
BACKGROUND
[0003] In alarm systems, such as building fire alarm systems, audio capabilities enable emergency messages to be passed between fire control panels and/or audio panels. Since building alarm systems impact public safety, standards have been developed by organizations in the United States and Europe. For example, some standards require backup amplifiers as part of the audio circuitry in case a primary amplifier fails.
[0004] Conventional voice control panels require users to manually wire backup amplifiers to primary amplifiers. In these systems, if the user decides to change the configuration of the amplifiers, the user needs to rewire the connections between the amplifiers. In addition, after the wiring is completed, these systems require the wiring to be tested manually to ensure the system is set up properly.
SUMMARY
[0005] Methods and systems consistent with the present invention overcome the limitations of conventional systems by integrating the wiring between primary and backup amplifiers into the card cage of a voice control panel. The integrated wiring reduces the complexity of the installation, reduces problems that may arise from faulty wiring, and results in reduced installation and wiring costs. In addition, the integrated wiring makes the voice control panels more modular because the user may modify the configuration between the primary and backup amplifiers with a flip of a switch.
[0006] Methods and systems consistent with the present invention also overcome the shortcomings of conventional systems by providing supervisory circuitry for the backup amplifiers. The supervisory circuitry ensures that the desired configuration is setup and functioning properly without having to perform any manual tests. Thus, the supervisory circuitry adds a redundancy feature that previously did not exist in voice control panels. It provides a much better way to detect and address problems in the voice control panel before the system becomes nonoperational.
[0007] In accordance with methods and systems consistent with the present invention, a method is performed by a backup amplifier. The method comprises receiving an indication that a primary amplifier failed; receiving an indication of a configuration for the failed primary amplifier; and configuring the backup amplifier to match the configuration of the failed primary amplifier.
[0008] In accordance with articles of manufacture consistent with the present invention, a computer-readable medium is provided. The computer-readable medium contains instructions for controlling a data processing system to perform a method. The method comprises receiving an indication that a primary amplifier failed; receiving an indication of a configuration for the failed primary amplifier; and configuring the backup amplifier to match the configuration of the failed primary amplifier.
[0009] In accordance with methods and systems consistent with the present invention, a method is performed by an amplifier for a voice control panel. The method comprises determining whether the amplifier is designated as a backup amplifier; and if it is determined that the amplifier is designated as a backup amplifier, determining whether the configuration of the voice control panel is correct.
[0010] In accordance with articles of manufacture consistent with the present invention, a computer-readable medium is provided. The computer-readable medium contains instructions for controlling a data processing system to perform a method. The method comprises determining whether the amplifier is designated as a backup amplifier; and if it is determined that the amplifier is designated as a backup amplifier, determining whether the configuration of the voice control panel is correct.
[0011] In accordance with methods and systems consistent with the present invention, a method is performed by a voice control panel. The method comprises determining a configuration of a primary amplifier; receiving an indication that the primary amplifier failed; and notifying a backup amplifier to match the configuration of the primary amplifier.
[0012] In accordance with articles of manufacture consistent with the present invention, a computer-readable medium is provided. The computer-readable medium contains instructions for controlling a data processing system to perform a method. The method comprises determining a configuration of a primary amplifier; receiving an indication that the primary amplifier failed; and notifying a backup amplifier to match the configuration of the primary amplifier.
[0013] Another embodiment consistent with the present invention is directed to a voice control panel comprising a first amplifier slot having a backup input, a second amplifier slot having a backup output, a third amplifier slot having a backup output, and a switch. The switch is connected to the backup input of the first amplifier slot that toggles between the backup output of the second amplifier slot and the backup output of the third amplifier slot.
[0014] An additional embodiment consistent with the present invention is directed to a voice control panel comprising a first amplifier slot having a backup input, a second amplifier slot having a backup input and a backup output, and a switch. The switch is connected to the backup input of the first amplifier slot that toggles between the backup input of the second amplifier slot and the backup output of the second amplifier slot.
[0015] Another embodiment consistent with the present invention is directed to a voice control panel comprising a first amplifier slot having a backup input and a second amplifier slot having a backup output, wherein the backup input of the first amplifier slot is connected to the backup output of the second amplifier slot.
[0016] A further embodiment consistent with the present invention is directed to a card cage for a voice control panel comprising a primary amplifier having a backup input, a backup amplifier having a backup output, and a connector connecting the backup input of the primary amplifier to the backup output of the backup amplifier.
[0017] Other systems, methods, features, and advantages of the present invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the present invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:
[0019] FIG. 1 depicts an exemplary topology diagram for a building fire alarm system;
[0020] FIG. 2 depicts a data processing system for a voice amplifier card (VAC) suitable for implementing methods and systems consistent with the present invention;
[0021] FIG. 3 depicts a data processing system for a voice control panel for implementing methods and systems consistent with the present invention;
[0022] FIG. 4 depicts a block diagram of exemplary circuitry between voice amplifier card slots in the cards cage of the voice control panel consistent with the present invention;
[0023] FIGS. 5A-C depict a flow diagram illustrating steps performed by the data processing system depicted in FIG. 2 , in accordance with methods and systems consistent with the present invention; and
[0024] FIG. 6 depicts a flow diagram illustrating steps performed by the data processing system depicted in FIG. 3 , in accordance with methods and systems consistent with the present invention.
[0025] Reference will now be made in detail to the description of the invention as illustrated in the drawings. While the invention will be described in connection with these drawings, there is no intent to limit it to the embodiment(s) disclosed. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 depicts an exemplary topology diagram 100 for a building fire and audio alarm system approach. The building fire and audio alarm system may have numerous fire control panels 102 and 104 , fire and voice control panels 106 and 108 , and voice control panels 110 . In other implementations there may be more or fewer devices in the system. In yet other implementations, additional panels such as security panels or HVAC control panels may be present. The panels 102 - 110 may be networked together by a data network 112 . The data network may have a physical layer of wire, radio waves, fiber optic cables, coaxial cable, or a combination of any of the above. Over the physical layer, additional protocol layers may be implemented to carry data, such TCP/IP network (commonly called the internet). The data network 112 may be configured as a local area network (LAN) that connects only the panels and building automation systems.
[0027] The fire and voice control panels, such as fire and voice control panel 106 , may have associated desk mounted microphones 114 and connections to emergency centers, such as a 911 dispatch center 116 . In other implementations, the desk microphone may be an internal microphone or other audio input device. Additionally, the voice control panels and the fire and voice control panels include voice amplifier cards (VAC) 118 - 122 with audio outputs for connection to speakers 124 - 128 , as depicted for fire and voice control panel 106 .
[0028] FIG. 2 depicts an exemplary data processing system 200 for the VAC suitable for practicing methods and systems consistent with the present invention. Data processing system 200 includes a processor 202 , supervisory circuitry 204 , memory 206 , audio input/output 208 , backup input/output 210 , a backup relay 212 , and configuration relays 214 . These internal components exchange information with one another via a system bus 216 . The supervisory circuitry 204 can be implemented with hardware, software firmware or any combination thereof. Although data processing system 200 contains a single processor, it will be apparent to those skilled in the art that methods consistent with the present invention operate equally as well with a multi-processor environment. More or less components can be used. For example, known data processing system components for VACs can be used, e.g., fire safety panel components.
[0029] Configuration relays 214 control the configuration of the amplifier. In particular, configuration relays 214 identify whether the amplifier has a class A configuration or a class B configuration, as is well known to one having ordinary skill in the art. The backup relay 212 connects VAC to its backup amplifier when VAC fails. The backup input 210 for each VAC includes an on-board termination resistor (not shown).
[0030] Memory 206 includes instructions 218 that may be executed to cause the data processing system 200 to perform any one or more of the methods or functions disclosed herein. The instructions 218 include a VAC supervisory backup manager application. The VAC supervisory backup manager application can be used to perform the logic described in FIGS. 5A-5C . The data processing system 200 may operate as a standalone device or may be connected, e.g., using a network, to other computer systems or peripheral devices.
[0031] FIG. 3 depicts an exemplary data processing system 300 for the voice control panel, e.g., panels 106 , 108 , 110 of FIG. 1 , suitable for practicing methods and systems consistent with the present invention. Data processing system 300 can may include a processor 302 , memory 304 , display 306 , communication interface 308 , and a card cage 400 . The card cage 400 includes card cage slots 402 , 404 , 406 and 408 adapted to receive VACs. In one embodiment, shown in FIG. 3 , the processor 302 , memory 304 including instructions 312 and communication interface 308 are incorporated into a mother board of the data processing system 300 (e.g., panels 106 , 108 , 110 ). In an alternative embodiment, the card cage 400 is adapted to include a slot for receiving a voice control card 301 (shown in phantom view in FIG. 3 ) that incorporates the processor 302 , memory 304 including instructions 312 and communication interface 308 . In this embodiment, the voice control card 301 would be in signal and/or data communication with the display 306 of the data processing system 300 or respective panel 106 , 108 and 110 . In either embodiment, the processor 302 is operatively configured to be in signal and/or data communication with the VACs inserted in the card cage slots 402 , 404 , 406 and 408 as described in further detail herein. More or less components and more or less card cage slots can be used. These components can exchange information with one another via a system bus 310 . The card cage 400 can connect with the system bus 310 directly and/or through the communication interface 308 . Communication interface 308 allows data processing system 300 to communicate with components of the system (e.g., VACs) and to the user, e.g., through a commissioning tool (described below). Although data processing system 300 contains a single processor, it will be apparent to those skilled in the art that methods consistent with the present invention operate equally as well with a multi-processor environment.
[0032] Memory 304 includes instructions 312 that may be executed to cause the data processing system 300 to perform any one or more of the methods or functions disclosed herein. The instructions 312 can include a VAC supervisory manager application. The VAC supervisory manager application can perform the logic described in FIG. 6 . The data processing system 300 may operate as a standalone device or may be connected, e.g., using a network, to other computer systems or peripheral devices.
[0033] FIG. 4 depicts a block diagram of exemplary circuitry between VAC slots in the card cage 400 of a voice control panel (e.g., 106 - 110 FIG. 1 ) consistent with the present invention. In one example, card cage 400 includes four slots 402 - 408 adapted to contain the VACs. One having skill in the art will appreciate that methods and systems consistent with the present invention may include a different number of slots in the card cage 400 . The audio outputs 410 , 412 , 414 of slots 402 - 406 may be connected to speakers (e.g., consistent with speakers 124 , 126 , 128 in FIG. 1 ). The backup output 424 of slot 408 is connected to the backup inputs 418 , 420 of slots 404 , 406 . Switch 426 switches the backup input 416 of slot 402 between the backup output 424 of slot 408 and the backup output 422 of slot 404 . Switch 426 may be any type of switching mechanism that can handle the voltage and current of the amplifier output. The slots 402 - 408 for VACs preferably are identical, except for addressing circuitry (e.g., hardwired identification pull-down resistors), which will allow the supervisory circuitry 204 of VAC to identify which slot the VAC is plugged into.
[0034] For purposes of explanation, FIG. 4 depicts two different backup configurations. Other types of configurations are possible. In the first configuration, when backup input 416 of slot 402 is connected to the backup output 424 of slot 408 , the VAC plugged into slot 408 is the backup amplifier for the primary amplifiers plugged into slots 402 , 404 , 406 . In the second configuration, when backup input 416 of slot 402 is connected to the backup output 422 of slot 404 , the VAC plugged into slot 408 is the backup amplifier for the primary amplifier plugged into slot 406 , and the VAC plugged into slot 404 is the backup amplifier for the primary amplifier plugged into slot 402 .
[0035] Although card cage 400 includes four amplifier slots 402 - 408 , a user need not plug amplifiers into all amplifier slots. For example, if the system is configured to have one backup amplifier to three primary amplifiers (the “3-1 configuration”) and if only one primary amplifier is needed, the user may plug the primary amplifier into any of slots 402 - 406 . Similarly, if the system is configured to have two primary amplifiers, with each of those backed up by an individual backup amplifier (the “1-1 configuration”) and only one primary amplifier is needed, the user may decide whether to use slots 406 and 408 for the primary and backup amplifiers, or slots 402 and 404 for the primary and backup amplifiers.
[0036] Using a commissioning tool, the user notifies VAC supervisory manager application 312 of the voice control panel how the card cage 400 is to be configured. For example, the user notifies VAC supervisory manager application 312 of the voice control panel whether the card cage 400 is in the 3-1 configuration or the 1-1 configuration, and the total number of primary and backup amplifiers that are included in the system. The VAC supervisory manager application 312 of the voice control panel, in turn, provides this information to the supervisory circuitry 204 of each VAC plugged into one of the card cage slots 402 - 408 . The supervisory circuitry 204 of VAC may thus determine whether the VAC functions as a primary amplifier or a backup amplifier depending on whether the card cage 400 is in the 3-1 configuration or in the 1-1 configuration.
[0037] The flow chart of FIGS. 5A-C provides additional details regarding the operation of the VAC (e.g., the supervisory circuitry 204 in combination with the VAC supervisory backup manager application 218 of the VAC) consistent with an implementation of the present invention. Whether a VAC is being used as a primary amplifier or a backup amplifier can be determined when the VACs are placed into the slots 402 - 408 of the card cage 400 . Since the VAC knows whether the card cage 400 is in the 3-1 configuration or the 1-1 configuration, the VAC initially determines whether it is designated as a backup amplifier based on what slot it is plugged into ( 502 ). If the VAC determines that it is designated as a backup amplifier, it determines the number of primary amplifiers it is designated to backup ( 504 ). VAC also measures the end of line (“EOL”) termination resistance ( 506 ). As discussed above, each amplifier's backup input includes an on-board termination resistor. Thus, the supervisory circuitry 204 of the backup amplifiers can detect several levels of EOL termination resistance by putting minor DC current through the output circuit.
[0038] VAC then determines if the EOL termination resistance is as expected ( 508 ). If VAC determines that the EOL termination resistance is not what it expects (i.e., if the system detects an error in the expected circuit connections), it sends an error notification to the VAC supervisory manager application 312 of the voice control panel ( 510 ). For example, if the backup amplifier sees no EOL resistor, then either it or the primary amplifier has a connection fault. In another example, if the backup amplifier in slot 408 sees one-third of the expected termination resistance, then switch 426 is in the wrong position. This could also be verified by the state of backup VAC in slot 404 , which should see an open in the same situation because it should not be connected to anything in the 1-1 configuration. The VAC supervisory manager application 312 of the voice control panel may notify the user regarding any detected error by displaying an appropriate message on the voice control panel display.
[0039] After sending the error notification or if the EOL termination resistance is as expected, VAC waits until it receives an indication of a primary amplifier failure ( 512 , FIG. 5B ). After receiving an indication of a primary amplifier failure, VAC determines if it received an indication of whether the failed amplifier is a class A or a class B amplifier ( 514 ). If VAC did receive an indication of the failed amplifier class, VAC then adjusts its configuration relays 214 to match the configuration of the failed amplifier ( 516 ), and notifies the failed amplifier through the VAC supervisory manager application 312 of the voice control panel to switch to VAC as the backup amplifier ( 518 ).
[0040] If at 502 , VAC determines that it is not designated as a backup amplifier (i.e., it determines that it is a primary amplifier), it waits until it detects a fault ( 520 , FIG. 5C ) and confirms that it is still functioning properly ( 522 ). If VAC determines that it is functioning properly, it notifies the system regarding the fault ( 524 ). If VAC does not receive a notification from the VAC supervisory manager application 312 to switch to the backup amplifier ( 526 ), it determines whether the system is functioning ( 528 ). If it determines that the system is functioning, it waits until it receives a notification from the system to switch to backup amplifier ( 526 ) and switches its backup relay to connect to its backup amplifier ( 530 ). If it determines at 522 or 528 that either it or the system is not functioning, it switches its backup relay to connect to its backup amplifier ( 530 ).
[0041] In conventional systems, the backup amplifiers were required to have the same configuration as the primary amplifiers. With the implementation of supervisory circuitry 204 in the present invention, the configuration of the backup amplifiers no longer needs to be set during installation. Instead, the backup amplifiers may adjust their configuration relays 214 to match the configuration of the primary amplifier after the primary amplifier fails, as discussed with respect to FIGS. 5A-C above.
[0042] The flow chart of FIG. 6 provides additional details regarding the operation of the voice control panel consistent with the implementation of supervisory circuitry 204 of respective VACs. When the user is configuring the card cage 400 , the VAC supervisory manager 312 identifies whether each primary amplifier has a class A or class B configuration. Thus, the VAC supervisory manager application 312 of voice control panel may determine the configuration for each primary amplifier ( 602 ). After the VAC supervisory manager application 312 of voice control panel receives an indication that one of the primary amplifiers failed ( 604 ), it notifies the backup amplifier regarding the configuration of the failed primary amplifier ( 606 ) and notifies the failed primary amplifier switch to its backup amplifier ( 608 ).
[0043] While various embodiments of the present invention have been described, it will be apparent to those of skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents. | Methods and systems consistent with the present invention provide an improved system that supervises the operation of a backup amplifier. The method comprises receiving an indication that a primary amplifier failed; determining a configuration of the primary amplifier; and configuring the backup amplifier to match the configuration of the primary amplifier. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to highly versatile exercise apparatuses. More particularly, the invention relates to a cable crossover exercise apparatus including a central weight stack and opposed extension arms. The invention also relates to a functional lift exercise apparatus including a central weight stack and substantially parallel extension arms. The invention further relates to a cable type exercise apparatus employing a pulley assembly with a 4:1 load ratio.
[0003] 2. Description of the Prior Art
[0004] The prior art of exercise apparatuses is replete with multipurpose machines providing users with a variety of possible exercising positions. Unfortunately, the majority of these exercise apparatuses are large, cumbersome and difficult to utilize.
[0005] Those skilled in the art will, therefore, appreciate the need for a compact, easy-to-use exercise apparatus which provides users with a variety of possible exercise positions. The present invention provides such an exercise apparatus.
[0006] In addition, these exercise apparatuses commonly employ a weight stack actuated by a cable which is pulled by users of the apparatus. Such arrangements present significant limitations affecting the usefulness of the exercise apparatus. For example, the range of exercises which may be performed with such cable actuated apparatuses is sometimes limited by the effective length of cable linking the weight stack with the user. In most instances, the effective useful length of the cable is limited by the height of the weight stack; that is, for each foot the cable is pulled by the user, the weight stack must rise a proportional distance. Where the rise of the weight stack is substantially equal to the distance which the cable is pulled, the effective useful length of the cable is limited to only a few feet since building weight stacks any larger would be cost prohibitive, as well as structurally undesirable.
[0007] Weight stack based exercise apparatuses also encounter problems as a result of the momentum created when the weight plates are lifted under the control of a cable. Specifically, when the weight plates are lifted upwardly at a fast pace, the generated momentum creates momentary reductions and increases in the perceived force encountered by the user of the exercise apparatus. Such momentary changes are highly undesirable.
[0008] As a result, a need further exists for an exercise apparatus overcoming the shortcomings of prior art cable assemblies. The exercise apparatus should provide an extended length of effective cable and reduce the undesirable effects of momentum created as the weight plates are moved up and down within the weight stack. The present invention provides such an exercise apparatus.
SUMMARY OF THE INVENTION
[0009] It is, therefore, an object of the present invention to provide an exercise apparatus including a resistance assembly and a cable linking a first extension arm and a second extension arm to the resistance assembly. The first extension arm includes a first end selectively supported adjacent the resistance assembly and a free second end from which the first strand of the cable system extends for engagement by a user. Similarly, the second extension arm includes a first end selectively supported adjacent the resistance assembly and a free second end from which the first strand of the cable system extends for engagement by a user. The first extension arm extends away from the second extension arm, moving the second end of the first extension arm away from the second end of the second extension arm to define an extended opposed spacing of the first and second strands.
[0010] It is also an object of the present invention to provide an exercise apparatus wherein the first extension arm and the second extension are substantially parallel as they extend from the resistance assembly.
[0011] It is still a further object of the present invention to provide an exercise apparatus wherein the cable passes over a series of pulleys which create a 4:1 load ratio for each user handle.
[0012] Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a side view of the functional lift exercise apparatus in accordance with the present invention;
[0014] [0014]FIG. 2 is a cross sectional view of the functional lift exercise apparatus along the line 2 - 2 in FIG. 1 with the weight stack shown in partial cross section;
[0015] [0015]FIG. 3 is a detailed perspective view of the first end of the extension arm;
[0016] [0016]FIG. 4 is a perspective view of the pivoting pulley;
[0017] [0017]FIG. 5 is a side view of the cable crossover exercise apparatus in accordance with the present invention;
[0018] [0018]FIG. 6 is a front view of the cable crossover exercise apparatus with the weight stack shown in partial cross section;
[0019] [0019]FIG. 7 is a detailed perspective view of the flange assembly of the cable crossover exercise apparatus;
[0020] [0020]FIG. 8 is a top view of the cable crossover exercise apparatus; and
[0021] [0021]FIG. 9 is a schematic showing the relative orientation of cable a guide pulley.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limited, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention.
[0023] With reference to FIGS. 1 to 3 , a functional lift exercise apparatuses 10 is disclosed. The functional lift exercise apparatus 10 includes a pair of parallel extension arms 12 , 14 positioned to facilitate a wide range of lifting type exercises.
[0024] The functional lift exercise apparatus 10 further includes a base structure 16 having a central user support member 18 with a free first end 20 and a second end 22 to which a weight stack 24 is secured. Between the first end 20 and the second end 22 , the central user support member 18 includes a platform 26 sized, shaped and constructed to support a standing user while he or she operates the present functional lift 10 . The base structure 16 , as well as the remaining structural components of the exercise apparatus 10 , are preferably formed from steel, although other materials may also be used without departing from the spirit of the present invention.
[0025] A single cable 28 links the user handles 30 with the weight stack 24 . The cable 28 is run through a series of pulleys to provide a 4:1 load ratio for each handle 30 . In this way, a four hundred pound stack of weight plates 32 may be moved by the application of one hundred pounds force at each handle 30 of the functional lift 10 (two hundred pounds total force when both handles are used simultaneously).
[0026] The 4:1 ratio reduces the inertia of the weight plates 32 by reducing the rate of movement of the weight plates 32 compared to the rate of travel at the handle 30 . Single hand movements allow the handle 30 to move four times faster than the weight plates 32 and dual hand movement allows the handles 30 to move twice the speed of the weight plates 32 .
[0027] The 4:1 ratio also provides single hand movements equal in length to four times the travel distance of the weight plates 32 . This allows extended movements, such as, for example, overhead lift and bicep curls in addition to the dead lift movements, to provide users with greater flexibility in choosing a desired resistance level.
[0028] Referring specifically to FIG. 2, the weight stack 24 includes a support frame 34 with vertical support members 36 aligned to support the stack of weight plates 32 . The weight plates 32 are supported for movement up and down in a conventional manner. In fact, the pulley system, which is discussed below in greater detail, is used to lift the weight plates 32 . The weight stack 24 is covered by a protective sleeve 38 positioned thereabout.
[0029] As briefly discussed above, a single cable 28 actuates the weight stack 24 and controls the movement of the weight plates 32 . The central portion 40 of the cable 28 is passed over first and second central upper pulleys 42 , 44 . The central upper pulleys 42 , 44 are positioned adjacent the upper end of the weight stack 24 , although the exact positioning of the central upper pulleys 42 , 44 may be varied without departing from the spirit of the present invention.
[0030] Opposite strands 46 , 48 of the cable 28 then extend downwardly within the weight stack 24 to respectively engage first and second movement pulleys 50 , 52 . The movement pulleys 50 , 52 are attached to a coupling member 54 directly attached to the stack of weight plates 32 . In this way, upward movement of the movement pulleys 50 , 52 causes the coupling member 54 to move upwardly, and ultimately lift the weight plates 24 against the force of gravity.
[0031] The first and second strands 46 , 48 then extend upwardly and respectively pass over first and second exit pulleys 56 , 58 . After passing over the exit pulleys 56 , 58 , and exiting the confines of the weight stack 24 , the opposite strands 46 , 48 extend downwardly until they enter the first and second extension arms 12 , 14 . Although a preferred orientation is disclosed for the various pulleys used in accordance with the present invention, those skilled in the art will readily understand that the exact orientation of the pulleys may be varied without departing from the spirit of the present invention.
[0032] The first and second extension arms 12 , 14 are pivotally coupled to the base portion of the weight stack 24 and extend outwardly toward the central user support member 18 , that is, parallel to the central user support member 18 . Each extension arm 12 , 14 pivots about a pivot axis and the pivot axes of the first and second extension arms 12 , 14 are substantially aligned.
[0033] The first and second extension arms 12 , 14 are substantially identical and will now be described with reference to the first extension arm 12 . Referring to FIGS. 1 and 3, the first extension arm 12 includes a first end 60 and a second end 62 . The first extension arm 12 is pivotally coupled, at a position near the first end 60 of the extension arm 12 , to a first side 64 of the weight stack 24 adjacent the base of the weight stack 24 (the second extension arm 14 is pivotally coupled to the opposite second side 66 of the weight stack 24 ). In fact, the first extension arm 12 is pivotally coupled in a manner allowing a user to select a desired orientation for the first extension arm 12 relative to the weight stack 24 and to lock the extension arm 12 in place. Movement of the first extension arm 12 is controlled by the inclusion of a counterweight 68 at the first end 60 of the first extension arm 12 .
[0034] With reference to FIG. 3, the first extension arm 12 includes a locking hole 70 . The locking hole 70 is located adjacent a pivot hole 72 through which a pivot pin 74 passes to pivotally couple the first extension arm 12 to the weight stack 24 . The locking hole 70 is aligned with a series of flange holes 76 formed on a semicircular flange 78 of the weight stack 24 . The semicircular flange 78 is positioned substantially parallel to the plane in which the first extension arm 12 rotates as it moves relative to the weight stack 24 .
[0035] In practice, and as those skilled in the art will readily appreciate, a locking pin 80 is passed though an aligned locking hole 70 and flange hole 76 to lock the extension arm 12 at a desired angular orientation relative to the weight stack 24 . When a user desires to change the angular orientation of the first extension arm 12 , the locking pin 80 is simply removed and the locking hole 70 is aligned with another flange hole 76 at which time the locking pin 80 is once again inserted in position to lock the first extension arm 12 relative to the weight stack 24 .
[0036] The second end 62 of the first extension arm 12 is fitted with a pivoting pulley 82 which guides the first strand 46 of the cable 28 as it exits the first extension arm 12 . With reference to the prior discussion regarding the pulley assembly employed in accordance with the present invention, once the first strand 46 of the cable 28 passes over the exit pulley 56 and moves downwardly into engagement with the extension arm 12 , the first strand 46 passes over a guide pulley 84 located at the first end 60 of the first extension arm 12 . The first strand 46 of the cable 28 passes over the first guide pulley 84 and enters the tubular passageway formed in the first extension arm 12 .
[0037] Upon reaching the second end 62 of the first extension arm 12 , the first strand 46 passes over the pivoting pulley 82 and is ready for engagement by a user of the present apparatus. The distal end of the first strand 46 of the cable 28 may be fitted with a wide variety of handles 30 known to those skilled in the art.
[0038] The pivoting pulley 82 is shown in greater detail in FIG. 4. Each pivoting pulley 82 includes a frame 86 with a central pivot 88 for rotatably supporting a pulley member 90 . The frame 86 is formed so as to cover the pulley member 90 and thereby prevent undesired access with the pulley member 90 as the cable 28 passes thereover. The frame 86 is further provided with a counterweight 92 opposite the pulley member 90 .
[0039] The frame 86 further includes a cylindrical coupling member 94 shaped and dimensioned for pivotal attachment to the second end 62 of the first extension arm 12 . The cylindrical coupling member 94 provides an opening through which the cable 28 passes as it extends from the extension arm 12 toward the pulley member 90 . In this way, the cable 28 passes along the axis about which the pivoting pulley 82 pivots relative to the extension arm 12 to provide greater freedom of motion as an individual attempts to draw the cable 28 in various directions during exercise.
[0040] Since the pivoting pulley 82 permits a great degree of flexibility with regard to the angle at which the cable 28 is drawn from the extension arm 12 the inclusion of the present pivoting pulleys 82 at the distal end of each extension arm 12 , 14 greatly increases the flexibility of the present exercise apparatus.
[0041] The respective ends of the first and second strands 46 , 48 are each provided with stop members 96 , 98 . As those skilled in the art will readily appreciate, the stop members 96 , 98 control motion of the single cable 28 to allow exercise by pulling the first strand 46 alone, the second strand alone 48 , or both strands at the same time.
[0042] In use, and after the first and second extension arms are properly positioned in a desired orientation, the use stands upon the central member, grips the handles secure to the ends of the respective strands and performs desired lifting exercises.
[0043] With reference to FIGS. 5 to 8 , a cable crossover exercise apparatus 110 is disclosed. As with the functional lift exercise apparatus 10 , the cable crossover exercise apparatus 110 includes a pair of extension arms 112 , 114 positioned to facilitate a wide range of lifting type exercises. In contrast to the functional lift exercise apparatus 10 , and as will be discussed in greater detail below, the extension arms 112 , 114 of the cable crossover 110 extend in opposite directions to provide the user with access to cable ends positioned for gripping when a user fully extends his or her arms outwardly in opposite directions.
[0044] The cable crossover exercise apparatus 110 includes a base structure 116 having a central support member 118 upon which a weight stack 124 is secured. In this way, the weight stack 124 forms the center of the cable crossover exercise apparatus 110 as the first and second extension arms 112 , 114 extend outwardly away from the weight stack 124 in opposite directions.
[0045] As with the functional lift exercise apparatus 10 , a single cable 128 links the user handles 130 to the weight stack 124 . The cable 128 is run through a series of pulleys to provide a 4:1 load ratio for each handle. In this way, a four hundred pound weight stack may be moved by the application of one hundred pounds force at each handle 130 of the cable crossover 110 (two hundred pounds total force when both handles are used simultaneously).
[0046] With reference to FIG. 6, the weight stack 124 secured to the central support member 118 includes support frame 134 having vertical support members 136 aligned to support a stack of weight plates 132 . The weight plates 132 are supported for movement up and down in a conventional manner. In fact, the pulley system, which is discussed below in greater detail, is used in lifting the weight plates 132 . The weight stack 124 is covered by a protective sleeve 138 positioned thereabout.
[0047] When force is applied by the user, the cable 128 lifts the stack of weight plates 132 . The central portion 140 of the cable 128 is passed over first and second central upper pulleys 142 , 144 . The central upper pulleys 142 , 144 are positioned adjacent the upper end of the weight stack 124 , although the exact positioning of the central upper pulleys 142 , 144 may be varied without departing from the spirit of the present invention.
[0048] First and second strands 146 , 148 of the cable 128 then extend downwardly within the weight stack 124 to respectively engage first and second movement pulleys 150 , 152 . The movement pulleys 150 , 152 are attached to a coupling member 154 directly coupled to the stack of weight plates 132 . In this way, upward movement of the movement pulleys 150 , 152 causes the coupling member 154 to move upwardly, and ultimately lifts the weight plates 132 upwardly against the force of gravity.
[0049] The first and second strands 146 , 148 then extend upwardly and respectfully pass over first and second exit pulleys 156 , 158 . After passing over the exit pulleys 156 , 158 , and exiting the confines of the weight stack 124 , the opposite strands 146 , 148 extend downwardly until they enter the first and second extension arms 112 , 114 which are discussed below in greater detail. Although a preferred orientation is disclosed for the various pulleys used in accordance with the present invention, those skilled in the art will readily understand that the exact orientation of the pulleys may be varied without departing from the spirit of the present invention.
[0050] The first and second extension arms 112 , 114 are pivotally coupled to a central portion of the weight stack 124 and extend outwardly from the central support member 118 . The first and second extension arms 112 , 114 respectively rotate about a first axis and a second axis, which are positioned to orient the first and second extension arms 112 , 114 in an opposed relationship. Specifically, the first and second extension arm 112 and 114 extend toward a user at a slight angle relative to a vertical plane in which the weight stack 124 lies. In this way, the ends of the extension arms 112 , 114 are moved from the stack to improve user access to the present apparatus 110 while exercising. As those skilled in the art will readily appreciate, the exact angular orientation of the arms is not critical and may be varied slightly without departing from the spirit of present invention.
[0051] The extension arms 112 , 114 are substantially identical and will now be described with reference to the first extension arm 112 . The first extension arm 112 includes a first end 160 and a second end 162 . In accordance with the preferred embodiment of the present invention, each the first arm 112 is approximately 32 inches from pivot point 174 to the end of the table, although those skilled in the art will appreciate that the length of the first extension arm 112 may be varied slightly without departing from the spirit of the present invention.
[0052] The first extension arm 112 is pivotally coupled, at a position near the first end 160 of the extension arm 112 , to a semicircular flange assembly 178 secured to the front of weight stack 124 . The semicircular flange assembly 178 includes a pair of opposed flat plates and is mounted to lie within the plane in which the first extension arm 112 rotates as it moves relative to the weight stack 124 . Movement of the first extension arm 112 is controlled by the inclusion of a counterweight 168 at the first end 160 of the first extension arm 112 .
[0053] The first extension arm 112 is pivotally coupled in a manner allowing a user to select a desired orientation for the extension arm 112 and lock the extension arm 112 in place. Specifically, the first extension arm 112 includes a locking hole 170 located adjacent a pivot hole 172 through which a pivot pin 174 passes to pivotally couple the first extension arm 112 to the semicircular flange assembly 178 , and ultimately, the weight stack 124 . The locking hole 170 is aligned with a series of flange holes 176 formed in the semicircular flange assembly 178 of the weight stack 124 .
[0054] In practice, and as those skilled in the art will readily appreciate, a locking pin 180 is passed though an aligned locking hole 170 and flange hole 176 to lock the first extension arm 112 at a desired angular orientation relative to the weight stack 124 . When a user desires to change the angular orientation of the first extension arm 112 , the locking pin 180 is simply removed and the locking hole 170 is aligned with another flange hole 176 at which time the locking pin 180 is once again inserted in position to lock the first extension arm 112 relative to the weight stack 124 .
[0055] The second end 162 of the first extension arm 112 is fitted with a pivoting pulley 182 to guide the first strand 146 of the cable 128 as it exits the first extension arm 112 . With reference to the prior discussion regarding the pulley assembly employed in accordance with the present invention, once the first strand 146 of the cable 128 pass over the exit pulley 156 and moves downwardly into engagement with the first extension arm 112 , the first strand passes over a guide pulley 184 located at the first end 160 of the first extension arm 112 . The first strand 146 of the cable 128 passes over the first guide pulley 184 and enters the tubular passageway formed in the first extension arm 112 .
[0056] In an attempt to reduce the tightening or loosening of the cable 128 as the first extension arm 112 is rotated, the first guide pulley 184 is positioned to ensure that the cable tension does not vary as the extension arm 112 is rotated. Specifically, and with reference to FIG. 9, the first guide pulley 184 is positioned to ensure that A:D=A:F=A:H.
[0057] Upon reaching the second end 162 of the first extension arm 112 , the first strand 146 passes over the pivoting pulley 182 and is ready for engagement by a user of the present apparatus 110 . The distal end of each strand 146 , 148 of the cable 112 may be fitted with a wide variety of handles 130 known to those skilled in the art.
[0058] The pivoting pulley 182 is substantially the same as that disclosed in FIG. 4 and discussed above in substantial detail. Since the pivoting pulley 182 permits a great degree of flexibility with regard to the angle at which the cable 128 is drawn from the first extension arm 112 , the inclusion of the present pivoting pulley 182 at the distal end of each extension arm 112 , 114 greatly increases the flexibility of the present exercise apparatus.
[0059] The respective ends of the first and second strands 146 , 148 are each provided with stop members 196 , 198 . As those skilled in the art will readily appreciate, the stop members 196 , 198 control motion of the single cable to allow exercise by pulling the first strand 146 alone, the second strand 148 alone, or both strands at the same time.
[0060] In use, and after the extension arms are properly positioned in a desired orientation, the user stands in front of the weight stack, grips the handles secure to the ends of the respective strands and performs desired lifting exercises.
[0061] While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims. | A highly versatile exercise apparatuses is disclosed. More particularly, the invention relates to a cable crossover exercise apparatus including a central weight stack and opposed extension arms. The invention also relates to a functional lift exercise apparatus including a central weight stack and substantially parallel extension arms. The invention further relates to a cable type exercise apparatus employing a pulley assembly with a 4:1 load ratio. | 0 |
This invention relates to a process for the preparation of TiCl 4 by the chlorination of raw materials containing titanium in the presence of reducing agents, separation of solid metal chlorides by cooling of the reaction gases and subsequent condensaton of the crude TiCl 4 and reduction of vanadium compounds present in the crude TiCl 4 with the formation of solid reaction products, followed by distillation.
BACKGROUND OF THE INVENTION
Titanium dioxide pigments are nowadays prepared not only by the sulphate process but also by the combustion process in which TiCl 4 and oxygen are directly converted into titanium dioxide pigments by heating to an elevated temperature.
The TiCl 4 required for this purpose is obtained by the chlorination of materials containing titanium, such as ilmenite, leucoxene or rutile, in the presence of carbon. The crude TiCl 4 obtained is contaminated with numerous other chlorides and with chlorine, the main impurities being the chlorides of iron, aluminium and silicon as well as the chlorides and oxychlorides of vanadium.
Removal of these impurities is essential if the TiO 2 pigments are to have a pure white color.
Most of the impurities, such as the chlorides of iron, aluminium and silicon, may be removed by distallation. The distillation of crude TiCl 4 results in the formation of thickened suspensions of the solid metal chlorides and of extremely finely divided residues of crude chlorination products which are difficult to evaporate to dryness, especially if they contain a high proportion of AlCl 3 . This distillation therefore entails a high energy consumption and/or losses in TiCl 4 yield.
It would therefore be preferable to separate the solid metal chlorides and the finely divided residues of the solid raw material of the chlorination process by filtration and to dry the filter cake. This method, however, becomes very expensive due to the difficulty of filtering the finely divided solids.
The product obtained after removal of the solid impurities still contains vanadium in the form of VOCl 3 or VCl 4 .
The removal of VOCl 3 and VCl 4 from the titanium tetrachloride by distillation is costly due to the similarity of their boiling points.
These compounds are therefore converted into solid, low valency vanadium chlorides by reduction.
A product containing only low vanadium concentrations (so-called pure TiCl 4 ) may then be obtained by distillation.
Known methods of purifications use, for example, H 2 S (DE-A No. 1 923 479), animal and vegetable oils, fats, waxes, resins and soaps, liquid or gaseous hydrocarbons, oils, fats, alcohols, ketones, organic acids, amines (CH-A No. 365 393, CH-A No. 262 267, DE-C No. 867 544, FR-A No. 1 466 478, FR-A No. 1 460 362), metals and metal salts (BE-A No. 539 078, DE-A No. 1 922 420, DE-B No. 1 271 693, U.S. Pat. Nos. 3,915,364, 2,871,094, 2,753,255, 2,560,424, 2,555,361, 2,530,735 and 2,178,685).
The purification of titanium tetrachloride with special cyclic aliphatic or aromatic compounds (DE-C No. 2 329 045) and with special amines (DE-C No. 2 325 924) is particularly advantageous.
It was an object of the present invention to provide a particularly advantageous process for the purification of TiCl 4 which would not have the disadvantages described above.
BRIEF DESCRIPTION OF THE INVENTION
It has surprisingly been found that the removal of the solid substances from crude TiCl 4 by filtration may be greatly facilitated by using the solid reaction products of the reduction of vanadium compounds as filtering aids for the filtration of crude TiCl 4 .
The solid reaction products are mainly the solid, low valency vanadium compounds, oxidized reducing agent and possibly residues of unreacted reducing agent.
DETAILED DESCRIPTION
The present invention thus relates to a process for the preparation of TiCl 4 by the chlorination of starting materials containing titanium and vanadium as an impurity, separation of the solid metal chlorides by cooling of the reaction gases followed by condensation of the crude TiCl 4 , and reduction of the vanadium compounds present in the crude TiCl 4 to form solid reduction reaction products, followed by distillation, characterised in that the solid reduction reaction products are used as filtering aids for the filtration of the crude TiCl 4 .
In one embodiment of the process according to the invention, the solid reduction reaction products used are substances which were separated from TiCl 4 by filtration before distillation.
In another embodiment of the process, the solid reduction reaction products used are the substances which are obtained as distilland sump during or after distillation.
According to yet another embodiment of the process, the solid reduction reaction products used are substances which are separated by filtration of the distillation sump.
When filtration of the crude TiCl 4 is carried out, the solid reduction reaction products are added to the crude TiCl 4 and/or used as precoat layer.
Reduction of the vanadium compounds is preferably carried out with organic hydrocarbons or organic amines.
Preferred embodiment of this type are anthracene, aniline or diphenylamine.
According to one particularly preferred embodiment of the process, the organic amine used is diphenylamine and 2.5 to 5 kg of diphenylamine are used per kg of vanadium.
Reduction of the vanadium compounds with organic hydrocarbons or organic amines is preferably carried out at 80° to 125° C.
In another preferred embodiment of the process, crude TiCl 4 containing chlorine and solid substances is dechlorinated before filtration because the presence of elementary chlorine increases the quantity of reducing agent used.
BRIEF DESCRIPTION OF THE DRAWING
The process according to the invention will now be explained in more detail with reference to FIGS. 1 to 3.
FIG. 1 illustrates the process of this invention in a block diagram flowchart.
FIG. 2 illustrates second embodiment of this invention by a flowchart block diagram.
FIG. 3 illustrates a third embodiment of this invention by a block diagram flowchart. Like-numbered apparatus elements in the FIGS. are the same.
DETAILED DESCRIPTION OF THE DRAWING
In FIG. 1, crude TiCl 4 (1) containing chlorine and solids is first dechlorinated to prevent excessive consumption of reducing component.
The removal of chlorine (2) may be carried out in a dechlorination column or by heating in a stirrer vessel to 100°-130° C., the chlorine (3) released from the TiCl 4 being displaced from the vessel by nitrogen.
The dechlorinated crude TiCl 4 (4) is mixed (5) with the filter cake II (22) which is the solid reaction products of reduction of the vanadium compounds and TiCl 4 adhering thereto. The resulting mixture (6) is filtered, preferably at 50°-100° C. (7), the solids components of the filter cake II (22) acting as filtration aids which loosen up the filter cake I (8) and thereby substantially increase the efficiency of filtration.
The filtrate I (14) now contains mainly VOCl 3 , VCl 4 and SiCl 4 as impurities. The vanadium compounds are reduced by the addition of reducing agent (16) to the filtrate I (14). The vanadium compounds are reduced in filtrate I (14) as described in DE-C Nos. 2 325 924 or 2 329 045 preferably at temperatures in the range of from 80° to 125° C. TiCl 4 (together with SiCl 4 ) is removed as pure TiCl 4 (19) from the resulting suspension (17) by distillation (18). The apparatus used for distillation is preferably a heated stirrer vessel, a horizontal evaporator or a forced circulation evaporator. The SiCl 4 is optionally removed from the TiCl 4 in a column connected in series with the distillation apparatus.
The sump (20) formed in the process of distillation (18) is filtered (21), preferably at 70° to 100° C. The filtrate II (23) obtained from this filtration II (21) is added to the filtrate I (14) either after or, preferably before reduction of the vanadium compounds (15).
The filter cake II (22) is discharged into the mixer (5) as described above to serve as filtration aid for the filtration I (7).
The filter cake II (22) may alternatively be used as precoat layer for the filtration I (7), in which case the filter is not purified after filtration II (21) but subjected to the dechlorinated crude TiCl 4 (4).
Part of the filter cake II (22) may be added to the crude TiCl 4 (4) as filtering aid while the remainder may be used as precoat layer.
The filter cake I (8) from filtration (7) contains all the solid substances resulting from the purification of the crude TiCl 4 . Drying (9) of the filter cake (8) may be carried out in driers with heating surfaces heated indirectly at the ambient pressure or at higher or lower pressures or it may be carried out directly on the filter with inert gas heated to 100°-120° C., preferably nitrogen. The TiCl 4 vapor (11) formed in the process is condensed (12) and the condensate (13) is added to the crude TiCl 4 (1,4) before or, preferably, after dechlorination (2). After this initial drying, the filter cake may be further dried by blowing with an inert gas, preferably nitrogen, preferably at a temperature of 50°-110° C., before it is discharged from the filter. The resulting mixture of inert gas and TiCl 4 vapor may be transferred to the stage of dechlorination of crude TiCl 4 (2) for expelling the chlorine, either immediately or after condensation of the major proportion of its TiCl 4 . The dried solids (10) are then removed from the process.
FIG. 2 illustrates a variation of the process according to the invention in which the filter cake II (27) is used as precoat layer for filtration I (24). The filter is therefore not cleaned after filtration II (26) but charged with dechlorinated crude TiCl 4 (4).
A filter cake (25) composed of two layers is obtained. This filter cake (25) also contains all the substances resulting from the purification of TiCl 4 and is dried by a method analogous to that of FIG. 1.
The vanadium compounds (15) in filtrate I (14) are then reduced as in FIG. 1. The procedure differs from that of FIG. 1, however, in that filtration II (26) is carried out immediately after reduction of the vanadium compounds (15). Distillation of TiCl 4 (29) is carried out on a filtrate II (28) which is free from solids. Circulation evaporators or horizontal evaporators are suitable for this purpose, optionally with a column arranged in series with the evaporator to enable the SiCl 4 to be removed from the pure TiCl 4 (19). The sump (30) of the distillation (29) is returned to the suspension (17).
The filter cake II (27) from filtration II (26) may alternatively also be mixed with the dechlorinated crude TiCl 4 (4) as in FIG. 1, in which case the solid components of filter cake II (27) used as filtering aids improve the efficiency of filtration I (24).
If desired, a proportion of filter cake II (27) may be added to the crude TiCl 4 while another portion is used as precoat layer.
FIG. 3 illustrates a variation of the process according to the invention analogous to that of FIG. 1. In this case, the sump (20) obtained from the distillation of TiCl 4 (18) is not filtered but directly added (5) to the dechlorinated, crude TiCl 4 (4). From 5 to 25% of the volume (17) fed into the TiCl 4 distillation (18) is normally removed as sump (20) and mixed with the dechlorinated, crude TiCl 4 (4). The disadvantage of having a larger quantity of TiCl 4 to filter is normally compensated for by the advantage that only one filtration is required for the whole process.
The filters used are pressure filters, preferably of the type of leaf filters or cartridge filters, from which the filter cake may be discharged intermittently.
The process according to the invention affords great advantages, especially for processing raw materials with only a low titanium content, such as titanium slag, synthetic rutile, leucoxene, ilmenite or Brazilian anatas, because separation of the large amounts of solid chlorides from crude TiCl 4 by the distillation of TiCl 4 is particularly difficult and direct filtration of crude TiCl 4 can in these cases only be carried out with a very low filtration output.
The advantages of the process according to the invention will now be illustrated with the aid of Examples.
EXAMPLE 1 (CORRESPONDING TO FIG. 1)
Crude TiCl 4 obtained from the chlorination of rutile sand contained 1.5% by weight of solids, 1050 ppm of vanadium in the form of VOCl 3 or VCl 4 and 580 ppm of chlorine. The crude TiCl 4 (1) was heated to 125° C. in a stirrer vessel (2) with TiCl 4 condenser attached. Nitrogen containing TiCl 4 obtained from blow-drying the filter cake I (8) was blown into the gas space of the container for 20 minutes. The chlorine-nitrogen mixture resulting from the condensation of TiCl 4 was transferred to an exhaust gas scrubber.
After this treatment, the dechlorinated crude TiCl 4 (4) contained less than 10 ppm of chlorine. The filter cake II (22) consisting of the products of reduction of the vanadium was then introduced into the stirrer vessel and mixed (5) with the crude TiCl 4 (4). The mixture (6) was cooled to 80° C. and filtered with a Fundabac® cartridge filter (DrM, Switzerland) at 5 bar (abs.) (7). The filtration output amounted on average to 2.8 m 3 of filtrate/h.m 2 of filter surface when the filter cake had reached a thickness of 25 mm. (When, for comparison, the filtration of crude TiCl 4 (1) was carried out without the addition of filter cake II (22), the filtration output was only 0.35 m 3 /h.m 2 when the cake had reached a thickness of 18 mm).
When filtration (7) had been completed, the turbid liquid was discharged and the filter cake was blown dry with nitrogen at 100° C. for 20 minutes. The TiCl 4 -containing nitrogen leaving the filter was used for the dechlorination (2) of the next batch of crude TiCl 4 . The remaining TiCl 4 was evaporated (11) from the crumbly filter cake I (8) in an indirectly heated drier (9) and fed into the crude TiCl 4 (1) after condensation (12). The dry solids (10) were removed for treatment of the residues.
The filtrate (14) obtained from filtration I (7) was collected in an interim container and heated batchwise to 115° C. in a stirrer vessel (15), and 4 kg of diphenylamine per m 3 were added (16). After 5 minutes, the resulting supsension (17) was discharged into a container from which it was continuously fed into a stirrer vessel with heating jacket (18) from which pure TiCl 4 (19) was evaporated off and finally condensed. A proportion of the suspension concentrated in the evaporator (18) was left to overflow as sump (20) and then filtered through a Fundabac® cartridge filter (21) after it had cooled to about 80° C. The filtrate (23) was added to the suspension (17) before the evaporation of TiCl 4 (18). The filter cake (22) was suspended in the dechlorinated, crude TiCl 4 (4) as described above, where it served as filtration aid for the filtration I (7). The filtration output (23) was about 3.2 m 3 of filtrate/h.m 2 of filter surface at a pressure of 4 bar (abs.) when the filter cake (22) had reached a thickness of about 25 mm.
The pure TiCl 4 (19) was colorless. It contained less then 2 ppm of vanadium and 28 ppm of SiCl 4 .
EXAMPLE 2 (CORRESPONDING TO FIG. 2)
Crude TiCl 4 (1) containing 2.9% by weight of solids with 640 ppm of V and 590 ppm of chlorine was obtained from the chlorination of Brazilian anatase. The crude TiCl 4 was dechlorinated (2) as in Example 1. The dechlorinated, crude TiCl 4 (4) was cooled to about 70° C. and filtered (24) through a Fundabac® cartridge filter at 5 bar (abs.). The cartridges of this filter were already covered with a layer of filter cake II (27) about 10 mm in thickness as precoat layer. When the filter cake reached a total thickness of about 15 mm, the filtration output in filtration I (24) was 0.8 m 3 /h.m 2 of filter surface. (By comparison, when direct filtration of crude TiCl 4 (1) was carried out, the average filtration output obtained with a filter cake not more than 0.6 mm in thickness was 0.3 m 3 /h.m 2 . When filter cake II (27) was added to the dechlorinated, crude TiCl 4 (4) as in FIG. 1, an averge filtration output of 0.9 m 3 /h.m 2 was obtained when the filter cake had a thickess of at the most about 15 mm.
The filter cake (25) was dried by a method analogous to that of Example 1.
The filtrate (14) was heated batchwise to 125° C. and 2.7 kg of diphenylamine per m 3 (16) were added (15). After cooling to about 75° C., the suspension (17) was filtered through a Fundabac® cartridge filter at 3.5 bar (abs.) (26). The average filtration output was 6 m 3 / h.m 2 until the maximum thickness of filtration cake of about 10 mm was reached. After discharge of the turbid liquor, the filter was directly supplied with dechlorinated, crude TiCl 4 (4) as described above (24).
Pure TiCl 4 (19) was distilled from the filtrate (28) of filtration II (26) in a horizontal evaporator wth condenser (29) attached. At the end of the horizontal evaporator remote from the inlet for filtrate, 5 to 10% of the quantity fed in (30) was withdrawn as sump and returned to the suspension (17). The pure TiCl 4 was colorless and contained less than 2 ppm of vanadium.
EXAMPLE 3 (CORRESPONDING TO FIG. 3)
Dechlorinated crude TiCl 4 (4) (as in Example 2) was mixed with the sump (20) of the TiCl 4 distillation (18) in a stirrer vessel (5). Filtration (7) and treatment of filter cake were carried out as in Example 1. The filtration output was 1.1 m 3 /h.m 2 of filter surface at a maximum filter case thickness of 15 mm. The filtrate (14) was heated batchwise to 125° C. and 2.4 kg of diphenylamine per m 3 (16) were added (15). Pure TiCl 4 (19) was then distilled from the suspension (17) containing the reaction products in a stirrer vessel (18). About 10% of the volume (17) fed in were removed in the evaporator (18) as sump (20) containing solid components and mixed with the dechlorinated, crude TiCl 4 (5).
The pure TiCl 4 was colorless and contained less than 2 ppm of vanadium. | An improved process for the preparation of TiCl 4 comprising
(a) chlorinating a raw material containing titanium and vanadium impurities to produce a crude TiCl 4 reaction product,
(b) separating the crude reaction product into solid by-products and TiCl 4 -containing liquid,
(c) reacting the TiCl 4 -containing liquid with a reducing agent whereby vanadium impurities are converted into solid compounds, and
(d) separating TiCl 4 from the solid vanadium compounds, is improved by adding solid products of the vanadium reduction reactions to the crude TiCl 4 reaction product prior to the separating step (b). | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 833,319, filed September 14, 1977, now U.S. Pat. No. 4,131,684 which in turn is a division of application Ser. No. 684,601, filed May 10, 1976, now abandoned. The amine precursors used to prepare the final ureide products form the subject matter of concurrently filed and copending application Ser. No. 971,172. The ureide end products form the subject matter of concurrently filed and copending application Ser. No. 971,174.
BACKGROUND OF THE INVENTION
More specifically, the present invention resides in the concept of certain nitrobenzamido or aminoloweralkylbenzamido-substituted-naphthalenemonosulfonic acids and salts thereof which are novel compounds useful as nitro precursors to the corresponding amine precursors to the corresponding ureide end products useful as inhibitors of connective tissue destruction.
Abnormal destruction of connective tissue by collagenase and/or neutral proteases causes tissue damage and/or tissue dysfunction. In these conditions an inhibitor of connective tissue destruction acting directly or indirectly would be useful in preventing, retarding, or reversing tissue damage and/or collagen diseases.
The term connective tissue refers to a matrix of at least three protein molecules, collagen, proteoglycan and elastin. These molecules play an important role in the structural integrity of normal tissues. Collagen, the most abundant protein in the body occupies a central position in the connective tissue matrix ["Biochemistry of Collagen", Ed. G. N. Ramachandran and A. H. Reddi, Academic Press, New York (1976); P. Bornstein, Ann. Rev. Biochem., 43, 567 (1974); J. Fessler and L. Fessler, Ann. Rev. Biochem., 47, 129 (1978)].
Collagen is, for example, the main structural component of the oral tissue (periodontal ligament, alveolar bone, gingiva, and cementum) [Fullmer, et al., J. Dental Research, 48, 646 (1969)]. Collagen amounts to 40% of cartilage protein, 90% of bone protein, and over 90% of dry dermis. Articular cartilage is the resilient tissue that covers the articulating extremities in synovial joints. It consists of collagen fibres that are intimately meshed in a hydrated gel of proteoglycan.
Proteoglycan, as it exists in cartilage, is a molecule in which sulfated polysaccharide chains are covalently linked to a protein backbone ["Dynamics of Connective Tissue Macromolecules", Ed. P. M. Burleigh and A. R. Poole, North Holland, Amsterdam (1975)].
Elastin is a major connective tissue component of pulmonary structure ["Elastin and Elastic Tissue", Ed. L. B. Sandberg, W. R. Gray, and C. Franzblau, Plenum Press, New York (1977)]. The breakdown of elastin of pulmonary connective tissue is considered the primary event in pulmonary emphysema [A. Janoff in "Proteases and Biological Control", Cold Spring Harbor Conference on Cell Proliferation, 2, 603 (1975)].
Degradation of fibrous collagen is initiated by a combination of neutral proteases and tissue collagenase as an integral part of a complex immunopathological process which results in the loss of collagen from normal tissue. Under normal conditions cellular mechanisms maintain a careful balance between the rates of collagen synthesis and degradation. However, in certain pathological conditions, the ensuing elevated levels of neutral proteases and collagenase can result in rapid collagen degradation and tissue dysfunction. For example, in periodontal disease, the generated elevated levels of neutral proteases and collagenase in the gingival crevicular fluid rapidly degrade the fibrous collagen supporting the teeth. Periodontal pockets result ultimately from collagen degradation, and as these pockets deepen, support of tooth is lost and alveolar bone is resorbed [K. Ohlsson, I. Ohlsson, and G. I. Basthall, Acta Odontol. Scand., 32, 51 (1974); L. M. Golub, S. Kenneth, H. McEwan, J. B. Curran, and N. S. Ramamurthy, J. Dental Research, 55, 177 (1976); L. M. Golub, J. E. Stakin and D. L. Singer, J. Dental Research, 53, 1501 (1974); L. M. Wahl, S. M. Wahl, S. E. Mergenhagen, and G. R. Martin, Proc. Natl. Acad. Sci. U.S., 71, 3598 (1974); Science, 187, 261 (1975)].
In arthritic conditions such as in rheumatoid arthritis, septic arthritis, and osteoarthritis elevated degradation of collagen and proteoglycan initiate rapid destruction of articular tissue [J. M. Evanson, J. J. Jefferey, and S. M. Krane, Science, 158, 499 (1967); E. D. Harris, D. R. Dibona and S. M. Krane, J. Clin. Invest., 48, 2104 (1969); E. D. Harris in Rheumatoid Arthritis, Medcom. Press, N.Y. (1974); Z. Werb, C. L. Mainardi, C. A. Vater, and E. D. Harris, New Eng. J. Med., 296, 1017 (1977); J. M. Dayer, R. G. Russell, and S. M. Krane, Science, 195, 181 (1977); E. D. Harris, C. A. Vater, C. L. Mainardi, and Z. Werb, Agents and Actions, 8, 35 (1978); D. E. Woolley, E. D. Harris, C. L. Mainardi, and C. E. Brinkerhoff, Science, 200, 773 (1978); E. D. Harris, C. S. Faulkner, F. E. Brown, Clin. Orthoped., 110, 303 (1975); M. G. Ehrlich, H. J. Mankin, H. Jones, R. Wright, and C. Crisper, J. Bone Jt. Surg., 57A, 565 (1975); S. Gordon, W. Newman, and B. Bloom, Agents and Action, 8, 19 (1978); "Mechanisms of Tissue Injury With Reference to Rheumatoid Arthritis", Ed. R. J. Perper, Ann. N.Y. Acad. Sci., 256, 1-450 (1975)].
Increased collagen degradation in bone can result in abnormal bone destruction as in osteoporosis [C. G. Griffith, G. Nichols, J. D. Asher, and B. Flannagan, J. Am. Med. Assoc., 193, 91 (1965); B. Gardner, H. Gray, and G. Hedyati, Curr. Top. Surg. Res., 2, 175 (1970); B. Gardner, S. Wallach, H. Gray, and R. K. Baker, Surg. Forum, 22, 435 (1971)]. Collagenase activity has also resulted in tissue damage in cholesteatoma [M. Abramson, R. W. Schilling, C. C. Huang, and R. G. Salome, Ann. Otol. Rhinol. Faryngol., 81, 158 (1975); M. Abramson and C. C. Huang, Laryngoscope, 77, 1 (1976)]. In corneal ulcerations that progress to loss of corneal integrity and function, collagenase has been implicated as a direct factor in corneal destruction [S. I. Brown, C. W. Hook, and N. P. Tragakis, Invest. Ophthamol., 11, 149 (1972); M. B. Berman, C. H. Dohlman, P. F. Davison, and M. Ghadinger, Exptl. Eye Res., 11, 225 (1971)]. Elevated levels of collagenease have also been observed in patients with epidermolysis bullosa, and a group of related genetic diseases of the skin [E. A. Bauer, T. G. Dahl, and A. Z. Eisen, J. Invest. Dermatology, 68, 119 (1977)].
Increased breakdown of elastin of the lung tissue by neutral proteases (elastase) may contribute to the lesions in pulmonary emphysema [I. Mandel, T. V. Darmle, J. A. Frierer, S. Keller, and G. M. Turino in Elastin and Elastic Tissue, Ed. L. B. Sandberg, W. R. Gray, and C. Franzblau, Plenum Press, N.Y., p. 221 (1977)].
A variety of substances, both naturally occurring and synthetically prepared, have been found to be inhibitors of connective tissue destruction, e.g., inhibitors of collagen degradation, that is, as collagenase inhibitors. Such substances include, for example, ethylenediaminetetraacetate, 1,10-phenanthroline, cysteine, dithiothretol and sodium auriothiomalate [D. E. Woolley, R. W. Glanville, D. R. Roberts, and J. M. Evanson, Biochem J., 169, 265 (1978); S. Seifter and E. Harper, Chap. 18, "The Collagenases" in The Enzymes (3rd. Edition), 3, 649-697, Ed. by P. D. Boyer, Academic Press, N.Y. (1971)]. In the eye, a number of studies using collagenase inhibitors directly applied to corneal ulcerations have been reported. Calcium ethylenediaminetetraacetate and acetylcysteine reduce the frequency of ulceration in the alkali burned rabbit [M. Berman and C. Dohlman, Arch. Ophthamol., 35, 95 (1975)]. Both cysteine and acetylcysteine have been effective in the treatment of acute and chronic corneal ulceration in the human, although the latter compound was preferred because of its greater stability [S. I. Brown, N. P. Tragakis, and D. B. Pease, Am. J. Ophthalmol., 74, 316 (1972); M. Berman in Trace Components of Plasma: Isolation and Clinical Significance, 7th Annual Red Cross Symposium, p. 225, Alan R. Liss. Inc., N.Y. (1976)].
Naturally occurring collagenase inhibitors include the serum components α 2 -macroglobulin and β1-anticollagenase [D. E. Woolley, R. W. Glanville, D. R. Roberts and J. M. Evanson, Biochem. J., 169, 265 (1978)].
While some compounds may inhibit the destructive effect of collagenase on connective tissue by acting directly on collagenase itself, other compounds may inhibit such destruction by coating, binding or competing with sights on the connective tissue in such a manner as to prevent collagenase from attacking it. The ureide end products prepared according to the present invention, however, are not to be restricted or limited to any particular mechanism or mode of action. Suffice it to say, that the ureides have utility as inhibitors of connective tissue destruction albeit in whatever manner or mode.
U.S. Pat. No. 2,687,436 discloses substituted 3-(2-naphthyl)-cyclohexanes useful in the treatment of collagen diseases. British Pat. Nos. 856,357 and 1,246,141, disclose 2-aryl-hexahydro-quinolizines and 1-hydroxylpraline derivatives, respectively, useful for treatment diseases affecting connective tissue. The closest known structurally related compound to the final product ureides prepared herein, and disclosed as having collagenase inhibiting activity, is found in Thromb. Res. 1977, 10(4), 605-11 wherein the trypanocidal agent trypan blue is reported as inhibiting the activity of collagenase, or a proteinase contaminant in the collagenase preparation. It is interesting, however, that in this same article, the ureide Suramin is reported as not inhibiting the action of collagenase. The closest known ureides to the final product ureides prepared herein, and not disclosed as inhibitors of connective tissue destruction or as collagenase inhibitors, are those ureides found in Journal of the Chemical Society, 3069 (1927), and in U.S. Pat. Nos. 1,218,654 and 1,308,071. The generic disclosure of the U.S. Pat. No. 1,308,071 patent encompasses a vast number of ureides and with proper selection, among the many possible variables, some of the final product ureides prepared herein may be encompassed within this broad generic disclosure. However, such disclosure by itself does not anticipate or render obvious such final product ureides.
SUMMARY OF THE INVENTION
This invention is concerned with novel nitrobenzamido or aminoloweralkylbenzamido-substituted-naphthalenemonosulfonic acids and salts thereof which may be represented by Formula I: ##STR1## wherein A is hydrogen or a pharmaceutically acceptable salt cation; B is hydrogen, lower (C 1 -C 6 ) alkanoyl or alkali metal; and R is hydrogen or lower (C 1 -C 3 ) alkyl.
A preferred form of the present invention is concerned with those ureides wherein neither the R nor the NH-group are ortho to the fixed portion of the carboxamido group (--NHCO--) in the bridgehead and such ureides may be represented by Formulae II, III and IV: ##STR2## wherein in the above formulae A, B and R are as defined with reference to Formula I.
By acceptable salt cation is meant an alkali metal; an alkaline earth metal; ammonium; primary amine, e.g. ethylamine, secondary amine, e.g., diethylamine or diethanolamine; tertiary amine, e.g., pyridine, triethylamine or 2-dimethylaminomethyldibenzofuran; aliphatic amine, e.g., dicamethylenediamine; or aromatic amine.
Representative compounds encompassed within this invention include, for example, 6-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt, 3-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(m-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(m-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(p-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(3-nitro-p-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(4-nitro-m-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(m-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(m-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-5-hydroxy-1-nphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 1-(m-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(p-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(3-nitro-p-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(4-nitro-m-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-8-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(m-nitroenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 2-(m-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 2-(p-nitrobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 2-(3-nitro-p-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 2-(4-nitro-m-toluamido)-5-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-1-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-4-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-5-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(m-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(p-nitrobenzamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(3-nitro-p-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 1-(4-nitro-m-toluamido)-8-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-3-hydroxy-2-naphthalenesulfonic cid, sodium salt; 4-(p-nitrobenzamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-3-hydroxy-1-naphthalensulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(m-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-2-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-2-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-2-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-2-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(m-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(p-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 8-(3-nitro-p-toluamido)-3-hydroxy-1-nphthalenesulfonic acid, sodium salt; 8-(4-nitro-m-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(p-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(3-nitro-p-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-7-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(m-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(p-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(3-nitro-p-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 7-(4-nitro-m-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(m-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(p-nitrobenzamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(3-nitrio-p-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 3-(4-nitro-m-toluamido)-7-hydroxy-1-naphthalenesulfonic acid, sodium salt; 6-(m-nitrobenzamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(p-nitrobenzamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(3-nitro-p-toluamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 6-(4-nitro-m-toluamido)-3-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(m-nitrobenzamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(p-nitrobenzamido)6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(3-nitro-p-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 3-(4-nitro-m-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-6-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(m-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(p-nitroenzamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5 -(3-nitro-p-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 5-(4-nitro-m-toluamido)-3-hydroxy-1-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(p-nitrobenzamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(3-nitro-p-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(4-nitro-m-toluamido)-6-hydroxy-2-naphthalenesulfonic acid, sodium salt; 4-(m-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid acetate (ester); 4-(p-nitrobenzamido)-3-hydroxy-1-naphthalenesulfonic acid acetate (ester); 4-(3-nitro-p-toluamido)-3-hydroxy-1-naphthalenesulfonic acid acetate (ester); 4-(4-nitro-m-toluamido)-3-hydroxy-1-naphthalenesulfonic acid acetate (ester); and acceptable salts thereof.
Since the ureides find utility as inhibitors of connective tissue destruction or as collagenase inhibitors in body fluids, as such they may be useful in ameliorating or preventing those pathological reactions resulting from the functioning of collagenase, and in the therapeutic treatment of warm-blooded animals having connective tissue disorders such as periodontal diseases and diseases of the teeth, osteoporosis, osteolysis, Paget's disease, hyperparathyroidism of renal failure, rheumatoid arthritis, septic arthritis, osteoarthritis, gout, acute synovitis, scleroderma, psoriasis, epidermolysis bullosa, keloids, blisters, cholesteatoma of the ear, and corneal ulceration. The compounds of the present invention may also be useful in those pathological states where excessive activity of neutral proteases causes tissue damage.
The usefulness of the nitro compounds of the present invention in preparing the corresponding amino precursors may be illustrated according to the following Flowchart A. ##STR3##
With reference to Flowchart A, a substituted-amino-naphthalenemonosulfonic acid 1 is dissolved in water, made basic with any suitable base such as, for example, an alkali acetate or alkali metal carbonate, reacted with an alkali acetate such as sodium acetate, filtered and reacted under an inert atmosphere, e.g., nitrogen, with an excess substituted nitrobenzoyl chloride 2, giving a substituted nitrobenzamido-substituted-naphthalenesulfonic acid 3. This nitro derivative 3 is then hydrogenated in the presence of a suitable catalyst, giving the corresponding amine derivative 4. The amine 4 is dissolved in a basic solution of pyridine and water and then phosgenated. The final ureide product 5 is extracted from conventional organic solvents such as ethanol or ether. The resulting compound may be converted to its salt in a known manner.
The substituted-aminonaphthalenemonosulfonic acid starting materials may be prepared in a manner similar to that disclosed in Elsevier's Encyclopedia of Organic Chemistry, Series III, Volume 12B, pp. 5381-82 and 5388-89 (1955). Representative starting materials include, for example, 3-amino-4-hydroxy-2-naphthalenesulfonic acid; 3-amino-4-hydroxy-1-naphthalenesulfonic acid; 6-amino-5-hydroxy-1-naphthalenesulfonic acid; 6-amino-5-hydroxy-2-naphthalenesulfonic acid; 7-amino-8-hydroxy-2-naphthalenesulfonic acid; 7-amino-8-hydroxy-1-naphthalenesulfonic acid; 7-amino-5-hydroxy-1-naphthalenesulfonic acid; 7-amino-5-hydroxy-2-naphthalenesulfonic acid; 6-amino-8-hydroxy-2-naphthalenesulfonic acid; 4-amino-1-hydroxy-2-naphthalenesulfonic acid; 1-amino-4-hydroxy-2-naphthalenesulfonic acid; 8-amino-5-hydroxy-1-naphthalenesulfonic acid; 8-amino-5-hydroxy-2-naphthalenesulfonic acid; 5-amino-8-hydroxy-2-naphthalenesulfonic acid; 5-amino-8-hydroxy-1-naphthalenesulfonic acid; 5-amino-1-hydroxy-2-naphthalenesulfonic acid; 8-amino-4-hydroxy-2-naphthalenesulfonic acid; 8-amino-4-hydroxy-1-naphthalenesulfonic acid; 1-amino-5-hydroxy-2-naphthalenesulfonic acid; 4-amino-8-hydroxy-1-naphthalenesulfonic acid; 6-amino-1-hydroxy-2-naphthalenesulfonic acid; 7-amino-4-hydroxy-2-naphthalenesulfonic acid; 7-amino-4-hydroxy-1-naphthalenesulfonic acid; 2-amino-5-hydroxy-1-naphthalenesulfonic acid; 8-amino-1-hydroxy-2-naphthalenesulfonic acid; 5-amino-4-hydroxy-2-naphthalenesulfonic acid; 5-amino-4-hydroxy-1-naphthalenesulfonic acid; 4-amino-5-hydroxy-2-naphthalenesulfonic acid; 1-amino-8-hydroxy-2-naphthalenesulfonic acid; 4-amino-3-hydroxy-2-naphthalenesulfonic acid; 4-amino-3-hydroxy-1-naphthalenesulfonic acid; 5-amino-6-hydroxy-1-naphthalenesulfonic acid; 5-amino-6-hydroxy-2-naphthalenesulfonic acid; 8-amino-7-hydroxy-2-naphthalenesulfonic acid; 8-amino-7-hydroxy-1-naphthalenesulfonic acid; 6-amino-7-hydroxy-2-naphthalenesulfonic acid; 4-amino-2-hydroxy-1-naphthalenesulfonic acid; 8-amino-3-hydroxy-1-naphthalenesulfonic acid; 5-amino-7-hydroxy-2 -naphthalenesulfonic acid; 4-amino-7-hydroxy-2-naphthalenesulfonic acid; 4-amino-7-hydroxy-1-naphthalenesulfonic acid; 7-amino-3-hydroxy-1-naphthalenesulfonic acid; 3-amino-7-hydroxy-1-naphthalenesulfonic acid; 6-amino-3-hydroxy-2-naphthalenesulfonic acid; 3-amino-6-hydroxy-2-naphthalenesulfonic acid; 4-amino-6-hydroxy-1-naphthalenesulfonic acid; 5-amino-3-hydroxy-1-naphthalenesulfonic acid; 4-amino-6-hydroxy-2-naphthalenesulfonic acid; and 1-amino-2-acetoxy-4-naphthalenesulfonic acid.
DETAILED DESCRIPTION OF THE INVENTION
The following will serve to illustrate the invention in more detail.
EXAMPLE 1
Nitro Precursor 4-hydroxy-6-m-nitrobenzamido-2-naphthalenesulfonic acid, sodium salt
A suspension of 180 g. of 6-amino-4-hydroxy-2-naphthalenesulfonic acid in 1800 ml. of water is adjusted to pH 7.2-7.5 with aqueous sodium hydroxide solution. The solution is filtered and to the filtrate is added 181.8 g. of sodium acetate trihydrate, followed by 190.8 g. of m-nitrobenzoyl chloride. The mixture is stirred vigorously under nitrogen at room temperature for 8 hours and then filtered. The solid is washed with water, ethanol and then ether and dried at room temperature. This tan solid (293 g.) is added to a mixture of 1500 ml. of water and 1180 ml. of 1 N sodium hydroxide, stirred under nitrogen for one hour, filtered and the filtrate is acidified with concentrated hydrochloric acid. The resulting precipitate is recovered by filtration, washed with water, ethanol, then ether and dried under high vacuum at room temperature giving 205 g. of 4-hydroxy-6-m-nitrobenzamido-2-naphthalenesulfonic acid, sodium salt.
EXAMPLE 2
Amine Precursor 6-(m-aminobenzamido)-4-hydroxy-2-naphthalenesulfonic acid
A suspension of 110 g. of 4-hydroxy-6-m-nitrobenzamido-2-naphthalenesulfonic acid, sodium salt is converted to a solution by the addition of sufficient 10 N sodium hydroxide. The solution is filtered and to the filtrate is added 25 g. of 10% palladium-on-carbon catalyst. The mixture is hydrogenated in a 2 liter Parr shaker for 23/4 hours at 25 psi. The reaction mixture is filtered through diatomaceous earth, diluted with water to a volume of 3.5 liters and acidified with concentrated hydrochloric acid. The resulting precipitate is recovered by filtration, washed with water, ethanol, then ether and dried overnight under high vacuum at room temperature, giving the desired product as a grey solid.
EXAMPLE 3
6,6'-[Ureylenebis(m-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid]disodium salt
A solution of 200 g. of 6-(m-aminobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, prepared as in Example 2, in a mixture of 3.2 liters of water and 280 ml. of pyridine is warmed to 40° C. and filtered through diatomaceous earth. The filtrate is phosgenaged at 18°-28° C. (ice bath cooling) by spraying gaseous phosgene into the mixture until it is strongly acidic. The resulting solid is recovered by filtration and washed with water until the filtrate is almost neutral. The resulting tan-pink paste is dissolved in a mixture of 48 g. of sodium hydroxide in 50 ml. of water at room temperature. The solution is filtered and the filtrate is poured into 12 liters of ethanol:ether (2:1) with vigorous stirring. The solid is recovered by filtration, washed with the ethanol:ether mixture, then ether and air dried giving 331 g. of a yellow powder. This powder is dissolved in 800 ml. of warm water, acidified with 45 ml. of acetic acid and filtered. A 200 ml. portion of water is added, the mixture is heated and then poured into 13.5 liters of ethanol:ether (2:1) with vigorous stirring. The mixture is filtered and the resulting gel is dissolved in 800 ml. of water. The solution is filtered through diatomaceous earth and the filtrate poured into 28.5 liters of ethanol:ether (2:1). The mixture is filtered and the precipitate washed with ethanol:ether (2:1), then ether, dried at room temperature and then dried at 105°-110° C. under high vacuum giving the desired product as a tan-pink powder.
EXAMPLE 4
Nitro Precursor 4-hydroxy-6-p-nitrobenzamido-2-naphthalenesulfonic acid, sodium salt
A 17.0 g. portion of 6-amino-4-hydroxy-2-naphthalenesulfonic acid is suspended in 175 ml. of water and adjusted to pH 8 with 5 N sodium hydroxide solution. A 12.17 g. portion of sodium acetate trihydrate is added, the mixture is stirred and then filtered. To the filtrate is added 13.67 g. of p-nitrobenzoyl chloride, with vigorous stirring under nitrogen. The mixture is stirred 4 hours. The solid is recovered by filtration, washed with water, ethanol, then ether, slurried in ether and dried in vacuo. This solid is suspended in a mixture of 120 ml. of water and 66 ml. of 1 N sodium hydroxide solution and stirred under nitrogen for one hour. The suspension is acidified with hydrochloric acid and the solid is collected by filtration, washed with water, ethanol, then ether and dried in vacuo, giving 14.5 g. of 4-hydroxy-6-p-nitrobenzamido-2-naphthalenesulfonic acid, sodium salt as a light yellow solid.
EXAMPLE 5
Amine Precursor 6-p-(Aminobenzamido)-4-hydroxy-2-naphthalenesulfonic acid
A 10.0 g. portion of 4-hydroxy-6-p-nitrobenzamido-2-naphthalenesulfonic acid sodium salt, prepared as in Example 4, is hydrogenated with palladium on carbon catalyst, as described in Example 2, giving 7.6 g. of the desired product as an off-white solid.
EXAMPLE 6
6,6'-[Ureylenebis(p-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid], disodium salt
A 6.0 g. portion of 6-(p-aminobenzamido)-4-hydroxy-2-naphthalenesulfonic acid, prepared as in Example 5, is suspended in 96 ml. of water. A 10.4 ml. portion of pyridine is added followed by 5 ml. of 5 N sodium hydroxide causing solution. The mixture is placed in a cold water bath and phosgene gas is passed in with vigorous stirring until the mixture is strongly acidic. The pink solid is collected by filtration, washed with water and then dissolved in a mixture of 4 ml. of 10 N sodium hydroxide and water and filtered. The filtrate is poured into 1200 ml. of ethanol:ether (1:1) with vigorous stirring. The resulting solid is collected by filtration, washed with ethanol:ether (2:1), then ether and dried in vacuo. This solid is dissolved in 20 ml. of water and acidified with 0.7 ml. of acetic acid. Sufficient 5 N sodium hydroxide is added to reach pH 12 and cause solution. A 1200 ml. portion of ethanol:ether (1:1) is added and the solid is collected by filtration, washed with ethanol:ether (2:1), then ether and dried in vacuo. This solid is dissolved in 40 ml. of water and acetic acid is added to pH 6. The resulting solid is collected by filtration, slurried in ethanol, filtered, washed with ethanol, then ether and dried, giving the desired product as 3.15 g. of a light pink solid.
EXAMPLE 7
Nitro Precursor 5-hydroxy-4-m-nitrobenzamido-1-naphthalenesulfonic acid, sodium salt
To a suspension of 50 g. of crude 1-amino-8-naphthol-4-sulfonic acid in 400 ml. of methanol is added sufficient 10 N sodium hydroxide to adjust the pH to 7.5. The resulting solution is filtered through Celite and then twice through a 600 ml. scintered glass funnel coated with magnesol. The filtrate is acidified to pH 3.2. The resulting solid is collected by filtration, washed with methanol, then ether giving 17.8 g. of solid purified 1-amino-8-naphthol-4-sulfonic acid.
To a solution of 10 g. of the above purified amine in 150 ml. of water is added sufficient 1 N NaOH to adjust the pH to 7.7. The solution is filtered and to the filtrate is added 10 g. of sodium acetate trihydrate. This mixture is flushed with a steady stream of argon and then 10 g. of m-nitrobenzoyl chloride is added with vigorous stirring. After 15 minutes, 200 ml. of water are added and stirring is continued for 4 hours. The mixture is filtered and the recovered solid is washed with water, twice with ethanol and then with ether. The solid is then washed with 400 ml. of warm ethanol which is then concentrated giving 5-hydroxy-4-m-nitrobenzamido-1-naphthalenesulfonic acid sodium salt as a bright yellow solid.
EXAMPLE 8
Amine Precursor 4-(m-aminobenzamido)-5-hydroxy-1-naphthalenesulfonic acid
A solution of 4.4 g. of the above nitro compound in a mixture of 150 ml. of water and 50 ml. of 1 N sodium hydroxide containing 500 mg. of 10% palladium-on-carbon catalyst is hydrogenated on a Parr apparatus. When hydrogen uptake is complete, the mixture is filtered through Celite and washed with water. The filtrate is acidified to pH 1.5 with concentrated hydrochloric acid. The resulting precipitate is filtered, washed with water, then ethanol and then ether and dried in vacuo at 110° C., giving the desired product as a gray powder.
EXAMPLE 9
4,4'-[Ureylenebis(m-phenylenecarbonylimino)]bis-5-hydroxy-1-naphthalenesulfonic acid, disodium salt
To a solution of 2.0 g. of 4-(m-aminobenzamido)-5-hydroxy-1-naphthalenesulfonic acid, prepared as in Example 8, in a mixture of 32 ml. of water and 2.8 ml. of pyridine is added 5.6 ml. of pyridine and more aqueous pyridine to effect solution. The solution is then phosgenated to acidity (pH 3.9), filtered and the solid washed with water until neutral. This solid is dissolved in 12 ml. of 1 N sodium hydroxide and added to 120 ml. of ethanol:ether (2:1). The mixture is concentrated to a residue which is dissolved in 15 ml. of water and 100 ml. of ethanol and 100 ml. of ether are added. The resulting solid is collected by filtration, washed once with 100 ml. of ethanol:ether (1:1), then ether. The solid is dissolved in 15 ml. of water and acidified to pH 6.3 with 0.5 ml. of acetic acid. The solution is warmed, filtered and the filtrate added to 135 ml. of ethanol:ether (2:1). A 45 ml. portion of ether is added and the solid is collected, washed with 50 ml. of ethanl:ether (1:1), then ether and dried in vacuo at 110° C. for 14 hours, giving the desired product.
EXAMPLE 10
6,6'-[Ureylenebis(p-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid]tetrasodium salt
To a stirred suspension of one g. of 6,6'-[ureylenebis(p-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid]disodium salt is added 1 N sodium hydroxide until solution occurs (pH 10-12). The solution is then poured into 350 ml. of ethanol:ether (2:1) with vigorous stirring and the precipitate is filtered, washed with ethanol:ether (2:1), ether and dried. The solid is reprecipitated from 5 ml. of water by 300 ml. of ethanol:ether (2:1) to give 300 mg. of product as a brownish solid.
EXAMPLE 11
6,6'-[Ureylenebis(m-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid]tetrasodium salt
In the manner described in Example 10, treatment of 6,6'-[ureylenebis(m-phenylenecarbonylimino)]bis[4-hydroxy-2-naphthalenesulfonic acid]disodium salt with sodium hydroxide gives the desired product.
EXAMPLE 12
Nitro Precursor 4-hydroxy-6-(3-nitro-p-toluamido)-2-naphthalenesulfonic acid, sodium salt
A 17.0 g. portion of 6-amino-4-hydroxy-2-naphthalenesulfonic acid is suspended in 175 ml. of water and adjusted to pH 8 with 5 N sodium hydroxide solution. A 12.17 g. portion of sodium acetate trihydrate is added, the mixture is stirred and then filtered. To the filtrate is added 13.67 g. of 4-methyl-3-nitrobenzoyl chloride with vigorous stirring under nitrogen. The mixture is stirred 4 hours. The solid is recovered by filtration, washed with water, ethanol, then ether, slurried in ether and dried in vacuo. This solid is suspended in 100 ml. of water and 56 ml. of 1 N sodium hydroxide, stirred under nitrogen for one hour, filtered and the filtrate acidified with concentrated hydrochloric acid. The resulting solid is slurried in 800-900 ml. of ethanol, stirred for 1/2 hour, filtered and the solid is washed with ethanol, then ether and dried in vacuo giving 11.2 g. of 4-hydroxy-6-(3-nitro-p-toluamido)-2-naphthalenesulfonic acid sodium salt.
EXAMPLE 13
Amine Precursor 6-(3-Amino-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid
A 10.0 g. portion of 4-hydroxy-6-(3-nitro-p-toluamido)-2-naphthalenesulfonic acid sodium salt is suspended in 200 ml. of water and 10 N sodium hydroxide solution is added until solution is complete (pH 11). The mixture is filtered and to the filtrate is added 2.5 g. of 10% palladium-on-carbon. The mixture is hydrogenated in a Parr shaker until no additional hydrogen is taken up, filtered through diatomaceous earth and washed with water. The combined filtrate and washing is acidified with hydrochloric acid and the solid is collected by filtration, washed with water, ethanol, then ether and dried in a pistol giving the desired product as 7.5 g. of an off-white solid.
EXAMPLE 14
6,6'-[Ureylenebis(4-methyl-3,1-phenylene)carbonylimino]bis[4-hydroxy-2-naphthalenesulfonic acid]disodium salt
A mixture comprising 6.0 g. of 6-(3-amino-p-toluamido)-4-hydroxy-2-naphthalenesulfonic acid, prepared as in Example 13, 15 ml. of pyridine, 3 ml. of 5 N sodium hydroxide and 92 ml. of water is warmed to produce solution, filtered and the filtrate is phosgenated in a cold water bath with gaseous phosgene, until strongly acidic and until thin layer chromatography shows no more starting amine. The solid is recovered by filtration and washed with water. This paste is dissolved in a mixture of 4 ml. of 10 N sodium hydroxide and 5 ml. of water and poured into 1200 ml. of ethanol:ether (1:1). The solid is collected by filtration, washed with ethanol:ether (2:1) and dried in vacuo. The solid is dissolved in 20 ml. of water and acidified with 0.7 ml. of acetic acid. A 10 ml. portion of water is added and the mixture is heated to solution on a steam bath and then poured into 750 ml. of ethanol:ether (2:1), with vigorous stirring. The resulting precipitate is collected by filtration, washed with ethanol:ether (2:1) and dried in a pistol, giving the desired product as 3.88 g. of a light pink solid.
EXAMPLE 15
Nitro Precursor 4-hydroxy-6-(4-nitro-m-toluamido)-2-naphthalenesulfonic acid, sodium salt
In the manner described in Example 12, reaction of 7-amino-4-hydroxy-1-naphthalenesulfonic acid with 4-methyl-3-nitrobenzoyl chloride and sodium acetate in water gives 4-hydroxy-6-(4-nitro-m-toluamido)-2-naphthalenesulfonic acid sodium salt as a yellow oil.
EXAMPLE 16
Amine Precursor 4-hydroxy-6-(4-nitro-m-toluamido)-2-naphthalenesulfonic acid
The oil prepared in Example 15 is then catalytically reduced as described in Example 13 to give the desired product as a white solid.
EXAMPLE 17
6,6'-[Ureylenebis(3-methyl-4,1-phenylene)carbonylimino]bis[4-hydroxy-2-naphthalenesulfonic acid]disodium salt
In the manner described in Example 14, reaction of 6-(4-amino-m-toluamido)-4-hydroxy-2-naphthalenesulfonic acid with phosgene in pyridine and water gives the desired product as a light pink solid.
EXAMPLE 18
______________________________________Preparation of Compressed TabletIngredient mg/Tablet______________________________________Active Compound 0.5-500Dibasic Calcium Phosphate N.F. qsStarch USP 40Modified Starch 10Magnesium Stearate USP 1-5______________________________________
EXAMPLE 19
______________________________________Preparation of Compressed Tablet - Sustained ActionIngredient mg/Tablet______________________________________Active Compound as Aluminum 0.5-500 (as acid Lake*, Micronized equivalent)Dibasic Calcium Phosphate N.F. qsAlginic Acid 20Starch USP 35Magnesium Stearate USP 1-10______________________________________
EXAMPLE 20
______________________________________Preparation of Hard Shell CapsuleIngredient mg/Capsule______________________________________Active Compound 0.5-500Lactose, Spray Dried qsMagnesium Stearate 1-10______________________________________
EXAMPLE 21
______________________________________Preparation of Oral Liquid (Syrup)Ingredient % W/V______________________________________Active Compound 0.05-5Liquid Sugar 75.0Methyl Paraben USP 0.18Propyl Paraben USP 0.02Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 22
______________________________________Preparation of Oral Liquid (Elixir)Ingredient % W/V______________________________________Active Compound 0.05-5Alcohol USP 12.5Glycerin USP 45.0Syrup USP 20.0Flavoring Agent qsPurified Water qs ad 100.0______________________________________
EXAMPLE 23
______________________________________Preparation of Oral Suspension (Syrup)Ingredient % W/V______________________________________Active Compound as Aluminum 0.05-5 Lake, Micronized (acid equivalent)Polysorbate 80 USP 0.1Magnesium Aluminum Silicate, Colloidal 0.3Flavoring Agent qsMethyl Paraben USP 0.18Propyl Paraben USP 0.02Liquid Sugar 75.0Purified Water qs ad 100.0______________________________________
EXAMPLE 24
______________________________________Preparation of Injectable SolutionIngredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol N.F. 0.9Water for Injection 100.0______________________________________
EXAMPLE 25
______________________________________Preparation of Injectable OilIngredient % W/V______________________________________Active Compound 0.05-5Benzyl Alcohol 1.5Sesame Oil qs ad 100.0______________________________________
EXAMPLE 26
______________________________________Preparation of Intra-Articular ProductIngredient Amount______________________________________Active Compound 2-20 mgNaCl (physiological saline) 0.9%Benzyl Alcohol 0.9%Sodium Carboxymethylcellulose 1-5%pH adjusted to 5.0-7.5Water for Injection qs ad 100%______________________________________
EXAMPLE 27
______________________________________Preparation of Injectable Depo SuspensionIngredient % W/V______________________________________Active Compound 0.05-5 (acid equivalent)Polysorbate 80 USP 0.2Polyethylene Glycol 4000 USP 3.0Sodium Choride USP 0.8Benzyl Alcohol N.F. 0.9HCl to pH 6-8 qsWater for Injection qs ad 100.0______________________________________
EXAMPLE 28
______________________________________Preparation of Dental PasteIngredient % W/W______________________________________Active Compound 0.05-5Zinc Oxide 15Polyethylene Glycol 4000 USP 50Distilled Water qs 100______________________________________
EXAMPLE 29
______________________________________Preparation of Dental OintmentIngredient % W/W______________________________________Active Compound 0.05-5Petrolatum, White USP qs 100______________________________________
EXAMPLE 30
______________________________________Preparation of Dental CreamIngredient % W/W______________________________________Active Compound 0.05-5Mineral Oil 50Beeswax 15Sorbitan Monostearate 2Polyoxyethylene 20 Sorbitan Monostearate 3Methyl Paraben USP 0.18Propyl Paraben USP 0.02Distilled Water qs 100______________________________________
EXAMPLE 31
______________________________________Preparation of Topical CreamIngredient % W/W______________________________________Active Compound 0.05-5Sodium Lauryl Sulfate 1Propylene Glycol 12Stearyl Alcohol 25Petrolatum, White USP 25Methyl Paraben USP 0.18Propyl Paraben USP 0.02Purified Water qs 100______________________________________
EXAMPLE 32
______________________________________Preparation of Topical OintmentIngredient % W/W______________________________________Active Compound 0.05-5Cholesterol 3Stearyl Alcohol 3White Wax 8Petrolatum, White USP qs 100______________________________________
EXAMPLE 33
______________________________________Preparation of Spray Lotion (non-Aerosol)Ingredient % W/W______________________________________Active Compound 0.05-5Isopropyl Myristate 20Alcohol (Denatured) qs 100______________________________________
EXAMPLE 34
______________________________________Preparation of Buccal TabletIngredient g/Tablet______________________________________Active Ingredient 0.003256 × Sugar 0.29060Acacia 0.01453Soluble Starch 0.01453F. D. & C. Yellow No. 6 Dye 0.00049Magnesium Stearate 0.00160 0.32500______________________________________
The final tablet will weigh about 325 mg. and may be compressed into buccal tablets in flat faced or any other tooling shape convenient for buccal administration.
EXAMPLE 35
______________________________________Preparation of LozengeIngredient g/Lozenge______________________________________Active Ingredient 0.0140Kompact® Sugar (Sucrest Co.) 0.71386 × Sugar 0.4802Sorbitol (USP Crystalline) 0.1038Flavor 0.0840Magnesium Stearate 0.0021Dye qsStearic Acid 0.0021 1.4000______________________________________
The ingredients are compressed into 5/8" flat based lozenge tooling. Other shapes may also be utilized.
EXAMPLE 36
______________________________________Preparation of Gelled Vehicles______________________________________Ingredient % W/W______________________________________Active Compound 9-11Sodium Chloride 0.9-1.2Buffer and Flavor qs --Purified Water qs ad 100______________________________________Ingredient % W/W______________________________________Active Compound 0.005-9Sodium Alginate 0.5-2Buffer and Flavor qs --Purified Water qs ad 100______________________________________Ingredient % W/W______________________________________Active Compound 0.005-9Hydroxypropyl Cellulose 0.5-2Buffer and Flavor qs --Purified Water qs ad 100______________________________________Ingredient % W/W______________________________________Active Compound 0.005-9Guar Gum 0.5-2Buffer and Flavor qs --Purified Water qs ad 100______________________________________
EXAMPLE 37
______________________________________Preparation of Oral Mouth RinseIngredient % W/V______________________________________Active Compound 0.05-20Alcohol U.S.P. 0-20Sorbitol 1-30Buffer and Flavor qs --Polysorbate 80 0.1-3Cetyl Pyridinium Chloride 0.025-0.20Purified Water qs ad 100______________________________________
EXAMPLE 38
______________________________________Preparation of Tooth PasteIngredient % W/W______________________________________Active Compound 0.05-15Glycerin 5-15Sorbitol 5-15Sodium Carboxymethylcellulose 0.5-2Magnesium Aluminum Silicate 0.1-1Carrageenin 0.25-2Preservative qs --Sodium Lauryl Sulfate 0.1-3Calcium Carbonate 25-45Flavor qs --Purified Water qs ad 100______________________________________
EXAMPLE 39
______________________________________Preparation of Dental PasteIngredient % W/W______________________________________Active Compound 0.05-20Carboxymethylcellulose 5-20Pectin 5-20Plastibase® 20-70Gelatin 5-20______________________________________
EXAMPLE 40
______________________________________Preparation of Dental OintmentIngredient % W/W______________________________________Active Compound 0.05-20Polyethylene Glycol 4000 50-80Polyethylene Glycol 400 10-40______________________________________
EXAMPLE 41
______________________________________Preparation of Dental Powder for Brushing orfor Use in Water Spray (e.g. Water Pik®)Ingredient % W/W______________________________________Active Compound 0.05-10Flavor qs --Wetting Agents qs --Dextrin qs ad 100______________________________________
EXAMPLE 42
______________________________________Preparation of Stick for Application to GumsIngredient % W/W______________________________________Active Compound 0.05-10Glycerin 5-10Propylene Glycol 40-80Sodium Stearate 6-10Flavor qs --Water 0-10______________________________________
EXAMPLE 43
______________________________________Preparation of Periodontal Packing Paste______________________________________Paste Part AIngredient % W/W______________________________________Active compound 0.05-20Caprylic acid 9.0Lauric acid 27.0Ethylcellulose (100 cps.) 2.0Polypale resin* 39.0Gum elemi 4.0Brominol** 4.0Mica (powdered) 7.5Chlorothymol 1.0Zinc acetate 2.0Bay oil (essential oil) 1.0Ethanol 1.5Paste Part BMagnesium oxide 43.0Zinc oxide 21.0Calcium hydroxide 3.5Copper oxide 2.0Mineral oil, Heavy 26.0Rosin oil 3.0Chlorothymol 1.4Cumarin (flavor) 0.1______________________________________ *Partially polymerized rosin (i.e. modified rosin) **Brominated olive oil
When equal parts of A and B are mixed together at 25° C. a hard mass is formed in about 3 minutes.
EXAMPLE 44
______________________________________Preparation of Periodontal Packing Paste______________________________________Part A (Powder)Ingredient % W/W______________________________________Active compound 0.05-20Canada Balsam, Neutral 8.5Rosin NF 8.5Calcium hydroxide 34.4Zinc oxide U.S.P. 46.6Part B (Liquid Hardener)Eugenol 85.0Turpentine oil, rectified 15.0______________________________________
A mixture of three drops of Part B added to 130 mg. of Part A produces a hard mass in about 2-3 minutes at 30° C.
The final product ureides may be administered internally to a warm-blooded animal to inhibit connective tissue destruction or collagenase, such inhibition being useful in the amelioration or prevention of those reactions causing connective tissue damage. A range of doses may be employed depending on the mode of administration, the condition being treated and the particular compound being used. For example, for intravenous or subcutaneous use from about 5 to about 50 mg/kg/day, or every six hours for more rapidly excreted salts, may be used. For intra-articular use for large joints such as the knee, from about 2 to about 20 mg/joint per week may be used, with proportionally smaller doses for smaller joints. The dosage range is to be adjusted to provide optimum therapeutic response in the warm-blooded animal being treated. In general, the amount of ureide administered can vary over a wide range to provide from about 1.5 mg/kg to about 100 mg/kg of body weight of animal per day. The usual daily dosage for a 70 kg subject may vary from about 100 mg to about 3.5 g. Unit doses can contain from about 0.5 mg to about 500 mg.
While in general the sodium salts of the acids of the ureides are suitable for parenteral use, other salts may also be prepared, such as those of primary amines, e.g., ethylamine; secondary amines, e.g., diethylamine or diethanolamine; tertiary amines, e.g., pyridine or triethylamine or 2-dimethylaminomethyldibenzofuran; aliphatic diamines, e.g., decamethylenediamine; and aromatic diamines, can be prepared. Some of these are soluble in water, others are soluble in saline solution, and still others are insoluble and can be used for purposes of preparing suspensions for injection. Furthermore, as well as the sodium salt, those of the alkali metals, such as potassium and lithium; of ammonia; and of the alkaline earth metals, such as calcium or magnesium, may be employed. It will be apparent, therefore, that these salts embrace, in general, derivatives of salt-forming cations.
In therapeutic use the ureides may be administered in the form of conventional pharmaceutical compositions. Such compositions may be formulated so as to be suitable for oral or parenteral administration. The active ingredient may be combined in admixture with a pharmaceutically acceptable carrier, which carrier may take a wide variety of forms depending on the form of preparation desired for administration, i.e., oral or parenteral. The ureides can be used in compositions such as tablets. Here, the principal active ingredient is mixed with conventional tabletting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate, dicalcium phosphate, gums, or similar materials as non-toxic pharmaceutically acceptable diluents or carriers. The tablets or pills of the novel compositions can be laminated or otherwise compounded to provide a dosage form affording the advantage of prolonged or delayed action or predetermined successive action of the enclosed medication. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids or mixtures of polymeric acids with such materials as shellac, shellac and cetyl alcohol, cellulose acetate and the like. A particularly advantageous enteric coating comprises a styrene maleic acid copolymer together with known materials contributing to the enteric properties of the coating. The tablet or pill may be colored through the use of an appropriate non-toxic dye, so as to provide a pleasing appearance.
The liquid forms in which the ureides may be incorporated for administration include suitable flavored emulsions with edible oils, such as, cottonseed oil, sesame oil, coconut oil, peanut oil, and the like, as well as elixirs and similar pharmaceutical vehicles. Sterile suspensions or solutions can be prepared for parenteral use. Isotonic preparations containing suitable preservatives are also desirable for injection use.
The ureides may also be administered topically in the form of ointments, creams, lotions and the like, suitable for the treatment of connective tissue dependent dermatological disorders.
Moreover, the ureides may be administered in the form of dental pastes, ointments, buccal tablets and other compositions suitable for application periodontally for the treatment of periodtontitis and related diseases of the oral cavity.
The term dosage form as described herein refers to physically discrete units suitable as unitary dosage for warm-blooded animal subjects, each unit containing a predetermined quantity of active component calculated to produce the desired therapeutic effect in association with the required pharmaceutical diluent, carrier or vehicle. The specification for the ureide dosage forms are indicated by characteristics of the active component and the particular therapeutic effect to be achieved or the limitations inherent in the art of compounding such an active component for therapeutic use in warm-blooded animals as disclosed in this specification. Examples of suitable oral dosage forms in accord with this invention are tablets, capsules, pills, powder packets, granules, wafers, cachets, teaspoonfuls, dropperfuls, ampules, vials, segregated multiples of any of the foregoing and other forms as herein described.
The inhibiting activity of representative ureides on the destruction of connective tissue has been demonstrated by one or more of the following identified tests: (i) Collagenase Assay, Test Code 006--This test measures the ability of human skin fibroblast collagenase to degrade radiolabeled native collagen fibrils. An active inhibitor inhibits the degradation of the collagen fibril; (ii) Crevicular Fluid Assay--In an analogous test, collagenase present in the crevicular fluid of imflamed gingival tissue was used to measure its ability to degrade radiolabeled native collagen fibrils. An active inhibitor would inhibit the degradation of the collagen fibril; (iii) Leukocyte Neutral Proteases Inhibitor Assay13 This test measures the ability of neutral proteases derived from human leukocytes to degrade radiolabeled proteoglycans entrapped in polyacrylamide beads. An active inhibitor inhibits the degradation of proteoglycans.
(i) Collagenase Assay--Test Code 006
Collgenase assays were performed by a modification of the method of Harper, et al., Biochem., 10, 3035 (1971). In a typical assay (total volume of 0.45 ml.), 100 μl. of the activated enzyme was added to the 14 C-labeled collagen fibrils (250 μl.) followed by 100 μl. of 50 mM cacodylate, pH 7.4 containing 5 mM calcium chloride. After incubation at 37° C. for 16 hours, the tubes were centrifuged in a Beckman microfuge for five minutes at full speed. An aliquot (200 μl.) of the supernatant, representing collagenase digestion products of the fibril, was assayed for radioactivity. The effect of the test compound on collagen degradation by collagenase was examined as follows:
Varying concentrations of the test compound (in distilled water) were added to the assay tubes containing active collagenase (total volume 450 μl.) and after 16 hours the amount of radioactivity in the supernatant was determined. Appropriate blanks and trypsin controls were run in parallel.
Table I shows that representative ureides possess collagenase inhibitory activity. The activities are expressed as % inhibition (lowering) of collagenase activity, i.e. based on the 0% value for the enzyme control.
TABLE I______________________________________Biological Activities(test conc.: 30 μg./ml.) % Inhibition ofCompound Collagenase______________________________________6,6'-[Ureylenebis(4-methyl-3,1- 73%phenylene)carbonylimino]bis-[4-hydroxy-2-naphthalenesul-fonic acid]disodium salt6,6'-[Ureylenebis(p-phenylene- 86%carbonylimino)]bis[4-hydroxy-2- 96% (DMA*)naphthalenesulfonic acid]di-sodium salttetrasodium salt 95%, 92%6,6'-[Ureylenebis(3,1-phenyl- 82%, 69%enecarbonylimino)]bis[4- 81% (DMA*)hydroxy-2-naphthalenesulfonicacid]disodium salttetrasodium salt 82%, 81%4,4-[Ureylenebis(3,1-phenyl- 84%, 69%enecarbonylimino)]bis[5- 60%, 55%hydroxy-1-naphthalenesulfonicacid]disodium salt______________________________________ *Dimethylacetamide
(ii) Crevicular Fluid Assay
Effect of Test Compounds on Gingival Crevicular Fluid Collagenase
Since studies by Golub, et al., Dental Res., 55, 1049 (1976) have shown that the crevicular collagenase plays a major role in the degradation of collagen in periodontal tissue, the effect of test compounds on collagen degradation by this system was examined. A volunteer with diagnosed periodontal disease was used. The area around the gum was dried and a sterile filter paper strip (2×13 mm., Harco Electronics, Ltd., Winnipeg, Canada) was inserted into the gingival crevice with the aid of a forceps. The gingival crevicular fluid that had accumulated in the periodontal pocket was absorbed by the filter paper strip in approximately one minute. After one minute, the filter paper strip was removed and the volume of the gingival crevicular fluid was measured with the aid of the Periotron (Harco Electronics, Ltd., Winnipeg, Canada). The volume of the fluid gathered from the crevice by the filter paper strip is translated by a unique transducer onto a digital readout screen. The relative wetness of the paper strip affects the flow of an electrical current. Hence, the greater the volume of the fluid (the greater tha paper's capacity to conduct the current) the higher the readout on the digital meter. After reading on the meter, 1 μl. of trypsin (1.5 μg./ml.) was added to the filter paper (to activate any latent collagenase present) and after five minutes at room temperature 1 μl. of aprotinin was added. The filter strip was layered on top of 14 C-collagen fibrils (250 μl. gel volume). Two hundred μl. of 50 mM cacodylate buffer, pH 7.4, containing 5 mM calcium chloride was added (final volume 450 μl.) and the tubes were incubated at 37° C. for approximately 90 hours. Some reaction mixtures contained test compounds at a final concentration of 30 μg./ml. The tubes were centifuged as described above and a 200 μl. aliquot of the clear supernatant was assayed for radioactivity.
The results of this test on a representative ureide are given in Table II.
TABLE II______________________________________ cpm Collagen Degraded/UnitCompound Periotron Reading______________________________________Diseased crevicular fluid 66 ± 9Diseased crevicular fluid 16 ± 6*+ 30 mcg./ml. of 6,6'-[ureylenebis(m-phenyl-enecarbonylimino)]bis[ 4-hydroxy-2-naphthalene-sulfonic acid]disodiumsalt______________________________________ *Statistically significant p<0.0005
(iii) Leukocyte Neutral Proteases Inhibitor Assay
Assays of Leukocyte Neutral Proteases using 3 H/ 35 S Labeled Proteoglycans
This assay system contained (total volume of 1 ml.) 60 mM Tris-Cl, pH 7.4; 2.5 mM calcium chloride; 2.5 mM magnesium chloride; 2 mg. (dry weight) of polyacrylamide beads entrapped with labeled proteoglycans, and an aliquot of the leukocyte neutral protease preparation. The reaction mixture was incubated at 37° C. for 30 minutes in a shaking water bath. The reaction was terminated by the addition of 0.2 ml. of 5% SDS in 5% HCl (v/v). After five minutes at room temperature, the mixture was centrifuged and the clear supernatant (0.6 ml.) was assayed for radioactivity. To determine the effect of the test compounds on degradation of proteoglycans by neutral proteases, various concentrations of the compounds were added to the reaction mixture. Appropriate blanks were included. The results of this test appear in Table III.
TABLE III______________________________________Leukocyte Neutral Proteases Inhibitor AssayConcentration of 6'6'-[urey-lenebis(m-phenylenecarbonyl- Percent Inhibitionimino)]bis(4-hydroxy-2-naph- of Neutralthalenesulfonic acid)diso- Protease Activitydium salt in mcg./ml. .sup.3 H .sup.35 S______________________________________0 0 00.5 0 01.0 17 312.0 21 375.0 47 7410.0 63 91______________________________________
Evidence seems to indicate that certain ureides tested interact by binding with the substrate, e.g., fibrillar collagen, and the resulting complex is then not readily susceptible to degradation by fibroblast collagenase. Evidence supporting this view has been obtained from the following experiments.
Fibrillar collagen was preincubated with the test compounds at 37° C. for 90 to 120 minutes. After this preincubation, the fibrillar collagen was pelleted by centrifugation and unbound test compound was removed by aspiration. Addition of collagenase to these pelleted mixtures resulted in a decreased degradation of collagen when compared to the preincubation mixtures that had not contained test compound. Therefore, the compounds protect preexisting collagen of the oral tissue from degradation by collagenase.
The test compounds are able to inhibit the degradation of collagen of gingival tissue. Dried pieces of human gingiva were incubated at 37° C. for 36 hours with fibroblast collagenase and leukocyte neutral protease in the presence of test compound (30 and 50 μg./ml.). Antibiotics were present to prevent bacterial growth. After incubation, the residual tissue was hydrolyzed in 6 N hydrochloric acid and the hydroxyproline content (collagen) was determined. When collagenase and neutral protease were added to human gingiva, approximately 100 μg of collagen/mg. dry tissue was digested. If the test compound was present, degradation of gingival collagen was inhibited. Results of this experiment are shown in Table IV.
TABLE IV______________________________________Enzymatic Degradation of Collagen of Human Gingiva mcg. of Collagen degraded per mg.Conditions of dry gingiva______________________________________Collagenase, neutral proteases 102.3Collagenase, neutral proteases 60.4plus 30 mcg./ml. of 6,6'-[urey-lenebis(m-phenylenecarbonyl-imino)]bis(4-hydroxy-2-naph-thalenesulfonic acid)disodiumsaltCollagenase, neutral proteases 27.4plus 50 mcg./ml. of 6,6'-[urey-lenebis(m-phenylenecarbonyl-imino)]bis(4-hydroxy-2-naph-thalenesulfonic acid)disodiumsalt______________________________________ | Certain nitro-benzamido-naphthalenemonosulfonic acids and salts thereof useful in the preparation of the corresponding amino precursors to the final product ureides which are useful as inhibitors of connective tissue destruction. | 2 |
RELATED APPLICATIONS
This application is a divisional application of Ser. No. 10/181,663, filed Feb. 24, 2003, now abandoned which is a continuation in part of Ser. No. 09/602,362, filed Jun. 22, 2000 now U.S. Pat. No. 6,911,529 which is a continuation in part of Ser. No. 09/451,739, filed Nov. 30, 1999, now U.S. Pat. No. 6,774,226 both of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to antigens associated with cancer, the nucleic acid molecules encoding them, as well as the uses of these.
BACKGROUND AND PRIOR ART
It is fairly well established that many pathological conditions, such as infections, cancer, autoimmune disorders, etc., are characterized by the inappropriate expression of certain molecules. These molecules thus serve as “markers” for a particular pathological or abnormal condition. Apart from their use as diagnostic “targets”, i.e., materials to be identified to diagnose these abnormal conditions, the molecules serve as reagents which can be used to generate diagnostic and/or therapeutic agents. A by no means limiting example of this is the use of cancer markers to produce antibodies specific to a particular marker. Yet another non-limiting example is the use of a peptide which complexes with an MHC molecule, to generate cytolytic T cells against abnormal cells.
Preparation of Such Materials, of Course, Presupposes a Source of the Reagents Used to generate these. Purification from cells is one laborious, far from sure method of doing so. Another preferred method is the isolation of nucleic acid molecules which encode a particular marker, followed by the use of the isolated encoding molecule to express the desired molecule.
Two basic strategies have been employed for the detection of such antigens, in e.g., human tumors. These will be referred to as the genetic approach and the biochemical approach. The genetic approach is exemplified by, e.g., dePlaen et al., Proc. Natl. Sci. USA 85: 2275 (1988), incorporated by reference. In this approach, several hundred pools of plasmids of a cDNA library obtained from a tumor are transfected into recipient cells, such as COS cells, or into antigen-negative variants of tumor cell lines which are tested for the expression of the specific antigen. The biochemical approach, exemplified by, e.g., O. Mandelboim, et al., Nature 369: 69 (1994) incorporated by reference, is based on acidic elution of peptides which have bound to MHC-class I molecules of tumor cells, followed by reversed-phase high performance liquid chromography (HPLC). Antigenic peptides are identified after they bind to empty MHC-class I molecules of mutant cell lines, defective in antigen processing, and induce specific reactions with cytotoxic T-lymphocytes. These reactions include induction of CTL proliferation, TNF release, and lysis of target cells, measurable in an MTT assay, or a 51 Cr release assay.
These two approaches to the molecular definition of antigens have the following disadvantages: first, they are enormously cumbersome, time-consuming and expensive; and second, they depend on the establishment of cytotoxic T cell lines (CTLs) with predefined specificity.
The problems inherent to the two known approaches for the identification and molecular definition of antigens is best demonstrated by the fact that both methods have, so far, succeeded in defining only very few new antigens in human tumors. See, e.g., van der Bruggen et al., Science 254: 1643-1647 (1991); Brichard et al., J. Exp. Med. 178: 489-495 (1993); Coulie, et al., J. Exp. Med. 180: 35-42 (1994); Kawakami, et al., Proc. Natl. Acad. Sci. USA 91: 3515-3519 (1994).
Further, the methodologies described rely on the availability of established, permanent cell lines of the cancer type under consideration. It is very difficult to establish cell lines from certain cancer types, as is shown by, e.g., Oettgen, et al., Immunol. Allerg. Clin. North. Am. 10: 607-637 (1990). It is also known that some epithelial cell type cancers are poorly susceptible to CTLs in vitro, precluding routine analysis. These problems have stimulated the art to develop additional methodologies for identifying cancer associated antigens.
One key methodology is described by Sahin, et al., Proc. Natl. Acad. Sci. USA 92: 11810-11913 (1995), incorporated by reference. Also, see U.S. Pat. No. 5,698,396, and application Ser. No. 08/479,328, filed on Jun. 7, 1995 and Jan. 3, 1996, respectively. All three of these references are incorporated by reference. To summarize, the method involves the expression of cDNA libraries in a prokaryotic host. (The libraries are secured from a tumor sample). The expressed libraries are then immunoscreened with absorbed and diluted sera, in order to detect those antigens which elicit high titer humoral responses. This methodology is known as the SEREX method (“Serological identification of antigens by Recombinant Expression Cloning”). The methodology has been employed to confirm expression of previously identified tumor associated antigens, as well as to detect new ones. See the above referenced patent applications and Sahin, et al., supra, as well as Crew, et al., EMBO J. 144: 2333-2340 (1995).
This methodology has been applied to a range of tumor types, including those described by Sahin et al., supra, and Pfreundschuh, supra, as well as to esophageal cancer (Chen et al., Proc. Natl. Acad. Sci. USA 94: 1914-1918 (1997)); lung cancer (Güre et al., Cancer Res. 58: 1034-1041 (1998)); colon cancer (Ser. No. 08/948,705 filed Oct. 10, 1997) incorporated by reference, and so forth. Among the antigens identified via SEREX are the SSX2 molecule (Sahin et al., Proc. Natl. Acad. Sci. USA 92: 11810-11813 (1995); Tureci et al., Cancer Res. 56: 4766-4772 (1996); NY-ESO-1 Chen, et al., Proc. Natl. Acad. Sci. USA 94: 1914-1918 (1997); and SCP1 (Ser. No. 08/892,705 filed Jul. 15, 1997) incorporated by reference. Analysis of SEREX identified antigens has shown overlap between SEREX defined and CTL defined antigens. MAGE-1, tyrosinase, and NY-ESO-1 have all been shown to be recognized by patient antibodies as well as CTLs, showing that humoral and cell mediated responses do act in concert.
It is clear from this summary that identification of relevant antigens via SEREX is a desirable aim. The inventors have applied this methodology and have identified several new antigens associated with cancer, as detailed in the description which follows.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
The SEREX methodology, as described by, e.g., Sahin, et al., Proc. Natl. Acad. Sci. USA 92: 11810-11813 (1995); Chen, et al., Proc. Natl. Acad. Sci. USA 94: 1914-1918 (1997), and U.S. Pat. No. 5,698,396, all of which are incorporated by reference. In brief, total RNA was extracted from a sample of a cutaneous metastasis of a breast cancer patient (referred to as “BR11” hereafter), using standard CsCl guanidine thiocyanate gradient methodologies. A cDNA library was then prepared, using commercially available kits designed for this purpose. Following the SEREX methodology referred to supra, this cDNA expression library was amplified, and screened with either autologous BR11 serum which had been diluted to 1:200, or with allogeneic, pooled serum, obtained from 7 different breast cancer patients, which had been diluted to 1:1000. To carry out the screen, serum samples were first diluted to 1:10, and then preabsorbed with lysates of E. coli that had been transfected with naked vector, and the serum samples were then diluted to the levels described supra. The final dilutions were incubated overnight at room temperature with nitrocellulose membranes containing phage plaques, at a density of 4-5000 plaque forming units (“pfus”) per 130 mm plate.
Nitrocellulose filters were washed, and incubated with alkaline phosphatase conjugated, goat anti-human Fcγ secondary antibodies, and reactive phage plaques were visualized via incubation with 5-bromo-4-chloro-3-indolyl phosphate and nitroblue tetrazolium.
This procedure was also carried out on a normal testicular cDNA library, using a 1:200 serum dilution.
A total of 1.12×10 6 pfus were screened in the breast cancer cDNA library, and 38 positive clones were identified. With respect to the testicular library, 4×10 5 pfus were screened, and 28 positive clones were identified.
Additionally, 8×10 5 pfus from the BR11 cDNA library were screened using the pooled serum described. Of these, 23 were positive.
The positive clones were subcloned, purified, and excised to forms suitable for insertion in plasmids. Following amplification of the plasmids, DNA inserts were evaluated via restriction mapping (EcoRI-XbaI), and clones which represented different cDNA inserts were sequenced using standard methodologies.
If sequences were identical to sequences found in GenBank, they were classified as known genes, while sequences which shared identity only with ESTs, or were identical to nothing in these data bases, were designated as unknown genes. Of the clones from the breast cancer library which were positive with autologous serum, 3 were unknown genes. Of the remaining 35, 15 were identical to either NY-ESO-1, or SSX2, two known members of the CT antigen family described supra, while the remaining clones corresponded to 14 known genes. Of the testicular library, 12 of the clones were SSX2.
The NY-ESO-1 antigen was not found, probably because the commercial library that was used had been size fractionated to have an average length of 1.5 kilobases, which is larger than full length NY-ESO-1 cDNA which is about 750 base pairs long.
With respect to the screening carried out with pooled, allogeneic sera, four of the clones were NY-ESO-1. No other CT antigens were identified. With the exception of NY-ESO-1, all of the genes identified were expressed universally in normal tissue.
A full listing of the isolated genes, and their frequency of occurrence follows, in tables 1, 2 and 3. Two genes were found in both the BR11 and testicular libraries, i.e., poly (ADP-ribose) polymerase, and tumor suppression gene ING1. The poly (ADP-ribose) polymerase gene has also been found in colon cancer libraries screened via SEREX, as is disclosed by Scanlan, et al., Int. J. Cancer 76: 652-58 (1998) when the genes identified in the screening of the BR11 cDNA library by autologous and allogeneic sera were compared, NY-ESO-1 and human keratin.
TABLE 1
SEREX-defined genes identified by autologous screening of BR11 cDNA
library
No.
Gene group
of clones
Comments
Expression
CT genes
10
NY-ESO-1
tumor, testis
5
SSX2
tumor, testis
Non-CT genes
5
Nuclear Receptor Co-Repressor
ubiquitous
4
Poly(ADP-ribose) polymerase
ubiquitous
2
Adenylosuccinatelyase
ubiquitous
2
cosmid 313 (human)
ESTs: muscle, brain,
breast
1
CD 151 (transmembrane protein)
ubiquitous
1
Human HRY Gen
RT-PCR: multiple
normal tissues
1
Alanyl-t-RNA-Synthetase
ubiquitous
1
NAD(+) ADP-Ribosyltransferase
unbiquitous
1
Human keratin 10
ESTs: multiple
normal tissues
1
Human EGFR. kinase substrate
ubiquitous
1
ING I Tumor suppressor gene
RT-PCR: multiple
normal tissues
1
Unknown gene, NCI_CGAP_Prl2
ESTs: pancreas, liver,
cDNA clone
spleen, uterus
1
Unknown gene
ESTs: multiple
normal tissues
1
Unknown gene
RT-PCR: multiple
normal tissues
TABLE 2
SEREX-defined genes identified by allogeneic screening of BR11 cDNA
library
No. of
Gene group
clones
Comments
Expression
CT genes
4
NY-ESO-1
tumor, testis
Non-CT genes
6
zinc-finger helicase
ESTs: brain, fetal heart,
total fetus
4
Acetoacetyl-CoA-thiolase
ubiquitous
3
KIAA0330 gene
ESTs: multiple normal
tissues
2
U1snRNP
ubiquitous
1
Human aldolase A
ubiquitous
1
Retinoblastoma binding protein 6
ESTs: tonsils, fetal
brain, endothelial cells,
brain
1
α2-Macroglobulin receptor
ubiquitous
associated protein
1
Human Keratin 10
ESTs: multiple normal
tissues
TABLE 3
SEREX-defined genes identified by screening of a testicular cDNA library
with BR11 serum
Gene group
No. of clones
Comments
Expression
CT genes:
12
SSX2
tumor, testis
Non-CT genes:
3
Rho-associated coiled-coil
ubiquitous
forming protein
3
Poly(ADP-ribose) polymerase
ubiquitous
3
Gene from HeLa cell, similar to
ubiquitous
TITIN
2
Gene from parathyroid tumor
RT-PCR: multiple
normal tissues
1
Transcription termination factor
ubiquitous
I-interacting peptide 21
1
Gene from fetal heart
ESTs: multiple normal
tissues
1
ING 1 tumor suppressor gene
RT-PCR: multiple
normal tissues
1
KIAA0647 cDNA
ESTs: multiple normal
tissues
1
KIAA0667 cDNA
ESTs: multiple normal
tissues
EXAMPLE 2
The mRNA expression pattern of the cDNAs identified in example 1, in both normal and malignant tissues, was studied. To do this, gene specific oligonucleotide primers were designed which would amplify cDNA segments 300-600 base pairs in length, using a primer melting temperature of 65-70° C. The primers used for amplifying MAGE-1,2,3 and 4 BAGE, NY-ESO-1, SCP1 and SSX1, 2, 3, 4 and 5 were known primers, or were based on published sequences. See Chen, et al. supra; Tureci, et al., Proc. Natl. Acad. Sci. USA 95: 5211-16 (1998). Güre, et al., Int. J. Cancer 72: 965-71 (1997); Chen, et al., Proc. Natl. Acad. Sci. USA 91: 1004-1008 (1994); Gaugler, et al., J. Exp. Med. 179: 921-930 (1994), dePlaen, et al., Immunogenetics 40: 360-369 (1994), all of which are incorporated by reference. RT-PCR was carried out for 35 amplification cycles, at an annealing temperature of 60° C. Using this RT-PCR assay, the breast cancer tumor specimen was positive for a broad range of CT antigens, including MAGE-1,3 AND 4, BAGE, SSX2, NY-ESO-1 and CT7. The known CT antigens SCP-1, SSX1, 4 and 5 were not found to be expressed.
An additional set of experiments were carried out, in which the seroreactivity of patient sera against tumor antigens was tested. Specially, ELISAs were carried out, in accordance with Stockert, et al., J. Exp. Med. 187: 1349-1354 (1998), incorporated by reference, to determine if antibodies were present in the patient sera. Assays were run for MAGE-1, MAGE-3, NY-ESO-1, and SSX2. The ELISAs were positive for NY-ESO-1 and SSX2, but not the two MAGE antigens.
EXAMPLE 3
Two clones (one from the breast cancer cDNA library and one from the testicular library), were identified as a gene referred to as ING1, which is a tumor suppressor gene candidate. See Garkavtsev, et al., Nature 391: 295-8 (1998), incorporated by reference. The sequence found in the breast cancer library, differed from the known sequence of ING1 at six residues, i.e., positions 818, 836, 855, 861, 866 and 874. The sequence with the six variants is set forth at SEQ ID NO: 1. The sequence of wild type ING1 is set out at SEQ ID NO: 2.
To determine if any of these differences represented a mutation in tumors, a short, PCR fragment which contained the six positions referred to supra was amplified from a panel of allogeneic normal tissue, subcloned, amplified, and sequenced following standard methods.
The results indicated that the sequences in the allogeneic tissues were identical to what was found in tumors, ruling out the hypothesis that the sequence differences were a tumor associated mutation. This conclusion was confirmed, using the testicular library clone, and using restriction analysis of ING1 cDNA taken from normal tissues. One must conclude, therefore, that the sequence information provided by Garkavtsev, et al., supra, is correct.
EXAMPLE 4
Additional experiments were carried out to determine whether genetic variations might exist in the 5′ portion of the ING1 gene, which might differ from the 5′ portion of the clone discussed supra (SEQ ID NO: 1). In a first group of experiments, attempts were made to obtain full length ING1 cDNA from both the breast tumor library, and the testicular library. SEQ ID NO: 1 was used as a probe of the library, using standard methods.
Four clones were isolated from the testicular library and none were isolated from the breast cancer library. The four clones, following sequencing, were found to derive from three transcript variants. The three variants were identical from position 586 down to their 3′ end, but differed in their 5′ regions, suggesting alternatively spliced variants, involving the same exon-intron junction. All three differed from the sequence of ING1 described by Garkavtsev, et al., in Nat. Genet. 14: 415-420 (1996). These three variants are set out as SEQ ID NOS: 1, 3 and 4.
All of the sequences were then analyzed. The ORFs of SEQ ID NOS: 2, 1 and 4 (SEQ ID NO: 2 is the originally disclosed, ING1 sequence), encode polypeptides of 294, 279 and 235 amino acids, of which 233 are encoded by the 3′ region common to the three sequences. These putative sequences are set out as SEQ ID NOS: 19, 5, and 7. With respect to SEQ ID NO: 3, however, no translational initiation site could be identified in its 5′ region.
EXAMPLE 5
The data regarding SEQ ID NO: 3, described supra, suggested further experiments to find additional ORFs in the 5-end of variant transcripts of the molecule. In order to determine this, 5′-RACE-PCR was carried out using gene specific and adapted specific primers, together with commercially available products, and standard methodologies.
The primers used for these experiments were:
CACACAGGATCCATGTTGAGTCCTGCCAACGGCGTGGTCGTGGTTGCTGG ACGCG
(SEQ ID NOS: 9 and 10), for SEQ ID NO: 1;
CCCAGCGGCCCTGACGCTGTCCGTGGTCGTGGTTGCTGGACGCG
(SEQ ID NOS: 11 and 12), for SEQ ID NO: 3; and
GGAAGAGATAAGGCCTAGGGAAGCGTGGTCGTGGTTGCTGGACGCG
(SEQ ID NOS: 13 and 14), for SEQ ID NO: 4.
Cloning and sequencing of the products of RACE PCR showed that the variant sequence of SEQ ID NO: 4 was 5′ to SEQ ID NO: 3, and that full length cDNA for the variant SEQ ID NO: 3 contained an additional exon 609 nucleotides long, positioned between SEQ ID NO: 3 and the shared, 3′ sequence referred to supra. This exon did not include an ORF. The first available initiation site would be an initial methionine at amino acid 70 of SEQ ID NO: 1. Thus, if expressed, SEQ ID NO: 3 would correspond to a molecule with a 681 base pair, untranslated 5′ end and a region encoding 210 amino acids (SEQ ID NO: 6).
EXAMPLE 6
The presence of transcript variants with at least 3 different trancriptional initiation sites, and possibly different promoters, suggested that mRNA expression might be under different, tissue specific regulation.
To determine this, variant-specific primers were synthesized, and RT-PCR was carried out on a panel of tissues, using standard methods.
SEQ ID NO: 1 was found to be expressed universally in all of the normal breast, brain and testis tissues examined, in six breast cancer lines, and 8 melanoma cell lines, and in cultured melanocytes. SEQ ID NO: 3 was found to be expressed in four of the six breast cancer lines, normal testis, liver, kidney, colon and brain. SEQ ID NO: 4 was only found to be expressed by normal testis cells and weakly in brain cells.
EXAMPLE 7
A further set of experiments were carried out to determine if antibodies against ING1 were present in sera of normal and cancer patients. A phase plaque immuno assay of the type described supra was carried out, using clones of SEQ ID NO: 1 as target. Of 14 allogeneic sera taken from breast cancer patients, two were positive at 1:200 dilutions. All normal sera were negative.
EXAMPLE 8
The BR11 cDNA library described supra was then screened, using SEQ ID NO: 1 and standard methodologies. A 593 base pair cDNA was identified, which was different from any sequences in the data banks consulted. The sequence of this cDNA molecule is set out at SEQ ID NO: 8.
The cDNA molecule set forth as SEQ ID NO: 1 was then used in Southern blotting experiments. In brief, genomic DNA was isolated from normal human tissue, digested with BamHI or Hind III, and then separated onto 0.7% agarose gel, blotted onto nitrocellulose filters, and hybridized using 32 P labelled SEQ ID NO: 1, at high stringency conditions (aqueous buffer, 65° C.). The probes were permitted to hybridize overnight, and then exposed for autoradiography. Two hybridizing DNA species were identified, i.e., SEQ ID NOS: 1 and 8.
EXAMPLE 9
The cDNA molecule set forth in SEQ ID NO: 8 was then analyzed. 5′-RACE PCR was carried out using normal fetus cDNA. Full length cDNA for the molecule is 771 base pairs long, without the poly A tail. It shows strong homology to SEQ ID NO: 1, with the strongest homology in the 5′ two-thirds (76% identity over nucleotide 1-480); however, the longest ORF is only 129 base pairs, and would encode a poly peptide 42 amino acids long which was homologous to, but much shorter than, the expected expression product of SEQ ID NO: 1.
In addition to the coding region, SEQ ID NO: 8 contains 203 base pairs of 5′-untranslated region, and 439 base pairs of 3′-untranslated region.
RT-PCR assays were carried out, as described supra. All of the normal tissues tested, including brain, colon, testis, tissue and breast, were positive for expression of this gene. Eight melanoma cell lines were tested, of which seven showed varying levels of expression, and one showed no expression. Six breast cancer cell lines were tested, of which four showed various levels of expression, and two showed no expression.
EXAMPLE 10
An additional breast cancer cDNA library, referred to as “BR17-128”, was screened, using autologous sera. A cDNA molecule was identified.
Analysis of the sequence suggested that it was incomplete at the 5′ end. To extend the sequence, a testicular cDNA library was screened with a nucleotide probe based upon the partial sequence identified in the breast cancer library. An additional 1200 base pairs were identified following these screenings. The 2011 base pairs of information are set forth in SEQ ID NO: 15.
The longest open reading frame is 1539 base pairs, corresponding to a protein of about 59.15 kilodaltons. The deduced sequence is set forth at SEQ ID NO: 16.
RT-PCR was then carried out using the following primers:
CACACAGGATCCATGCAGGCCCCGCACAAGGAGCACACAAAGCTTCTAGG ATTTGGCACAGCCAGAG
(SEQ ID NOS: 17 and 18)
Strong signals were observed in normal testis and breast tissue, and weak expression was observed in placenta.
No expression was found in normal brain, kidney, liver, colon, adrenal, fetal brain, lung, pancreas, prostate, thymus, uterus, and ovary tissue of tumor cell lines tested, 2 of the breast cancer lines were strongly positive and two were weakly positive. Of melanoma two of 8 were strongly positive, and 3 were weakly positive. Of lung cancer cell lines, 4 of 15 were strongly positive, and 3 were weakly positive.
When cancer tissue specimens were tested, 16 of 25 breast cancer samples were strongly positive, and 3 additional samples were weakly positive. Two of 36 melanoma samples were positive (one strong, one weak). All other cancer tissue samples were negative.
When Northern blotting was carried out, a high molecular weight smear was observed in testis, but in no other tissues tested.
EXAMPLE 11
Further experiments were carried out using the tumor sample referred to in example 10, supra. This sample was derived from a subcutaneous metastasis of a 60 year old female breast cancer patient. Total RNA was extracted, as described supra. Following the extraction, a cDNA library was constructed in K-ZAP expression vectors, also as described supra. Screening was carried out, using the protocol set forth in example 1. A total of 7×10 5 pfus were screened. Fourteen reactive clones were identified, purified, and sequenced. The sequences were then compared to published sequences in GenBank and EST databases. These analyses indicated that the clones were derived from seven distinct genes, two of which were known, and five unknown. The two known genes were “PBK-1” (three clones), and TI-227 (one clone). These are universally expressed genes, with the libraries referred to supra showing ESTs for these genes from many different tissues.
With respect to the remaining 10 clones, six were derived from the same gene, referred to hereafter as “NY-BR-1.” Three cDNA sequences were found in the EST database which shared identity with the gene. Two of these (AI 951118 and AW 373574) were identified as being derived from a breast cancer library, while the third (AW 170035), was from a pooled tissue source.
EXAMPLE 12
The distribution of the new gene NY-BR-1 referred to supra was determined via RT-PCR. In brief, gene specific oligonucleotide NY-BR-1 primers were designed to amplify cDNA segments 300-600 base pairs in length, with primer melting temperatures estimated at 65-70° C. The RT-PCR was then carried out over 30 amplification cycles, using a thermal cycler, and an annealing temperature of 60° C. Products were analyzed via 1.5% gel electrophoresis, and ethidium bromide visualization. Fifteen normal tissues (adrenal gland, fetal brain, lung, mammary gland, pancreas, placenta, prostate, thymus, uterus, ovary, brain, kidney, liver, colon and testis) were assayed. The NY-BR-1 clone gave a strong signal in mammary gland and testis tissue, and a very faint signal in placenta. All other tissues were negative. The other clones were expressed universally, based upon comparison to information in the EST database library, and were not pursued further.
The expression pattern of NY-BR-1 in cancer samples was then tested, by carrying out RT-PCR, as described supra, on tumor samples.
In order to determine the expression pattern, primers:
caaagcagag cctcccgaga ag (SEQ ID NO: 20) and cctatgctgc tcttcgattc ttcc (SEQ ID NO: 21)
were used.
Of twenty-five breast cancer samples tested, twenty two were positive for NY-BR-1. Of these, seventeen gave strong signals, and five gave weak to modest signals.
An additional 82 non-mammary tumor samples were also analyzed, divided into 36 melanoma, 26 non small cell lung cancer, 6 colon cancer, 6 squamous cell carcinoma, 6 transitional cell carcinoma, and two leiyomyosarcomas. Only two melanoma samples were positive for NY-BR-1 expression.
The study was then extended to expression of NY-BR-1 in tissue culture. Cell lines derived from breast tumor, melanoma, and small cell lung cancer were studied. Four of six breast cancer cells were positive (two were very weak), four of eight melanoma (two very weak), and seven of fourteen small cell lung cancer lines (two very weak) were positive.
EXAMPLE 13
In order to determine the complete cDNA molecule for NY-BR-1, the sequences of the six clones referred to supra were compiled, to produce a nucleotide sequence 1464 base pairs long. Analysis of the open reading frame showed a continuous ORF throughout, indicating that the compiled sequence is not complete.
Comparison of the compiled sequence with the three EST library sequences referred to supra allowed for extension of the sequence. The EST entry AW170035 (446 base pairs long) overlapped the compiled sequence by 89 base pairs at its 5′ end, permitting extension of the sequence by another 357 base pairs. A translational terminal codon was identified in this way, leading to a molecule with a 3′-untranslated region 333 base pairs long. The 5′ end of the molecule was lacking, however, which led to the experiment described infra.
EXAMPLE 14
In order to determine the missing, 5′ end of the clone described supra, a commercially available testis cDNA expression library was screened, using a PCR expression product of the type described supra as a probe. In brief, 5×10 4 pfus per 150 mm plate were transferred to nitrocellulose membranes, which were then submerged in denaturation solution (1.5M NaCl and 0.5 M NaOH), transferred to neutralization solution (1.5 M NaCl and 0.5M Tris-HCl), and then rinsed with 0.2M Tris-HCl, and 2×SSC. Probes were labelled with 32 P and hybridization was carried out at high stringency conditions (i.e., 68° C., aqueous buffer). Any positive clones were subcloned, purified, and in vivo excised to plasmid PBK-CMV, as described supra.
One of the clones identified in this way included an additional 1346 base pairs at the 5′ end; however, it was not a full length molecule. A 5′-RACE-PCR was carried out, using commercially available products. The PCR product was cloned into plasmid vector pGEMT and sequenced. The results indicated that cDNA sequence was extended 1292 base pairs further, but no translation initiation site could be determined, because no stop codons could be detected. It could be concluded, however, that the cDNA of the NY-BR17 clone comprises at least 4026 nucleotides, which are presented as SEQ ID NO: 22. The molecule, as depicted, encodes a protein at least about 152.8 kDA in molecular weight. Structurally, there are 99 base pairs 5′ to the presumed translation initiation site, and an untranslated segment 333 base pairs long at the 3′ end. The predicted amino acid sequence of the coding region for SEQ ID NO: 22 is set out at SEQ ID NO: 23.
SEQ ID NO: 23 was analyzed for motifs, using the known search programs PROSITE and Pfam. A bipartite nuclear localization signal motif was identified at amino acids 17-34, suggesting that the protein is a nuclear protein. Five tandem ankyrin repeats were identified, at amino acids 49-81, 82-114, 115-147, 148-180 and 181-213. A bZIP site (i.e., a DNA binding site followed by a leucine zipper motif) was found at amino acid positions 1077-1104, suggesting a transcription factor function. It was also observed that three repetitive elements were identified in between the ankyrin repeats and the bZIP DNA binding site. To elaborate, a repetitive element 117 nucleotides long is trandemly repeated 3 times, between amino acids 459-815. The second repetitive sequence, consisting of 11 amino acids, repeats 7 times between amino acids 224 and 300. The third repetitive element, 34 amino acids long, is repeated twice, between amino acids 301-368.
EXAMPLE 15
The six clones described supra were compared, and analysis revealed that they were derived from two different splice variants. Specifically, two clones, referred to as “BR17-8” and “BR 17-44a”, contain one more exon, of 111 base pairs (nucleotides 3015-3125 of SEQ ID NO: 22), which encodes amino acids 973-1009 of SEQ ID NO: 23, than do clones BR 17-1a, BR17-35b and BR17-44b. The shortest of the six clones, BR17-128, starts 3′ to the additional exons. The key structural elements referred to supra were present in both splice variants, suggesting that there was no difference in biological function.
The expression pattern of the two splice variants was assessed via PT-PCR, using primers which spanned the 111 base pair exon referred to supra.
The primers used were:
aatgggaaca agagctctgc ag (SEQ ID NO: 24) and gggtcatctg aagttcagca ttc (SEQ ID NO: 25)
Both variants were expressed strongly in normal testis and breast. The longer variant was dominant in testis, and the shorter variant in breast cells. When breast cancer cells were tested, co-typing of the variant was observed, (7 strongly, 2 weakly positive, and 1 negative), with the shorter variant being the predominant form consistently.
EXAMPLE 16
The frequency of antibody response against NY-BR-1 in breast cancer patients was tested. To do this, a recombinant protein consisting of amino acids 993-1188 of SEQ ID NO: 23 was prepared. (This is the protein encoded by clone BR 17-128, referred to supra). A total of 140 serum samples were taken from breast cancer patients, as were 60 normal serum samples. These were analyzed via Western blotting, using standard methods.
Four of the cancer sera samples were positive, including a sample from patient BR17. All normal sera were negative.
An additional set of experiments was then carried out to determine if sera recognized the portion of NY-BR-1 protein with repetitive elements. To do this, a different recombinant protein, consisting of amino acids 405-1000 was made, and tested in Western blot assays. None of the four antibody positive sera reacted with this protein indicating that an antibody epitope is located in the non-repetitive, carboxy terminal end of the molecule.
EXAMPLE 17
The screening of the testicular cDNA library referred to supra resulted, inter alia, in the identification of a cDNA molecule that was homologous to NY-BR-1. The molecule is 3673 base pairs in length, excluding the poly A tail. This corresponded to nucleotides 1-3481 of SEQ ID NO: 22, and showed 62% homology thereto. No sequence identity to sequences in libraries was noted. ORF analysis identified an ORF from nucleotide 641 through the end of the sequence, with 54% homology to the protein sequence of SEQ ID NO: 23. The ATG initiation codon of this sequence is 292 base pairs further 3′ to the presumed initiation codon of NY-BR-1, and is preceded by 640 untranslated base pairs at its 5′ end. This 640 base pair sequence includes scattered stop codons. The nucleotide sequence and deduced amino acid sequence are presented as SEQ ID NOS: 26 and 27, respectively.
RT-PCR analysis was carried out in the same way as is described supra, using primers:
tct catagat gctggtgctg atc (SEQ ID NO: 28) and cccagacatt gaattttggc agac. (SEQ ID NO: 29)
Tissue restricted mRNA expression was found. The expression pattern differed from that of SEQ ID NO: 22. In brief, of six normal tissues examined, strong signals were found in brain and testis only. There was no or weak expression in normal breast tissues, and kidney, liver and colon tissues were negative. Eight of ten 10 breast cancer specimens tested supra were positive for SEQ ID NO: 26. Six samples were positive for both SEQ ID NO: 22 and 26, one for SEQ ID NO: 22 only, two for the SEQ ID NO: 26 only, and one was negative for both.
EXAMPLE 18
Recently, a working draft of the human genome sequence was released. This database was searched, using standard methods, and NY-BR-1 was found to have sequence identity with at least three chromosome 10 clones, identified by Genbank accession numbers AL157387, AL37148, and AC067744. These localize NY-BR-1 to chromosome 10 p11.21-12.1.
The comparison of NY-BR-1 and the human genomic sequence led to definition of NY-BR-1 exon-intron organization. In brief, the coding region of the gene contains essentially 19 structurally distinct exons with at least 2 exons encoding 3′ untranslated regions. Detailed exon-intron junction information is described at Genbank AF 269081.
The six ankyrin repeats, referred to supra, are all found within exon 7. The 357 nucleotide repeating unit is composed of exons 10-15. The available genomic sequences are not complete, however, and only one of the three copies was identified, suggesting that DNA sequences between exons 5 and 10 may be duplicated and inserted in tandem, during genetic evolution. In brief, when the isolated NY-BR-1 cDNA clone was analyzed, three complete and one incomplete copy of the repeating units are present. The exon sequences can be expresses as exons 1-2-3-4-5-6-7-8-9-(10-11-12-13-14-15)-(10A-11A-12A-13A-14A-15A)-(10B-11B-12B-13B-14B-15B)-(10C-11C-12C-13C-14C)-16-17-18-19-20-21, wherein A, B & C are inexact copies of exon 10-15 sequences. Cloned, NY-BR-1 cDNA has 38 exons in toto.
It was noted, supra, that the sequence of NY-BR-1 cDNA was not complete at the 5′ end. Genonic sequence (Genbank AC067744), permitted extension of the 5′ end. Translation of the 5′ genonic sequence led to the identification of a new translation initiation site, 168 base pairs upstream of the previously predicted ATG initiation codon. This led to an NY-BR-1 polypeptide including 1397 amino acid longer, 56 residue of which are added at the N-terminus, compared to prior sequence information, i.e.:
(SEQ ID NO: 30)
MEEISAAAVKVVPGPERPSPFSQLVYTSNDSYIVHSGDLRKIHKAASRGQ
VRKLEK.
EXAMPLE 20
Reference was made, supra, to the two difference splice variants of NY-BR-1. Comparison of the splice variants with the genomic sequence confirmed that an alternate splicing event, with the longer variant incorporating part of intron 33 into exon 34 (i.e., exon 17 of the basic exon/intron framework described supra).
Key structural elements that were predicted in NY-BR-1, described supra, are present in both variants, suggesting that there is no difference in biological function, or subcellular location.
EXAMPLE 21
As with NY BR-1, the variant NY-BR-1.1, described supra, was screened against the working draft of the human genome sequence. One clone was found with sequence identity, i.e., GenBank AL359312, derive from chromosome 9. Thus, NY-BR-1 and NY-BR-1.1 both appear to be functioning genes, on two different chromosomes. The Genbank sequence referred to herein does not contain all of NY-BR-1.1, which precludes defining exon-intron structure. Nonetheless, at least 3 exons can be defined, which correspond to exons 16-18 of the NY-BR-1 basic framework. Exon-intron junctions are conserved.
EXAMPLE 22
A series of peptides were synthesized, based upon the amino acid sequence of NY-BR-1, as set forth in SEQ ID NO: 23. These were then tested for their ability to bind to HLA-A2 molecules and to stimulate CTL proliferation, using an ELISPOT assay. This assay involved coating 96-well, flat bottom nitrocellulose plates with 5 ug/ml of anti-interferon gamma antibodies in 100 ul of PBS per well, followed by overnight incubation. Purified CD8 + cells, which had been separated from PBL samples via magnetic beads coated with anti-CD8 antibodies were then added, at 1×10 5 cells/well, in RPMI 1640 medium, that had been supplemented with 10% human serum, L-asparagine (50 mg/l), L-arginine (242 mg/l), L-glutamine (300 mg/l), together with IL-2 (2.5 ng/ml), in a final volume of 100 ul. CD8 + effector cells were prepared by presensitizing with peptide, and were then added at from 5×10 3 to 2×10 4 cells/well. Peptides were pulsed onto irradiated T2 cells at a concentration of 10 ug/ml for 1 hour, washed and added to effector cells, at 5×10 4 cells/well. The plates were incubated for 16 hours at 37° C., washed six times with 0.05% Tween 20/PBS, and were then supplemented with biotinylated, anti-interferon gamma specific antibody at 0.5 ug/ml. After incubation for 2 hours at 37° C., plates were washed, and developed with commercially available reagents, for 1 hour, followed by 10 minutes of incubation with dye substrate. Plates were then prepped for counting, positives being indicated by blue spots. The number of blue spots/well was determined as the frequency of NY-ESO-1 specific CTLs/well.
Experiments were run, in triplicate, and total number of CTLs was calculated. As controls, one of reagents alone, effector cells alone, or antigen presenting cells alone were used. The difference between the number of positives in stimulated versus non-stimulated cells, was calculated as the effective number of peptide specific CTLs above background. Three peptides were found to be reactive, i.e.:
LLSHGAVIEV
(amino acids 102-111 of SEQ ID NO: 23)
SLSKILDTV
(amino acids 904-912 of SEQ ID NO: 23)
SLDQKLFQL
(amino acids 1262-1270 of SEQ ID NO: 23).
The complete list of peptides tested, with reference to their position in SEQ ID NO: 23, follows:
Peptide
Position
FLVDRKVCQL
35-43 of SEQ ID NO: 23
ILIDSGADI
68-76 of SEQ ID NO: 23
AVYSEILSV
90-98 of SEQ ID NO: 23
ILSVVAKLL
95-103 of SEQ ID NO: 23
LLSHGAVIEV
102-111 of SEQ ID NO: 23
KLLSHGAVI
101-109 of SEQ ID NO: 23
FLLIKNANA
134-142 of SEQ ID NO: 23
MLLQQNVDV
167-175 of SEQ ID NO: 23
GMLLQQNVDV
166-175 of SEQ ID NO: 23
LLQQNVDVFA
168-177 of SEQ ID NO: 23
IAWEKKETPV
361-370 of SEQ ID NO: 23
SLFESSAKI
430-438 of SEQ ID NO: 23
CIPENSIYQKV
441-450 of SEQ ID NO: 23
KVMEINREV
449-457 of SEQ ID NO: 23
ELMDMQTFKA
687-696 of SEQ ID NO: 23
ELMDMQTFKA
806-815 of SEQ ID NO: 23
SLSKILDTV
904-912 of SEQ ID NO: 23
KILDTVHSC
907-915 of SEQ ID NO: 23
ILNEKIREEL
987-996 of SEQ ID NO: 23
RIQDIELKSV
1018-1027 of SEQ ID NO: 23
YLLHENCML
1043-1051 of SEQ ID NO: 23
CMLKKEIAML
1049-1058 of SEQ ID NO: 23
AMLKLELATL
1056-1065 of SEQ ID NO: 23
KILKEKNAEL
1081-1090 of SEQ ID NO: 23
VLIAENTML
1114-1122 of SEQ ID NO: 23
CLQRKMNVDV
1174-1183 of SEQ ID NO: 23
KMNVDVSST
1178-1186 of SEQ ID NO: 23
SLDQKLFQL
1262-1270 of SEQ ID NO: 23
KLFQLQSKNM
1266-1275 of SEQ ID NO: 23
FQLQSKNMWL
1268-1277 of SEQ ID NO: 23
QLQSKNMWL
1269-1277 of SEQ ID NO: 23
NMWLQQQLV
1274-1282 of SEQ ID NO: 23
WLQQQLVHA
1276-1284 of SEQ ID NO: 23
KITIDIIFL
1293-1301 of SEQ ID NO: 23
The foregoing examples describe the isolation of a nucleic acid molecule which encodes a cancer associated antigen. “Associated” is used herein because while it is clear that the relevant molecule was expressed by several types of cancer, other cancers, not screened herein, may also express the antigen.
The invention relates to nucleic acid molecules which encode the antigens encoded by, e.g., SEQ ID NOS: 1, 3, 8, 15, 22 and 26 as well as the antigens encoded thereby, such as the proteins with the amino acid sequences of SEQ ID NOS: 5, 6, 7, 16, 23, 27, and 30. It is to be understood that all sequences which encode the recited antigen are a part of the invention.
Also a part of the invention are proteins, polypeptides, and peptides, which comprise, e.g., at least nine consecutive amino acids found in SEQ ID NO: 23, or at least nine consecutive amino acids of the amino acids of SEQ ID NO: 30. Proteins, polypeptides and peptides comprising nine or more amino acids of SEQ ID NO: 5, 6, 7, 16 or 27 are also a part of the invention. Especially preferred are peptides comprising or consisting of amino acids 102-111, 904-912, or 1262-1270 of SEQ ID NO: 23. Such peptides may, but do not necessarily provoke CTL responses when complexed with an HLA molecule, such as an HLA-A2 molecule. They may also bind to different MHC or HLA molecules, including, but not being limited to, HLA-A1, A2, A3, B7, B8, Cw3, Cw6, or serve, e.g., as immunogens, as part of immunogenic cocktail compositions, where they are combined with other proteins or polypeptides, and so forth. Also a part of the invention are the nucleic acid molecules which encode these molecules, such as “minigenes,” expression vectors that include the coding regions, recombinant cells containing these, and so forth. All are a part of the invention.
Also a part of the invention are expression vectors which incorporate the nucleic acid molecules of the invention, in operable linkage (i.e., “operably linked”) to a promoter. Construction of such vectors, such as viral (e.g., adenovirus or Vaccinia virus) or attenuated viral vectors is well within the skill of the art, as is the transformation or transfection of cells, to produce eukaryotic cell lines, or prokaryotic cell strains which encode the molecule of interest. Exemplary of the host cells which can be employed in this fashion are COS cells, CHO cells, yeast cells, insect cells (e.g., Spodoptera frugiperda ), NIH 3T3 cells, and so forth. Prokaryotic cells, such as E. coli and other bacteria may also be used. Any of these cells can also be transformed or transfected with further nucleic acid molecules, such as those encoding cytokines, e.g., interleukins such as IL-2, 4, 6, or 12 or HLA or MHC molecules.
Also a part of the invention are the antigens described herein, both in original form and in any different post translational modified forms. The molecules are large enough to be antigenic without any posttranslational modification, and hence are useful as immunogens, when combined with an adjuvant (or without it), in both precursor and post-translationally modified forms. Antibodies produced using these antigens, both poly and monoclonal, are also a part of the invention as well as hybridomas which make monoclonal antibodies to the antigens. The whole protein can be used therapeutically, or in portions, as discussed infra. Also a part of the invention are antibodies against this antigen, be these polyclonal, monoclonal, reactive fragments, such as Fab, (F(ab) 2 ′ and other fragments, as well as chimeras, humanized antibodies, recombinantly produced antibodies, and so forth.
As is clear from the disclosure, one may use the proteins and nucleic acid molecules of the invention diagnostically. The SEREX methodology discussed herein is premised on an immune response to a pathology associated antigen. Hence, one may assay for the relevant pathology via, e.g., testing a body fluid sample of a subject, such as serum, for reactivity with the antigen per se. Reactivity would be deemed indicative of possible presence of the pathology. So, too, could one assay for the expression of any of the antigens via any of the standard nucleic acid hybridization assays which are well known to the art, and need not be elaborated upon herein. One could assay for antibodies against the subject molecules, using standard immunoassays as well.
Analysis of SEQ ID NO: 1, 3, 4, 8, 15, 22 and 26 will show that there are 5′ and 3′ non-coding regions presented therein. The invention relates to those isolated nucleic acid molecules which contain at least the coding segment, and which may contain any or all of the non-coding 5′ and 3′ portions.
Also a part of the invention are portions of the relevant nucleic acid molecules which can be used, for example, as oligonucleotide primers and/or probes, such as one or more of SEQ ID NOS: 9, 10, 11, 12, 13, 14, 17, 18, 20, 21, 24, 25, 28, and 29 as well as amplification products like nucleic acid molecules comprising at least nucleotides 305-748 of SEQ ID NO: 1, or amplification products described in the examples, including those in examples 12, 14, etc.
As was discussed supra, study of other members of the “CT” family reveals that these are also processed to peptides which provoke lysis by cytolytic T cells. There has been a great deal of work on motifs for various MHC or HLA molecules, which is applicable here. Hence, a further aspect of the invention is a therapeutic method, wherein one or more peptides derived from the antigens of the invention which bind to an HLA molecule on the surface of a patient's tumor cells are administered to the patient, in an amount sufficient for the peptides to bind to the MHC/HLA molecules, and provoke lysis by T cells. Any combination of peptides may be used. These peptides, which may be used alone or in combination, as well as the entire protein or immunoreactive portions thereof, may be administered to a subject in need thereof, using any of the standard types of administration, such as intravenous, intradermal, subcutaneous, oral, rectal, and transdermal administration. Standard pharmaceutical carriers, adjuvants, such as saponins, GM-CSF, and interleukins and so forth may also be used. Further, these peptides and proteins may be formulated into vaccines with the listed material, as may dendritic cells, or other cells which present relevant MHC/peptide complexes.
Similarly, the invention contemplates therapies wherein nucleic acid molecules which encode the proteins of the invention, one or more or peptides which are derived from these proteins are incorporated into a vector, such as a Vaccinia or adenovirus based vector, to render it transfectable into eukaryotic cells, such as human cells. Similarly, nucleic acid molecules which encode one or more of the peptides may be incorporated into these vectors, which are then the major constituent of nucleic acid bases therapies.
Any of these assays can also be used in progression/regression studies. One can monitor the course of abnormality involving expression of these antigens simply by monitoring levels of the protein, its expression, antibodies against it and so forth using any or all of the methods set forth supra.
It should be clear that these methodologies may also be used to track the efficacy of a therapeutic regime. Essentially, one can take a baseline value for a protein of interest using any of the assays discussed supra, administer a given therapeutic agent, and then monitor levels of the protein thereafter, observing changes in antigen levels as indicia of the efficacy of the regime.
As was indicated supra, the invention involves, inter alia, the recognition of an “integrated” immune response to the molecules of the invention. One ramification of this is the ability to monitor the course of cancer therapy. In this method, which is a part of the invention, a subject in need of the therapy receives a vaccination of a type described herein. Such a vaccination results, e.g., in a T cell response against cells presenting HLA/peptide complexes on their cells. The response also includes an antibody response, possibly a result of the release of antibody provoking proteins via the lysis of cells by the T cells. Hence, one can monitor the effect of a vaccine, by monitoring an antibody response. As is indicated, supra, an increase in antibody titer may be taken as an indicia of progress with a vaccine, and vice versa. Hence, a further aspect of the invention is a method for monitoring efficacy of a vaccine, following administration thereof, by determining levels of antibodies in the subject which are specific for the vaccine itself, or a large molecule of which the vaccine is a part.
The identification of the subject proteins as being implicated in pathological conditions such as cancer also suggests a number of therapeutic approaches in addition to those discussed supra. The experiments set forth supra establish that antibodies are produced in response to expression of the protein. Hence, a further embodiment of the invention is the treatment of conditions which are characterized by aberrant or abnormal levels of one or more of the proteins, via administration of antibodies, such as humanized antibodies, antibody fragments, and so forth. These may be tagged or labelled with appropriate cystostatic or cytotoxic reagents.
T cells may also be administered. It is to be noted that the T cells may be elicited in vitro using immune responsive cells such as dendritic cells, lymphocytes, or any other immune responsive cells, and then reperfused into the subject being treated.
Note that the generation of T cells and/or antibodies can also be accomplished by administering cells, preferably treated to be rendered non-proliferative, which present relevant T cell or B cell epitopes for response, such as the epitopes discussed supra.
The therapeutic approaches may also include antisense therapies, wherein an antisense molecule, preferably from 10 to 100 nucleotides in length, is administered to the subject either “neat” or in a carrier, such as a liposome, to facilitate incorporation into a cell, followed by inhibition of expression of the protein. Such antisense sequences may also be incorporated into appropriate vaccines, such as in viral vectors (e.g., Vaccinia), bacterial constructs, such as variants of the known BCG vaccine, and so forth.
Other features and applications of the invention will be clear to the skilled artisan, and need not be set forth herein. The terms and expression which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expression of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention. | The invention relates to newly identified cancer associated antigens. It has been discovered that each of these molecules provokes antibodies when expressed by a subject. The ramifications of this observation are also a part of this invention. | 2 |
FIELD OF THE INVENTION
This invention relates to an electrical article such as a connector and more particularly a method of assembling thereto a filter of a tape, laminated construction, by mounting the tape filter on portions of the exterior surface of the connector housing.
BACKGROUND OF THE INVENTION
The increasing use of high speed digital pulses for communication has led to the use of sensitive components to receive and manipulate such signals This sensitivity has in turn made the components vulnerable to unwanted frequencies transmitted thereto on the same signal paths as the wanted signal frequencies. To solve the problem caused thereby, a number of developments have led to patents that purport to filter out unwanted frequencies utilizing electrical connectors as the vehicle for accommodating appropriate filters having appropriate characteristics. U.S. Pat. No. 4,695,115 granted Sep. 22, 1987, is drawn to a telephone connector with bypass capacitor and teaches the use of capacitors built into the connector to filter out unwanted frequencies from signals carried on signal contacts of a connector. There, the filters are termed "tombstone capacitors" and means are provided for interconnecting such capacitors between the signal paths and grounding paths. As will be discerned, the filters occupy a considerable volume of the total volume of the connector.
U.S. Pat. No. 4,772,224 granted Sep. 20, 1988 represents a modular electrical connector which includes capacitors and additionally, ferrite inductors to provide filtering. As with U.S. Pat. No. 4,695,115, the filter elements take up considerable volume of the device, particularly in terms of the height of the device from a printed circuit board or part of the assembly served by the filtered connector.
Accordingly, it is an object of the present invention to provide a connector having a filter that adds minimally to the packaging dimensions of the connector. It is a further object to provide the combination of multi-pin electrical connector in conjunction with a thin tape filter disposed on the exterior surface of the connector housing in an unobtrusive way, generally conforming to the shape of the exterior surfaces while innocuously traversing openings thereinto. It is a still further object to provide a simple, and readily manufacturable filter construction that adapts itself to use on connectors and other electrical articles such as printed circuit boards and transmission cable.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a filter assembly consisting essentially of one or more thin foil signal electrodes and one or more grounding electrodes separated by a thin coating of dielectric material with the area of the electrodes, in conjunction with the dielectric constant of the material and the spacing between electrodes, selected to provide a capacitance effectively filtering out unwanted frequency components and allowing desired frequency components to pass through signal transmission circuits. The unwanted frequency components are in essence grounded by the filter through a connection to a grounding means. The filter may include the electrodes and dielectric material laminated together, or additionally, a thin dielectric film utilized as a carrier to hold the assembly of electrodes and dielectric material in a position for manufacturing and application.
In one embodiment, the present invention achieves the foregoing objectives through the use of an electrical connector having a plastic housing with an exterior surface essentially of a conventional configuration. The connector includes signal contacts carried by the housing with post portions extending from the bottom of the housing and a grounding contact, including a shield structure over the front or mating face of the connector, with post portions extending down from the bottom or mounting face of the connector, the post portions to be inserted into respective apertures of the printed circuit board of a circuit assembly being soldered thereto. Signals transmitted to the connector by a mating connector are carried by their signal contacts to signal traces on the circuit assembly through printed circuit board conductive traces extending from connections with the contacts at the apertures, to components within the assembly that receive and utilize such signals for communication purposes. The combination is disclosed in U.S. patent application Ser. No. 07/971,028 filed Nov. 3, 1992 and assigned to the assignee hereof.
In combination with the connector, which may be in the form of a telephone receptacle that mates with a telephone connector plug, the electrodes of the filter, both signal and ground, have holes therein through which are fitted the contacts of the connector, suitably terminated thereto such as by solder joints, with the filter tape lamination being thereafter folded around from the bottom of the connector housing, over the back and top of the housing with the grounding electrode being joined to the shielding and grounding of the connector as by solder. An insulative layer is provided over the portions of the electrodes except at the soldering sites, such as by spraying of a polymeric coating thereover or lamination to a polymeric film.
The invention contemplates application for a broad range of connectors, including at least one signal contact and at least one grounding contact with separate tape structures for separate signal contacts in accordance with the size of the capacitor required or with a common ground and separate electrodes for separate signal contacts. The invention also contemplates, in certain applications, a lamination having a common grounding electrode with separate signal electrodes for the filter capacitor. The filter of the invention being as mentioned tape-like and laminated is, in all events, made quite thin and flexible so as to be foldable over and pressed against substantially flat portions of the outside surface of the connector housing and attached thereto as by adhesive or bonding or structures intended to hold the filter in place on the housing so that the connector/filter assembly can be handled as one element. The filter tapes may be mechanically secured to the connector housing by means of the solder joints with signal and ground contacts of the connector, and optionally further secured by a plastic covering thereover assembled to the connector after soldering. Through this technique, the volumetric change by adding the filter is minimized and the invention is adaptable to existing connector designs, being added thereto in a straightforward assembly technique.
The filter of the present invention can also be utilized with other electrical articles such as printed circuit boards, where the signal and ground electrodes could be soldered directly to exposed contact pads of the board's signal and ground traces, for example. The filter could also be used around a length of shielded signal transmission cable.
The method of the present invention includes the steps of providing a tape filter for a particular selected connector, electrically connecting each signal electrode with a portion of corresponding signal terminal of the connector extending from the connector housing or at least exposed along the surface of the housing, wrapping the tape filter along outer surfaces of the connector so that it is disposed adjacent the surfaces thereof, and electrically connecting each ground electrode with a ground shell or shield of the connector.
An embodiment of the present invention will now be described by way of example with reference to the accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view showing an electrical connector positioned above two representative tape filters of the present invention prior to an assembly thereof;
FIG. 2 is a view of the elements of FIG. 1 in partial assembly;
FIG. 3 is a side, elevation and partially sectioned view of the end of the filter as connected to a contact of the connector;
FIG. 4 is an isometric view of the connectors of FIGS. 1 and 2 in the fully assembled condition;
FIG. 5 is an isometric view of the end of the filter and the connection to the ground circuit of the connector;
FIG. 6 is a side and elevation view of the connector and filter of FIG. 1;
FIG. 7 is a side and elevation view of the connector just prior to complete assembly;
FIG. 8 is a side and elevation view of the connector as shown in FIG. 4; and
FIG. 9 is a plan view of an alternate embodiment of tape filter showing a pair of signal electrodes.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, an electrical article such as connector assembly 10 is shown to include a connector 12 and a pair of filters 32 and 32, prior to assembly of connector and filters The connector 12 may be taken to be a modular telephone receptacle jack of a well-known type mountable to a printed circuit board (not shown) at a board connection or mounting face 25. Connector 12 receives into a cavity at a mating face 29, a modular telephone plug (not shown) connected to telephone cable to interconnect such cable and the signals carried thereon through the connectors to the circuit board, telephone receiver, facsimile receiver, and/or computer. The signals transmitted through the plug and jack connectors to the circuit receiving signals may carry unwanted frequencies that find their way onto the cable through radiation of fields, induction, leakage from other circuits and the like. It is these unwanted frequency components that can cause error, particularly with respect to the interpretation of digital 1 and 0 information that makes up digital transmission. It is the purpose of the present invention to filter out the unwanted frequencies while allowing the frequencies that constitute the proper signal representations, namely, voltage levels, to pass through the connector and into the circuit and apparatus receiving such signals.
Construction of a connector like 12 is relatively well known, and includes a plastic housing 14 having on the face thereof a shielding and grounding structure 16 that includes posts 18 extending from the bottom of the connector as shown in FIGS. 1 and 2 for connection to circuits of the board. Housing 14 includes a series of grooves denominated 20 that extend from the top and through selected rearwardly projecting portions. Grooves 20 contain sets of signal contacts 22 and 24, offset as shown in FIG. 1, with the contacts ending in posts 28,26 coextending below the bottom surface or mounting face 25 to be terminated to conductive traces of the board, along with the grounding post 18 of shield 16. The front ends of contacts 22 and 24 (not shown) are formed to extend into the plug-receiving cavity at mating face 29 to receive pin portions of contacts of the mating plug connector connected to signal cable. Housing 14 includes a resilient mounting fastener 30 also extending from the bottom or mounting face 25 of the connector that plugs into a corresponding aperture of the circuit board served by the connector. The fastener 30 is shown in more detail in FIGS. 6 to 8 to include an interior slot, a barbed edge 31 that will latch and lock the connector housing 12 to the board prior to soldering posts 18, 26, and 28 to the board.
The shielding structure 16 includes opposed side portions 15 and at the top thereof a portion 17 as shown in FIGS. 1, 2, 4 and 5 and, as shown in FIGS. 4, 5, and 8 is folded down against the top surface of housing 12. As can also be discerned from the various figures, the housing 12 has an exterior surface comprised of a top, rear, sides, and a bottom. The top and sides represent relatively flat planar surfaces, the rear also containing flat surfaces as well as the reliefs as shown in the various figures.
In accordance with the invention, representative filters are included for two of the six signal contacts, the filters being shown carried by two filter elements 32 and 32'; it being understood that all six signal conductors can be filtered in the manner to be described. As can be seen in FIG. 1, the filter element 32 includes an upper electrode 34 and a lower electrode 38. A substrate of dielectric material 36 is provided therebetween in the manner shown in FIG. 3. At the forward end of the element 32 is a finger 35 of upper electrode 34 defining a signal connection section, apertured as at 37 with the aperture aligned to receive the inner post 28 inserted therethrough and soldered thereto as by a solder fillet S as shown in FIG. 3. At the rear is a grounding finger 39 of lower electrode 38 defining a ground connection section that is soldered to ground shielding structure 16 in final assembly. Posts 26,28 defining signal connection sites spaced from each other, and top portion 17 of shield 16 defines a ground connection site remote from all signal connection sites. Finger 35 is shown laterally staggered and otherwise electrically separated from the other filter element 32' to allow clearance and nonengagement with a post 26 extending therepast for termination to electrode 34' of element 32', noting the finger 35' and aperture 37' associated with post 26. Element 32' also includes a grounding finger 39'.
Each of the filter elements is comprised then of an upper electrode 34 and a lower electrode 38 separated by a substrate 36 of dielectric material. Such an element can be formed such as by first laminating respective layers of conductive material to respective surfaces of a sheet of the dielectric material, after which an etching process defines the boundaries of the respective electrodes, in which process a plurality of such tape filters can conveniently be fabricated. Preferably outwardly facing surfaces of the electrodes have an insulative covering after etching, such as by spraying with a polymer paint or by lamination to a polymeric film, except at soldering sites of the electrodes. The individual electrodes 34,34', one for each of the signal contacts associated with one post 28 and one for each signal contact associated with one post 26 and with common grounding electrodes 38 and 38', have areas selected in conjunction with the particular dielectric material having a particular dielectric constant and the thickness of the coating 36 to provide a desired capacitance associated with each signal contact and, in essence, connecting each signal contact through the capacitive material to ground through the common ground electrode 38. As is well known, capacitance is a function of area of electrode, dielectric constant of the dielectric material, and the spacing between electrodes with capacitance values decreasing as the space between electrodes is increased and with capacitance increasing with the dielectric value increasing.
In accordance with one embodiment of the invention, the electrodes were formed of foils each on the order of about 0.0014 inches thick, with the substrate on the order of 0.002 inches thick, the package thus formed being on the order of 0.005 inches thick. A film of polymeric material such as RHEOPLEX LC 40 acrylic emulsion adhesive sold by Rohm and Haas, Inc., Philadelphia, Pa. having a matrix of acrylic polymer with barium titanate filler homogeneously dispersed therein on the order of about fifty percent by weight, with particle size of about one micron, was employed for the dielectric material. The conductive layers were of half-ounce copper which were joined to the sheet of dielectric material with a three-ply heat and pressure laminating machine.
The lamination thus formed was found to have a capacitance varying between 400 and 480 picofarads when the individual electrodes were on the order of 0.200 inches wide and 1 inch in length. The resulting capacitance provided an attenuation beginning at on the order of several dB insertion loss at slightly less than 10 Mhz rising to on the order of 12 to 15 dB at around 100 MHz and peaking for the 400 picofarad capacitance at about 34 dB at around 250 MHz. The 480 picofarad sample had an insertion loss at slightly less than 30 dB at a frequency of around 200 to 300 MHz. The use of an appropriate amount of barium titanate in the polymer further provides a voltage withstanding of 1000 volts or greater, needed for certain FCC requirements.
Alternatively a pair of opposing foils of anodized aluminum could be utilized, laminated to a sheet of the barium titanate-filled polymer; or a coating of barium titanate-filled polymer may be screen printed or sprayed onto one sheet of foil as the other foil sheet is then laminated thereonto; and then after application of masking of appropriate geometry, the foil sheets are etched in conventional manner to result in a structure similar to the etched electrode structure described above, after which dielectric coating such as 350 CC epoxy sold by Mavidon Corp., Palm City, Fla., may be applied to one or both electrode outer surfaces. The tape filters may then be cut from the sheet of dielectric material.
The filters 32 and 32' were in turn laminated with a thin insulating film shown as layers 134 and 138 in FIG. 3. In the embodiment shown, layer 138 is between filter elements 32 and 32' thereby electrically isolating electrode 38 from electrode 34', in the fashion shown in FIG. 2 with the various separate electrodes soldered to the various contacts 22 and 24 at respective post portions 26 and 28. The lamination was folded around from the bottom of the connector housing 14, up the back, resting on the flat surfaces thereof, and across the top in the manner shown in FIG. 7, traversing grooves 20 and 18 seen in FIGS. 1 and 2 and being disposed between raised lips 41 of housing 12 for protection against the side edges being snagged and the filters becoming dislodged or otherwise stressing the solder termination joints. The filter elements 32,32' are shaped and dimensioned such that the signal connection sections defined by fingers 35,35' are staggered with respect to each other and are adjacent respective signal connection sites (posts 26,28); ground connection sections defined by fingers 39,39' are staggered with respect to each other and are adjacent the ground connection site defined by top portion 17 of shield 16.
With the end of the elements 32 and 32, folded down against the upper surface, the projection 17 was then folded down over the top of the fingers 39 and 39' of the filters in the manner shown in FIG. 8 and in the manner shown in FIG. 5. As can be seen in FIG. 5, a solder fillet S' interconnects finger 39 of electrode 38 to projection 17 and thus to shielding structure 16 and the fillet solder S'' connects the finger 39' to electrode 38' of element 32' to the same grounding structure. In this fashion, two filter elements such as 32 and 32' may be folded as shown and terminated to the grounding structure. It may be desired after soldering, for a plastic covering to be molded over the filter tapes for protection thereof, or alternatively a premolded plastic cover to be secured to the connector over the filter tapes by conventional methods to protect the filter tapes.
The invention contemplates additional elements such as 32 that may be individually grounded rather than commonly grounded as shown and terminated by using fingers such as 39 and 39' appropriately. The invention also contemplates that where necessary to achieve a desired capacitance, the area of the electrodes, such as electrodes 34, may be increased for a given signal contact with additional elements provided for the remaining signal electrodes. Also contemplated is the use of additional area achieved by providing electrodes 40 extending over the sides of the housing in the manner shown in phantom in FIG. 8, such additional area providing an increased capacitance for the device.
The invention contemplates a use with one signal contact and one ground contact or with two, four, or six contacts. For example, FIG. 9 is an alternate embodiment of tape filter 80 adapted to filter two contacts by means of one tape structure. Tape filter 80 is shown having two signal electrodes 82,84 on a common side of the dielectric substrate, separated by a gap 86. A single common ground electrode 88 is disposed across the opposed surface of the substrate. Each of the signal electrodes 82,84 have respective fingers 90,92 extending to traverse the axis of the corresponding signal terminals of the connector (not shown), with the terminals received through respective apertures 94,96 through the fingers 90,92 and soldered thereto, upon assembly of the tape filter to the connector. Ground electrode 88 is shown to include grounding fingers 98 extending beyond the extent of signal electrodes 82,84 for soldering to a ground shield of the connector (not shown).
Various layouts utilizing various portions of the exterior area of the housing may be employed with adequate areas for the desired capacitance as indicated. Having now described the invention to enable a preferred practice thereof, claims are appended intended to define what is inventive. | An electrical connector assembly (10) includes at least one signal contact (22) and one grounding structure (16) mounted in a dielectric housing (12) having flat exterior surface portions (19). A filter (32) is associated with each signal contact, if desired, and is in tape form with dielectric material (36) laminated between broad area electrodes (34,38) with the tape attached to the housing exterior surface (14); the dielectric material is selected to have a dielectric constant and thickness to provide a desired capacitance between signal and ground electrodes (34,38). The method includes electrically joining the signal and ground electrodes to the signal contact (22) and grounding structure (16) while pressing the tape filter along and against the exterior housing surfaces (19) between the connections, for the electrodes (34,38) of the filter to be connected between the signal contact and ground structure to effectively insert the filter in the signal path to ground. | 8 |
FIELD OF INVENTION
[0001] The present invention is in the field of security documents. In particular it is about a reversibly pressure-sensitive device which can be incorporated into, or affixed onto, or printed onto a security document, and which exhibits a visible color change under a moderate applied pressure, such as can be produced by a human finger.
STATE OF THE ART
[0002] Piezochromic devices, which reversibly change color with applied pressure, are known in the art. EP-A 0 530 369 (Myashita) discloses an indolinospiroben-zothiopyran derivative which is obtained as microfine orange-red crystals. Upon application of moderate pressure—rubbing of the surface of a coating comprising them—, these crystals turn into a brilliant deep blue, and remain so until they are exposed to visible light, where upon they turn back to their initial orange color.
[0003] WO-A 03/089227 (Lutz) discloses an application of piezochromic materials as pressure indicator in the cover layer of a roll used in a papermaking machine.
[0004] WO-A 2005/092995 (Leroux) is about a reversible piezochromic system which can be applied in the form of a printing ink, e.g. to protect banknotes from forgery. The system comprises the combination of an electron donating compound and an electron accepting compound. The electron donating compound is a ionochromic substance, in this case a pH-sensitive dye. The electron accepting compound must exhibit acidity high enough to develop the color of the ionochromic compound when brought in contact with the latter, but low enough to allow for the reversibility of the color change. Both types of compounds are combined in a coating composition and applied to a substrate. Upon application of pressure or friction, a strong color develops, which fades away within a minute or two.
[0005] The principal disadvantage of the system of WO-A 2005/092995 in security printing applications is the considerable time it takes the system to revert to its original state after the application of pressure and the concomitant color change. A piezochromic system exhibiting rapid reversible color change with pressure, in both directions, would be highly desirable.
SUMMARY OF THE INVENTION
[0006] The present inventors have now surprisingly found that a fully reversible, rapidly reacting piezochromic device, useful for application as a security element on value documents, banknotes, etc., can be realized on the basis of a different physical, noteworthy a mechanical principle.
[0007] The reversibly piezochromic security element of the present invention is based on a collection of optically contrasting pigment particles, comprised in a film or a coating layer of an elastic polymer.
[0008] The present invention discloses as well a coating composition for the production of a reversibly piezochromic security element, comprising a collection of optically contrasting pigment particles in a liquid or pasty polymerizable precursor monomer or oligomer, able to be cured to an elastic solid.
[0009] In the so obtained elastic solid, upon compression or elongation of the elastic polymer, the density and/or the orientation of the pigment particles changes; this results in a visible color change, given the optically contrasting property of the pigment particles. Said visible color change in response to compression or elongation is reversible, in that, upon release of the external pressure, the arrangement of the pigment particles in said elastic polymer reverts to its initial state. The visible color effect can be perceived either in the vicinity of the pressure exerting tool, or from the back side of the device if the back side is visibly transparent, or else through the pressure exerting tool, if this latter is visibly transparent.
[0010] The collection of optically contrasting pigment particles, in the present context, means any kind of pigment particles or any mixture of pigment particles which are visible within the elastic polymer. The pigment does not necessarily need to be of a same single type; the collection of pigment particles may thus comprise various types of pigments, noteworthy one or more parts of pigments chosen from the following, preferred options.
[0011] Preferred pigment particles are of non-spherical shape, in particular they are needle-shaped or plate- or flake-shaped particles.
[0012] Most preferred pigments for embodying this invention are the thin-film interference pigments, in particular the optically variable pigments disclosed in U.S. Pat. No. 4,705,300; U.S. Pat. No. 4,705,356; U.S. Pat. No. 4,721,271 and in the thereto related documents. These pigments comprise a Fabry-Pérot reflector/dielectric/absorber layer structure, wherein the reflector is preferably of a metal, such as aluminium, chromium, nickel, or a metal alloy. The dielectric is preferably of magnesium fluoride (MgF 2 ) or of silicon dioxide (SiO 2 ), and the absorber is preferably of chromium, nickel, or carbon.
[0013] The preferred flakes for embodying the invention have a diameter between 10 and 50 micrometers.
[0014] The needle-shaped or the plate- or flake-shaped particles are preferably comprised within the elastic polymer in an oriented state; such orientation can be effectuated through the application of corresponding shear forces, such as disclosed in DE 196 39 165 C2. Alternatively, the pigment particles can be oriented through the application of external fields, e.g. magnetic fields such as disclosed in EP 1 641 624 and in WO 2008/046702 A1. To this aim, the pigment particles need to be responsive to the chosen external fields. FIG. 1 schematically shows how the pigment particles in the coating can be oriented.
[0015] The preferred pigment particles for embodying the invention are selected from the magnetic or magnetizable pigment particles.
[0016] The pigment is present in the elastic polymer in a concentration of between 5 and 20 wt-%, preferably of between 10 and 15 wt-%.
[0017] In the most preferred embodiment, the pigment particles, preferably pigment flakes, are about vertically oriented with respect to the plane of the coating. “Vertically”, in the context of the present disclosure, means that the needle-axis of needle-shaped particles is within 30° from the normal to the plane, respectively that the flake-axis of flake-shaped particles is within 30° from the plane of the film or coating.
[0018] The elastic polymer is obtained through the polymerization of an appropriate precursor monomer or oligomer. A liquid or pasty coating composition is formed by dispersing the pigment particles and adequate additives in the polymerizable precursor. The coating composition is applied to a substrate in the form of a film, using an appropriate coating or printing technique, to produce, if so desired, an as well a determined orientation of the pigment particles. The applied coating composition is subsequently cured (hardened) to yield an elastic material comprising the pigment particles. The resulting film is useful as a piezochromic security device.
[0019] In a preferred embodiment, the surface of the piezochromic security device is additionally covered by an at least partially transparent protecting film, to prevent accidental mechanical damages. A preferred protecting film is a transparent polymer foil. The protecting film can, however, also be any other type of protecting coating, such as a UV-varnish or the like.
[0020] In a further embodiment of the piezochromic security device, the film of elastic polymer containing the pigment particles is comprised between two at least partially transparent protecting films.
[0021] A particularly preferred embodiment concerns an optically variable piezochromic element, wherein the pigment is a, preferably magnetic, optically variable pigment, consisting of non-transparent, reflective flakes, which are of the order of 1 micrometer thick and have a planar extension of the order of 10 to 50 micrometers, and whose spectrally selective reflectivity (color) depends on the viewing angle with respect to the plane of the flake. “Optically variable”, in the context of the present disclosure, means having a viewing- or incident-angle dependent color.
[0022] Preferably, the optically variable pigment flakes are magnetic or magnetizable flakes, so as to allow for their orientation in the coating composition through the application of an external magnetic field, prior to hardening it to an elastic solid.
[0023] Upon application of a moderate pressure, a stretching or a shearing force, such as can be exerted by a human finger, to the cured elastic composition comprising the optically variable flakes, the flakes subjected to the pressure change their orientation within the elastic composition, which results in a local, highly visible color change. Upon release of the pressure, the stretching or the shearing force, the flakes immediately return into their former positions, i.e. the pressure-dependent color change is rapid and fully reversible.
[0024] The effect of mechanical compression on a collection of oriented pigment flakes comprised in an elastic coating is illustrated in FIG. 2 : At the place of compression of the elastic coating, the pigment flakes adopt a lower angle towards the plane of the coating, thus showing an enhanced specular reflection.
[0025] The effect of mechanical elongation on a collection of oriented pigment flakes comprised in an elastic coating is illustrated in FIG. 4 : In the elongated elastic coating, the flakes adopt a lower angle towards the plane of the coating, and thus show enhanced specular reflection.
[0026] In a preferred embodiment, the coating composition containing the optically contrasting pigment particles is used as a security element on a substrate such as a value document, a banknote, an identity document, an access- or a banking card, or on a label serving for tax collection purposes.
[0027] Preferably, the piezochromic security element is covered by an at least partially transparent polymer foil, which is preferably applied before the curing operation.
[0028] This allows for protecting the elastic coating from being inadvertently or intentionally scratched away. Said foil may also be the over-laminating foil of a credit- or access card, or of a transportation title, which may have the additional function of protecting the sensitive information on these documents from being tampered. Said foil can also be part of a stamping foil assembly.
[0029] As obvious to the skilled person, there may be, depending on the application, a need for additional layers between the piezochromic security element and the said polymer foil, such as for promoting adhesion, for providing release properties, or for still other technical and/or esthetical purposes.
[0030] In a particularly preferred embodiment of the security device, the elastic coating composition containing the flakes is comprised between two polymer foils, at least one of which being at least partially transparent. This allows for applying the verification pressure, e.g. by a human finger, from a first side of the security device, whilst observing the resulting color change from the second side of the security device, i.e. the foil/elastic coating/foil assembly.
[0031] Such foil/elastic coating/foil assemblies may be used on banknotes in the form of security threads, windows or affixed stamping foils. For application as a security thread, the foil assembly is cut into elongated stripes, which are incorporated into security paper during the papermaking, as known to the skilled in the art. In order to observe the visible effect of pressure, the security thread must not be buried entirely within the paper, but exposed in some parts, such as is the case with a window-thread (see EP-A-0 400 902). For application as a window, the foil assembly is either used as the base layer of the security document, which carries an opacifying coating where no window is to appear (see WO 98/13211), or, alternatively, incorporated into the paper during the papermaking process, as known to the skilled in the art (see EP-A-0 860 298). For application as a stamping foil, the foil assembly is produced on a releasable carrier foil, and preferably provided with a heat-activatable glue layer, as known to the skilled person (see WO 92/00855).
[0032] Disclosed is as well a process for making a reversibly piezochromic security element for the forgery-protection of value documents, the process comprising the steps of
a) providing a substrate; b) applying a coating composition comprising a collection of optically contrasting pigment particles in a liquid or pasty polymerizable precursor monomer or oligomer to at least part of the substrate; c) curing the coating composition to an elastic polymer.
[0036] In a preferred embodiment of the process, the optically variable flake pigment is a magnetic or magnetizable pigment, and step b) comprises the magnetic orienting of said flake pigment in the applied coating with the help of an external magnetic field.
[0037] Said magnetic orienting is preferably performed using an engraved plate of magnetized permanent magnetic material, such as disclosed in WO 2005/002866 and WO 2008/046702.
[0038] The process may also include the additional step of covering the applied coating composition by an at least partially transparent polymer foil.
[0039] The substrate used in the process may further be an at least partially transparent polymer foil.
[0040] The security element according to the invention can be used for the counterfeit protection of a security document or item, such as a value document, a banknote, an identity document, an access-card, a banking card, or a label serving for tax collection or other purposes.
[0041] Further disclosed is a security document or item, such as a value document, a banknote, an identity document, an access-card, a banking card, or a label serving for tax collection or other purposes, carrying a security element according to the present invention.
DETAILED DESCRIPTION
Polymer
[0042] Preferably, the polymer binder used to comprise the pigment is a high molecular weight elastic polymer, which allows for a fully reversible, elastic change of dimensions under the influence of external pressure or force, such that the original dimensions are restored after removal of the pressure or force quickly or almost instantaneously at room temperature.
[0043] The polymers which can be used as the elastic binder, to embody the piezochromic security element, include but are not limited to highly flexible polymers such as natural and synthetic rubbers including styrene-butadiene copolymer, acryl ate latex systems, polychloroprene (neoprene), nitrile rubber, butyl rubber, polysulfide rubber, cis-1,4 polyisoprene, ethylene-propylen terpolymers (EPDM rubber), silicone rubber and polyurethane rubber, porous silicones, as well as other suitable polymers disclosed in the art.
[0044] In order to obtain a maximum of visible effect upon compression or elongation of the pigment-containing elastic polymer, it is of advantage to use non-spherical pigment particles, such as needles or flakes, and in particular, to produce an orientation of the pigment particles in the elastic binder matrix.
[0045] The position orientations of the pigment particles in the elastic binder must subsequently be fixed through a curing of the binder, so as to adopt the elastic state. A rapid curing system is of advantage, and UV- or EB (electron beam) curing coating compositions are correspondingly preferred, because they allow an immediate in situ fixation of the pigment particles subsequent to the coating process.
[0046] However, thermally curing elastic polymer systems, such as 2-component silicones, can also be employed; in this case, the orientation of the pigment particles must be maintained during the initial stages of the thermal curing process, through external forces, such as a magnetic field, until the polymer is sufficiently solidified to maintain the pigment particles in place and orientation.
[0047] Furthermore, for health and environmental reasons, it is of advantage to keep the solvent content of the coating composition low. Therefore, solvent-less formulations are a preferred option.
Pigment Incorporation
[0048] The pigment concentration in the coating composition should be chosen such that a maximum of visible effect is produced upon application of a moderate pressure, such as possible with a fingertip. In case of a flake pigment, e.g. the optically variable pigment flakes disclosed in U.S. Pat. No. 4,838,648, the pigment concentration should be chosen such that a maximum surface coverage would be obtained in the printed film if the flake particles were to align horizontally after printing, i.e. with their large surface parallel to the imprinted substrate surface. For obtaining a maximum visible effect, the pigment particles are preferably oriented close to vertically with respect to the substrate plane.
[0049] Flake-shaped thin-film optical interference pigments which can be used to embody the present invention are described in U.S. Pat. No. 4,705,300; U.S. Pat. No. 4,705,356; U.S. Pat. No. 4,721,271 and thereto related disclosures.
[0050] Magnetic optically variable pigments, allowing for a magnetic orientation of the pigment particles by the means of an external magnetic field, have been disclosed in WO 02/073250; U.S. Pat. No. 4,838,648; EP-A-686675; WO 03/00801 and U.S. Pat. No. 6,838,166; these documents are incorporated herein by reference.
[0051] On the other hand, the pigment concentration should not be excessively high, in order to allow the flake pigment to rotate, such as to yield a good visible contrast between the compressed and the released state of the flake-pigment containing elastic polymer. The optimum concentration of the flake pigment in the elastic polymer depends on the particular pigment properties such as the particle size and the specific weight, as well as of coating parameters such as the final coating thickness, and should therefore be determined ad casum by the skilled person so to obtain the best visual effect in each application. The optimal pigment concentration is generally somewhere between 1 and 30 weight percent of the ink, in most cases between 5 and 15 wt %.
[0052] The mean particle size and the size distribution in a particular pigment lot have an influence on the achievable result. A rather large particle size (flake diameter in the range of 10 to 50 μm) and a size distribution as homogenous as possible are required for obtaining an optimum effect. However, the larger the flake diameter, the thicker the coating must be to allow for a vertical orientation of the pigment in the coating film.
[0053] The coating composition comprising the flake pigment particles is preferably applied onto a rigid substrate surface via a liquid-ink printing technique, such as screen-printing or bar-coating. The final thickness of the applied and hardened coating layer is highly depending on the used pigment and is preferably of the order of 50 μm or higher, so as to allow for the easy rotation of the pigment flakes to adopt a vertical position.
[0054] Any orientation of the pigment flakes in a position which is substantially different from an alignment in the plane of the film or coating layer will exhibit a certain color change upon the application of pressure. However, the color change is strongest with the pigment particles disposed in the elastic polymer in a position close to vertical with respect to the substrate plane. It is further not advisable to use, for this particular application, a coating thickness which is much less than the diameter of the pigment flakes.
[0055] Materials and technology for the orientation of magnetic particles in coating compositions, as well as corresponding printing processes, have been disclosed in U.S. Pat. No. 2,418,479; U.S. Pat. No. 2,570,856; U.S. Pat. No. 3,791,864; DE 2006848-A; U.S. Pat. No. 3,676,273; U.S. Pat. No. 5,364,689; U.S. Pat. No. 6,103,361; US 2004/0051297; US 2004/0009309; EP-A-710508, WO 02/090002; WO 03/000801; WO 2005/002866, US 2002/0160194; WO 2006/061301; WO 2006/117271; WO 2007/131833; WO 2008/009569; WO 2008/046702; these documents are incorporated herein by reference.
[0056] The coating composition can further comprise other types of pigments and/or dyes; thus it may noteworthy comprise non-magnetic optically variable pigments, additive-color-mixing pigments, iridescent pigments, liquid crystal polymer pigments, metallic pigments, magnetic pigments, UV-, visible- or IR-absorbing pigments, UV-, visible- or IR-luminescent pigments, UV-, visible- or IR-absorbing or luminescent dyes, as well as mixtures thereof. The coating composition may further comprise forensic taggants, e.g. as disclosed in EP-B-0 927 750.
[0057] The reversible piezochromic security element of the present invention is now further illustrated by the figures and by the following, non limiting examples.
[0058] FIG. 1 schematically depicts the alignment of optically variable magnetic pigment flakes in an elastic coating with the help of an external magnetic field.
[0059] FIG. 2 schematically depicts the origin of the optical effect resulting from an elastic deformation due to compression of a coating comprising oriented flake pigments.
[0060] FIG. 3 illustrates the effect of finger pressure on the optical properties of a coating comprising oriented optically variable magnetic pigments, as seen through a glass plate carrying the coating.
[0061] FIG. 4 schematically depicts the origin of the optical effect resulting from an elastic deformation due to elongation of a coating comprising oriented flake pigments.
[0062] FIG. 5 illustrates the effect of elongation on the optical properties of a coating comprising oriented optically variable magnetic pigment: a) without stretch; b) under stretch.
[0063] FIG. 6 schematically depicts an application of the pressure sensitive coating of the present invention as security element on an ID-card.
EXAMPLE 1
Optically Variable Magnetic Pigment in a 2-Component Silicon Elastomer
[0064] A coating composition for producing a pressure-sensitive optically variable security element according to the present invention was formulated by dispersing optically variable magnetic pigment particles in the heat curable solvent-less 2-component silicon elastomer Sylgard 527 Primerless Silicone Dielectric Gel (Dow Coming).
[0065] The two components of Sylgard 527 were thoroughly mixed at room temperature in a 0.9:1.1 by weight ratio. The Sylgard 527 gel comes as a kit, comprising components A and B in separate containers. The two components are typically mixed in a ratio of 1:1 by weight. A somewhat firmer gel can be obtained by increasing the ratio of part B to Part A in the initial mixture.
[0066] Subsequently, magnetic optically variable pigment (Flex Products Inc., Santa Rosa, Calif., “green-to blue”, 5-layer design Cr/MgF 2 /Ni/MgF 2 /Cr, as disclosed in U.S. Pat. No. 4,838,648) was dispersed in the Sylgard 527 mixture at a concentration of 10 wt-%, and the pigment-containing coating composition was deposited at about 100 μm thickness with the help of a coating bar (hand-coater) onto a transparent polymer foil (100 μm PVC from Puetz-Folien) or onto a glass plate (microscopy slide).
[0067] The so obtained films were pre-dried on a hot plate for 5 min at 80° C., in order to increase the viscosity of the Sylgard 527 binder. The pigment particles in the coating were then oriented to a close to vertical position with respect to the substrate plane, using a “plastoferrite” magnet such as described in WO 2008/046702 A1. The resulting film appeared homogenously grey and partly transparent. The film was kept on the magnet until the viscosity of the Sylgard binder was high enough to retain the positions and orientations of the pigment particles comprised in it, and was then cured in an oven for 30 minutes at 150° C. The cured film was highly flexible and showed a mechanically resilient behavior. In order to protect the so obtained film against mechanical damage (scratching), it was covered with a transparent self adhesive foil.
[0068] Upon compressing the elastic film between a fingertip and the substrate, a clear and fully reversible color change from dark grey to bright green was observed from the back side of the substrate ( FIG. 3 ).
EXAMPLE 2
Optically Variable Magnetic Pigment in a UV-Curable Dielectric Gel
[0069] A coating composition for producing a pressure-sensitive optically variable security element according to the present invention was formulated by dispersing optically variable magnetic pigment particles in the UV-curable 1-component solventless silicon dielectric gel X3-6211 Encapsulant (Dow Corning).
[0070] The same magnetic optically variable pigment as in example 1 was dispersed in the Silicon gel X3-6211 at a concentration of 7.5 wt-%, and the pigment-containing coating composition was deposited at about 100 μm thickness with a coating bar (hand-coater) onto a transparent polymer foil (100 μm PVC from Puetz-Folien) or onto a glass plate (microscopy slide).
[0071] The pigment particles in the X3-6211 binder were then orientated so as to form an angle close to 60° with respect to the substrate plane, using a magnet such as described in WO 2008/046702 A1, and dried in-situ using a conventional UV-radiation curing unit as known in the art.
[0072] The cured film was highly flexible and had a resilient behavior. In order to protect the film against mechanical damage, it was covered with a transparent self adhesive foil.
[0073] Upon compressing the elastic film between a fingertip and the glass plate, a reversible clear change from dark grey to bluish green was observed.
EXAMPLE 3
Light Diffractive Pigment in a 2-Component Silicon Elastomer
[0074] A coating composition for producing a pressure-sensitive security element according to the present invention was formulated by dispersing an aluminium flake pigment in the heat curable solvent-less 2-component silicon elastomer Sylgard 527 Primerless Silicone Dielectric Gel (Dow Corning) as described in example 1.
[0075] The SpectraFlair pigment Silver 1500-20 (FLEX Products, JDSU, California) was dispersed in the Sylgard 527 mix at a concentration of 8 wt-%, and the pigment-containing coating composition was deposited at about 100 μm thickness with the help of a coating bar (hand-coater) onto a glass plate (microscopy slide).
[0076] The obtained films were cured in an oven for 30 minutes at 150° C. and was then covered with a transparent self adhesive foil. When compressing the elastic film between a fingertip and the substrate, a change from silver to multiple, bright rainbow colors was observed from the back side of the substrate.
EXAMPLE 4
Effects of Stretching an Elastic Coating Comprising Oriented Optically Variable Pigment Flakes
[0077] A coating composition for producing a shear force-sensitive security element according to the present invention was formulated by incorporating optically variable magnetic pigment particles in the UV-curable 1-component solvent-less silicon dielectric gel X3-6211 Encapsulant (Dow Corning) as described in example 2.
[0078] A band of the dispersion was deposited at about 100 μm thickness with the help of a coating bar (hand-coater) onto a transparent polymer foil (100 μm PVC from Puetz-Folien). After orientation of the pigment particles close to vertical with respect to the substrate plane, the film was partly dried by UV curing and a second polymer foil was put on the film surface to form a sandwich-like arrangement. The elastic film was then further cured with UV. FIG. 5 a illustrates the unstretched, oriented coating between 2 flexible substrates, which has a dark grey appearance. FIG. 5 b shows the effect of mechanical stretching on the coating of FIG. 5 a: a clear and fully reversible color change from dark grey to bright green is observed.
EXAMPLE 5
Application Example of an Optically Variable Magnetic Pigment in a UV-Curable Dielectric Gel
[0079] The pressure sensitive coating composition descried in example 2 can for example be used as security element on an ID card, as illustrated in FIG. 6 . The manufacturing of the plastic card typically includes the 4 steps of i) plastic compounding/molding of the of the core sheet, ii) printing, iii) lamination and iv) cutting/embossing. In order to obtain a two-side pressure sensitive feature, three circles were cut, as indicated, into a core plastic sheet following the molding step i), and filled with a pressure sensitive coating composition prepared as given in example 2. After UV curing of the pressure sensitive coating, the plastic core sheet was over-laminated on both sides with each a transparent foil. The card can otherwise be processed as usual (printing, cutting etc.).
[0080] The pressure sensitive element of this plastic card shows a clear shift from dark to green when touched from the back while observing from the front side. Alternatively, the middle circle on the front side can be touched to induce, through mechanical transmission of pressure by the laminated cover layer, a color shift from dark to green in the outer 2 circles when observed from the front side.
[0081] The given examples illustrate how a piezochromic security element can be produced through the orientation and fixation of flake-like pigment particles within a highly flexible and resilient elastic polymer layer, which is preferably produced through the application of a solventless and UV-curable precursor material. Depending on the thickness of the elastic polymer layer, optimized optical effects are obtained with pigment concentrations between 5 and 15 wt-%. Improved effects are obtained with relatively thick films; the achievable thickness is, however, limited by process factors of the printing process and by the drying limitations.
[0082] Based on the information given in the description and in the examples, the skilled in the art will be able to derive further embodiments of the disclosed invention. | The invention discloses a reversibly piezochromic security element for the forgery-protection of value documents, the security element being characterized in that it comprises a collection of optically contrasting pigment particles in a film or a coating layer of an elastic polymer. In a particular embodiment, the particles are optically variable pigment flakes, oriented in a position which is substantially different from an alignment in the plane of the film or coating layer. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and a device for driving a plasma display panel (PDP).
Increasing number of pixels in a PDP due to a large screen or a high definition cause increase of power consumption. It is necessary to reduce the power consumption for reducing load of a driving device and for taking measures against heat.
2. Description of the Prior Art
As a color display device, a surface discharge AC type PDP is commercialized. The surface discharge type has electrodes (display electrodes X and display electrodes Y) to be anodes and cathodes in display discharge for ensuring luminance. The display electrodes X and Y are arranged on a front substrate or a back substrate in parallel, and address electrodes (third electrodes) are arranged so as to cross the display electrode pairs. There are two forms of display electrode arrangement. In one form, a pair of display electrodes is arranged for each row of a matrix display. In another form, display electrodes X and display electrodes Y are arranged alternately at a constant pitch. In the latter form, each of the display electrodes except both ends of the arrangement works for displays of two neighboring rows. Regardless of the arrangement form, the display electrode pairs are covered with a dielectric layer.
In a surface discharge type PDP display, one of the display electrodes (pair) assigned to each row is used as a scan electrode for row selection, so as to generate address discharge between the scan electrode and the address electrode, and address discharge between the display electrodes triggered by the address discharge between the scan electrode and the address electrode. In this way, addressing is performed for controlling electrification quantity (wall charge quantity) of the dielectric layer in accordance with display contents. After addressing, sustain voltage (also called drive voltage) Vs having alternating polarity is applied to the display electrode pair. The sustain voltage Vs satisfies inequality (1).
Vf XY −Vw XY <Vs <Vf XY (1)
Here, Vf XY denotes discharge start voltage between the display electrodes, and Vw XY denotes wall voltage between the display electrodes.
When the sustain voltage Vs is applied, cell voltage (sum of drive voltage applied to the electrode and the wall voltage) exceeds the discharge start voltage Vf XY only in the cell having a predetermined quantity of the wall charge so that surface discharge is generated on the substrate surface for a display. As an application period is shortened, light emission can be observed as if it is continuous.
A discharge cell of the PDP is basically a binary light emission element. Therefore, a half tone is realized by setting an integral light emission quantity of each discharge cell in a frame period in accordance with a gradation value of input image data. The color display is a type of the gradation display, and a display color is determined by a combination of luminance values of three primary colors. As a gradation display, there is used a method in which a frame is made of plural subframes (subfields for an interlace display) having a luminance weight, and the integral light emission quantity is set by a combination of on and off of the light emission for each subframe. A general driving sequence is as follows. A subframe period that is assigned to each subframe includes a reset period for equalizing charge distribution of the screen, an address period for forming the charge distribution in accordance with display contents, and a display period (or a sustain period) for generating display discharge (or sustain discharge) of the number of times in accordance with the gradation value by applying a pulse train having alternating polarities. Though lengths of the reset period and the address period are constant regardless of the luminance weight, a length of the display period is longer as the luminance weight is larger.
In the conventional driving method, a sustain pulse Ps having a simple rectangular waveform with an amplitude Vs is applied to a display electrode X and a display electrode Y alternately in the display period as shown in FIG. 17 . In other words, the display electrode X and the display electrode Y are temporarily biased to potential Vs alternately. Thus, the pulse train having alternating polarities is applied across the display electrode X and the display electrode Y (refereed to as an interelectrode XY). The difference between a pulse base potential (usually the ground level GND) and the bias potential, which is the sustain voltage Vs, is set to a value within a drive margin. The drive margin is defined as a difference between the discharge start voltage Vf and the minimum applied voltage Vsm necessary for sustaining a lighted state. If the sustain voltage Vs is the voltage Vf and above, the discharge is generated also in cells that were not lighted in the addressing period. If the sustain voltage Vs is less than Vsm, a lighted cell becomes a non-lighted state.
Since cells of the PDP are capacitive load for a power source, current flows so as to charge capacitance (CP) of the cell when the sustain pulse Ps is applied. Usually, the display discharge is generated with some delay after the terminal voltage of the capacitance reaches the sustain voltage Vs, while discharge current (referred to as light emission current) flows simultaneously. In the conventional method, the discharge current is supplied to the cell from a power source circuit connected to the PDP. For this reason, a path for supplying the power is long and passes many circuit devices such as switching transistors, so there was a problem of a large power loss and thereby degrading efficiency of the light emission.
SUMMARY OF THE INVENTION
An object of the present invention is to reduce the power loss and to increase the efficiency of the light emission.
According to the present invention, capacitance between display electrodes is charged sufficiently for generating display discharge, and after that a current path between a power source and a cell is cut off. Values of charge voltage and charge period are set so that the cut-off timing and the display discharge are overlapped. When display discharge is generated in the cut-off period, the discharge current is supplied to a discharge gap from the charged capacitance. In this case, a path of the discharge current that flows more rapidly than the charge current to the capacitance is located within the cell, so a power loss is smaller than the conventional structure in which the discharge current is supplied from the power source.
FIG. 1 shows a basic drive voltage waveform and a discharge current waveform according to the present invention. The drive voltage waveform is characterized by a step-like waveform including a step for applying voltage Vo higher than sustain voltage Vs to the interelectrode XY, a succeeding step of high impedance and a step for applying the sustain voltage Vs. The high impedance step is a step for cutting off power supply from the power source to the cell. The time for applying the voltage Vo from the leading edge of the waveform is denoted by “To”, and the time of the high impedance step is denoted by “Td”. In this waveform, a lot of power is supplied to capacitance of the interelectrode XY in the early stages by applying the voltage Vo. After that, when discharge is generated, power is consumed for current flowing in discharge gas. If the external power supply is stopped before the discharge finishes, the power for the current flowing in the discharge gas is supplied from the capacitance of the interelectrode XY. After that, the application voltage is set to an appropriate value of voltage Vs before the discharge finishes, so that the wall charge quantity at the end of the discharge is controlled to be suitable for sustaining.
FIG. 2 is a graph showing dependence of efficiency on the voltage Vo. FIG. 3 is a graph showing drive voltage margin. The light emission efficiency depends on a rate of a part of the discharge current that is supplied from the capacitance. It is desirable to set the voltage Vo such that a peak of the discharge current appears during the period for cutting off the electric path. As shown in FIG. 3, sufficient drive margin can be secured even if the voltage Vo is altered. According to the drive waveform of the present invention, a power loss can be reduced without decreasing the drive margin, so that the light emission efficiency can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a basic drive voltage waveform and a discharge current waveform according to the present invention.
FIG. 2 is a graph showing dependence of efficiency on the voltage Vo.
FIG. 3 is a graph showing drive voltage margin.
FIG. 4 shows a structure of a display device according to the present invention.
FIG. 5 is a plan view showing a cell arrangement of a display screen.
FIG. 6 is a perspective view showing a cell structure of a PDP.
FIG. 7 is a plan view showing a shape of a display electrode.
FIG. 8 shows a concept of a frame division.
FIG. 9 shows a first example of drive waveforms.
FIG. 10 shows a second example of the drive waveforms.
FIG. 11 shows a third example of the drive waveforms.
FIG. 12 shows a fourth example of the drive waveforms.
FIG. 13 shows a fifth example of the drive waveforms.
FIG. 14 shows dependence of the efficiency on the voltage Vo in the fifth example of the drive waveforms.
FIG. 15 shows an example of a driving circuit.
FIG. 16 is a timing chart of switching.
FIG. 17 shows a conventional drive voltage waveform.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be explained more in detail with reference to embodiments and drawings.
FIG. 4 shows a structure of a display device according to the present invention. The display device 100 comprises a surface discharge type PDP 1 having a color display screen of n rows and m columns, and a drive unit 70 for controlling light emission of cells. The display device 100 is used as a wall-hung television set or a monitor of a computer system.
The PDP 1 comprises a pair of substrate structures 10 and 20 . The substrate structure means a structure of a glass substrate on which electrodes and other elements are arranged. The PDP 1 includes display electrodes X and Y that constitute electrode pairs for generating display discharge and are arranged in the same direction, and address electrodes A that are arranged so as to cross the display electrodes X and Y. The display electrodes X and Y extend in the row direction (horizontal direction) of the screen and are covered with a dielectric layer and a protection film. The display electrode Y is used as a scan electrode. The address electrode A extends in the column direction (vertical direction) and is used as a data electrode. In FIG. 4, suffixes (1, n) of the reference numerals of the display electrodes X and Y indicate arrangement orders of the corresponding “rows”, while the suffixes (1-m) of the reference numerals of the address electrodes A indicate arrangement orders of the corresponding “columns”. The row is a set of cells of the number of columns (m) having the same arrangement order in the column direction, while the column is a set of cells of the number of rows (n) having the same arrangement order in the row direction. In addition, the letters R, G and B in parentheses indicate the light emission color of the cell corresponding to the element having the letter.
The drive unit 70 includes a controller 71 , a power source circuit 73 , an X driver 81 , a Y driver 84 and an A driver 88 . The drive unit 70 is supplied with frame data Df that indicate three luminance levels of red (R), green (G) and blue (B) colors along with various kinds of synchronizing signals from external equipment such as a TV tuner or a computer. The frame data Df are memorized temporarily in a frame memory of the controller 71 . The controller 71 converts the frame data Df into subframe data Dsf for gradation display, which are sent to the A driver 88 . The subframe data Dsf are a set of display data of one bit per cell. The value of each bit indicates on or off of the light emission for a cell in a corresponding subframe, more specifically whether the address discharge is necessary or not. In the case of interlace display, each of fields in a frame is made of plural subfields, and the light emission control is performed for each of the subfield. However, the contents of the light emission control are the same as the case of progressive display.
FIG. 5 is a plan view showing a cell arrangement of a display screen.
In the display screen, a discharge space 30 is divided into plural columns by partitions 29 that meander regularly, so that column spaces 31 having wide portions (the portion in which the width in the row direction is large) 31 A and narrow portions (the portion in which the width is small) 31 B arranged alternately. In other words, each of the partitions 29 is meandered at a constant pitch and constant amplitude in a plan view, so that the distance between the neighboring partitions 29 becomes smaller than a predetermined value at a constant pitch in the column direction. The predetermined value means a value that can suppress the discharge and is determined by discharge conditions such as a gas pressure. The structure in which the column space 31 between the neighboring partitions is continuous over all rows has some advantages of easy drive by priming for each row, uniformity of film thickness of fluorescent material layers and easy exhaust treatment in a manufacturing process. Since surface discharge is hard to be generated in the narrow portion 31 B, the wide portion 31 A substantially contributes to the light emission. Therefore, cells are arranged on alternate columns in each row. Noticing two neighboring rows, the column positions of the arranged cells alternate in every column. In other words, the cells are arranged zigzag in both the row direction and the column direction. Each of the cells C is a structure within one wide portion 31 A in the display screen. In FIG. 5, five representative cells C are denoted by circles indicated by chain lines (the area of each circle is a bit larger than the real scale to be seen easily). In the PDP 1 , three cells of R, G and B colors constitute one pixel, and the arrangement form of three colors in the color display is a triangle (delta) arrangement form. The delta arrangement has an advantage in high definition compared with an inline arrangement since the width of the cell in the row direction is larger than one third of the pixel pitch. In addition, the rate of non-lighted areas in the screen is small, so that high luminance display can be realized. It is not necessary that the horizontal direction is the row direction. The vertical direction can be the row direction while the horizontal direction can be the column direction.
FIG. 6 is a perspective view showing a cell structure of the PDP.
The PDP 1 includes a front glass substrate 11 whose inner surface is provided with the display electrodes X and Y, a dielectric layer 17 and a protection film 18 , and a back glass substrate 21 whose inner surface is provided with the address electrodes A, an insulator layer 24 , partitions 29 and the fluorescent material layers 28 R, 28 G and 28 B. Each of the display electrodes X and Y includes a transparent conductive film 41 constituting a surface discharge gap and a metal film 42 as a bus conductor. The display electrodes X and Y are arranged alternately at a constant pitch (with the surface discharge gap) in the column direction. The gap direction of the surface discharge gap, i.e., the opposing direction of the display electrodes X and Y is the column direction.
FIG. 7 is a plan view showing a shape of the display electrode.
Each of the display electrodes X and Y includes a transparent conductive film 41 that extends in the row direction meandering in the column direction and a band-like metal film 42 that extends in the row direction meandering along the partition 29 so as to avoid the wide portion 31 A. The transparent conductive film 41 has a curved band-like shape and is patterned in a shape having a gap forming portion arching from the metal film 42 toward the wide portion 31 A in each column. In each of the wide portions 31 A, the gap forming portion of the display electrode X and the gap forming portion of the display electrode Y face each other, so that a drum-like surface discharge gap is formed. In the pair of gap forming portions facing each other, the opposing sides are not parallel. The width of the band-like transparent conductive film 41 may alter regularly.
This electrode shape enables reduction of the interelectrode capacitance without increasing the surface discharge gap (the minimum distance between electrodes) compared with a linear band-like shape. In addition, since the distance between the transparent conductive film 41 and the metal film 42 is large in the middle of the wide portion 31 A in the row direction, the intensity of the electric field in the gap between the transparent conductive film 41 and the metal film 42 decreases, so that a discharge interference between rows can be prevented. In addition, as a side effect, shading effect of the metal film 42 is reduced so that the light emission efficiency increases.
FIG. 8 shows a concept of a frame division. In a display using the PDP 1 , a frame F of the input image data is divided into q subframes SF so that a color is reproduced by on-off control of lighting. In other words, each frame F is replaced with a set of q subframes SF. The subframes SF are provided with weights, e.g., 2 0 , 2 1 , 2 2 , . . . 2 q−1 in order so as to set the number of times of the display discharge in each subframe SF. Though the subframe arrangement is in the weight order in FIG. 8, other order can be adopted. Redundant weighting can be adopted for reducing quasi contour. In accordance with this frame structure, a frame period Tf that is a frame transfer period is divided into q subframe periods Tsf, and one subframe period Tsf is assigned to each subframe SF. In addition, the subframe period Tsf is divided into a reset period TR for initialization, an address period TA for addressing and a display period TS for sustaining. The lengths of the reset period TR and the address period TA are constant regardless of the weight, while the length of the display period TS is longer as the weight is larger. Therefore, the length of the subframe period Tsf is also longer as the weight of the corresponding subframe SF is larger. The driving sequence is repeated for each subframe. The order of the reset period TR, the address period TA and the display period TS is common to each of the q subframes SF.
Hereinafter, drive waveforms in the display period TS, which are relevant to the present invention, will be exemplified.
FIG. 9 shows a first example of the drive waveforms. In this example, three kinds of potential, which are positive voltage, lower positive voltage and the ground voltage are set for each of the display electrodes X and Y. The application time of the highest voltage is short, and a high impedance period shown by the broken line is provided at the switching time from the high voltage to the low voltage. Similar drive can be performed by negative low voltage, negative high voltage and the ground level. The application time of the low voltage is short, and a high impedance period may be provided at the switching time from the low voltage to the high voltage. There are two absolute values of potential difference except zero volts at the interelectrode XY in this example. This example has an advantage that only a single output polarity is required in the power source.
FIG. 10 shows a second example of the drive waveforms. The drive waveforms in this example have three set potentials including positive voltage, negative voltage and the GND level. The positive voltage is applied to one of the display electrodes X and Y, while the negative voltage is applied to the other. The application time of the negative voltage is short, and the high impedance period is provided at the switching time from the negative voltage to the ground level. In the same way, it is possible to shorten the positive voltage the application time, and to provide the high impedance period at the switching time from the positive voltage to the ground level. There are two absolute values of the potential difference except zero volts at the interelectrode XY. This example has an advantage that the power source can be realized using a device having low withstand voltage.
FIG. 11 shows a third example of the drive waveforms. The drive waveforms in this example have positive high voltage, positive low voltage and the ground level. The positive high voltage is applied to one of the display electrodes. After a short time the other display electrode is separated from the power source to be the high impedance state, and then positive low voltage is applied. These can be replaced with negative low voltage, negative high voltage and the ground level. There are two absolute values of the potential difference except zero volts at the interelectrode XY.
FIG. 12 shows a fourth example of the drive waveforms. This example corresponds to a case where electrode potential setting in the third example is shifted to negative polarity side. These drive waveforms have positive voltage, the ground level and negative voltage. A pair of display electrodes X and Y is set to negative potential simultaneously. After that one of the display electrodes is set to positive potential, and after a short time the other display electrode is set to the high impedance state and then to the ground level. Alternatively, it is possible that the display electrodes X and Y are set to the positive voltage simultaneously, then one of the display electrodes is set to the negative potential, after a short time the other display electrode is set to the high impedance state and then to the ground level. There are two absolute values of the potential difference except zero volts at the interelectrode XY. In this example, compared with the above-mentioned second example, the period between the time of the high impedance state and the previous potential switching time is long, so the request of response to the switching device that is used for the electrode potential control is relieved.
FIG. 13 shows a fifth example of the drive waveforms. The drive waveforms in this example have positive voltage, the ground level and negative voltage. One of the display electrodes is set to negative potential, and then the other display electrode is set to positive potential. After a short time, the display electrode at the negative potential is set to the high impedance state, and then the display electrode at the high impedance state is set to the ground level. Alternatively, it is possible that one of the display electrodes is set to the positive potential, then the other display electrode is set to the negative potential, and after a short time the display electrode at the positive potential is set to the high impedance state, and then the display electrode at the high impedance state is set to the ground level. There are three absolute values of the potential difference except zero volts at the interelectrode XY. Until the polarity of the interelectrode XY voltage is reversed, there is a single pulse. From the leading edge of the pulse, there is a first level, a second level and a third level. Among them, the second level is the maximum voltage. In order to generate display discharge in the high impedance period, the first level must be lower than the third level.
Noting the voltage of the interelectrode XY and comparing this fifth example with the first through fourth examples explained above, the high impedance period is delayed from the leading edge of the pulse. This delay works to adjust the overlap of the display discharge generating time and the high impedance period. FIG. 14 shows dependence of the efficiency on the voltage Vo using the period Ts for keeping the first level as a parameter. As shown in FIG. 14, the fifth example has an advantage that high efficiency can be obtained even if the voltage Vo is low.
FIG. 15 shows an example of the driving circuit. FIG. 16 is a timing chart of the switching. Here, the case of generating the drive waveforms of the fourth example will be explained.
The illustrated circuit includes terminals XTP 1 and YTP 1 that are connected to the power source for generating the positive voltage, switches XSw 1 and YSw 1 for switching current path between output terminals XOUT and YOUT connected to the PDP 1 and the terminals XTP 1 and YTP 1 , rectifier elements XD 1 and YD 1 forming current paths from the switches XSw 1 and YSw 1 to the output terminals XOUT and YOUT, terminals XTP 2 and YTP 2 that are connected to the power source for generating the negative voltage, switches XSw 2 and YSw 2 for switching current paths between the terminals XTP 2 and YTP 2 and the output terminals XOUT and YOUT, rectifier elements XD 2 and YD 2 for forming current paths from the output terminals XOUT and YOUT to the switches XSw 2 and YSw 2 , terminals XTP 3 and YTP 3 that are connected to the ground line, switches XSw 3 and YSw 3 for switching current paths between the terminals XTP 3 and YTP 3 and the output terminals XOUT and YOUT, rectifier elements XD 3 and YD 3 for forming current paths from the switches XSw 3 and YSw 3 to the output terminals XOUT and YOUT, terminals XTP 4 and YTP 4 that are connected to the ground line, switches XSw 4 and YSw 4 for switching current paths between the terminals XTP 4 and YTP 4 and the output terminals XOUT and YOUT, rectifier elements XD 4 and YD 4 for forming current paths from the output terminals XOUT and YOUT to the switches XSw 4 and YSw 4 , terminals XTP 5 and YTP 5 that are connected to the power source for generating the positive voltage, rectifier elements XD 5 and YD 5 for forming current paths from the output terminals XOUT and YOUT to the terminals XTP 5 and YTP 5 , terminals XTP 6 and YTP 6 that are connected to the power source for generating the negative voltage, and the rectifier elements XD 6 and YD 6 for forming current paths from the terminals XTP 6 and YTP 6 to the output terminals XOUT and YOUT.
In the drive waveforms, a drive period of two pulses is divided into T 1 , T 2 , T 3 , T 4 , T 5 , T 6 , T 7 and T 8 . In the periods T 1 and T 5 , both the display electrodes X and Y are set to the negative potential. In the periods T 2 and T 6 , one of the display electrodes X and Y is set to the positive potential, and the other is set to the negative potential. In the periods T 3 and T 7 , the display electrodes that were set to the negative potential in the period T 2 or the period T 6 are set to the high impedance state. In the periods T 4 and T 8 , one of the display electrodes X and Y is set to the positive potential, and the other is set to the ground potential.
In the period T 1 , the switches XSw 2 and YSw 2 are closed so as to set the output terminals XOUT and YOUT to the negative potential. On this occasion, the switches XSw 4 and YSw 4 can be either closed or opened. In the period T 1 the switches XSw 1 , XSw 3 , YSw 1 and YSw 3 are opened. In addition, the switches XSw 2 and XSw 4 are opened till the period T 2 .
In the period T 2 , the switch XSw 1 is closed so as to set the output terminal XOUT to the positive potential. On this occasion, the switch XSw 3 for flowing current from the ground line to the output terminal XOUT can be either closed or opened. In the period T 2 , the switch YSw 2 is closed, so the output terminal YOUT is set to the negative potential. The switch YSw 4 can be either closed or opened.
In the period T 3 , the switches XSw 1 , XSw 2 , XSw 3 and XSw 4 maintain the state of the period T 2 . In the period T 3 , the switch YSw 2 is opened so as to shut off the power supply from the negative power source. In this state, the output terminal YOUT is lower than the ground level. Since the rectifier element YD 4 is connected, the output terminal YOUT is set to the high impedance state even if the switch YSw 4 is closed. In addition, if discharge is generated in this period T 3 , potential of the output terminal YOUT rises. If the potential rises largely, potential difference at the interelectrode XY becomes small, and the wall charge cannot be formed sufficiently, resulting in the drive margin failure. In the period T 3 , the switch YSw 4 for flowing current from the output terminal YOUT to the ground line is closed, so as to set potential of the output terminal YOUT below the ground level.
In the period T 4 , the switches XSw 1 , XSw 2 , XSw 3 and XSw 4 maintain the state of the period T 2 . The switches YSw 3 and YSw 4 are closed so as to fix the output terminal YOUT to the ground level.
In the periods T 5 -T 8 , the switching is performed with exchanging the relationship between the display electrode X and the display electrode Y in the periods T 1 -T 4 .
While the presently preferred embodiments of the present invention have been shown and described, it will be understood that the present invention is not limited thereto, and that various changes and modifications may be made by those skilled in the art without departing from the scope of the invention as set forth in the appended claims. | A method for driving a PDP is provided in which power loss is reduced and light emission efficiency is improved while applying a voltage pulse train so as to generate display discharge whose number of times corresponds to luminance in cells to be lighted. A drive step of one pulse for generating one time of display discharge includes steps of supplying current to a pair of display electrodes of the cells to be lighted from a drive power source so as to charge capacitance between the display electrodes so that voltage between the display electrodes exceeds display discharge start voltage and cutting off a current path between the display electrode pair and the drive power source at least in a part of a period from start to end of the display discharge. | 6 |
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The present invention relates to a solid fuel igniter, and more particularly to an igniter that provides for uniform packing of solid fuel pieces, thereby enabling the fuel pieces to reach a self-ignition preparatory state.
[0003] An additional fire source, using tinder, and so on, is necessary in the initial stage of heating the solid fuel to directly enkindle the solid fuel pieces packed in a bottom portion of the igniter.
[0004] (b) Description of the Prior Art
[0005] In recent times, it has become popular for restaurants to provide a dining method using a tabletop charcoal grill to cook, such as hot pot restaurants, charcoal grill restaurants, and so on. Such charcoal grill methods use large quantities of solid fuel. Referring to FIG. 1 , in order to prepare in advance a large quantity of fuel to produce a primary self-ignition state, a conventional solid fuel igniter uses a bucket 1 , which is partitioned by disposing a dome-shaped grill 11 at a middle portion therein. Air inlets 13 are defined in a lower portion close to a bottom opening 12 of the bucket 1 , and a handle 14 is affixed to a side of the bucket 1 to facilitate emptying out solid fuel pieces 10 that have completed self-ignition. A primary fire 2 is prepared under the bucket 1 to enkindle the solid fuel pieces 10 .
[0006] Flames 20 from the primary fire 2 positioned below the bucket 1 penetrate the dome-shaped grill 11 , thereby transmitting heat energy to the lower packed solid fuel pieces 10 within the bucket 1 .
[0007] However, because the flames 20 rise and concentrate along a center line, thus, fuel pieces 10 A positioned close to an inner circumference of the bucket 1 are not only unable to directly receive heat energy from the flames 20 , moreover, because of cold air drawn in by the air inlets 13 , the fuel pieces 10 A will have a lower temperature, which results in a slow speed of heat energy transmission. A catalytic self-ignition phenomenon first occurs in an upward sloping tapered space 21 formed at a center of the stacked solid fuel pieces 10 relative to center of the bucket 1 . Moreover, the fuel pieces 10 positioned in the tapered space 21 often burn excessively, whereas the fuel pieces 10 A positioned at the inner circumference are unable to reach a uniform self-ignition preparatory state. In addition, the conventional igniter is only able to provide a finite space, which fixes the number of solid fuel pieces 10 that can be packed therein for preheating.
SUMMARY OF THE INVENTION
[0008] The present invention particularly provides an improved structure for a solid fuel igniter, wherein a heat source generating chamber is used to generate a primary fire, and an inverse tapered enclosing body is disposed on top of the generating chamber to provide for loading solid fuel pieces therein. A contracted bottom end of the inverse tapered enclosing body is disposed on a top end opening of the generating chamber, thus, heat energy generated by the generating chamber heats a smaller number of the fuel pieces packed at the bottom contracted opening of the inverse tapered enclosing body.
[0009] The solid fuel pieces packed at the bottom contracted opening of the enclosing body are the first to be heated by the primary fire in the generating chamber, and the heat generated after the solid fuel pieces have achieved self-ignition serves as a secondary upward heating source, which subjects the fuel pieces packed in upper portions of the enclosing body to successive and uniform secondary heating.
[0010] To enable a further understanding of said objectives and the technological methods of the invention herein, brief description of the drawings is provided below followed by detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a side structural view of a conventional igniter.
[0012] FIG. 2 shows a side structural view of an igniter according to the present invention.
[0013] FIG. 3 shows an elevational view of a protective shield configured to surround the igniter according to the present invention.
[0014] FIG. 4 shows a side view of the igniter additionally configured with expanding enclosing bodies according to the present invention.
[0015] FIG. 5 shows a side view of the igniter being used to cook food according to the present invention.
[0016] FIG. 6 shows a side view of the igniter being used to keep warm according to the present invention.
[0017] FIG. 7 shows an elevational view of a generating chamber installed with a valve for adjusting airflow according to the present invention.
[0018] FIG. 8 shows an elevational view of the generating chamber installed with an auxiliary oil gas burner device according to the present invention.
[0019] FIG. 9 shows a side view of a manually operated fan device configured within the generating chamber according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to FIG. 2 , which shows an embodiment of an igniter 300 of the present invention, comprising a primary fire generating chamber 3 , on top of which is disposed an enclosing body 4 having a top end of any cross sectional shape and a lower end of narrower cross section, for instance, an inverse tapered enclosing body 4 . A grill 32 for holding solid fuel pieces 10 is disposed at a top end opening of the generating chamber 3 . A feed hole 31 is defined in a side of the generating chamber 3 , which provides for placing and removing tinder 30 .
[0021] In addition to a tapered shape, the enclosing body 4 can further assume a hemispherical shape that embraces a curved inner oblique line to form a cone-shaped enclosing body. In order to make the description simple, the following details only disclose the tapered enclosing body 4 .
[0022] A plurality of assisting air inlets 41 and air vents 42 are defined in a bottom and a top periphery portion of the Inverse tapered enclosing body 4 respectively.
[0023] Frame legs 5 are joined to a periphery of the igniter 300 by means of connecting brackets 52 , and braces 51 joined to the frame legs 5 provide outward bracing support.
[0024] The grill 32 disposed on the generating chamber 3 supports the loaded solid fuel pieces 10 , and heat energy generated by burning the tinder 30 in the generating chamber 3 is transmitted upwards towards the top end opening of the generating chamber 3 .
[0025] The upwardly expanding design of the inverse tapered enclosing body 4 enables the fuel pieces 10 to gradually increase in number as they are stacked from a lowest layer to a highest layer within the enclosing body 4 .
[0026] According to the basic concept of the present invention, the heat energy generated within the primary fire generating chamber 3 is first transmitted upwards towards a first layer of fuel pieces 10 B loaded at a bottom end opening of the inverse tapered enclosing body 4 , which are thus subjected to a heating effect, thereby causing the first layer of fuel pieces 10 B to reach a self-ignition state in advance of the other upper layers. The relatively large heat energy generated by the relatively smaller number of fuel pieces 10 B in the first layer is radially transmitted upwards, thereby igniting each layer of the fuel pieces 10 as the radiating heat progressively passes therethrough.
[0027] Regardless of the method used to stack the fuel pieces 10 , the lower fuel pieces 10 closest to a fire source of the generating chamber 3 are inevitably the first to reach a self-ignition state. In addition, prior to reaching ignition point, because the fire pieces 10 also have a heat blocking effect, thus, the lower layer fuel pieces 10 B stacked closest to the fire source reach a self-ignition state in advance of the upper layers of fuel pieces 10 .
[0028] The first layer of fire pieces 10 B serves as a fire source for secondary transformation according to the embodiment of the present invention. The primary fire generated in the generating chamber 3 first heats the closest first layer of fire pieces 10 B, which undergo self-ignition, thereby generating high secondary heat energy that propagates thermal waves. The next upper layer of fire pieces 10 then undergo secondary heating by the thermal waves, thereby enabling the upper fuel pieces 10 to achieve self-ignition.
[0029] Timing for the initial stage of self-ignition to occur is when a majority of the fire pieces 10 have red-hot ignition spots. The lower layer fire pieces 10 B will naturally form relatively larger ignition spots, and is the preferred time to achieve overall synchronous self-ignition, which enables obtaining complete heat energy. The timing for self-ignition can be brought forward or delayed according to user requirements.
[0030] Furthermore, a heat insulating layer 43 can be additionally disposed around an exterior of the inverse tapered enclosing body 4 , thereby providing a heat retaining function and a blocking heat from transmitting outwards.
[0031] Referring to FIG. 2A , in order to avoid the danger of being burnt by exterior heat from the igniter 300 , the present invention is further configured with a heat blocking and isolating protective shield 50 , which stands upright and surrounds the igniter 300 . The protective shield 50 is basically fabricated from a sheet body, and through holes 503 can be punched in a breadth of the sheet body to achieve an airflow circulation effect, reduce material weight or economize on material. The protective shield 50 is formed to assume a ring shape and joined to the igniter 300 with connecting members 501 , 502 . Any material having a heat blocking effect can be adopted as material for the protective shield 50 . Furthermore, the protective shield 50 can be also fabricated by weaving of strip-form material or wire-form material.
[0032] If position of a bottom end opening 500 of the protective shield 50 is lower than that of the base of the primary fire generating chamber 3 , then the bottom end opening 500 functions as a frame leg, thereby causing the primary fire generating chamber 3 to suspend, and preventing the generating chamber 3 from coming in contact with the ground.
[0033] Furthermore, a feed hole 504 is defined in the protective shield 50 at a position that enables fuel to be fed into the primary fire generating chamber 3 .
[0034] Referring to FIG. 3 , which shows a stacking method used to expand ignition effectiveness of the igniter 300 of the present invention, wherein a first expanding enclosing body 40 or a second expanding enclosing member 400 is stacked atop a top expanded opening 45 of the enclosing body 4 . Expanding form of the first expanding enclosing body 40 and the second expanding enclosing body 400 have the same tapered gradient as the enclosing body 4 of the igniter 300 . The upwardly expanding stacked enclosing bodies 40 , 400 are used to contain an additional quantity of the fire pieces 10 ready for ignition. Furthermore, any hardware component that enables fastening together or mutually inserting and assembly of the stacked enclosing bodies 40 , 400 can be affixed between the mutually stacked enclosing bodies 40 , 400 .
[0035] The heat insulating layer 43 can be similarly disposed around a periphery of the first or the second expanding enclosing body 40 , 400 , and auxiliary handles 44 affixed to each of the expanding enclosing bodies 40 , 400 facilitate stacking and unstacking of the expanding enclosing bodies 40 , 400 .
[0036] Referring to FIG. 4 , which shows the igniter 300 of the present invention, wherein the top expanded opening 45 of the inverse tapered enclosing body 4 is further strengthened with a mechanical structure, thereby enabling a pot 6 to be directly disposed on the igniter 300 . A lower exterior of the pot 6 sits on an inner edging of the expanded opening 45 , and waste heat produced after burning the solid fuel pieces 10 is outwardly discharged through the air vents 42 . Mechanical reinforcement of the expanded opening 45 thus provides for disposing the pot 6 thereon and cooking food, thereby realizing multifunctionality as a stove. Disposition relationship between the pot 6 and the expanded opening 45 can adopt any butt form mutual fitting or any hardware fastening component to assist in fixing placement of the pot 6 on the expanded opening 45 .
[0037] Referring to FIG. 5 , because the igniter 300 of the present invention is generally used outdoors, if the outdoor temperature is relatively cold, a protruding cover-form, grid-like far-infrared producing converter can be disposed atop the expanded opening 45 of the enclosing body 4 . A bottom end opening 70 of the cover-form far-infrared converter 7 is joined to the top expanded opening 45 of the enclosing body 4 , and a plurality of air holes 71 are defined in a surface of the far-infrared producing converter 7 . The heat generated after igniting the solid fuel 10 is first transmitted upward towards the far-infrared producing converter 7 , wherefrom radiation of far-infrared wavelength is emitted, which can be used to keep warm.
[0038] Referring to FIG. 6 , the feed hole 31 defined in the primary fire generating chamber 3 provides for feeding the tinder 30 , and area size of the feed hole 31 is sufficient for a hand to pass through, whereas an airflow passage is a through hole of larger area, which enables a large amount of air to flow from the generating chamber 3 through the grill 32 and up towards the inverse tapered enclosing body 4 . Slowing of burning rate is controlled by reducing supply of oxygen, which is realized by means of an adjusting valve that enables adjusting size of the airflow passage through relative positioning of the feed hole 31 . The adjusting valve can be a valve of any form, and an embodiment of the present invention discloses a valve 8 that envelops a breadth of the feed hole 31 , and, a valve opening 82 of similar shape is defined in the valve 8 to correspond to the feed hole 31 .
[0039] Furthermore, the valve 8 is rotated with a toggle arm 81 to open and close the valve opening 82 , thereby adjusting relative area size of the feed hole 31 , and extreme limits present a completely closed state or a completely open state. Hence, altering the amount of air entering the generating chamber 3 by using the toggle arm 81 to adjust the valve 8 enables regulating burning rate of the solid fuel 10 .
[0040] Referring to FIG. 7 , apart from using tinder to kindle the primary fire within the generating chamber 3 , the present invention can further adopt an oil gas burner as a heat source, wherein a burner head 91 is disposed within the generating chamber 3 . Oil gas passes through a pipe line 92 , and a valve 93 controls the amount entering the generating chamber 3 ; whereafter flames are produced by burning the oil gas at the burner head 91 .
[0041] Furthermore, the feed hole 31 in conjunction with functionality of the aforementioned valve 8 effectuates an open and close adjusting operation.
[0042] Referring to FIG. 8 , which shows the present invention with a manually operated fan device 101 further disposed at a lower end of the generating chamber 3 . The fan device 101 is driven by a shaft configuration through an amplifying gear set 102 , and the hand of a user operates a jointed arm 103 to actuate and amplify rotating speed of coaxially-arranged fan blades 104 , creating a fan effect that blows air A into the generating chamber 3 .
[0043] When the fan device 101 is used as a stove in an embodiment of the present invention, then the ring-shaped valve 8 can be closed to seal the feed hole 31 .
[0044] It is of course to be understood that the embodiments described herein are merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | A solid fuel igniter that provides for initial heating of solid fuel pieces to expedite reaching a self-ignition preparatory state. The igniter comprises a primary fire generating chamber, wherein heat energy is generated and transmitted upwards to an enclosing body having a top opening of wide cross section that tapers downwards to a lower end of narrower cross section. The enclosing body holds the solid fuel pieces packed therein, and a primary fire in the generating chamber heats a smaller number of the solid fuel pieces packed on the bottom of the enclosing body, which generate spontaneous and intense heat energy that propagates thermal waves uniformly upward, thereby enabling all of the solid fuel pieces to uniformly reach the self-ignition preparatory state. | 0 |
[0001] The present invention relates to 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride of formula (I):
[0002] in crystalline form. The invention also relates to the process for the isolation by crystallisation of the compound (I) and to its use for the preparation of pharmaceutical compositions for inhalation in combination with suitable carriers or vehicles.
BACKGROUND OF THE INVENTOIN
[0003] 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]2(1H)-quinolinone monohydrochloride is known from the European patent n. EP 0 147 719 as a bronchodilator provided with a potent beta-2-adrenoceptor stimulating action.
[0004] The compound, that has been also defined as 8-hydroxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphenyl)-1-methylethyl)amino]ethyl }carbostyril hydrochloride and referred to as TA 2005, has been further developed by the applicant under the experimental code CHF 4226.
PRIOR ART
[0005] The process for the preparation of TA 2005 is described in EP 0 147 719, example 4. In particular, the process for the isolation of the crude product is reported in step (3-a), wherein the insoluble materials obtained after the catalytic hydrogenation of 3.5 g of 8-benzyloxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphenyl)-1-methylethyl)amino]ethyl}carbostyril hydrochloride in tetrahydrofuran (100 ml) and water (10 ml) are collected by filtration and washed with an aqueous 10% ethanol solution. The filtrate and washings are combined, and the combined solution is concentrated under reduced pressure to remove solvent. The residue is crystallised with a mixture of ethanol, water and isopropyl ether, and crystalline precipitates are collected by filtration. 2.38 g of 8-hydroxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphenyl)-1-methylethyl)amino]ethyl}carbostyril hydrochloride are obtained as colorless crystals.
[0006] The yield was of 83% and the final product showed the following characteristics:
melting point: 170.0-171.5° C. (decomp.) [α] D 22 −64.40° (c=1.00, methanol) IRν max nujol (cm −1 ): 3300 (broad), 1640, 1610, 1600
OBJECT OF THE INVENTION
[0010] The invention relates to 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride in crystalline form having suitable characteristics for the preparation of pharmaceutical compositions for inhalation in combination with suitable carriers or vehicles.
[0011] The compound will be identified hereinafter for sake of brevity also with the code CHF 4226.
[0012] The compound of the invention is preferably administered by inhalation.
[0013] Formulations for inhalation wherein the active compound is in solid form include dry powder compositions to be delivered by a dry powder inhaler (DPI), aerosol compositions comprising a suspension of fine drug particles in a propellant gas to be delivered by a pressurized metered-dose inhaler (pMDI) and aerosol composition in form of aqueous suspensions to be delivered by a nebulizer.
[0014] The efficacy of this route of administration can be limited by the problem encountered in making appropriate and consistent dosages available to the lungs.
[0015] One of the most important features is to ensure uniform distribution of the active compound in the formulation, particularly when it is highly potent and has to be given in low doses.
[0016] Moreover, the solid compound in the composition should be as pure as possible and endowed with the required chemical and physical stability.
[0017] In addition, in the compositions for inhalation, the active compound at the solid state should be present in the form of finely divided particles of a controlled particle size which does not exceed approximately a mass median diameter (MMD) of 10 μm, preferably 6 μm, more preferably 5 μm, in order to achieve maximum penetration into the lungs.
[0018] Said particles are conventionally prepared by techniques such as micronization or grinding.
[0019] Such techniques can produce particles which have regions of partially amorphous structure and are liable to change their structure when kept in various environmental conditions and/or processed for the preparation of pharmaceutical compositions.
[0020] Therefore, the particles of the active compound should be provided with an adequate degree of crystallinity in order to be highly stable during the grinding or micronization process and sufficiently stable for the subsequent pharmaceutical use.
[0021] The aim of the present invention is thus to provide a stable crystalline 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride.
[0022] Another aim of the invention is to provide a process for the preparation of the compound with an adequate degree of crystallinity. The compound of the invention is chemically and physically stable and maintains the same degree of crystallinity, also after having undergone micronization or grinding processes.
[0023] In the prior art, in order to obtain 8-hydroxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphenyl)-1-methylethyl)amino]ethyl } carbostyril hydrochloride, after collecting the crude product and washing with an aqueous 10% ethanol solution, the filtrate and washings were combined and the combined solution was concentrated under reduced pressure to remove the solvent, the residue was crystallised with a mixture of ethanol, water and isopropyl ether, and crystalline precipitates were collected by filtration, but no teaching was given on how to perform the crystallisation process.
[0024] It has now been found that in said process of crystallisation, wherein the residue obtained after removing the solvent is dissolved by heating in an ethanol water mixture (95:5) and the solution is concentrated under reduced pressure to remove part of the solvent, the volume to which the solution is reduced is critical. It has indeed been found that the solution should be concentrated to a volume equal to or higher than ⅓ of its initial volume. Moreover the isopropyl ether has to be added to the concentrated solution slowly, in not less than 5 minutes and at a temperature higher than 30° C.
[0025] The above specified conditions allow to obtain an homogeneous solution wherein a uniform and regular crystalline growth takes place.
[0026] In fact it has been found that if the volume of the concentrate of the crude product is too small and in particular smaller than ⅓ of its initial volume and the addition of isopropyl ether is effected too fastly, for example in less than 5 minutes, the highly concentrated crude compound rapidly precipitates, thick unfilterable slurries are formed, the compound incorporates high levels of mother liquors consisting of solvents and impurities dissolved therein and it can be isolated very hardly. Moreover, when isolated and dried, it includes a significant amount of impurities.
[0027] Furthermore, a high percent amount of compound in amorphous state is present and, as highlighted before, particles of amorphous structure can cause a number of problems when included in inhalation formulations: in fact this kind of particles are extremely cohesive, tend to stick together and tend to absorb ambient moisture at their surfaces during the time.
[0028] So there is the need for a compound with an adequate degree of purity and an adequate degree of crystallinity.
[0029] The present invention provides CHF 4226 in a pure crystalline form and a process for preparation thereof.
[0030] In order to prepare the crystalline compound of the invention, crude 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride which has been obtained for example according to the method disclosed in EP 0 147 719 by crystallisation from a mixture of ethanol, water and isopropyl ether is recrystallised from a suitable solvent.
[0031] A suitable recrystallisation solvent is a protic solvent such as ethanol, isopropanol or their aqueous mixtures. The preferred solvent is an ethanol-water mixture.
[0032] The most suitable recrystallisation solvent is al ethanol-water mixture in a ratio from 97:3 to 95:5 v/v. Advantageously, after the dissolution of the crude compound in the above mentioned solvent and before the isolation of the final product, an intermediate step of distillation of the aqueous ethanolic solution under reduced pressure is carried out, to remove residual isopropyl ether from the mixture as well as to improve the yield.
[0033] Preferably the distillation process is continued until the solution is reduced to a volume comprised between ½ and ⅓ of the initial volume.
[0034] The recrystallisation process according to the invention allows an effective removal of the impurities up to levels equal to or lower than 0.5%, preferably 0.2%, even more preferably 0.1% in order to obtain the compound in a pure crystalline form provided with suitable characteristics to be used for the preparation of pharmaceutical compositions for inhalation in combination with suitable carriers or vehicles.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The method of EP 0 147 719, whose teaching is incorporated in full in the present application, involves the filtration and washing with aqueous ethanol of the suspension obtained after the catalytic hydrogenation of 8-benzyloxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphenyl)-1-methylethyl)amino]ethyl}carbostyril hydrochloride to remove the catalyst. The solution is concentrated under reduced pressure to remove the solvent. According to the present invention the residue obtained after removing the solvent is dissolved by heating in an ethanol water mixture in the preferred ratio of 95:5 and the solution so obtained is concentrated under reduced pressure, preferably comprised between 200 and 400 mbar, at a temperature comprised between 30° C. and 55° C., preferably at a temperature from 45 to 50° C., to a volume comprised between ½ and ⅓ of the initial volume. Then diisopropyl ether is slowly added to the warm solution under stirring. The addition of diisopropyl ether is performed in at least 5 minutes, preferably in more than 10 minutes and more preferably in an interval from 20 to 30 minutes.
[0036] The mixture is then cooled under stirring at a temperature between 0° C. and 10° C. for 1 to 2 hours and the solid is isolated and washed with ethanol.
[0037] The wet crude product is suspended in ethanol, heated under reflux at 75-78° C. and slowly added with water until a clear solution is obtained. The solution is filtered and the filter is washed with ethanol. The warm solution is concentrated, under stirring, under reduced pressure, at a temperature not lower than 40° C., preferably comprised between 40 and 50° C., more preferably comprised between 45 and 48° C., to a volume ranging from about ½ to about ⅓ of its starting volume. The product begins to crystallise from the solution giving rise to a suspension. The suspension is slowly cooled and kept at a temperature from about 0 to 10° C., preferably from about 0 to 5° C., for at least 1 hour and up to 20 hours or more, under stirring. The solid is recovered by filtration, washed with ethanol and finally dried in a conventional manner, for example by air drying, drying under reduced pressure, or drying in the presence of a sterile inert gas to give the crystalline compound.
[0038] The 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride obtainable using the method described above was investigated to determine: the melting point by Differential Scanning Calorimetry (DSC), the specific optical rotatory power [α] D 20 , the enantiomeric purity by capillary zone electrophoresis and by High Performance Liquid Chromatography (HPLC), the amount of total impurity by HPLC and the X-ray powder diffraction (XRD) pattern.
[0039] The 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride of the present invention is characterized by:
[0040] a melting range of 180°-200° C. (with decomposition), preferably of 185-195° C. (with decomposition), more preferably of 190-195° C. (with decomposition) determined by DSC at a scan rate of 10° C./min.;
[0041] a specific optical rotatory power [α] D 20 (c=1.00, methanol) of −68.0°;
[0042] an enantiomeric purity higher than 99.0%, preferably higher than 99.5%, determined by capillary zone electrophoresis and by HPLC;
[0043] impurity levels of less than 0.5%, preferably less than 0.2%, even more preferably less than 0.1%, determined by HPLC;
[0044] a X-ray powder diffraction pattern identical or substantially identical to that listed under the example below. Suitably the compound has inter alia one or more of the following characteristic XRD peaks: 12.2; 13.6; 16.3; 18.0; 18.2; 19.2; 21.4; 21.9; 22.8; 23.5; 24.2; 24.9; 26.6; 28.5; 29.4; 29.9; and 33.9±0.2 degrees/2 theta;
[0045] a crystalline degree, expressed as weight % of the crystalline compound with respect to the total weight of the compound, of at least 90%, preferably of at least 93%, even more preferably of at least 95%, determined according to a microcalorimetric method developed in-house.
[0046] The following example illustrates the present invention.
EXAMPLE
Crystallisation of 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride (CHF 4226 monohydrochloride)
[0047] In order to prepare a crystalline CHF 4226 according to the present invention, the residue which has been obtained, for example, after the catalytic hydrogenation of 8-benzyloxy-5-{(1R)-1-hydroxy-2-[N-((1R)-2-(p-methoxyphhenyl)-1-methylethyl) amino]ethyl}carbostyril hydrochloride (100 g) as described in the step 3-a of Example 4 of EP 0 147 719 was dissolved in about 1300 ml of ethanol and 100 ml of water and concentrated in a rotary evaporator (Tbath=55° C.; vacuum=−0.8 bar) until the residual volume was about 600 ml. Isopropyl ether (560 ml) was dropped in the warm solution (T=45-50° C.) in 30 min. The mixture was cooled at 5-10° C. and stirred for 60 minutes until the crystallization process is completed, then it was filtered in a Buckner filter washing the solid with 200 ml of ethanol.
[0048] The wet crude 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxy phenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride (154.6 g; corresponding to 73 g if dried at 60° C. under vacuum) was suspended in ethanol (580 ml) and the suspension was heated at 78° C. under reflux; 25 ml of water were slowly dropped in, until a clear solution was obtained. The hot solution was filtered in a Buckner filter, washing with 150 ml of ethanol. The filtered solution was concentrated under vacuum (Tbath=55-65° C.; vacuum=250-300 mbar; Tsolution=45-48° C.), distilling about 360 ml of solvent. Vacuum was disconnected and 390 ml of ethanol were added to the residual suspension, stirring at 45° C. until an homogeneous suspension was obtained. The suspension was cooled at a temperature lower than 5° C. in 90 min., then it was kept at 5° C. for 20 hours. The suspension was filtered in a Buckner filter, washing with 150 ml of ethanol. The solid was then dried under vacuum at 60° C. for 24 hours. 58.4 g of 8-hydroxy-5-[(1R)-1-hydroxy-2-[[(1R)-2-(4-methoxyphenyl)-1-methylethyl]amino]ethyl]-2(1H)-quinolinone monohydrochloride were obtained (80.0% yield), having the following characteristics:
melting range 190-194° C. (decomposition), determined by DSC at a scan rate of 10° C./min.; specific optical rotatory power [α] D 20 (c=1.00, methanol)=−68.0°;
[0051] enantiomeric purity higher than 99.5%, determined by capillary zone electrophoresis;
[0052] total impurities: less than 0.10%;
[0053] the X-ray powder diffraction (XRD) pattern is shown in FIG. 1 and is represented by the following major peaks:
Angle [°/2 θ] Rel. Int. [%] 12.3 21.0 13.6 54.2 16.4 64.9 18.0 37.5 18.4 44.5 19.3 50.1 21.4 55.8 21.9 100.0 22.9 35.6 23.6 36.9 24.3 88.4 25.0 21.4 26.7 32.5 28.6 22.6 29.5 30.5 29.9 14.8 34.0 20.4
[0054] The crystalline degree of the compound has been determined according to a differential scanning calorimetry (DSC) method developed in-house based on the measurement of the heat of fusion.
[0055] Said method uses a scan rate of 130° C./min to evaluate the percentage of crystalline compound in a sample by determining the ratio between the ΔH (heat of fusion) of the sample with respect to the ΔH of a 100% crystalline reference standard, determined in the same range of temperature and in the same experimental conditions. The 100% crystalline reference standard was prepared by suspending the compound in ethanol, then filtering to eliminate the residual amorphous compound dissolved in ethanol, and drying.
[0056] The method was applied to samples of the compound of the Example as such, and after grinding or micronization. All the samples showed a cristallinity degree higher than 90% which was maintained also after subjecting the compound to processes of grinding and micronization. | The invention relates to 8-hydroxy-5-[(1R)-1-hydroxy-2[[(1R)-2-(4-methoxyphenyl)-1-methyl ethyl]amino]ethyl]-2 (1 H)-quinolinone monohydrochloride of formula (I) in crystalline form, provided with suitable characteristics in order to be used for the preparation of pharmaceutical compositions for inhalation in combination with suitable carriers or vehicles and the process for its preparation. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention deals with restraint of a child seated in a grocery shopping cart in a manner which will prevent injury.
[0003] 2. Descriptions of Related Art
[0004] Current seat belts for children in shopping carts are secured only at the extremities adjacent to the peripheral boundaries of the cart. A child is thereby enabled to slide laterally providing room for the child to slip from the belt and stand up. This can result in the cart tipping and consequent injuries to the child.
[0005] There are a number of warnings related to the safety of children riding in shopping cart seats. As examples, the American Academy of Pediatrics in an August 2006 committee report noted how common shopping cart injuries resulting from carts tipping are. The report also noted how often this resulted in serious head and neck injuries. The U.S. Consumer Product Safety Commission has noted the number of shopping cart injuries to children and is launching a safety program to reduce such injuries. The American Academy of Pediatrics in a recent report even recommended that parents consider alternatives to placing children in shopping carts to reduce the potential for injury.
[0006] It would be desirable if a seat belt could be configured to make it more difficult for a child to escape from a seat belt and to prevent a belted child from standing up.
SUMMARY OF THE INVENTION
[0007] The present invention provides a seat belt which is attached to vertical bars at the back of a shopping cart seat and arranged to closely encircle the waist of a seated child. Seat belt length adjustments permit a close encirclement of the child's waist to substantially eliminate the possibility of the child escaping from the seat belt. The seat belt is restrained to move only a predetermined distance upward with respect to the cart to reduce the distance a child can raise himself when restrained by the seat belt. Such a combination greatly minimizes the possibility of a child either being able to escape the belt restraint and stand up and tip the cart over, or being able to rise up sufficiently without escaping the belt, to tip the cart over.
[0008] The apparatus includes a first embodiment which employs a seat belt formed from two seat belt straps, each having a length adjustment. A first connector is provided to enable connecting one end of the two seat belt straps together. The first connector is used to attach the seat belt around a child seated in a cart seat, and the seat belt length adjustment permits tightening the belt to effect a secure attachment around the child.
[0009] The end of the seat belt straps opposite the first connector are attached near the opposite ends of an attachment strap. A second connector is arranged to connect the opposite ends of the attachment strap together. The attachment strap is sized to fit around spaced apart rods forming the rear of a child's cart seat to secure the attachment strap in place. This also secures the seat belt in place.
[0010] One end of a position strap is attached perpendicular to the attachment strap between the seat belt attachment points. The opposite end of the position strap is formed into a loop sized to fit around the outside of the second connector.
[0011] The position strap is extended from the attachment strap over the top of the cart seat, and the end loop is placed around the female end of the second connector before the second connector is closed. With the position strap loop around the second connector before it is closed, closing the connector will both connect the attachment strap around the vertical rear seat rods and also secure the position strap over and around the horizontal top of the cart seat. With this arrangement the position strap limits both the vertical translation of the seat belt and a belted child with respect to the cart seat.
[0012] Such an apparatus, which can be connected and disconnected easily and rapidly, comprises a first embodiment of the apparatus that can be used at multiple locations.
[0013] A second embodiment obtains the same results with a similar apparatus connected together in a similar way as the first embodiment. However, with the second embodiment, the seat belt straps are connected to the attachment strap by means of a pair of grommets which extends through a planar display. The planar display is sized to overlie the area at the rear of the cart seat. The apparatus is arranged to locate the display immediately in front of and aligned with the rear area of the cart seat.
[0014] In this embodiment, a ring connector attaches two loops at the ends of the attachment strap and a loop at the end of the position strap. This arrangement also attaches the apparatus to the rear of the cart seat and limits the vertical translation of the seat belt with respect to the cart.
[0015] Since the second embodiment is more difficult to connect to a cart because of use of the ring connector, and the inclusion of a display suitable for advertising, this apparatus is more likely to be used by a store because of the permanent attachment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The objects and features of the present invention will become more manifest to those skilled in the art upon a reading of the following descriptions, taken in connection with the accompanying drawings and wherein:
[0017] FIG. 1 is a side view of a cart with a child seated in the cart seat and secured by the first embodiment of the apparatus;
[0018] FIG. 2 is an end portion of FIG. 1 ;
[0019] FIG. 3 is a perspective view of apparatus 1 ;
[0020] FIG. 4 is a perspective view of the back portion of a cart seat with apparatus 1 attached;
[0021] FIG. 5 is a perspective view of apparatus 2 ; and
[0022] FIG. 6 is a perspective view of the back portion of a cart seat with apparatus 2 attached.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A first embodiment of the apparatus is shown in FIGS. 1-4 . Apparatus 1 has a seat belt 10 , formed by two equal length seat belt straps 10 A, an attachment strap 12 and a vertical position strap 14 . Attachment strap 12 attaches seat belt 10 to the back of cart seat 16 A of cart 16 . Position strap 14 positions the vertical location of seat belt 10 with respect to cart seat 16 A and limits the vertical translation of the seat belt with respect to the seat. Connector 10 B is preferably a conventional rapid release connector with a male part having a pair of flexible extensions each having an outer directed projection arranged to engage opposed outer openings in a mating receptacle in a female part. The male and female parts of connector 10 B are connected by extending a pair of opposed flexible extensions each having a centered outward projection from the male part into mating receptacles in the female part until the two outer directed projections oppose two mating outer openings in the female receptacle where they can spring outward and lock the two parts together. The male and female parts of connector 10 B are separated by pressing both male extensions inward together until the centered outer projections clear the mating openings in the female part which permits the parts to be separated. While this is the preferred connector for this apparatus, any other connector that provides rapid connection and disconnection of the parts will suffice.
[0024] Seat belt straps 10 A each have one end attached to connector 10 B. Slide adjusters 10 C are provided for each strap 10 A to permit changing the length of seat belt 10 to fit each child.
[0025] The ends of seat belt straps 10 A opposite connector 10 B are attached equal distances from opposite ends of attachment strap 12 . The ends of attachment strap 12 are connected together by connector 12 A which has a male part 10 A 1 and a female part 12 A 2 and is the same type of connector as connector 10 B. However, any other connector which can connect and disconnect the straps readily will suffice.
[0026] Position strap 14 has one end attached perpendicularly to attachment strap 12 between the connection points of seat belt straps 10 A. Straps 14 and 10 A are attached together in the same plane by being sewed together. Position strap 14 has a loop 14 A formed in the end opposite attachment strap 12 which is sized to fit around the outside of female part 12 A 2 of connector 12 to secure the position strap to the attachment strap. This is accomplished by placing apparatus 1 as shown in FIG. 2 with the ends of attachment straps 12 extending between vertical seat rods 16 B with position strap 14 extending upward. Position strap 14 is extended over and around horizontal seat top 16 C. Loop 14 A is positioned around female connector 12 A 2 and male connector 12 A 1 inserted to complete connecting the attachment strap 12 to cart 16 and position strap 14 around horizontal seat top 16 C.
[0027] With apparatus 1 connected to cart 12 in this manner, a child 18 can be placed on cart seat 16 A and seat belt 10 attached around the child 18 by connecting the two parts of connector 10 B together. Size adjustment is then made using slide adjustors 10 C to fit seat belt 10 snugly around the child. A snug fit will prevent the child from escaping the seat belt 10 . In addition, position strap 14 will result in seat belt 10 being secured above the waistline. In this location, strap 10 will prevent the child from standing because of the engagement of the strap with the horizontal seat top 16 C. This will eliminate the danger of the child standing and tipping the cart.
[0028] Apparatus 2 , shown in FIGS. 4 and 5 , are second embodiments of apparatus used to safely restrain a child seated in a grocery cart. As described earlier, apparatus 2 uses a number of the same elements and arrangements of the first embodiment. Apparatus 2 has a seat belt 20 , formed by two seat belt straps 20 A, an attachment strap 22 and a position strap 24 . In addition, apparatus 2 has a planar display sheet 21 with a pair of grommets 21 A extending through the sheet. Display sheet 21 can be formed from a plurality of sheets including a transparent outer sheet, an adjacent advertising sheet, and a support sheet. Rivets 21 B around the periphery connect the various sheets of display sheet 21 together.
[0029] Straps 20 A each have one end connected to connector 20 B. Slide adjusters 20 C are provided for each strap 20 A to permit changing their length to fit each child. The ends of seat belt straps 20 A opposite connector 20 B are each attached equally offset from the ends of attachment strap 22 through grommets 21 A of sheet 21 to attachment strap 22 . Seat belt straps 20 A are attached to attachment strap 22 in the same plane by sewing them together. The ends of attachment strap 22 each terminate in an end loop 22 A.
[0030] Position strap 24 has one end attached perpendicularly to attachment strap 22 between the attachment points of seat belt straps 20 A. Position strap 24 and attachment strap 22 are again attached together in the same plane by sewing them together. Position strap 24 has a loop 24 A formed in the end opposite attachment strap 22 .
[0031] End loops 22 A of attachment strap 22 and end loop 24 A of position strap 24 are all connected together by ring connector 22 B with apparatus 2 position with respect to cart seat 26 A as shown in FIG. 6 . This arrangement locates display sheet 21 adjacent to the back of cart seat 26 A with position strap 24 around horizontal seat top 26 C and attachment strap 22 around vertical seat rods 26 B. In this position sheet 21 is displayed without interfering with any of the safety features of the apparatus. Attaching both end loops 22 A and end loop 24 A together completes the connection of apparatus 2 to cart seat 26 A. The adjustments to fit a particular child and the resulting restrictions to the movement of the child with respect to the cart seat are the same for embodiment 2 as for embodiment 1.
[0032] The above are just two examples of the modifications and changes that are possible and would occur to one skilled in the art, therefore it is contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention as defined in the appended claims.
[0033] It will be understood that this disclosure, in many respects, is only illustrative. Changes may be made in details, particularly in matters of shape, size, material, and arrangement of parts without exceeding the scope of the invention. Accordingly, the scope of the invention is as defined in the language of the appended claims. | Apparatus for securing a child safely in a cart seat. A seat belt has a connected attachment belt which is used to attach the apparatus to the rear bars of a cart seat. A position strap, which is attached to the attachment belt, extends around the top of the cart seat to restrict the vertical displacement of the seat belt and belted child with respect to the seat cart. A second embodiment provides a planar display located at the rear of the cart seat as part of the apparatus. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of my prior copending appliction Ser. No. 300,246, filed Oct. 24, 1972 now abandoned.
SUMMARY
The present invention relates to an improved composition of matter suitable for in vivo implantation as a wear surface and to the method of preparing such composition of material.
An object of the present invention is to provide an improved composition of material suitable for in vivo implantation which exhibits high resistance to wear.
Another object is to provide an improved wear material which has low friction and is highly resistant to wear.
A further object is to provide an improved wear material which when subjected to frictional movement has minimum galling and releasing of particles responsive thereto.
Still another object is to provide an improved method of preparing a wear material of fibers and resin so that the fibers are generally aligned with the wear surface.
A still further object is to provide an improved composition of material for in vivo implantation which may be sterilized by the usual sterilization procedures and apparatus, such as a steam autoclave, without being adversely affected thereby.
Still another object is to provide an improved composition of material for in vivo implantation which in addition to the above desired features of having low friction and substantial resistance to wear is white in color.
These and other objects and advantages of the present invention are hereinafter set forth and explained.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A wear material suitable for in vivo implantation is adapted to be sterilized in a steam autoclave, does not include anything which would be toxic or cause a body reaction and has a surface exhibiting low friction and high resistance to wear.
One preferred form of wear material of the present invention includes carbon fibers and a resin such as polytetrafluorethylene which are prepared in a manner to position the carbon fibers in generally parallel relationship to the surface of the wear material.
This wear material which has been found suitable for implantation as hereinbefore described has a composition of more than 15 percent by volume to 65 percent by volume carbon fibers and particles and less than 85 percent by volume to 35 percent by volume of polytetrafluorethylene resins such as is marketed by Du Pont as their TFE resin.
A preferred composition of material for implantation is 40 percent by volume fibrous carbon or graphite and 60 percent by volume of the TFE fluorocarbon polymer. A composition which has exhibited excellent wear properties and low friction is one containing 30 percent by volume fibrous carbon or graphite, 10 percent by volume particulate carbon or graphite and 60 percent by volume TFE polymer. Generally it is preferred that the ratio of total fibrous and particulate carbon to fibrous carbon be from 1 to 1 to 5 to 1.
A specific preferred composition providing 40% by volume carbon fiber filler includes graphite fiber sold by Carborundum Company under the name GY 2F, 12.0 grams; Du Pont Teflon, TFE-6 Resin, 2.76 grams; and Du Pont Teflon, TFE-7 Resin, 24.8 grams. Another useful composition providing 40% by volume fluorinated carbon fiber includes fluorinated graphite fiber prepared by Marchem Company, Houston, Texas, 19.6 grams, Du Pont Teflon TFE-6 Resin, 2.76 grams, and Du Pont Teflon, TFE-7 Resin, 24.8 grams. Another useful composition includes graphite fiber sold by Carborundum Company under the name GY 2F, 10.8 grams, particulate carbon sold by Biocarbon, Tarzana, California (technically described as vitreous carbon frit), 3.6 grams, Du Pont Teflon, TFE-6 Resin, 2.8 grams, Du Pont Teflon, TFE-7 Resin, 25 grams. This Composition provides 30% by volume carbon fiber filler and 10% by volume particulate carbon filler.
The wear composition is prepared by mixing the resin and carbon or graphite with a suitable solvent such as isoparaffinic hydrocarbon in a high speed, high shear mixer. The amount of solvent is adjusted to the size of the mixer. For example, in a mixer of 500 milliliters, 375 milliliters of solvent is used for dry ingredients weighing approximately 50 grams. Mixing is carried out until a complete uniform slurry is produced.
The mixed slurry is filtered. The filtration is preferred to be by vacuum filter such a Buechner funnel, and should proceed until the residual solvent left in the filter cake is less than approximately 20 percent by weight.
Following filtration, the filter cake is placed between the platens of a heated press and is compressed at levels of from 500 to 3,000 psi and at a temperature between 100° F. and 250° F. for periods from 1 to 5 minutes. The conditions are adjusted so that the solvent level after compression is less than 15 percent by weight. Optionally, the compressed filter cake may be dried in an oven to remove all solvent at temperatures between 150° F. and 500° F. and for times up to several hours.
Next, the compressed filter cake is run through the nip of heated rolls which are heated to a temperature between 100° F. to 250° F. This temperature is adjusted to the particular volatility of the solvent. The thickness of the cake is reduced in decrements of approximately 20/1000ths of an inch to a thickness between 20/1000ths and 60/1000ths of an inch.
When the desired thickness is reached, the temperature of the rolls is elevated to between 280° F. and 360° F. and the thickness of the material during each subsequent pass is reduced to one-half of its thickness. To maintain the desired thickness, the sheet of material is doubled after each pass and then is run through the next pass at 90° to the previous pass. This procedure may be carried out from four to eight times depending on the apparent toughness of the product at a given stage of rolling. It may be desirable to roll down to one-half original thickness in steps of 5/1000ths or 10/1000ths of an inch.
It should be noted that the sheet material produced by the preceding rolling step can be formed into particular shapes if desired by compression molding, vacuum drawing, and other shaping operations at relatively low pressures and the shaped material can then be compression sintered in an appropriate mold to retain such shape.
When the rolling is completed, the material is sintered at a temperature from 610° F. to 680° F. for periods from 30 minutes to several hours depending on the thickness of the stock. It should be noted that if the product contains residual solvent which is slow to evaporate, extended periods of drying at temperatures from 300° F. to 500° F. may be used prior to sintering to assure removal of the solvent. When fluorinated particulated filler are used, it is recommended that the solvent be removed before rolling since difficulty may be encountered with blistering of the sheet stock during sintering if the solvent is not removed. In certain materials which are difficult to dry it may be desirable to vacuum dry the filter cake before rolling to avoid the blistering problem.
If desired, the sintering step may be a pressure sintering step in which the material is placed between the platens of a heated press at a temperature in the range from 640° F. to 740° F., preferably 700° F. at a pressure in the range from 50 p.s.i. to 5,000 p.s.i., preferably 2,000 p.s.i. and for a period of time from 1 to 30 minutes, preferably 5 minutes. The material is moved directly from the press and rapidly cooled by forced air connection or immersion in a room temperature water bath. This pressure sintering may be used in place of or in addition to the above described sintering step. This technique may also be used to prepare multi-ply laminates from unsintered stock.
The preferred forms of such wear material include the fibrous carbon. This material has improved wear properties and low friction. It is believed that the reason for such improved properties results from the orientation of the carbon fibers to a position generally parallel to the wear surface. In such position, the carbon fibers would not have a tendency to break off and thereby create an extreme wear problem and further since the carbon fibers have a low coefficient of friction, the exposure of the carbon fibers on the wear surface would not cause a drastic increase in friction as might be expected with other materials.
The improved wear material may use for its matrix any perfluorinated high polymer such as polytetrafluoroethylene (Teflon TFE), a polyhexafluoropropylene or a co-polymer of hexafluoropropylene and tetrafluoroethylene which is commercially available from Du Pont under the name Teflon FEP resin or mixtures of such polymers.
Also if desired, the reinforcing additive may be carbon fibers, perfluorocarbon fibers, fluorinated carbon fibers, fluorinated carbon particles or a combination of two or more of the foregoing types of carbon fibers. The use of the fluorinated carbon fibers is advantageous since the fluorination reduces the critical surface tension of the fibers to the order of 20 dynes per centimeter thereby more closely matching the critical surface tension of the matrix polymer. This matching provides substantially greater adhesion between the matrix polymer and the reinforcing additive. The fluorinated carbon fibers are also believed to be advantageous as the fluorination changes the surface of the carbon fibers to further reduce the friction in the wear material.
In such matching of surface tension of the reinforcing additive or filler and the matrix polymer. They may both be selected to have the same critical surface tension or either may be processed to match the other. For example, polytetrafluorocarbon fibers and particles may be used with a perfluorocarbon matrix. Examples of such processing of the latter type of material would be fibers and particles of carbon, hydrocarbon or other organic material (such as polyimide) which have been treated to have a surface fluorination. The process of fluorinating the surface of carbon materials is known and is disclosed in the J. L. Margrave et al. U.S. Pat. No. 3,674,432, issued July 4, 1972 and in the article "Method Harnesses Direct Fluorination" appearing in the Jan. 12, 1970 edition of Chemical & Engineering.
It has been found that a suitable material may be provided by a composition of a filler element such as a fluorinated carbon or a fluorinated hydrocarbon or a fluorinated organic material (such as fluorinated polyimide) in either particulate or fibrous form and a sintered perfluorinated high polymer resin retaining said filler element in the structure.
Another preferred composition of wear material may be produced utilizing a high molecular weight polyethylene (HMWPE) in certain formulations. For example, very suitable materials were produced from the following recipes:
(a) 20% (Vol.) carbon fiber
20% (Vol.) Teflon TFE fiber
20% (Vol.) Teflon TFE-6 resin, and
40% (Vol.) HMWPE
(b) 20% (Vol.) carbon fiber,
15% (Vol.) Teflon TFE fiber,
15% (Vol.) Teflon TFE-6 resin, and
50% (Vol.) HMWPE
These formulations are banded at a temperature in the range of 100° F. to 150° F. (preferably 120° F.) are rolled at a temperature in the range of 230° F. to 300° F. (preferably 270° F.) and are sintered at a temperature in the range of 500° F. to 540° F., a pressure in the range of 500 to 2500 psi and for a period from 1 to 4 minutes.
Still another formulation which provides a white, tough material having low friction and low wear is a combination of 50% to 85% (Vol.) HMWPE and equal parts of Teflon TFE fiber and Teflon TFE-6 resin. This composition is rolled at a temperature in the range from 200° F. to 300° F. and is sintered at a temperature in the range from 350° F. to 440° F., at a pressure between 200 and 1,000 psi and for periods up to 2 minutes.
It has been unexpectedly found that with such high percentages of the HMWPE the absence of the Teflon TFE resin appears to prevent adequate cohesion of the structure during rolling. It is postulated that the resin provides internal lubrication which allows the proper cohesion of the composition during the rolling process. The addition of at least 0.5 percent (Vol.) of this resin appears to be adequate for the desired cohesion.
As used herein "high molecular weight polyethylene" shall means polyethylene having a molecular weight greater than about one million such as the Hercules Corporation product sold under the trademark "Hi Fax 1900".
The method of producing these additional compositions of wear material of the present invention are substantially as hereinabove described except that formulation and temperature ranges are modified as previously mentioned with respect to each of said formulations to adjust for the particular properties of each component and to produce the preferred composition of material with each formulation.
The wear material of the present invention has a particular application for in vivo implantation when bio-compatible materials are used but may have other applications not limited to biocompatible materials.
From the foregoing it can be seen that the improved wear material results from a combination of a filler element such as carbon fibers or polytetrafluoroethylene fibers in a matrix of a perfluorinated high polymer resin alone or in combination with a high molecular weight polyethylene resin with the orientation of the fibers being controlled by the method of preparing the material so that they are generally parallel to the material surface which orientation decreases friction and increases wear resistance of the material. | A composition of material suitable for in vivo implantation to provide a wear surface which composition includes carbon fibers, perfluorocarbon fibers, fluorinated carbon fibers, fluorinated carbon particles, fluorinated hydrocarbon fibers, fluorinated hydrocarbon particles, polytetrafluoroethylene fibers or combinations thereof and polytetrafluoroethylene resins alone or with a high molecular weight polyethylene all of which composition is processed to align a substantial portion of the fibers with the wear surface. The preferred method of preparing such composition of material includes the steps of mixing, filtering, compressing, rolling, sintering and drying. | 8 |
The present application is a continuation-in-part of application Ser. No. 08/759,888, filed Dec. 3, 1996, now U.S. Pat. No. 5,837,168 which is considered as being part of the disclosure of the present application and is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to devices for generating foam for use in fire fighting and specifically to a foam generator which provides for automatic balancing of pressure differentials between incoming pressurized water and pressurized air.
Foam generators utilizing pressurized water and pressurized air in combination with a surfactant are useful in fire fighting. There are certain well known means of mixing air, water, and a surfactant to generate foam, including mixing chambers, venturis, and nozzles.
U.S. Pat. No. 4,981,178 issued to Bundy on Jan. 1, 1991 discloses an apparatus for generating fire-fighting foam using a mixing chamber.
U.S. Pat. No. 4,505,431 issued to Huffman on Mar. 19, 1985 for "Apparatus for Discharging Three Commingled Fluids" and U.S. Pat. No. 4,474,680 issued to Kroll on Oct. 2, 1984 for "Foam Generating Apparatus and Method" disclose venturi-type foam generators.
It has been very difficult in the past to produce a simple device for generating foam from the mixing of pressurized air and pressurized water. (The foam also requires the presence of a soap or surfactant which is introduced into the water prior to the foam generator.) Pressure balancing between incoming pressurized air and incoming pressurized water requires elaborate measures to control both the air volume and pressure and the water volume and pressure. It has generally been necessary to use very complicated devices to balance the volumes and pressures or to require the operator to manually adjust the volumes and pressures on a continuous basis during operation to maintain a balance. Thus a skilled operator is typically required to operate such systems.
If a balanced pressure is not maintained, the quality of the foam being generated can be affected. Various types of foam may be desirable for particular applications. In some situations a dry foam is desirable; in other situations, a wetter foam is desirable. Too much water or too much air can result in a foam that is not efficient for the intended purpose. For example, in some situations, the most desirable type of foam contains sufficient moisture to aid in smothering a fire while it is sufficiently dry to cling to surfaces. If a balanced pressure and volume of water and air is not maintained, the result can be a foam that is either too wet or too dry or that has other deficiencies with respect to the desired quality. The volume of water in relation to the volume of air determines the consistency of the generated foam, so the control of both pressure and volume is necessary to assure the desired foam quality.
The prior art emphasizes the importance of maintaining balanced pressures between the water and air supplies. Bundy, at column 3, beginning at line 12, discusses the problem of achieving the proper combination of air pressure and volume with water pressure and volume to achieve the desired quality of foam. Bundy also discusses the desirability of maintaining equal pressure in the air and water supplies.
The prior art has addressed the problem of balancing the air and water supply pressure in a foam generator by various expedients as mentioned above. Even with the fairly complex and expensive means employed, the operation of a foam generating apparatus for fire fighting requires the services of an experienced operator and even then much experimentation is necessary. For example, even the simple act of changing a hose attached to the apparatus often requires difficult and time consuming rebalancing of the system.
It has been suggested that a high degree of turbulence may contribute to the quality of foam produced in that a finer foam structure is obtained. Foam comprised of large bubbles is less useful for typical fire-fighting applications. It may therefore be desirable to both balance the pressures of the incoming water and air and do so in a way that maximizes turbulence.
Prior foam generating systems lack a means to automatically cut off the flow of water and air into the system's hose when the hose nozzle is turned off. This may create an unsafe condition if system air and water pressures are not precisely balanced. If the system water pressure exceeds the system air pressure, closing the nozzle may cause a "slug" of water to build inside the hose. When the operator again opens the nozzle and expects a relatively low-density foam to emerge, the slug of water that squirts forth may cause the operator to lose control of the hose. Conversely, if the system air pressure exceeds the system water pressure, a pocket of air may build in the hose when the nozzle is closed. Subsequent opening of the nozzle may send forth a burst of oxygen onto a flame thereby aiding the spread of a fire rather than extinguishing it. Either a slug of water or burst of air may thus result in serious injury to the hose operator or bystanders. Given the difficulty in prior art foam generating systems of maintaining a precise balance between system air and water pressure, it has been difficult to prevent these unsafe conditions.
The problems and limitations of the prior art are overcome by the present invention as summarized below.
SUMMARY OF THE INVENTION
The present invention is an apparatus for generating foam for use in fire fighting. The invention utilizes a unique mixing chamber designed to automatically balance the dynamic pressure of incoming air and water streams and thereby produce high-quality foam even if the incoming static air and water pressure vary significantly. This allows the foam generator to work in a wide variety of situations and environments, even with makeshift compressor and pump equipment, without the necessity of complicated calibration steps. Such versatility is highly desirable for firefighting, especially in rural areas where specialized equipment may be unavailable.
In the present invention, pressurized water (including a surfactant) and pressurized air are introduced in such a way as to automatically achieve the desired balance between water and air pressures, and also produce a highly turbulent environment which conduces to the formation of a high quality foam. The apparatus includes an automatic regulator that stops the flow of air and water when the nozzle is turned off, thereby preventing the safety hazard created if the hose were to fill with unmixed water or air. This automatic regulator also prevents the backpressure in the hose from exceeding either the incoming air or water pressure.
The water and air pressures in a foam generator derive from three components: a static or head pressure, which is the input pressure from the water pump and air compressor of the system; a dynamic pressure within the mixing chamber, which is determined by the flow rate of water and air input into the chamber; and a residual pressure or backpressure from the hose. Prior art foam generators have attempted to balance the static water and air pressure. In conventional systems, this balance is necessary since if either pressure exceeds the other, it will prevent the formation of high-quality foam. Thus conventional foam generators are only effective for firefighting purposes if the input air and water are at precisely the same pressure.
The present invention, by contrast, focuses on dynamic pressure as a means to both balance the water and air pressure within the mixing chamber and to achieve a highly turbulent environment conducive to excellent foam quality. In the present invention, water is introduced into a restricted area in the mixing chamber with an ever-widening area for expansion as it travels farther toward the air source. The water pressure falls as the water travels through the widening area approaching the air inlets, such that a point is eventually reached where the water pressure falls to equal the air pressure it encounters. If either the static air or water pressure is changed, the equalization point may move further or closer to the air or water inlets, but will still lie somewhere between the two inlets so that mixing will occur. Thus equalization of dynamic pressures takes place automatically due to the design of the mixing chamber. As long as the static pressures are maintained within a certain range, the system will automatically readjust and still deliver excellent-quality foam since an equalization pressure will still be reached. The energy lost as the water and air lose energy is converted into turbulence that serves to thoroughly mix the water and air and thereby produce high-quality foam.
In order to achieve this rapid conversion of the dynamic pressures of the incoming water and air into turbulent energy, the incoming water and air streams should be directed onto a surface which stops or splatters the streams, or against another stream. In addition to balancing the water and air pressures, the "splattering" effect also produces the highly desirable turbulent environment and separates the incoming water into fine droplets to speed mixing with the incoming air.
In the preferred embodiment of the invention, the heart of the foam generator is two plates housed in a chamber where pressurized air and water are introduced into the restricted area between the two plates. The pressurized water is introduced through an opening in one plate. The pressurized air is introduced into the restricted area through a number of channels bored through the other plate. The air channels may appear in an annular grove, placed on the surface of the plate, that circumscribes the water inlet. While introducing the pressurized air into an annular groove is not necessary to the practice of the present invention, it does serve to improve mixing of the water and air by producing still more turbulence upon exit of the water and air from between the two plates.
In the preferred embodiment, the two plates are provided with flat surfaces, and when in operation, are in close proximity to each other. The narrow restricted area between the plates provides part of the mechanism that helps to equalize the pressure between the incoming water and the incoming air. Preferably the two plates are placed in such proximity that the turbulence effect created by the plate walls is significantly enhanced.
The water/surfactant solution and the air will intermingle in this restricted area in a highly turbulent fashion, and upon exiting the restricted area will produce a foam. The consistency of the foam can be adjusted by the operator by adjusting the incoming water pressure or volume, the incoming air pressure or volume, or by moving the plates relative to one another.
In some embodiments the air inlets may be set at an angle, such that the air inlets are turned somewhat toward the water inlet. It is believed that forcing the pressurized air between the plates at this angle, which preferably is about a 45°, creates even greater turbulence when the air and water meet, thus improving the quality of the resulting foam.
It is therefore an object of the present invention to provide for a self-balancing, foam-generating mechanism using pressurized water and pressurized air.
A further object of the present invention is to provide for a foam-generating mechanism using pressurized water and pressurized air which is simple and economical to construct and easy to operate.
An additional object of the present invention is to provide for a foam-generating mechanism using pressurized water and pressurized air which produces varying qualities and quantities of foam and accepts varying lengths and types of hoses without requiring complicated and delicate rebalancing of air and water pressures.
A further object of the present invention is to provide for a foam-generating mechanism using pressurized water and pressurized air that may be used with a wide assortment of different compressors and water pump mechanisms and may be operated by less skilled persons.
A still further object of the present invention is to provide for highly turbulent mixing of the pressurized water and air to produce an exceptionally high-quality foam.
Yet another object of the present invention is to provide a foam-generating mechanism with a regulator that automatically cuts off the flow of pressurized air and water into the system when the nozzle is closed, thus preventing the dangerous situation of a slug of water or burst of air emerging from the hose when the nozzle is reopened.
Further objects and advantages of the present invention will be apparent from a consideration of the following detailed description of the preferred embodiments in conjunction with the appended drawings as briefly described following.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exterior perspective view of a chamber containing the foam generating plates and having incoming lines for pressurized water and air and an exit for foam generated in the chamber.
FIG. 2 is a sectional elevation view of the chamber of FIG. 1 showing the pressurized water plate and the pressurized air plate located to the top and bottom respectively of the chamber with the foam generating area therebetween.
FIG. 3 is a sectional plan view of the chamber showing the pressurized air plate and the annular groove thereon.
FIG. 4 is a schematic diagram showing the components of a complete foam generating system employing the present invention.
FIG. 5 is a perspective view of a second embodiment of the present invention for use in high pressure situations in which the plates are carried on respective plugs which are held to the chamber by bolts.
FIG. 6 is a sectional view of the embodiment of FIG. 5.
FIG. 7 is a sectional plan view of a third embodiment of the present invention with an adjustable distance between the plates and a foam exit tube that is perpendicular to the air and water inlets.
FIG. 8 is a sectional plan view of a fourth embodiment of the present invention having a fixed distance between the plates and a water inlet and foam outlet that are in line with one another.
FIG. 9 is a schematic diagram showing a preferred embodiment of the regulator and automatic cut-off system of the present invention.
FIG. 10 is a schematic diagram of a detail section from FIG. 9 showing the operation of the pressure regulator cylinder and automatic cut-off microswitch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention may be described with reference to FIGS. 1 and 2. A chamber 10 is provided which accepts an incoming pressurized water line 20 and pressurized air line 313. Foam generated in the chamber 10 exits through the outlet 40.
The heart of the present invention is found in the provision for two plates 50, 60 where the incoming water and air are introduced to each other. The shape of the chamber 10 in which the foam is generated is not critical to the invention, although the chamber 10 should allow space around the plates 50, 60 for the generated foam to exit. Furthermore, it is desirable to avoid shaping the chamber 10 such that a spiraling action is induced in the foam. Such action can separate foam into its primary constituents by centrifugal force.
The pressurized water plate 50 is simply a circular disc 51 with a bore 52 through the center for the introduction of pressurized water to a restricted area 70 between the plates 50, 60. The bore 52 may be reduced by an orifice for better control of the pressure and for adjustment of the volume of the incoming water. As will be discussed hereinafter, the pressurized water contains an admixture of surfactant which is introduced to the pressurized water prior to the chamber 10 by various means well known in the art.
As shown in FIGS. 2 and 3, the pressurized air plate 60 is likewise a circular disc 61 having a restricted area-facing surface 62 on which an annular groove 63 is disposed on the surface 62 and may be located at various radial distances from the periphery of the surface 62. In some embodiments, it may be desirable to place surface roughening features such as ripples or grooves between the annular groove 63 and the periphery of the surface 62 in order to enhance turbulence and mixing. The annular groove 63 is fed pressurized air from a plurality of radial passages 64 communicating with an inlet bore 65. The inlet bore 65 in turn communicates with the incoming pressurized air line 30. Alternatively, the radial passages 64 may be replaced by a plenum receiving pressurized air and communicating with the annular groove 63 by simple openings. When a plenum is employed it may be desirable to have the pressurized air enter the plenum at right angles to the openings communicating with the annular groove 63 in order to ensure an even pressure among the openings and therefore at all points on the annular groove 63.
FIG. 4 is an overall schematic of a complete system incorporating the present invention showing an air compressor 80 connected by air line 81 leading to the air inlet 30 of the chamber 10, and a water pump 82 connected to water reservoir 84 and to water line 83 leading to the water inlet 20 of the chamber 10. Not shown are valves in the air line 81 and the water line 83 for setting the volume and pressure of the incoming water and air. Also shown in the schematic is a soap reservoir 85 and dispenser 86 into the water inlet line 83.
FIGS. 5 and 6 show a second preferred embodiment of the present invention. There are three primary pieces to the preferred embodiment of the foam generator of the present invention. The assembled foam generator is shown in perspective in FIG. 5. First, there is a housing 90, which is preferably constructed of stainless steel. The housing is a T-shaped hollow chamber having an water inlet section 91 and air inlet section 92 across the top of the "T" and a foam outlet section 93 at the base of the "T". The foam outlet section 93 at the base of the T-shaped chamber is reduced to a pipe which is the nozzle opening 94 or connection point for a hose. While the prior art normally uses the hose as part of the foam generating apparatus, the present invention requires only a minimal length of hose. Foam is generated in the housing 90 and available in close proximity to the nozzle opening 94.
Fitting into the housing 90 are two plugs 95, 96, preferably of plastic, which fit in respective open ends 97, 98 of the water inlet section 91 and air inlet section 92, respectively, at the top of the T of the housing 90. These two plugs 95, 96 incorporate the plates 100, 101, which introduce pressurized water and air into the restricted area 104 between the two plates 100, 101.
A section of the embodiment of FIG. 5 showing the two plates 100, 101 is given in FIG. 6. Each plug 100, 101 is provided with a flange 102, 103, respectively, which fits against the respective open ends 97, 98, and serve to fix the plugs into position so as to form a restricted area 104 of the requisite width. Each plug 95, 96 is reduced to a middle section 105, 106 sized to fit tightly in either open end 97, 98. Each plug is further reduced to an inner section 107, 108. When the two plugs 95, 96 are assembled into the housing 90, the restricted area 102 between the two plugs 95, 96 is set at the desired distance.
Plate 100 introduces pressurized water into the restricted area 102 through a bore 112 which is connected to the inlet water supply by an integral water inlet connection 113. Likewise, plate 101 introduces pressurized air into the restricted area 102 through an annular groove 114 fed by radial passages 115 from an inlet bore 116 provided with an integral air inlet connection 117. The generation of foam is otherwise identical to that described above for the embodiment of FIGS. 1-4.
A device sized to deliver foam to a 11/2 inch hose from a 100 psi water supply and 100 psi air supply would have inlets 91, 92 about 3 inches in diameter. The foam outlet section 93 at the base of the T-shaped chamber is reduced to a pipe approximately the diameter of the hose. In this sized embodiment, the outermost part of each flange 102, 103 is about 6 inches in diameter. Each plug 95, 96 is reduced to a 3 inch diameter middle section 105, 106 to fit tightly in either open end 97, 98. Each plug is further reduced to an inner section 107, 108 of about 2 inches in diameter. In this embodiment, when the two plugs 95, 96 are assembled into the housing 90, the restricted area 102 between the two plugs 95, 96 is preferably about 3/16 inch.
As shown in FIGS. 5 and 6, the two plugs 95, 96 are held to the housing 90 by four bolts 110 through holes in the flanges 102, 103. Although not critical, it is desirable that a space 111 be left around the plates 100, 101 and the restricted area 102 to allow the free exit of foam generated between the plates 100, 101.
A third preferred embodiment of the present invention is shown in FIG. 7. This embodiment uses a chamber of generally cylindrical shape, with a water inlet 120 directed into the center of one end of the chamber. Air inlet 122 passes through this same end of the chamber, allowing pressurized air to pass into the chamber and then through air orifices 132 in first plate 133. Air orifices 132 are angled toward the center of the chamber and thus toward the direction that water will travel when it enters through water inlet 120 and strikes second plate 131. Second plate 131 includes an adjustment feature 130, which may be in the form of a threaded bolt that extends through the opposite end of the chamber. Adjustment feature 130 allows the operator to vary the width of the restricted area between first plate 133 and second plate 131 which will affect the type of foam that is produced. In this way the operator may create whichever type of foam is necessary for a given application, such as when a dryer foam is needed to adhere to vertical surfaces, or a wetter foam is needed for spraying foam long distances against a wind. The foam exits the chamber at foam outlet 124.
A fourth preferred embodiment of the present invention is illustrated in FIG. 8. Like the embodiment of FIG. 7, this embodiment uses a chamber of generally cylindrical shape, with a water inlet 134 directed into the center of one end of the chamber. Air inlet 136 allows pressurized air to pass into the chamber and then through air orifices 144 in first plate 145. Air orifices 144 are angled as in the embodiment of FIG. 7. In this embodiment, second plate 143 is fixed in position relative to first plate 145 by bolts. The foam exits the chamber through foam outlet 138, which extends from the opposite end of the chamber through which water inlet 134 passes.
The system by which air and water pressure is regulated in the preferred embodiment of the foam generator apparatus is illustrated in FIGS. 9 and 10. Water is drawn from water reservoir 194 and pressurized by water pump 146. A surfactant from soap reservoir 148 is added to the pressurized water by soap dispenser 150. The mixture is pumped through water manifold 152, then through water check valve 154 which prevents backflow of water or air through the system. Flow sensor 156 feeds flow information to flow indicator 192, which may be used by the operator to adjust the system to reach a desired volume of water per unit time. The water then flows through water valve 158 (the function of which will be described below) and into mixing chamber 160.
Turning now to the pressurized air side of the system, compressor 196 forces pressurized air through air manifold 162 and through air valve 164 (the function of which will be described below), then through flow control valve 166 and air flow meter 168. Based on the reading on air flow meter 168, the operator may adjust flow control valve 166 to reach a desired air flow volume per unit time. Air then flows through air check valve 170, which prevents the backflow of air or water through the system, and into mixing chamber 160. Foam created in mixing chamber 160 travels through hose 172 and out through nozzle 174.
Pressure regulator 182 (shown in detail in FIG. 10) is used to cut off the flow of air and water automatically when nozzle 174 is closed, thereby preventing the buildup of either a slug of water or burst of air in hose 172. When nozzle 174 is closed, backpressure builds in the hose and back through the chamber, which quickly exceeds the system static air pressure. This backpressure forces diaphragm 200 in pressure regulator 182 upward. The arm extending vertically from diaphragm 200 thus presses against contact arm 198 of microswitch 180, causing contact arm 198 to bridge the two electrical contacts of microswitch 180 and close the electrical circuit formed thereby. Closing this circuit activates electric solenoid 186, which ill turn actuates shut-off control valve 188, which simultaneously closes both water valve 158 and air valve 164. This prevents the flow of either water or air to mixing chamber 160, thus preventing the buildup of a slug of water or burst of air in hose 172 when nozzle 174 is closed.
Once nozzle 174 is opened again, the system backpressure will fall, thereby allowing diaphragm 200 to fall and opening the electrical circuit previously closed by contact arm 198 of microswitch 180. Spring return 190 will then simultaneously open water valve 158 and air valve 164. This will allow water and air to again enter chamber 160 and thus the system will begin generating foam again automatically.
Alternatively, the pressure regulator could use a controller (not shown) in communication with microswitch 180 that activates microswitch 180 when the system backpressure rises above a threshold value. Once microswitch 180 is activated, water valve 158 and air valve 164 will simultaneously close. When the system backpressure falls below the threshold value, the controller deactivates microswitch 180 thereby allowing spring return 190 to simultaneously open water valve 158 and air valve 164. The controller can be preset to a certain threshold pressure value, or can include means (such as a dial or keypad) to enter the threshold pressure desired by the operator.
In operation of the preferred embodiments described herein, the incoming static water pressure is generally set to a level in excess of the incoming static air pressure. The difference is not critical. The pressure at the periphery of the plates is determined by the outlet back pressure due to the chamber size, the hose, nozzle, and any orifice or restriction in the outlet side of the system. The pressure at the center of the plates is determined by the inlet water pressure, and the pressure available at the annular grooves is determined by the inlet air pressure. The back pressure at the periphery of the plates is at some level higher than atmospheric, but lower than either the pressure at the water inlet or the air inlet. Air is of course compressible, while water is not. It is believed therefore that due to the lower air pressure and the compressibility of the air, a balanced pressure between the air and water is reached at some radial point between the air inlet at the annular groove and the water inlet at the central bore. This radial equilibrium point will shift radially between the air and water inlets depending on the incoming volume and pressure of water, thus automatically balancing the two. As the back pressure changes, the pressure at the balance point will change proportionally. The balancing of the dynamic water pressure and air pressure is therefore automatic without the need for intervention by the user. This mechanism is believed to explain the operation of the present invention but the invention is not limited thereto. Additional adjustment of the mechanism to enhance the quality and quantity of the foam is possible through adjustment of the size of the restricted area between the two plates.
Furthermore, it is desirable that the proximity of the plates be such as to induce a high degree of turbulence into the mixing. This is accomplished by putting the two plates in close proximity. Thus a large proportion of the mixing takes place between the plates and the hose is not as necessary to act as a turbulent mixing chamber. This frees the operator from any problems involved in rebalancing the system when hoses or lengths of hoses are changed. Furthermore, since the hose is not occupied by unrestricted air, the hose may be operated at peak capacity resulting in maximum flow and increased trajectory for the foam exiting from the nozzle of the hose. Better mixing before the hose also allows better foam quality with finer structure when such is desirable. In those embodiments of the present invention utilizing plates that are movable relative to one another so as to vary the size of the restricted area between them, the water pressure within the mixing chamber may also be regulated by movement of the plates.
The present invention also has the advantage that it allows more flexibility in the use of pumps and compressors. As an example, one large pump might supply several foam lines independently of each other. Oversize pumps and compressors may be utilized without alteration. The present invention allows the air pressure to fluctuate which enables the compressor to cycle without adverse effect on the foam.
Although the preferred embodiment has been described with respect to a version of the present invention in which two plates are used and each plate introduces only water or air to the restricted area between for mixing, an alternative embodiment may employ two plates in which one plate serves as the impingement: surface and the other plate contains passages for introducing both pressurized air and a pressurized solution of water and surfactant. This arrangement utilizes the same principles for operation, but may have advantages allowing a compact design.
The present invention has been described with reference to certain preferred and alternative embodiments which are considered exemplary only and not limiting to the full scope of the invention as set forth in the appended claims. | Apparatus for generating foam for use in fire fighting having two plates housed in a chamber which respectively introduce pressurized air and a water/surfactant solution between the two plates where foam is generated and emitted from an aperture on the side of the chamber. The pressurized water/soap solution enters the chamber through an orifice in one plate. Pressurized air enters the chamber through a number of channels bored through the other plate, such channels appearing in an annular grove which circumscribes the water inlet. The plates are provided with surfaces which are brought together to form a restricted area therebetween. The restricted area balances the pressure between the incoming water and the incoming air by achieving an equilibrium at some particular radius out from the center of the two plates. This equilibrium radius moves in and out from the center as necessary to keep the two pressures balanced. The apparatus also includes a pressure regulating system that automatically cuts off the flow of pressurized water and air when the foam dispensing nozzle is turned off. | 8 |
FIELD OF THE INVENTION
This invention relates to a light fixture, and more particularly to a light fixture adapted for use in vehicles, including land recreational vehicles and boats.
BACKGROUND OF THE INVENTION
Light fixtures of the kind particularly adapted for use in vehicles, including land recreational vehicles and boats, have long been known. Popular prior fixtures are typically mounted on an interior wall or ceiling of, for example, a boat cabin or travel trailer or motor home and are wired to the battery supply of the vehicle (typically 12 volts DC power) for actuation by a slider switch on the exposed base of the fixture. Typically, such a prior fixture has a light transmitting lens mounted forwardly on the base to leave exposed to view a substantial portion of the base perimeter wall. Such lens may be removably fixed on the base in various ways, one way being to provide the lens with a laterally outward extending perimeter flange that slips under a lip on the base. In one prior dual lamp fixture, two separate lenses are provided, one to cover each lamp. In one such prior dual lamp fixture, five separate major pieces are needed to define a common base, the two lenses and means connecting the lenses to the base. In prior single and twin lamp fixtures of this general kind, the outward appearance is of a multi-piece, sharp-edged assembly defined by one or two blocklike masses. In general, prior lamps of this kind have been relatively expensive to make and, in view of the substantial number of parts, required a relatively large and costly manufacturing and maintenance inventory.
Accordingly, the object and purposes of the present invention include provision of a light fixture, particularly adapted for use in vehicles, including land recreational vehicles and boats, and which is capable of overcoming various disadvantages of prior fixtures of the general type discussed above.
Further objects and purposes of the invention will be apparent to persons acquainted with apparatuses of this general type upon reading the present specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a dual lamp light fixture embodying the invention.
FIG. 2 is a view similar to FIG. 1 but enlarged and with a portion of the lens broken away to show a portion of the front of the base and means connecting the lens and base.
FIG. 3 is a view substantially taken on the line 3--3 of FIG. 2.
FIG. 3A is an enlarged fragment of FIG. 3.
FIG. 3B is a schematic circuit diagram of the apparatus of FIGS. 1-3.
FIG. 4 is a sectional view substantially taken on the line 4--4 of FIG. 2 and with the lamp socket removed.
FIG. 5 is an enlarged fragment of FIG. 3.
FIG. 6 is an enlarged fragment of FIG. 3.
FIG. 6A is a view similar to FIG. 6 but with the base removed and showing merely a mounting means of the lens.
FIG. 6B is a fragmentary sectional view substantially taken on the line 6B-6B of FIG. 6.
FIG. 7 is a view similar to FIG. 2 but showing a modification, namely a single, rather than double, lamp light fixture.
FIG. 8 is a fragmentary sectional view substantially taken on the line 8-8 of FIG. 7.
FIG. 9 is an enlarged fragment of FIG. 8.
FIG. 10 is an enlarged rear view of the puck of FIG. 3A.
According to the invention, a light fixture, particularly adapted for use in vehicles, including land recreational vehicles and boats, comprises a base fixable on a mounting surface of a vehicle and means for mounting a lamp to shine forward from the base. A light transmitting lens is mountable in front of the base and for covering a lamp mounted on the base.
DETAILED DESCRIPTION
A light fixture 10 (FIGS. 1-3), embodying the invention, includes a generally rectangular base 11, the front face 13 of which is covered by a removable lens 12.
The base 11 here comprises an outer sidewall 14 at the perimeter thereof and extending rearward from the front face 13 and having a rear edge 17 to engage a mounting surface 15 (FIG. 3), typically, the front surface of a wall or ceiling panel 16 of a vehicle, for example, of a land recreational vehicle, such as a travel trailer or motor home or of a boat cabin. Thus, when so installed, the rear edge 17 of the base sidewall 14 engages the front mounting surface 15 of the panel 16, preferably in a substantially continuous manner around the periphery of the base 11. The base 11 is releasably fixed to the panel 16 by any convenient means, here screws 20. In the FIG. 2 embodiment, four such screws 20 are spaced along the perimeter portion of the base front face 13. In the embodiment shown, the screws 20 are flathead screws and are received in countersunk holes 21 (FIG. 2) in the front face 13 of the base 11 adjacent the sidewall 14. In the embodiment shown, one such screw and screw hole are substantially centered along each side of the base 11.
The base 11 is laterally elongate. The base 11 has two forward opening recesses 20 formed by depressions in the front face 13 and in which respective lamps 22 are to be located. The lamps 22 may be conventional, here for example 12 volt lamps of the kind typically used in vehicle interior lighting.
The recesses 23 act as reflective wells for their respective lamps 22. The recesses 23 are separated by a central longitudinally extending ridge 24 which extends across the central width of the front face of the base 11. As seen in FIG. 4, the central portion of the ridge 24 extends forward somewhat beyond the plane of the forward edge 25 of the sidewalls 14. Centered atop the ridge 24 (FIGS. 2 and 3) is a conventional push button switch 26.
In one unit embodying the invention, the switch 26 was a Model 987 Flat-Pac made by Judco located at Harbor City, Calif.
The switch 26 is fixed to the front face 27 of the ridge 24 by any conventional means not shown. An actuating push button 28 (FIG. 3A) protrudes forward from the front face of the switch 26 and is spring biased forward. A rearward displacement of the push button 28 changes the state of the switch 26, which state is held until the next push.
The sides 31 of the ridge 24 converge slightly as they extend forward to give the ridge 24 a forward tapering cross-section as seen in FIG. 3A. Fixed, by any conventional means not shown, to the opposite sides 31 of the ridge 24 are conventional lamp sockets 32 which fixedly but removably receive respective ones of the lamps 22 in a conventional manner. The sockets 32 extend perpendicularly from respective sides 31 of the ridge 24 and thus, in view of the taper of the ridge in cross-section, the sockets 32 and lamps 22 angle somewhat forwardly as they extend into the respective recesses 23 of the base 11. Further, as seen in FIG. 2, each ridge side 31 has a portion 33 which angles acutely from the remainder of the corresponding ridge side 31 and thus angles at less than 90° to the length axis LA of the base. The sockets 32 are mounted on respective ones of these angled portions 33 of the ridge sides 31 as seen in FIG. 2. Further as seen in FIG. 2, the angled side portion 33 of the left recess 23 angles up and leftward whereas the angled sidewall portion 33 of the right recess 23 angles down and rightward. The presence of the angled portions 33 of the ridge sides 31 effectively makes the shape of each recess, as seen from the front in FIG. 2, five-sided. More of interest, the sockets 32 are mounted on the respective angled ridge side portions 33. Thus, the left socket 32L is spaced somewhat above the base longitudinal axis LA whereas the right socket 32R is spaced somewhat therebelow. In consequence, the sockets 32, as seen from the front in FIG. 2, extend from the ridge side portions 33 toward the base longitudinal axis LA, here in a manner to place the filament center FC of the corresponding lamp 22 substantially on the base longitudinal axis LA. Each recess 23 in the base 11 is shaped to reflect forward the light from its corresponding lamp 22 in a relatively even manner, over the forward facing area of the corresponding recess 23.
As seen schematically in FIG. 3A, insulated wires 34, 35 and 36 extend rearward from the switch 26 through a suitable hole 37 centered in the front face 27 of the ridge 24. Insulated wires 40R and 41R extend from the rightward socket 32R (FIG. 3A). Similarly, insulated wires 40L and 41L extend from the left lamp socket 32L (see FIGS. 2 and 3B). The wire pair 40R, 41R and the wire pair 40L, 41L each extend from their respective socket 32R and 32L through a respective hole (as at 38 in FIG. 4) in the corresponding ridge side portion 33R and 33L into the rear facing recess 42 defined within the ridge 24.
The interior structure of the switch 26 may be of a variety of types. FIG. 3B simply shows schematically one possible circuit arrangement of switch 26, lamps 22R and 22L and a battery B. The battery B may, for example, be the vehicle's storage battery and located remote from the light fixture 10. Elongate insulated wires 80 and 81 here connect respective switch contacts 43' and 43" to the opposite terminals of the battery B. In FIG. 3B, the switch 26 is shown to have a pair of ganged movable contacts 43' and 43" respectively alternatively engageable with fixed contact set R', S', T' and R", S", T" which are connected as shown to the switch wires 34, 35 and 36, in turn connected as shown to the lamp wires 40R, 41R, 40L and 41L. The switch 26 particularly shown in FIG. 3B thus has a first position represented by engagement of fixed contacts R' and R" in which no lamp is lit, a second position represented by engagement of fixed contacts S' and S" in which one lamp 22R is lit and a third position represented by contact with fixed contacts T' and T" in which both lamps 22R and 22L are lit. Mechanisms by which successive actuations of the push button 28 can result in staging of movable switch contacts 43' and 43" to the above mentioned R, S and T contact sets, or their equivalent, are conventionally known and need not be further discussed here.
The switch 26 and lamp sockets 32 are fixed to their corresponding surfaces of the ridge 24 by any conventional means not shown.
The lens 12 (FIGS. 1, 3 and 4) is Convexly shaped and of laterally dimension exceeding the lateral dimension of the base 11, such that the lens 12 has a peripheral portion 50 extending laterally beyond and laterally surrounding the base. The convexly shaped lens 12 thus covers the base and is disposed in front thereof, the lens 12 here curving rearward as it extends laterally outward past the sidewall 14 of the base 11. The peripheral edge 51 of the lens is thus spaced laterally outboard from the base sidewall 14. The peripheral edge 51 is located almost as far to the rear as the rear edge 17 of the base, so as to lie very close to the front of a panel 16 on which the base is fixed. In this way, the lens hides the base from view, no matter what the location of the viewer in front of the panel 16 on which the light fixture 10 is mounted.
The lens 12 is, in the preferred embodiment shown, removably fixed to the base 11 by snap fit connection which requires no tools for installation of the lens on the base or removal of the lens from the base. More particularly, the snap fit connection is provided at several places spaced along the perimeter of the base. In the embodiment shown, such locations are each approximately centrally located on each of the four sides of the base 11.
In the preferred snap fit connection shown in FIGS. 6 and 6B, the sidewall 14 of the base, at approximately mid-height, is provided with a substantially rectangular hole 60 (FIG. 6). The hole 60 is of substantially greater extent in the forward-rearward direction than in the lateral or perimetral direction (see for example FIG. 3A). The portion of the snap fit connection on the lens 12 (FIGS. 6, 6A and 6B) comprises a fin 61 fixed to the lens peripheral portion 51 at its back face, as by integrally molding the fin 61 with the lens 12. The fin is substantially perpendicular to the adjacent lens peripheral portion 50 and extends laterally therefrom to its inner edge 62 which is adapted to extend rearward closely along the base sidewall 14 at the hole 60 therein.
The fin has a tab 63 (here integral) extending from its inner edge 62 laterally into the hole 60 in the base sidewall 14. The tab has a sloped rear edge 64 for sliding rearward along the sidewall 14 of the base and into the hole 60 therein. The peripheral portion 50 of the lens 12 is sufficiently flexible as to deflect outward to allow the tab 63 to slide over the forward facing corner 65 of the base and along the base sidewall 14 rearwardly toward the hole 60, to allow the tab 63 to reach and drop into such base hole 60. The tab 63 has a front edge 66 which extends substantially parallel to the axis of the hole 60, and to the plane of the lens peripheral edge 51. The tab front edge 66 thus interferes in a steplike manner with the front end of the base hole 60 to block unintended forward escape of such tab 63 from such hole 6 and thereby lock the lens 12 on the base 11.
Thus, the particular light fixture shown in FIGS. 1-6 is provided with four such holes 60 circumferentially distributed on the sidewall 14 on the base 11 and four corresponding fins 61 with tabs 63 similarly peripherally distributed on the laterally inner or rear face of the lens 12 for fixedly but removably securing the lens on the front of the base 11. To install the lens 12 on the base 11, one merely pushes the lens 12 rearward toward the base 11 in a substantially centered manner, whereby the sloped rear edges 64 of the tabs 63 skid rearwardly along the outside of the base sidewalls 14 and snap into the holes 60 therein. Removal of the lens from the base is accomplished by springing laterally outward (to the right in FIG. 6) the peripheral portion 50 of the lens 12 adjacent each finger 61, so as to draw the corresponding tabs 63 out of their respective holes 60, whereby the lens 12 can then be moved forward off the base 11.
The tabs 63 and holes 60 (FIG. 6) are so located with respect to each other that the lens 12 lies very close to the front facing corner edge 65 of the base 11, so that light from the lamps 22 will be effectively blocked from scattering laterally outwardly past such corner edge 65. Accordingly, light from the lamps 22 tends to be transmitted forwardly through the central portion 70 of the lens 12. This tends to substantially eliminate irregular splashes of light laterally beyond the sides 14 of the base 11 and particularly beyond the peripheral edge 51 of the lens 12.
A central, generally square-shaped depression 71 in the lens 12 is concave forwardly and convex rearwardly (FIGS. 1 and 3A) and is located directly in front of the switch 26. The rear wall 72 of the depression 71 has a centrally located rearwardly protruding projection 73, here of substantially semicircular cross-section (FIG. 3A). The projection 73 is centered on and snugly abuts the front end of the push button 28 of the switch 26. The central portion 70 of the lens 12 is sufficiently flexible that light rearward finger pressure of the user on the lens at the depression 71 will cause the projection 73 to depress the switch push button 28 sufficient to change the state of the switch and thereby of the FIG. 3B circuit to advance the lighting sequence of the lamps 22R and 22L through another step in their sequence. Manual release of the rearward pressure on the depression 72 allows the projection 73 and central portion 70 of the lens to return to their forward rest position shown in solid line in FIG. 3A. Upon release of the manual rearward pressure on the depression 72, the switch push button 28 returns to its normal rest forward position shown in solid lines in FIG. 3A and the state of the circuit 3B remains stable until the next manual depression of the central lens depression 72.
A puck 74 of generally square plan (FIGS. 1 and 10) is of size and shape to fit snugly in the lens depression 72 substantially flush with, or slightly forwardly protruding with respect to, the front face of the lens 12. The puck 74 is preferably fixed in the lens depression 72 by any suitable adhesive. The front of the puck has a central shallow finger dent 75 which positively prevents sidewise skating of the user's finger used to rearwardly depress the lens central portion and depression 72. The finger dent 75 and outline of the puck 74 serve as visual targets for the finger of the user intended to actuate the switch 26. Whereas the sides of the puck 74 and of the depression 71 in the lens front face are substantially perpendicular to the plane of the front face of the central portion of the lens, one side 76 of the puck 74 and the corresponding side of the depression 72 are slightly sloped to assure that the puck 74 will fit easily into and lie flat in the lens depression 72. The puck 74 is preferably of a nontransparent plastic material and thus also serves to hide the switch 26 from the view of an observer located in front of the lens 12.
OPERATION
The light fixture 10 can be installed as follows. With the lens 12 removed from the base 11, the rear edge 17 of the base is applied against the front face of a panel (in, for example, a land recreational vehicle or boat) and the screws 20 are inserted in their holes 21 in the base and threaded into the material of the vehicle panel 16. This rigidly fixes the base 11 to the front of the panel 16 in the manner shown in FIG. 3. The wires 80 and 81 (FIGS. 3 and 3B) are led rearwardly from the fixture 10 through a hole 82 in the panel 16 to a suitable electrical power source, for example, a battery B, which may be a vehicle 12 volt battery. This completes the electrical connections shown in FIG. 3B.
Bulbs 22L and 22R are conventionally installed in the sockets 32L and 32R, respectively. Thereafter, the lens 12 can be snapped into place in front of the base 11 in the manner above described, namely by sliding the tabs 63 rearward along the corresponding sidewalls 14 of the base 11 until such tabs snap into the corresponding holes 60 in the sides 14 of the base 11. With the lens 12 so fixed on the base 11, the projection 73 on the rear side of the central portion of the lens 12 bears on the push button 28 (FIG. 3A) of the switch 26 but does not activate same. Installation of the lamp is thus complete.
To switch the lamp between its all-lamps-off, one-lamp-on, two-lamps-on sequence of states, the user simply displaces rearwardly the puck 74, in turn depressing the switch push button 28 sufficient to change the state of the switch 26 and thus advance the switch 26 another step in the sequence.
To remove the lens 12, so as to replace a bulb 22 or the like, the user simply pulls forwardly and laterally outward on the rear peripheral edge 51 of the lens adjacent each fin 61. This springs the outer peripheral portion of the lens laterally outward and pulls the corresponding tabs 63 out of their respective holes 60 and thereby allows the lens to travel forwardly away from the base 11. The lens can be removed from and replaced on the base repeatedly over time, to the extent needed to replace bulbs 22 or the like.
The base 11 can be inexpensively and easily formed as a one-piece sheet metal stamping and painted a pale, light reflecting color, e.g. white, at least on the front face 13 thereof. In one embodiment, the base was of 0.020 inch stamped steel with a side 14 height of about 3/4 inch and overall dimensions of about 103/4 inches length and 43/4 inches width. In one device constructed according to the invention, the lens was of 0.030 inch thick clear plastic, for example a tenite CAB (cellulose acetate butyrate) material, produced by injection molding. The puck, in one device constructed according to the invention, was of a rigid opaque plastic and about 0.13 inch thick by about 3/4 inch on a side.
MODIFICATION
FIGS. 7, 8 and 9 disclose a modified light fixture 10A which is similar to the light fixture 10 above described, except as follows.
The modified fixture 10A is a single lamp fixture, rather than a double lamp fixture as above disclosed in FIGS. 1-7. The fixture 10A thus has a base 11A with only a single recess 23A, socket 32A and lamp 22A. Instead of a central ridge 24 as in FIGS. 1-7, the modified base 11A has a widened side platform 90 (at the right side thereof in FIGS. 7 and 8) which extends less far forward than the remaining sides 14A. It is this side platform 90 on which mounts the push button switch 26A behind the rearward lens depression 71A. The depression 71A and the puck 74A fitted therein are thus located where the lens 12A begins to curve rearward toward its overhanging upward portion 50A.
Installation and operation of the single lamp fixture 10A are similar to those above described with respect to the dual lamp fixture 10 of FIGS. 1-6 and thus need no further description.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A light fixture, particularly adapted for use in vehicles, including land recreational vehicles and boats, comprises a base fixable on a mounting surface of a vehicle and including provision for mounting a lamp to shine forward from the base. A light transmitting lens mounts in front of the base for covering a lamp mounted on the base. The lens is convexly shaped and laterally overhangs the base with a peripheral portion adapted to lie close to the mounting surface at a height less than the height of the base. The lens has a central portion extending from the peripheral portion and overlapping the base for transmitting light from a lamp on the base. A lamp actuating switch is located on the base under the lens and upon depression of the lens by the user changes the state of the switch and the condition of illumination of the light fixture. | 5 |
FIELD OF THE INVENTION
The invention pertains to the field of cleaning heavily soiled surfaces in the food processing industry. More particularly, the invention pertains to a method for the periodic cleaning of heavily soiled food processing equipment either on site or after dissembling the soiled equipment.
BACKGROUND OF THE INVENTION
In food processing industries where grease, protein, starch, etc. build up into layers of varying thickness and soil the surfaces of equipment, processes must be periodically shut down for equipment cleaning. Various formulations and methods have been used in an attempt to resolve this problem. Conventional formulations have included various surfactants with alkaline cleaning agents containing chlorine. Due to the presence of chlorine in the alkaline agent, the longer molecular structures of the protein, starch and grease components are cleaved into shorter molecular structures which are then capable of being emulsified by surfactants and flushed away.
One problem associated with such formulations is that the chlorine content of the cleaning solutions creates a negative environmental impact. Furthermore, chlorine accelerates the corrosion of metallic components, as well as the degradation of various rubber gaskets and seals. It is therefore desirable to formulate solutions for cleaning heavily soiled surfaces in the food processing industry which avoid the problems caused by using conventional chlorine-based formulations.
Various attempts have been made to achieve the desired result of cleaning these heavily soiled surfaces while not compounding environmental pollution. For example, U.S. Pat. No. 5,567,444 discloses the use of potentiated ozone as a cleaning agent. The ozone is generated by creating an electrical charge to contact a solution containing hydrogen peroxide and peroxyaliphatic carboxylic acid. Although ozone is known to have a relatively short lifetime after being generated, one of the disadvantages of using this molecule relates to its status as a possible environmental hazard since it is known to be a major contributor to the formation of smog in urban areas.
U.S. Pat. No. 5,855,217 discloses a device for cleaning soiled food processing equipment in which a hydrogen peroxide solution containing an alkyl amine oxide is added to a chlorine free alkaline foam cleaning agent no more than 1 minute prior to application to the soiled surface to be cleaned. The alkaline cleaning agent is foamed before being mixed with the hydrogen peroxide solution. The examples show a cleaning efficiency rate of only between 41.5% and 75.5%, which may be acceptable under some, although not all, industrial cleaning operational standards.
In U.S. Pat. No. 5,861,366, the patentees disclose the use of enzymes plus surfactants to clean soiled food processing equipment. They mention a number of conventional formulations that may be combined with these enzymes to augment the cleaning process. They emphasize that their formulation is free of chlorine and alkaline metal hydroxides. While enzymes may exhibit less negative environmental impact, they typically lack the cleaning efficiency required in many industrial operations with limited time constraints.
Another approach is provided by the disclosure of U.S. Pat. No. 6,686,324 B1. This patent teaches a low foaming cleaning solution for cleaning and disinfecting medical and dental equipment by removing light organic soiling. The cleaning solution also includes a variety of surfactants, polyphosphates, sequestering agents and corrosion inhibitors. It is not suggested that this formulation be used to clean the heavily soiled surfaces of food processing equipment.
U.S. Pat. No. 6,998,376 B1 discloses a method and formulations for cleaning equipment used to prepare coffee. The alkaline cleaning solution contains at least one peroxidic compound generating about 1.5% active oxygen. No mention is made of utility in the cleaning of heavily soiled surfaces of the equipment used in the food processing industry.
Recent U.S. Patent Publications 2006-0046945 and 2006-0042665 disclose a method for the cleaning in place of soiled industrial equipment. However, they merely disclose a multistep process using conventional cleaning chemicals. They appear to claim that a pre-treatment, which can be either acidic or caustic, improves cleaning efficiencies. It is not clear, though, how this is an advancement over the known art.
What is desired is a more efficient formulation and method for use with “clean out-of-place” (COP), “clean-in-place” (CIP) and foam cleaning operations to remove heavy soil from surfaces of the equipment used in the food processing industry. This and other objectives will become apparent from the following detailed description of the invention.
SUMMARY OF THE INVENTION
The improvement consists of a method for cleaning the surfaces of food processing equipment that is heavily soiled with food processing byproducts, such as grease, starch and proteinaceous materials. This equipment must be cleaned on a regular basis to maintain processing efficiency and to prevent the proliferation of bacteria, viruses and other elements that can negatively affect human health.
The improved cleaning method consists of applying two separate cleaning compositions that are mixed together at the point of application to the soiled surfaces of food processing equipment. One composition contains an aqueous oxidizing agent and the other composition contains a source of aqueous hydroxide ions. Both compositions are mixed together immediately prior to being applied to the soiled surfaces. The cleaning formulation may be applied either as a foam or a gel in order to enhance residence time on the soiled surface. The cleaning compositions may also be applied as liquids. The combined formulation utilizes the weak Bronsted acidity of the oxidizing agents in interaction with the hydroxide ions to generate perhydroxyl ion and other active oxygen species that are significantly more effective at cleaning heavily soiled food processing equipment than each cleaning composition if applied separately.
DETAILED DESCRIPTION OF THE INVENTION
The improved cleaning process is a method of applying to the surfaces of heavily soiled food processing equipment a cleaning formulation including a combination of two separate cleaning compositions. In one embodiment, the two cleaning compositions are mixed together under pressure at the time of application to the surfaces of the food processing equipment by use of a conventional pressure spraying device. This type of on-site cleaning operation is referred to in the industry as “environmental sanitation” or “foam cleaning” or “hard surface cleaning”, and is typically used to clean the exterior surfaces, walls and floors of food processing equipment. The pressure spraying device aerates the mixed compositions such that the cleaning formulation is ejected from the spray nozzle as either a gel or foam. The gel form is preferable in that it provides a greater surface residence time for the cleaning formulation, thereby improving cleaning performance. In an alternate embodiment of the invention, the two cleaning compositions are combined in water to form a low-viscosity mixture that is allowed to reside in or on soiled surfaces, or is recirculated through these surfaces for a pre-determined period of time. This type of cleaning operation is referred in the industry as “clean-in-place” (CIP) or “recirculation cleaning”. A preferred CIP operation applies to its use in “boil out” or “fryer boil out” cleaning operations.
A first element [1A] of the first cleaning composition primarily provides a source of aqueous hydroxide ions. Preferably, alkali metal hydroxides are employed which include lithium hydroxide, sodium hydroxide, and potassium hydroxide. The preferred amount of alkali metal hydroxide in this cleaning composition is from about 0.1 percent by weight to about 50 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 25 percent by weight to about 45 percent by weight. In use, the first cleaning composition is diluted with water. Preferably, the dilution is from about 0.25 fl. oz. per gallon to about 64.0 fl. oz. per gallon. The preferred dilution range is from about 0.5 fl. oz. per gallon to about 15.0 fl. oz per gallon. The most preferred is a range of about 1.0 fl. oz. per gallon to about 5.0 fl. oz per gallon. In the most preferred range, the active hydroxide alkalinity level in the diluted solution is approximately 0.4% to approximately 2.0% by weight.
A second element [1B] of the first cleaning composition includes alkali metal salts of various homo- and heteropolymer soil dispersants and water scale inhibitors of the acrylate monomer type, having average molecular weights ranging from about 1,000 to about 12,000 g/mole. Examples of suitable materials include, but are not limited to: the homopolymer Acumer™ 1000; and the heteropolymers Acumer™ 2100, and Acumer™ 3100 from Rohm and Haas Co. The preferred amount of the second element is from about 0.1 percent by weight to about 5.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 percent to about 3.0 percent by weight.
A third element [1C] of the first cleaning composition includes alkali metal salts of organophosphonic acid soil dispersants and scale inhibitors. Examples of such materials include, but are not limited to: amino tris(methylenephosphonic acid) [Phos 2]; 1-hydroxyethylidene disphosphonic acid [Phos 6]; and 2-phosphono-1,2,4-butanetricarboxylic acid [Phos 9]; all available from Buckman Laboratories Inc. The preferred amount of the third element is from about 0.1 to about 5.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
A fourth element [1D] of the first cleaning composition includes surfactants. Examples of suitable surfactants include, but are not limited to: disodium cocoamphodipropionate (Miranol™ from Rhodia Inc.); alkyl polysaccacharide ether (Glucopon™ 225 DK from Cognis Inc.); monosodium N-lauryl-β-iminodipropionate (Deriphat™ 160-C from Cognis Inc.); sodium lauryl sulfacte; sodium octyl sulfate; and dodecyldimethylamine oxide (Ammonyx™ LO from Stepan Inc.). The preferred amount of the fourth element is from about 0.1 to about 10.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
A fifth element [1E] of the first cleaning composition includes various hydrotropes as phase coupling agents. Examples of suitable hydrotopes include, but are not limited to: sodium xylene sulfonate (SXS-40 from Pilot Inc) and sodium cumene sulfonate (Stepanate™ SCS-40 from Stepan Inc.). The preferred amount of this element is from about 0.1 to about 10.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
A sixth element [1F] of the first cleaning composition includes various inorganic salts as cleaning performance enhancing agents. Examples of suitable inorganic salts include, but are not limited to: sodium metasilicate pentahydrate (Metso Pentabead™ 20 from PQ Corp.); liquid potassium silicate (Kasil™ #1 from PQ Corp.); and sodium tripolyphosphate (from Hydrite Chemical Inc.). The preferred amount of this element is from about 0.1 to about 10.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
A seventh element [1G] of the first cleaning composition includes various carbon-containing molecules as wetting agents. Examples of suitable wetting agents include, but are not limited to: sodium gluconate (FCC Grade from Hydrite Chemical); block, graft and network heteropolymers of ethylene oxide and propylene oxide (Pluronic™ L-64 from BASF Inc.); and sodium glucoheptonate (Milco™ 150G from Milport Enterprises). The preferred amount of this material is from about 0.1 to about 10.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
An eight element [1H] of the first cleaning composition includes defoamers. Examples of suitable defoamers include, but are not limited to: polydimethylsiloxane emulsions (GE SAG™ 730 Silicone from GE Silicones) and non-silicone defoamers (Industrol™ DF-204 Defoamer from BASF). The preferred amount of this material is from about 0.001 to about 1.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.01 to about 0.5 percent by weight.
A ninth element [1J] of the first cleaning composition includes chelants and/or sequestrants. Examples of suitable molecules for this purpose include, but are not limited to: citric acid/sodium citrate; and methyltrinitriloacetic acid (Trilon™ M from BASF Inc.). The preferred amount of this element is from about 0.1 to about 10.0 percent by weight, based on the total weight of the first cleaning composition. The most preferred range is from about 0.5 to about 3.0 percent by weight.
The second cleaning composition provides a source of aqueous oxidizing agents. The primary element [2A] in this component is hydrogen peroxide, which is dissolved in water. The source of aqueous hydrogen peroxide may also be derived by dissolving various solid peroxygen compounds (persalts) such as alkali metal perborates, alkali metal percarbonates, alkali metal peroxymonosulfates and their hydrated forms. The preferred weight percentage of hydrogen peroxide is in the range of approximately 0.1 to 50 percent, based on the total weight of the second cleaning composition. More preferably, the amount is approximately 20 to 40 percent by weight, with the most preferred amount being approximately 30 to 35 percent by weight.
A second element [2B] of the second cleaning composition includes various organophosphonic acid soil dispersants and scale inhibitors. Examples of suitable compounds include, but are not limited to: amino tris(methylenephosphonic acid [Phos 2]; 1-hydroxyethylidene diphosphonic acid [Phos 6]; and 2-phosphono-1,2,4-butanetricarboxylic acid [Phos 9]; all available from Buckman Laboratories Inc. The preferred amount of the second element is from about 0.1 to about 10 percent by weight, based on the total weight of the second cleaning composition. The most preferred range is from about 1 to about 5 percent by weight.
A third element [2C] of the second cleaning composition includes oxygen bleach activators to generate surface-active peracids. Examples of suitable materials include, but are not limited to: C6-C8 alcohol ether carboxylic acid (Macat™ AEC-8964 from Mason Chemical Inc.); and C12 ether carboxylic acid (Macat™ AEC-126 from Mason Chemical Inc.). The preferred amount of this element is from about 0.1 to about 3.0 percent by weight, based on the total weight of the second cleaning composition. The most preferred range is from about 0.5 to about 1.2 percent by weight.
A fourth element [2D] of the second cleaning composition includes surfactants to boost cleaning performance. Examples of suitable surfactants include, but are not limited to: alkali metal n-octyl sulfonates (Bioterge™ PAS-8S from Stepan Inc.); decyldimethylamine oxide (Ammonyx™ DO from Stepan); octyldimethylamine oxide (FMB™ AO-8 from Lonza Inc.); and decyltrimethylammonium bromide (from Sigma-Aldrich Inc.). The preferred amount of this element is from about 0.1 to about 10 percent by weight, based on the weight of the second cleaning composition. The most preferred amount is from about 0.5 to about 3.0 percent by weight.
The method of the present invention includes the steps of preparing separate first and second cleaning solutions. Then, the first and second cleaning solutions are fed into a pressure spraying device which blends the two solutions with water and forces them out of a nozzle under pressure, such as by use of compressed air, toward the surface of the soiled food processing equipment.
Alternatively, the first cleaning solution is added to a mixing tank, recirculation tank or a fixed piece of food processing equipment such as a kettle, fryer, vat or some other part of the processing equipment that is capable of holding, and has been previously filled with, a volume of water. After complete dissolution of the first cleaning solution, the second cleaning solution is added to the existing aqueous mixture. The resulting blend is then mixed and allowed to contact the soiled surfaces by standing or by recirculation for a period of time sufficient to clean the soiled surface, followed by a water rinse.
The preferred amount of the aqueous hydroxide ion component, on a weight basis, from the first cleaning composition, in the final cleaning formulation is approximately 0.1% to approximately 5.0% active caustic. The most preferred amount is approximately 0.5% to 1.0% active caustic. The amount of aqueous oxidizing agent from the second cleaning solution, present in the final cleaning formulation is from approximately 0.1 fl. oz. to approximately 1.0 fl. oz. per gallon of the cleaning formulation. Most preferred is approximately 0.2 fl. oz. to approximately 0.8 fl. oz.
When utilized, the pressure spraying device can aerate the first and second cleaning solutions or premixed cleaning formulation so that it is applied as a foam, or it may be blended to form a gel, depending upon the proportions of the first and second cleaning compositions utilized. Examples of conventional foaming cleaning devices that can be employed include the Foam-It Foam King Single Pickup unit, the Lafferty Wall Mount Dual Pickup unit and the Lafferty Portable 2-Wheel LCDU Dual Pickup unit. The gel or foam is allowed to remain on the soiled surface for from approximately 5 to approximately 30 minutes, after which time it is rinsed off with potable water.
EXAMPLES
A) Brewery CIP
Amount:
(based on the total weight of
the first cleaning solution)
First cleaning solution:
(designation)
Sodium hydroxide (1A)
35%
Sodium salt of amino(tris)methylene-
2.0%
phosphonic acid (1C)
Sodium salt of 2-phosphono-1,2,4-butane-
2.0%
tricarboxylic acid (1C)
Sodium salt of polyacrylic acid polymer
2.0%
(1B)
Second cleaning solution:
(designation)
Hydrogen peroxide (2A)
33%
2-phosphonobutane-1,2,4-tricarboxylic
3.0%
acid (2B)
C6-C8 alcohol ether carboxylic acid (2C)
0.8%
After every brewing cycle, the kettles and processing equipment are to be cleaned-in-place (CIP). The cleaning formulation was applied as a non-foaming solution with recirculating flow for the standard cleaning period of 30 minutes. The result was that the soiled equipment was completely cleaned. The benefit was that the level of hydroxide alkalinity was able to be reduced by 20% when compared to previously employed cleaning processes.
B) Environmental Sanitation/Foam Cleaning
Amount:
First cleaning solution:
(based on the total weight of
(designation)
the first cleaning solution)
Sodium salt of polyacrylic acid (1B)
2.0%
Sodium octyl sulfate (1D)
2.0%
Sodium lauryl sulfate (1D)
2.0%
Sodium hydroxide (1A)
35%
Second cleaning solution: (same as above)
The food processing equipment included 304 stainless steel. The cleaning formulation was applied as a foam to the food processing equipment and the surrounding floor areas. The result was that the food processing equipment was thoroughly cleaned and, of significance, the cleaning efficacy of the surrounding floor area improved by approximately 50% when compared to conventional cleaners.
C) Fryer boil out (CIP)
Amount
First cleaning solution:
(based on the total weight of
(designation)
the first cleaning solution)
Sodium hydroxide (1A)
30%
Sodium salt of aminotrismethylenephos-
2.0%
phonic acid (1C)
Sodium salt of polyacrylic acid (1B)
2.0%
Second cleaning solution: (same as above)
The cleaning formulation was applied as a non-foaming solution into a convective clean-in-place (CIP) boil out operation. The normal cycle time of approximately 2 hours was reduced by 30 minutes due to the increased efficacy of the improved cleaning formulation.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | A method for cleaning the surfaces of food processing equipment that are heavily soiled with food processing byproducts, such as grease, starch and proteinaceous materials. The cleaning method consists of applying two separate aqueous cleaning solutions that are mixed together. One solution contains an aqueous oxidizing agent and the other solution contains a source of aqueous hydroxide ions. Both solutions are mixed together immediately prior to being applied to the soiled surfaces. The combined formulation utilizes the weak Bronsted acidity of the oxidizing agents in interaction with the hydroxide ions to generate perhydroxyl ions and other active oxygen species, which are significantly more effective at cleaning heavily soiled food processing equipment than each cleaning solution alone. | 2 |
This application is a continuation of continuation-in-part U.S. application Ser. No. 552,736 filed Feb. 25, 1975 now abandoned which evolved from United States application Ser. No. 330,020 filed June 2, 1973 entitled "PULSATION REDUCER", now U.S. Pat. No. 3,867,963.
BACKGROUND OF INVENTION
This invention relates generally to pulsation reducers and more particularly to pulsation reducers for use in applications such as positive displacement fluid pumps and is intended to reduce impact loading on valves, fluid conduit pump bearings, pump drives, piston seals, on piston type pumps, and gear teeth and seals and housings of gear pumps etc.
Small high pressure positive displacement pumps particularly of the type that are often used in spray wash machines for example that disclosed in U.S. Pat. No. 3,238,890 Sadler et al issued Mar. 8, 1966 are often driven directly by an 1800 rpm electric motor, and utilize two opposed pistons, thus 3600 cycles per minute of pressure impulses and flow variations must be accomodated. If no pulsation reducer is used the whole pressure system is subject to impact loading (water hammer) at that frequency so that a pump delivering an average pressure of five hundred p.s.i. can, depending on the resiliency of the piping, hose etc., be subject to very great pressure variations a condition which is very damaging to pumps and flexible hose etc.
In U.S. Pat. No. 3,867,963, several embodiments of pulsation reducers utilizing a flexible wall structure consisting essentially of a Belleville spring-cover plate assembly having on its convex side a covering elastomeric diaphragm, sealingly held in a recess by its outer periphery so that on being subjected to fluid pressure the flexible wall structure will deflect outwardly to a mean position, and thereafter oscillate inwardly and outwardly responsive to pressure variations.
The original application also disclosed restrictors to inhibit outward flow of fluid from the pulsation reducer, and disclosed an over pressure control valve wherein deflection of a flexible wall structure byond a predetermined limit lifted a valve plunger from the seat of the control valve to permit return of over pressure fluid back to the intake side of the pump.
While I did state in original application "a pressure limitation valve . . . actuated by an adjustable lost motion linkage . . . may be incorporated into the body of my pulsation reducer, to permit return of over pressure fluid", I did not adequately illustrate how a pressure limitation valve could be arranged to function as an unloading valve, i.e. when pressure builds up in the system byond a predetermined working pressure a valve plunger is lifted from the seat of the pressure limitation valve, where it is normally held by internal pressure, and is moved away from the seat by a spring thereby permitting fluid to flow to the intake side of the pump through the unloading valve, and permit the pressure in the system to drop to a predetermined lesser pressure than the working pressure without re-engaging the valve plunger. When the pressure in the system is permitted to drop still lower, the flexible wall structures moves inwardly still further and force the valve plunger onto its seat to stop the flow of fluid to the intake side of the pump, so that internal pressure within the system will again rise to the working pressure.
By adjustably mounting the seat portion of the pressure limitation valve on one flexible wall structure, and the valve plunger actuating portion of the pressure limitation valve on the opposed flexible wall structure, the relative motion between the valve parts is doubled relative to using the movement of only one flexible wall for this purpose. This makes valve actuation less sensitive to small movements of the flexible wall structure and makes `in operation` adjustments of upper and lower pressure limits possible. Furthermore, in the event of failure of either flexible wall structure because of, for example, the breaking of a Belleville spring, pressure in the system will immediately be reduced to a pressure less than the working pressure of the system.
PRIOR PRACTICE
To improve the life of such pumps and associated fluid conduit systems pulsation reducers or accumulators which use gas as a spring medium have been used, however, such pulsation reducers tend to be large and require frequent servicing, and/or require a source of high pressure gas for re-charging: they are also expensive, and difficult, or imposible to repair or recondition.
OBJECTS
To provide a pulsation reducer which provides a high degree of attenuation within a desired pressure range.
To provide pulsation reducer which utilizes the deflection characteristics of a Belleville spring having its centre hole covered by a plate, and supported against axial movement at its outer periphery and sealed to prevent leakage, to provide a variable volume to accomodate variations in the rate of flow of fluid under pressure.
To provide a pulsation reducer which achieves attenuation of liquid from a pulsating source by providing a fluid chamber connected thereto having flexible wall structures supported therein, the flexible walls including Belleville springs with cover plates secured thereto in covering relation over the hole in the springs to yieldingly provide support for sealing means to retain fluid within the chamber so that responsive to an increase in pressure within the pulsation reducer the flexible wall structures deflect outwardly to increase the volume contained within the fluid chamber, and vice-versa.
To provide a pulsation reducer whose working pressure can be changed by exahanging the spring elements.
To provide a pulsation reducer which can be serviced in situ.
To provide a pulsation reducer which has no sliding fluid seals or expanding or contracting gas filled or constrained bladders to effect pressure attenuation and therefor does not require gas either for charging or replenishing.
To provide a pulsation reducer which is inexpensive to manufacture is easily assembled and economical to service and maintain.
To provide a pulsation reducer including at least one flexible wall structure which is adapted to receive a part of a pressure control valve and cause the control valve part to oscillate toward and away from another part of the pressure control valve which may be connected to the fluid chamber, or preterably to an opposed flexible wall structure, the control valve including a seat, and a valve poppet respectively, a lost motion inkage or connection so that if the valve is a relief valve, deflection of the flexible walls beyond a predetermined amount will unseat the poppet from the valve seat and permit the over pressure fluid to escape through the valve seat back to the intake side of the pump. If the valve is an unloading valve, deflection of the flexible wall structure byond a predetermined amount will unseat the valve poppet, which is normally held closed by internal fluid pressure, a poppet spring will then move the poppet away from the valve seat to the extent permitted by the lost motion linkage, and fluid will pass through the valve seat, however, a restriction such as a throttling valve or orifice in the return fluid line retains sufficient pressure within the pulsation reducer to prevent sufficient return of the flexible wall structures to reengage the unloader valve poppet in the valve seat eg. the pressure may drop from 600 psi to 70 psi. If the pressure in the pulsation reducer is reduced still further, as for example by opening a spray gun nozzler, the flexible wall structures will move closer together and the poppet will be forced into engagement with the valve seat cutting off the return flow of fluids and pressure in the pulsation reducer will build up to a working pressure of the example 550 psi.
To provide a pulsation reducer having Belleville springs which utilizes movement of the resilient wall structure resulting from deflection of the Belleville springs to actuate a lost motion linkage which in turn operates pressure limiting valve which may be either a pressure relief valve, or an unloading valve.
To provide a combination pulsation reducer and control valve which can be adjusted to operate either as an over pressure relief valve, or as an unloader valve.
To provide a conbination pulsation reducer and control valve having two axially opposed flexible wall structures. One flexible wall structure having adjustably secured therein a valve seat with a by pass fluid passage extending through the flexible wall to the exterior of the pulsation reducer and the second flexible wall structure having adjustably secured therethrough a lost motion mechanism to control engagement and disengagement of a contained valve poppet with the valve seat on the opposed flexible wall structure, the relative limits of motion of the valve poppet with respect to the valve seat being adjustable from the exterior of the second flexible wall structure through the lost motion mechanism. With the control valve adjusted to operate in the unloading mode, the valve poppet is held against the valve seat by fluid pressure during working operation whereas during unloading, the valve popeet is held away from the valve seat by a poppet spring.
PRINCIPAL OF OPERATION
My invention uses one or more Belleville springs with a plate, secured in hole covering relation over the convex side of the Belleville spring by suitable fastening means including stepped washers, to provide flexible wall structures which support elastomeric disphragms that extend over the flexible wall structures and with either integral peripheral rings, or "O" rings engage inner body portions of my pulsation reducer in fluid sealing relation. The inner surface of the diaphragm acts as a fluid barrier to contain fluid within the body portion of my pulsation reducer. One or more flexible wall structures with covering diaphragms are provided in my pulsation reducer.
On being subjected to pressure the elastomeric diaphragm presses against the flexible wall structures, the outer periphery of which are supported by suitable means against axial movement, and deflect the flexible wall structures outwardly.
The Belleville spring size, thickness and free cone height are chosen to give a desired load deflection characteristic. For technical details of Belleville Spring design and characteristics reference is made to Transsactions of the American Society of Mechanical Engineers, May 1936, Volume 58 No. 4 for derivations of appropriate Belleville Spring Data in a paper by Almen and Laszlo.
If the ratio of the free height h, of the cone, to the thickness, t, of the Belleville spring is greater than about 0.4 i.e. h/5 0.4 the deflection vs. load characteristics will not be linear, and as h/t approaches 1.41 the load vs. deflection curve for a Belleville spring "flattens out" and again raises so that within a limited range of deflection within the "flattened out" range above referred to deflection can be varied with little if any change in applied load, deflection beyond the flattened out range requires increasing load.
If the Belleville spring is selected so that the working pressure within my pulsation reducer applies a load to the spring at the flattened out portion of the afore described curve, substantial variation in deflection of the Belleville spring or springs, and thus in the volume of the fluid contained within my pulsation reducer can be made with little change in pressure, and ideally with only enough pressure to overcome internal friction within the Belleville spring, the elastomeric diaphragm, and friction due to the miniscule radial movement of the Belleville spring as it contracts relative to the plate, and inertia of the masses of the assembly.
However, as a range of working pressures are required to accomodate slight differences in pump sizes and wear as well as variations in orifice size for example it is more practical to select Belleville springs having an h/t ratio less than 1.41 but greater than 0.6 so that within a working pressure nominally of 500 p.s.i. a cyclical variation of 5 to 10% in pressure is required to deflect the Belleville spring assembly back and forth to the extent necessary to attain the required attenuation.
The effect attained by selecting Belleville springs which are deflected to the extent and within the range proposed above is comparable to providing a large air chamber to attenuate a pump having a small displacement, or providing an accumulator charged with gas pressure to just under the mean working pressure of the pump.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the drawings wherein like numerals refer to like parts wherever they occur;
FIG. 1 is an end view of a double flexible wall pulsation reducer;
FIG. 2 is a sectional view of a pulsation reducer taken along the line 2--2 of FIG. 1 illustrating a single stage double flexible wall pulsation reducer;
FIG. 3 is a sectional view of an alternative pulsation reducer provided with two compartments interconnected by a flow restricting orifice;
FIG. 4 is an end view of a flexible wall structure including concentric Belleville springs and plate assembly; and
FIG. 5 is a section view of the flexible wall assembly taken along line 5--5 of FIG. 4.
FIG. 6 is a sectional view of an alternative form of pulsation reducer incorporating a pressure limiting valve within its body taken on line 2--2 of FIG. 1;
FIG. 7 is a sectional view taken on line 7--7 of FIG. 6 showing the location of inlet, outlet and return conduit connections for a pulsation reducer incorporating a pressure limiting valve;
FIG. 8 is a sectional view of a single stage pulsation reducer taken on line 8--8 of FIG. 9, and
FIG. 9 is a fitting end view of a single stage pulsation reducer in accordance with this invention.
FIG. 10 is a sectional view of an alternative form double flexible wall pulsation reducer.
FIG. 11 is a sectional view of a double flexible wall pulsation reducer with a body like that of FIG. 10 illustrating a pressure control valve having parts adjustably secured to each of the flexible walls to provide a combined pulsation reducer and unloading valve.
FIG. 11a is a fragmentary sectional view showing the positional relationship between parts of the pressure control valve of FIG. 11 when the fluid system is subjected to a pressure just below the pressure at which the valve plunger would be lifted from the valve seat.
FIG. 11B is a fragmentary sectional view showing the positional relationship between parts of the pressure control valve of FIG. 12 after the system has exceeded the pressure at which unloading is initiated, and wherein the flexiable wall structures have partially retracted permitting fluid at a pressure less than the working pressure of the system to flow through the pressure control valve to a return line (not shown)
FIG. 12 is a sectional view of a flexible wall structure as shown in FIG. 10.
FIG. 13 is an enlarged partial sectional view of the region A of FIG. 12.
In accordance with my invention a pulsation reducer 1 includes one or more openings 2 in a body 9 to receive a pre-formed elastomeric diaphragm 3 seated in abutting axial relation against a shoulder 4, and in sealing contact against a perimeter portion 5 of the openings 2. The inner surface of the diaphragm 3 provides a fluid barrier to retain fluid within the pulsation reducer 1, and internal pressure within the body 9 tends to increase the sealing effect of the peripheral portions 6 of the diaphragms 3 against the perimeter portions 5 of the openings 2. A Belleville spring 7 is seated in the opening 2 with the apex side of the Belleville cone directed inwardly, a generally circular cover plate 8 having means to retain it concentric with the Belleville spring 7 is disposed in engagement with the inner surface of the Belleville spring 7 so that the outer surface of the diaphragm 3 bears against the inner surface of the Belleville spring 7 and the cover plate 8. An annular spring 11 (TRUARK®) is disposed in a grooves 10 in the openings 2 and bears against the outer peripheral edge of the Belleville spring 7 and holds the outer peripheral edge axially fixed when fluid pressure is exerted within the pulsation reducer 1.
On being subjected to internal fluid pressure the diaphragm 3 presses against the cover plate 8 and the Belleville spring 7 causing deflection of the Belleville spring 7.
The Belleville spring 7 will deflect outwardly to a means position and will oscillate in and out relative to the means position, in responsive to variations in the fluid pressure. While the elastomeric diaphragm 3 deflects to accomodate relative pivoting motion between the Belleville springs 7 and the openings 2, and also between the Belleville springs 7 and the cover plate 8.
The puslation reducer may be provided with one threaded inlet 12, and one or more outlets 13. If no oulets 13 are in the embodiments illustrated in FIGS. 2 and 3 single Belleville springs and cover plates are held in position by a pre-formed elastomeric diaphragm 3. FIGS. 4 and 5 illustrate an alternative form which uses two concentric nested Belleville springs 17 and 18 with a cover plate 19 all held in assembled relation by a stepped disc 20 secured as by a spot weld 21 between the cover plate 19 and the stepped can be arranged in analogous manner to achieve greater flexibility of design.
The principal reason for resorting to nested concentric arrangements of Belleville springs is to permit greater volume displacement for the same outer diameter with less maximum stress in the Belleville springs for a given pressure variation, and to reduce the loading stress between the Belleville springs 7 and the cover plate 8.
Many structural variations may be resorted to modify the function and use to which my pulsation reducer may be put, for example, a pressure limitation valve, either directly pressure actuated, or indirectly actuated by an adjustable lost motion linkage, which unseats a spring biased valve plunger responsive to movement of one or more Belleville springs, may be incorporated into the body of my pulsation reducer, to permit return of over pressure fluid through a suitable conduit to the intake of the pump. Or an unloading valve may be attached by suitable means such as a thread connection in the body of my pulsation reducer to permit return flow of fluid to the intake side of the pump.
The embodiment illustrated by way of example in FIG. 6 and generally designated 36 utilizes deflection of a Belleville spring 7 to unseat a plunger 30 seated in a valve seat 28 which may be suitably sealed as with an O Ring 29 in a mating socket 27 in the rigid divider 15'. Any suitable lost motion arrangement may be provided to permit a pre-determined deflection of the Belleville spring 7 to occur before the valve plunger 30 is lifted from the seat 28. A spring 32 bears against an elastomeric diaphragm 3' and against an apertured cap 31 which is fixed as by spot welding or soldering to the plunder 30. To effect unseating of the plunger 30 on over deflection of the Belleville spring 7. A headed adjustment bolt 33 having the head portion movably contained between the plunger 30 and the cap 31 extends through a suitable self sealing opening in the centre of the elastomeric diaphragm 3'. A threaded portion of the bolt 33 adjustably extends through a correspondingly threaded hole in the centre of cover plate 8'. The threaded end of the adjustment bolt is provided with a suitable adjustment slot 35, and a locking nut 34 provided on the outer end of adjustment bolt 33 is provided to secure the adjustment bolt in pre-determined adjustable position by jamming the locking nut 34 against the outside surface of the plate 8'. Thus upon exceeding a pre-determined pressure, valve plunger 30 is unseated by engagement between the head of bolt 33 and the inside of cap 31.
Internal pressure within chamber 9" together with force exerted by spring 32 are sufficient to effect sealing engagement between the plunger 30 and the seat 28 at pressures less than a pre-determined maximum pressure until plunger 30 is unseated.
For symmetry of forces and to provide space in the embodiment of FIG. 6 the over pressure relief valve is located on or near the axis of the Belleville springs 7 and therefore an interconnecting orifice 16' not shown in FIG. 6 has been shown in FIG. 7 to provide for fluid interconnection between fluid chambers 9' and 9" shown in FIG. 6. Thus at less than pre-determined pressure fluid enters the embodiment of FIGS. 6 and 7 through 12' passes through orifice 16' and exits through 13'. If pressure exceeds the pre-determined pressure sufficient fluid will pass through valve seat 28, return conduit 26 and return fitting 25 to prevent over deflection of the Belleville springs 7, and to allow fluid to be returned to the intake side of a pump as for example when the trigger of a spray wash gun is released.
A single Belleville spring pulsation reducer illustrated in FIGS. 8 and 9 resorted to for economy of construction or to conserve space. This embodiment generally designated 42 may be provided with flats or a hexagon for a wrench for ease of installation. If a relatively constant pressure is to be attenuated and a Belleville spring is selected to match the pressure closely i.e. a Belleville spring having an afore described flattened deflection curve within the range of deflection utilized, there should be as little resistance to inward and outward flow of fluid as possible, however, if a range of pressure is to be attenuated a Belleville spring having a greater range of working pressures may be used, and to improve damping of pulsations a flow restriction valve comprising a seat portion 37 suitably sealed as with an O ring 38 in a seat 39 in the body in communication between the inlet 12" and the pressure chamber 9" is provided with an appertured poppet 40 held into the seat 39 by a spring 41 bearing against the elastomeric diaphragm 3, so that there is very little resistance to passage of fluid into chamber 9", but considerable resistance to passage of fluid out of chamber 9" in reverse flow, thus damping of only that portion of the output of a reciprocating pump which enters the pulsation reducer is provided, and the rate at which fluid is returned by the pulsation reducer can be controlled by varying the area of the orifice in appertured poppet 40.
A suitable washer (not shown) may be provided on the outer side of the Belleville springs of my pulsation reducer either for decorative purposes, or to serve as a stop to prevent accidental over deflection of my Belleville springs.
The embodiments illustrated in FIGS. 10 and 11 have bodies 102 which are generally similar to that of FIGS. 1 and 2 but are machined from a short piece of metal tube rather than being of cast construction as shown in FIGS. 1 and 2, and the positional relationship of threaded inlet 105 and outlet holes 106 and 107 are the same as 1" and 13' and 25 of FIG. 7.
Similar recesses 103 are machined into each end of the body 102 of sufficient depth to provide shoulders for sealing engagement with "O" rings 114, and to receive in turn, elastomeric diaphragms 111, and Belleville springs 108. Retaining ring grooves 104 are machined into the recesses 103 to receive TRUARC® spring rings 112 which support the O rings 114, the elastomeric diaphragms 111, and the outer peripheral portion of the Belleville spring part 108 of the flexible wall structures and prevent significant axial displacement and yet allow for relative pivoting between the Belleville springs and the body 102.
While internal pressure will assist in retaining fluid sealing engagement when the flexible wall structure is deflected outwardly it is desirable to compress the elastomeric diaphragms 111 and the O rings 114 by an amount at least equal to the distance that the Belleville springs 108 deflect outwardly in the region of the O rings 114.
The flexible wall structure illustrated in FIG. 12 consists of a Belleville spring 108 yieldingly damped between a double dished cover plate 110 and a stepped washer 109 by a screw 113. FIG. 13, an enlargement of portion A in FIG. 12 illustrates a preferred shape of the portion of the cover plate which engages the Belleville spring 108. A curved engagement surface having a radius R is provided on the cover plate 110 so that as the Belleville spring is deflected a combined rolling and sliding action will occur between the contacting surfaces. By this provision wear is spread over a larger surface area on both the cover plate 110 and the Belleville spring 108.
During assembly the space between the dished washer 109, the cover plate 110 and the Belleville spring is packed with a suitable lubricant such as molybdenum disulfide grease to further improve the effective life of the flexible wall structure.
To reduce the thickness and therefor the mass of the cover plate 110 and to provide the contact radius R, I prefer to press form the cover plate 10 in a coining die from high tensile sheet steel discs. Also to retain acceptable concentricity of the flexible wall structures, the dished washer 109 is also press formed with enough radial and axial clearance in the part which extends into the aperture of the Belleville spring 108 so that it will not bind therein when the Belleville spring is deflected. The dished washer 109 becomes in effect a spring to yieldably hold the flexible wall structure together and concentric at all deflections thereof.
In the embodiment shown in FIG. 10 the flexible wall structures are held together with a screw 113 which extends through the dished washer 109 in threaded engagement with cover plate 110. In the embodiment of FIG. 11 the flexible wall structures are also held together by threaded engagement and functions substantially identically as flexible walls. However, the flexible walls of FIG. 11 are each provided with parts of a pressure control valve.
The left hand flexible wall of FIG. 11 includes a female part 121 of a pressure control valve which is machined from hexagonal metal stock and extends from the interior of the pulsation reducer through an elastomeric washer 120, an elastomeric disphragm 111', in threaded engagement with a cover washer 110', a stepped washer 109' and a lock nut 130. The female part is provided with a through passage having at its outer end a female pipe 129 to receive a return line fitting (not shown). At its inner portion, the female part 121 is machined to provide an abutment shoulder for a spring 124, and the inner end of female part 121 is machined to provide a valve seat.
The right hand flexible wall of FIG. 11 includes a male part 122 of a pressure control valve which is also machined from hexagonal metal stock and extends from the enterior of the pulsation reducer through an elastomeric washer 120, an elastomeric diaphragm 111', in threaded engagement with a cover washer 110', a stepped washer 109', and a lock nut 131. An inwardly flanged sleeve 123 is secured as by crimping its other end to the inner end of the male part 122, and a cupped valve poppet 125, provided with an outwardly extending flange to provide an abutment for the spring 124 and extends radially byond the spring to also provide an abutment for engagement with the inwardly directed flange of the sleeve 123.
The male part 122 is provided with a stepped through bore, the outer portion being threaded, and the inner portion being cylindrical and smooth. An adjustment screw 126 slotted at 133 at its outer extremity and threaded for the outer part of its length and cylindrical for the inner part of its length and dimentioned to closely match the cylindrical and threaded portions of the bore of the male part 122 is provided with an O ring groove to accomodate O ring 128, and is also provided at its inner end with a socket to receive an elastomeric plug (or spring) 127, is adjustably screwed into the bore of male part 122. The elastomeric plug 127 is adapted to adjustably and releasably engage the inner end of the valve plunger 125. The valve plunger 125, the spring 124 and the flanged sleeve 123 constitute a lost motion mechanism.
When pressure in the pulsation reducer is less than the unloading pressure, the elastomeric plug 127 presses the valve plunger 125 against the valve seat of female part 121 preventing escape of any fluid through the female part 121. The elastomeric plug (or spring) 27 being much stiffer than the spring 124 can compress the spring 124 without being itself appreciably compressed.
As the pressure builds up in the pulsation reducer both flexible walls deflect outwardly. Internal fluid pressure experts a force on the valve plunger 125 great enough to overcome the force of the spring 124 which biases the valve plunger 125 toward the male part 122. As deflection proceeds the elastomeric plug 127 desengage the valve poppet 125 and internal fluid pressure continues to hold the valve poppet against the seat of female part 121 and the flexible walls are free to oscillate in and out without effecting the pressure control valve.
At a predetermined pressure above the working pressure of the system in which the pulsation reducer is used the inwardly directed flange of sleeve 23 will engage the outwardly directed flange of the valve poppet 125 (See FIG. 11a) and lift the valve plunger off the valve seat of female part 121 against the force exerted by internal fluid pressure. Whereupon the spring 124 will move the valve poppet away from the valve seat and into contact with the elastomeric plug 127.
With the valve seat uncovered pressure in the pulsation reducer will drop to a pressure less than the working pressure (See FIG. 11b) through escape of fluid through the female part 21. A suitable flow restriction in the return line (not shown) will retain sufficient pressure in the pulsation reducer to prevent complete return of the flexible wall structures and the spring 124 will hold the valve plunger away from the seat of female part 121, and a stable unloading pressure wall remain in the system. If pressure in the system is permitted to drop still further as for example by opening a spray gun valve, the flexible wall structures will retract further, and the elastomeric plug 127 will force the valve poppet 125 against the force of spring 124 into contact with the seat of female part 121, and pressure in the system will return to working pressure.
In the described mode the pressure control valve acts as an unloader valve. If however the elastomeric plug (or spring) 127 is made longer than illustrated, or if the adjusting screw 126 is screwed in far enough as that the plug or spring always remains in pressure contact with the valve plunger 125, the control valve will act as a pressure relief valve only.
Initial adjustment of the pressure control valve is achieved by screwing female part 121 and male part 122 into the threaded cover plates 110' against the yielding elastomeric washers 120 and flexible diaphragms 111' and securing the dished washers 109' in position with lock nuts 130 and 131 respectively, and inserting the flexible wall structures in the openings 103 and securing them in position with spring rings 112 as shown in FIG. 11. Upper pressure limits may be adjusted by using a screw driver engaged in slot 132 at the outer end of male part 122 to further compress (to reduce upper pressures and vis-versa) elastomeric washer 120 and unloading pressure may be varied using a screw driver in slot 133 of adjustment screw 126.
It should be noted that while for simplicity of illustration stepped washers such as 20, or 109 as are illustrated in FIGS. 5 and 10 respectively have not been shown in FIGS. 2, 3, 6 it is intended that such washers with means for securing such to cover plates 8 and 8' be used if required as for example if sheet form rather than pre-formed elastomeric diaphragms are used and stepped washers or the equivilent are required to retain the flexible wall structures concentric.
Cast iron, malleable cast iron, cast, formed, or forged steel suitably machined and coated to resist corrosion are preferred materials for the body of my pulsation reducer, and stainless steel or brass are preferred for springs, valves, parts and seats.
A plurality of my pulsation reducers may be placed in series or parallel relation to increase their attenuation capacity.
In place of an elastomeric diaphragm to effect a fluid tight seal O rings of suitable elastomeric material have been used seated in suitable O ring grooves in a stepped part of opening 2 (not shown) and in the outer peripheral region of the plate 8 (not shown) to bear directly against the Belleville springs 7. This arrangement has proven satisfactory, however, because of the need to use special materials to achieve protection from corrosion if O rings are used I prefer to use a single piece preformed elastomeric diaphragm to separate the Belleville springs 7, or 17 and 18, the spring clip 11 as well as the plates 8 and 19 respectively from the fluid in the pulsation reducer.
Highly corrosive liquids can be attenuated in my pulsation reducer if the body portion is formed of stainless steel or alternatively the interior of my pulsation reducer may be lined with inert material such as epoxy resin, or the same elastomeric material of which my diaphragm 3 are formed.
Many variations in form structure and use of my pulsation reducer will readily occur to those skilled in the art. Therefore, it will be understood that I intend to cover by the appended claims all such variations which fall within the true spirit and scope of my invention: | A mechanism for smoothing out the flow from the output of a positive displacement pump consists of one or more flexible wall structures consisting of a Belleville spring and a cover plate held over the hole in the Belleville spring by a stepped washer secured to the cover plate set into one or more openings in a fluid container. Means is provided to hold the flexible wall structures in the openings with the convex side extending inwardly into the opening. An elastomeric diaphragm is disposed over the flexible wall structures in sealing relationship with the openings in the body of the fluid container. The flexible wall structures deflect outwardly responsive to fluid pressure within the container, and fluctuations in pressure within the container cause variations in the deflection of the flexible wall structures thereby providing a variable volume within the fluid container. To utilize deflection of the flexible wall structures to control pressure in the container adjustable control valve parts are mounted through the flexible wall structures and a lost motion mechanism which will permit the flexible walls to deflect outwardly to a working pressure position, but will, if deflected still further, open the control valve and permit fluid to return to the intake side of the pump. The control valve may be set up to function as a relief valve, or alternatively, as an unloader valve to permit pressure within the pulsation reducer to drop below normal working pressure. A further reduction in pressure will cause the control valve to close and pressure in the pulsation reducer will increase to working pressure. | 5 |
BACKGROUND AND FIELD OF THE INVENTION
The present invention relates to stationary, tower mounted broadcast antennas, and more particularly to improvements therein resulting in reduced wind loading.
Commercial broadcasters, particularly in the FM and TV broadcasting field, commonly employ broadcast antennas which are mounted upon tall towers typically located at high elevations within the broadcast service area. Both because the antenna is mounted on a tall tower, and because the tower itself is generally constructed at an elevated location, the wind acting upon the tower mounted antenna is normally unrestricted by trees, buildings, etc. The tower upon which the antenna is mounted must be constructed to withstand the loading introduced by the wind passing through the antenna. This windloading may be quite great, particularly during storms.
It is therefore desirable to construct the antennas in such a fashion that the amount of wind loading introduced thereby is reduced to a minimum. This is particularly true of replacement antennas, where the strength of the existing tower constrains the maximum windloading of the new antenna.
SUMMARY OF THE INVENTION
Tower mounted antennas often include elongated members oriented in both vertical and horizontal directions to form, for example, reflectors or portions of the antennas themselves. It has now been recognized that the cross sectional configuration of these horizontally or vertically disposed elements may be selected to reduce the wind loading introduced thereby.
It is an object of the present invention to provide an improvement in a tower mounted antenna which reduces the wind loading thereof.
It is another object of the present invention to provide a tower mounted antenna wherein the vertically and horizontally disposed elements have cross sectional configurations selected to take advantage of the known directional characteristics of the wind passing therethrough.
In accordance with the present invention, a stationary, tower mounted broadcast antenna structure is provided having horizontally disposed elongated members through which the wind must flow. The horizontally disposed elongated members have a cross section which is streamlined in the horizontal plane whereby wind load introduced by the horizontal members is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and advantages of the present invention will become more readily apparent from the following detailed description, as taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an elevation view of an antenna reflector including horizontal members and vertical members having cross sections in accordance with the teachings of the present invention;
FIGS. 2A and 2B are cross sectional views of conventional horizontal members;
FIG. 3 is a cross sectional view of one embodiment of a horizontal member in accordance with the teachings of the present invention;
FIGS. 4 and 5 illustrate one bay of a top mount antenna wherein the teachings of the present invention may be usefully employed; and
FIG. 6 is a view of a tapered beam formed by joining two differently sized horizontal bars together.
DETAILED DESCRIPTION
In tower mounted antennas, wind load is dependent upon the aerodynamics of the antenna with respect to the direction of air flow at any particular moment. If the antenna could be streamlined with respect to the direction from which the wind was blowing, the wind load of the antenna could be significantly reduced. It is known, of course, that the wind will generally travel in a horizontal plane. Unfortunately, the point on the compass from which the wind will come will vary significantly from time to time.
Antennas often include elongated members which are disposed in horizontal or vertical orientations. Many times, for example, the antenna will include a reflector composed of open grids of horizontal and vertical members. Such a reflector is illustrated for exemplary purposes in FIG. 1. This reflector 10 will be mounted to a tower by means not shown in FIG. 1 so that the elements 12 are horizontally disposed, and the elements 14 are vertically disposed. Conventionally, the elements 12 will be spaced apart from one another by approximately one tenth of a wavelength at the mean operating frequency of the antenna, as will the vertical elements 14, so that the reflector 10 appears as a solid sheet of conductive material at the wavelength at which the antenna associated with the reflector 10 normally operates. The reflector 10 generally, and the elements 12 and 14 more particularly, will be electrically conductive and will be connected to earth ground in any conventional manner.
The horizontal and vertical strength requirements for the horizontal members in the reflector of FIG. 1 are normally such that their cross sectional depth may be smaller than their cross sectional width. This is because an open grid reflector of this type is naturally better adapted to withstand vertical loads than horizontal loads. Vertical loads can be effectively transmitted through the vertical members to be distributed among the horizontal members in a truss or frame arrangement. This is not the case with most horizontal loads, particularly those acting perpendicular to the reflector plane. In other words, the vertical loads can be carried by using the horizontal members in tension or compression rather than in bending. Horizontal forces, on the other hand, will generally be supported by the horizontal members in bending.
Conventionally, the vertical and horizontal elements of antennas and their reflectors are made up of bars having either a circular or rectangular cross section, as illustrated in FIGS. 2A and 2B. If the horizontal members having the circular cross section of FIG. 2A are used, naturally the width W and depth D will be the same. Consequently, a circular member selected to meet the cross sectional width requirement will have a greater depth than necessary. Since the excess depth presents a greater surface area to the air flow AF, excess windloading results. By using horizontal members having a rectangular cross section instead, the depth dimension may be selected independently of the width dimension. A smaller depth can thus be used, reducing the surface area which is exposed to horizontal air flow AF. Unfortunately air drag associated with a flat surface (such as the leading surface LS of the rectangular bar) is approximately 50% greater than for a circular member of the same height.
By streamlining the horizontal members in the horizontal plane, a horizontal member having reduced wind load may be constructed. One embodiment of a horizontal member in accordance with the teachings of the present invention is illustrated in FIG. 3. In this Figure, the horizontal members are comprised of bars having a cross section corresponding approximately to that obtained by truncating a circular cross section at 20% of its diameter. This cross sectional configuration provides adequate stiffness and strength for use in reflectors such as that illustrated in FIG. 1, while also reducing wind loading. In fact, due to the streamlined profile of these horizontal members they have a drag which is perhaps 1/4 to 1/3 that of a circular cross section of the same depth.
The streamlining of the horizontal members as described is effective to reduce the wind loading thereof because it is known that the wind will generally be passing through the reflector in a horizontal direction. Since the point on the compass from which the wind will originate may vary widely, no preferred streamlining plane exists for the vertical members. It is therefore presently preferred that the vertical members 14 of the reflectors of FIG. 1 be provided with a circular cross section. The cross sectional diameter of these vertical members may be substantially smaller than would be required for correspondingly sectioned horizontal members, since the vertical members are not required to be load supporting in the sense that the horizontal members are.
For reflectors, such as that illustrated in FIG. 1, the horizontal members and vertical members may be interconnected by drilling appropriately sized holes transversely through the center of the horizontal members and inserting the circular vertical members through the openings thus produced. In the preferred embodiment the vertical and horizontal members are then welded, although of course they may instead be fastened together in any other convenient fashion, as by screws, bolts, etc.
FIGS. 4 and 5 provide elevation and plan views, respectively, of an antenna structure comprised of a single bay of a top mount circularly polarized broadcast antenna. This bay 20 includes three circularly polarized antennas 22, 24 and 26, equally spaced circumferentially about a mast 28. Reflectors 30, 32 and 34 are secured to the mast at circumferential locations equally spaced between the antennas. As can best be seen in FIG. 4, each two of these reflectors (such as reflectors 30 and 34 of FIG. 4) serve as a ground plane for the antenna spaced between them. The vertical and horizontal elements of the reflectors 30, 32 and 34 will preferably be constructed as described previously with respect to reflector 10.
Windloading of the reflectors 30, 32 and 34 may be further reduced by reducing the cross sectional size of the portion of the horizontal members adjacent their distal end. This is possible since the loading on the horizontal members diminishes as a function of distance from the supporting mast. In this embodiment the horizontal members may comprise several differently sized bars attached together to approximate, for example, a tapered beam. As shown in FIG. 6, a smaller bar S can be lapped with larger bar L, flat surface to flat surface, and easily welded together. When used in the reflectors of FIGS. 4 and 5 the horizontal members would be disposed with the smaller bar located near the distal end of the reflector, where strength requirements are reduced.
Further benefits can be realized by using similar techniques to reduce the wind loading of the antennas, themselves, and/or other portions of the supporting structure. In FIGS. 4 and 5 it can be seen that the antennas include horizontal elements such as 36, 38 and 40, and vertically disposed elements such as 42, 44, and 46. Again, preferably the horizontal members will be streamlined in the horizontal plane whereas the vertical members will have a circular cross section.
Of course, generally a large number of these bays will be commonly mounted on the single mast 28, spaced at selected intervals therealong. An antenna of this general nature is described in the co-pending application of Donovan, United States Ser. No. 957,030, filed on Nov. 2, 1978.
Although the invention has been described with respect to a preferred embodiment, it will be appreciated that various rearrangements and alterations of parts may be made without departing from the spirit and scope of the invention, as defined in the appended claims. | Stationary antenna structures are disclosed including horizontally disposed elongated members (12) which are streamlined in the horizontal plane to reduce windloading. In the illustrated embodiments these members have a curved upper surface and a flat lower surface (FIG. 3). Vertically disposed members (14) are provided with a circular cross section since the point on the compass from which the wind originates will vary. | 7 |
[0001] This application claims the benefit of priority from the prior Japanese Patent Application No. 2007-002940, filed Jan. 11, 2007, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to optimization of coordinates of a rough cutting tool at cutting work completion, which optimization is essential in order to suppress self-excited vibration responsible for a decrease in machining accuracy and breakage of a rotating tool or a milling cutter and to perform a stable finish cutting work, in a so-called shoulder cutting, in which a milling cutter is moved to work a groove and a periphery of a boss while rotating.
[0003] In a cutting work with a milling cutter, a milling cutter is in some cases low in stiffness to be responsible for generation of that relative vibration between the milling cutter, which vibration is classified into forced vibration and self-excited vibration. A cutting edge of the milling cutter passes through the work to cause a cutting force to act between the milling cutter and the work and the cutting force generates relative displacement whereby the former forced vibration is generated. At this time, the milling cutter or the work vibrates at a cutting frequency determined by a product of the rotating speed of the milling cutter and the number of cutting edges thereof, and in the case where vibration is great, noise and vibration of a milling machine are generated.
[0004] On the other hand, with the latter self-excited vibration, there is generated vibration having a frequency close to a natural frequency of the milling cutter. Such vibration has a feature in that it does not occur just after cutting is begun, but vibration is gradually amplified as cutting proceeds. In this case, a natural frequency of a mechanical system is generally several hundreds Hz in many cases and so noise due to the vibration becomes a relatively high sound.
[0005] There is established an approach, in which the self-excited vibration is modeled by the regenerative theory of vibration as exemplified by, for example, Y. Altintas and E. Budak: Analytical Prediction of Stability Lobes in Milling, Annals of the CIRP Vol. 44, No. 1 (1995) pages 357 to 362 and predicted in numerical analysis. In the theory, a matter that a milling cutter is increased in vibration together with cutting is called a regenerative effect. Specifically, the self-excited vibration is a phenomenon that in a single-degree-of-freedom analytic model shown in FIG. 1 , when a wave surface, which is formed by a cutting edge of a milling cutter 1 one cycle ago cutting a work 2 while vibrating, is cut by a cutting edge, which passes next time, a cutting area 3 become wave-shaped as shown in FIG. 1 and vibration of the milling cutter, which is generated due to variation of a chip thickness of the work 2 , is increased as cut proceeds.
[0006] In FIG. 1 , a chip thickness h(t) of the work 2 at time t is represented by the equation (1) with the use of a tooth passing period Δt, a displacement Δx(t) of the milling cutter, and a chip thickness at first according to a working condition, that is, a feed rate h 0 .
[0000] h ( t )= h 0 −Δx ( t−Δt )+Δ x ( t ) (1)
[0007] On the other hand, in the case of the single-degree-of-freedom shown in FIG. 1 , an equation of motion of the milling cutter is represented by the equation (2) with the use of a mode mass m, which is a factor to determine a compliance transfer function 41 , a spring constant k, a damping ratio c, and an external force F.
[0000] F=m{umlaut over (x)}+c{dot over (x)}+kx (2)
[0008] Also, the external force F in the above-mentioned equation is a cutting force acting between the milling cutter 1 and the work 2 and can be represented by the equation (3) with the use of a chip thickness h(t), an axial depth (a) of cut (an amount, by which the milling cutter 1 cuts in a direction perpendicular to a plane of the drawing in FIG. 1 ), and a proportional constant K, that is, a cutting constant K determined by a combination of a tool geometry and a work material.
[0000] F=aKh ( t ) (3)
[0009] Accordingly, the equation of motion of the milling cutter 1 is given by the equation (4) from the equation (2) and the equation (3).
[0000] {umlaut over (m)}x+c{dot over (x)}+kx=aKh ( t ) (4)
[0010] It is possible to evaluate a transfer function of the system represented by the equation (1) and the equation (4) to calculate a stable axial depth (a) of cut for various tooth passing periods Δt.
[0011] The tooth passing period Δt can be converted into a rotational frequency when the number of cutting edges of the milling cutter is known. By beforehand predicting a chatter-free axial depth (a) of cut to form a NC program, correction of the NC program due to generation of self-excited vibration is made unnecessary, thus enabling a remarkable reduction in man-hour. In view of a vibrational degree of freedom in X direction and in Y direction, it is possible to obtain a stability lobes in a short period of time without repeatedly calculating an acceleration, velocity and displacement acting between the milling cutter and the work, which correspond to respective points of time in a time domain.
[0012] FIGS. 2 a and 2 b are views illustrating a state, in which a grooving work is performed by the use of a milling cutter 1 . FIG. 2 a is a cross sectional view taken along a rotational axis of the milling cutter 1 and FIG. 2 b is a top view as viewed in a direction along the rotational axis of the milling cutter 1 . In this case, when a cutting area 3 (hatched portion), in which a cutting edge 5 of the milling cutter 1 cuts off the work 2 , is projected in a feed direction of the milling cutter 1 , a rectangular shape shown in FIG. 4 a is resulted. Also, when the cutting area 3 is projected in the direction along the rotational axis of the milling cutter 1 , a shape defining a part of a crescent as shown in FIG. 4 b is resulted. The milling cutter 1 is analyzed by a model, which uses compliance transfer functions 41 and 42 in x and y directions.
[0013] Also, in case of further performing a finishing cut on a side of a groove of the work 2 , the milling cutter 1 is moved horizontally relative to the work 2 as shown in the cross sectional view of FIG. 3 and the cutting area 3 on the left and the right of the groove is further subjected to a finishing cut.
[0014] On the other hand, FIG. 4 shows an example, in which the milling cutter is used to perform a cutting work on an L-shaped corner portion of the work. Here, in case of performing a finishing cut on a side and a bottom surface of a cut portion, on which a rough cutting is performed, it is general that after a finishing cut, in which the cutting area 31 is removed from the side of the work 2 as shown in FIG. 4 a , is first performed, the milling cutter 1 is caused to separate from the side of the work 2 as shown in FIG. 4 b and the milling cutter 1 is caused to cut into the bottom surface of the work 2 .
[0015] In this case, since a non-cut portion 33 is formed in a region, in which the side and the bottom surface of the work 2 intersect each other, as apparent from FIG. 4 b , it becomes necessary to use the milling cutter 1 to perform a cutting work on the side and the bottom surface of the work 2 in one stroke in order to restrict the non-cut portion to perform a finishing cut in two regions on the side and the bottom surface of the work 2 .
[0016] As described above, in a shoulder cutting with the use of a milling cutter, self-excited vibration of the milling cutter is liable to occur at the time of a finishing cut and a finishing cut with high accuracy is difficult since a cutting area is not rectangular-shaped but L-shaped in cross section when the finishing cut is performed.
[0017] However, a conventional method of predicting a self-excited vibration can accommodate for only the case where the cutting area 3 projected in the feed direction of the rotating tool as shown in FIG. 2 is rectangular-shaped in cross section, and involves a problem that it is not possible to beforehand predict that condition, in which self-excited vibration is not generated in a finishing cut of a work, in which a cutting area is not rectangular-shaped in cross section, in other words, which has a L-shaped cross section, when a finishing cut is performed after a rough cutting. As a result, when a NC program is formed, man-hour is unlimitedly increased, which causes a bottleneck in a finishing cut in shoulder cutting.
[0018] The invention is related to an approach to prediction of self-excited vibration of cut to cope with such problem, in other words, prediction of a cutting starting position (coordinates) of a rough cutting tool so that generation of self-excited vibration is suppressed in a finishing cut and further a cutting work at the time of the finishing cut becomes maximum in efficiency.
[0019] Prior to describing specific means for solving the problem, an explanation is given to chatter-free axial depth of cut when an oscillatory type of a rotational axis in a milling cutter is maintained in a stable state.
[0020] FIG. 5 is a drawing illustrating the case of a two-degree-of-freedom analytic model, that is, the case where a center of a tool during no vibration and the center of the tool during vibration are disposed two-dimensionally away from each other. According to the publication “Analytical Prediction of Stability Lobes in Milling”, those cutting forces Fx and Fy in X direction and in Y direction, which act on a milling cutter 1 , is represented by the equation (5) with the use of displacements Δx, Δy of the milling cutter 1 during vibration in X direction and in Y direction where the X direction is a feed direction of the milling cutter.
[0000]
[
F
x
F
y
]
=
1
2
a
·
Kt
·
[
a
xx
a
xy
a
yx
a
yy
]
[
Δ
x
Δ
y
]
(
5
)
[0021] However, a xx , a xy , a yx , a yy , respectively, in the equation (5) are represented by the following equations (6) to (9);
[0000]
a
xx
=
∑
j
=
0
N
-
1
-
g
(
φ
j
)
[
sin
2
φ
j
+
Kr
(
1
-
cos
2
φ
j
)
]
(
6
)
a
xy
=
∑
j
=
0
N
-
1
-
g
(
φ
j
)
[
(
1
+
cos
2
φ
j
)
+
Kr
sin
2
φ
j
]
(
7
)
a
yx
=
∑
j
=
0
N
-
1
g
(
φ
j
)
[
(
1
-
cos
2
φ
j
)
-
Kr
sin
2
φ
j
]
(
8
)
a
yy
=
∑
j
=
0
N
-
1
g
(
φ
j
)
[
sin
2
φ
j
-
Kr
(
1
+
cos
2
φ
j
)
]
(
9
)
[0022] ; where, j indicates number of a cutting edge of a milling cutter, N indicates the number of cutting edges of the milling cutter, Φj indicates a rotating angle of a j-th cutting edge of the milling cutter, a indicates an axial depth of cut of the milling cutter 1 , Kt and Kr indicate cutting constants determined by a tool geometry of the milling cutter and a work material, and a xx , a xy , a yx , a yy , respectively, indicate cutting force factors in x, xy, yx, y directions and are functions of time.
[0023] Also, g(Φj) is given by the equation (10);
[0000] g (φ j )=1←φ st <φ j <φex
[0000] g (φ j )=0←φ j <φ st , φ ex <φj (10)
[0024] ; where, as shown in FIG. 5 , Φst indicates an entry angle of a cutting edge, Φex indicates an exit angle of a cutting edge, it is meant that the milling cutter 1 and the work 2 are in contact with each other in the range of Φst<Φj<Φex, and it is meant that the milling cutter 1 and the work 2 are not in contact with each other in the range of Φj<Φst and Φj>Φex.
[0025] Further, the cutting force factors are represented by a matrix (11) and then the equation (5) is converted into the equation (12).
[0000]
[
A
]
=
[
a
xx
a
xy
a
yx
a
yy
]
(
11
)
[
F
x
F
y
]
=
1
2
a
·
Kt
·
[
A
]
[
Δ
x
Δ
y
]
(
12
)
[0026] A matrix [A] is a function of a rotating angle Φj of the milling cutter in the equations (6) to (9), that is, a function of time during rotation. In order to make handling of the equation simple, the equation (13) is used to find a matrix [A 0 ] of a time-invariant cutting force;
[0000]
[
A
0
]
=
1
T
∫
0
T
[
A
]
t
(
13
)
[0027] ; where, T indicates a period, during which a cutting edge of the milling cutter performs cutting, and it is shown that a cutting force is integrated over a cutting period of a cutting edge and averaged by the time. Since this is equal to one obtained by integration with respect to a pitch Φp of a cutting edge of the milling cutter and averaging, the equation (13) is rewritten into the equation (14).
[0000]
[
A
0
]
=
1
φ
p
∫
φ
st
φ
ex
[
A
]
φ
(
14
)
[0028] The cutting edge pitch Φp is represented by the equation (15).
[0000]
φ
p
=
2
π
N
(
15
)
[0029] By defining the matrix [A 0 ] of a time-invariant cutting force as the equation (16), the following equations (17) to (20) are obtained since cutting force factors α xx , α xy , α yx , α yy , respectively, in the equation (16) are equal to ones obtained by integrating the equations (6) to (9) with respect to a rotating angle Φj.
[0000]
[
A
0
]
=
N
2
π
[
α
xx
α
xy
α
yx
α
yy
]
(
16
)
α
xx
=
1
2
[
cos
2
φ
-
2
K
r
φ
+
K
r
sin
2
φ
]
φ
st
φ
ex
(
17
)
α
xy
=
1
2
[
-
sin
2
φ
-
2
φ
+
K
r
cos
2
φ
]
φ
st
φ
ex
(
18
)
α
yx
=
1
2
[
-
sin
2
φ
+
2
φ
+
K
r
cos
2
φ
]
φ
st
φ
ex
(
19
)
α
yy
=
1
2
[
-
cos
2
φ
-
2
K
r
φ
-
K
r
sin
2
φ
]
φ
st
φ
ex
(
20
)
[0030] Subsequently, assuming that a tool compliance transfer function Φ(iω) is given by the equation (21) with the use of tool compliance transfer functions Φxx, Φyy, Φxy, Φyx in x, y, xy, and yx directions, displacements Δx, Δy in x and y directions are given by the equation (22) with the use of the equation (21) and cutting forces Fx and Fy in x and y directions, so that a loop transfer function of a vibration system, which is composed of a milling cutter and a work and in which vibration of a cutting edge one cycle ago is fed back to a chip thickness this time by the principle of the regenerative, is represented by the equation (23).
[0000]
[
Φ
(
ω
)
]
=
[
Φ
xx
(
ω
)
Φ
xy
(
ω
)
Φ
yx
(
ω
)
Φ
yy
(
ω
)
]
(
21
)
[
Δ
x
Δ
y
]
=
[
Φ
(
ω
)
]
[
Fx
(
ω
)
Fy
(
ω
)
]
(
22
)
F
(
ω
)
=
1
2
a
·
Kt
(
1
-
ω
T
)
[
A
0
]
[
Φ
(
ω
)
]
·
F
(
ω
)
(
23
)
[0031] From the loop transfer function, a characteristic equation required for discrimination of stability of the vibration system is given by the following equation (24).
[0000]
det
[
[
I
]
-
1
2
Kt
·
a
·
(
1
-
-
ω
T
)
[
A
0
]
[
Φ
(
ω
)
]
]
=
0
(
24
)
[0032] Here, using the equations (25) and (26), the equation (24) becomes the equation (27).
[0000]
[
Φ
0
]
=
[
A
0
]
[
Φ
(
ω
)
]
(
25
)
Λ
=
-
N
4
π
a
·
Kt
(
1
-
-
ω
T
)
(
26
)
det
[
[
I
]
+
Λ
[
Φ
0
(
ω
)
]
]
=
0
(
27
)
[0000] Here, Λ indicates an eigenvalue of a matrix [Φ0 (iω)].
[0033] As a condition that a vibration system represented by the loop transfer function in the equation (23) should be made stable, it is required that Λ have a negative real part, so that it is possible to calculate the eigenvalue Λ of the matrix [Φ0 (iω)] to calculate a chatter-free axial depth a of cut for a vibration frequency ω and a tooth passing period T with the use of the equation (26).
[0034] By the way, in the conventional method of predicting a self-excited vibration, a cutting area of a work is rectangular-shaped in cross section and so a cutting force matrix in the equation (12) is modeled in numerical expression as in the equations (6) to (9), so that a matrix [A 0 ] of a time-invariant cutting force can be represented in numerical expression as in the equations (17) to (20) by the equation (14).
[0035] In case of subjecting a side and a bottom surface of a work after rough cutting to a finishing cut in one stroke, which is an object in the invention, however, a cutting area is not rectangular-shaped but L-shaped in cross section, and therefore, analysis must be done by using different entry angles Φst and different exit angles Φex with respect to the case where the side surface is cut, and the case where the bottom surface is cut, respectively.
SUMMARY OF THE INVENTION
[0036] Hereupon, in the invention, a compliance transfer function of a finishing cutter, a cutting constant determined by a combination of a shape of a cutting edge of the finishing cutter and a work material, a diameter of the finishing cutter, number of edges of the finishing cutter, a diameter of the rough cutter, number of edges of the rough cutter, coordinates and a range of coordinates upon starting cutting are made to be input values; subsequently, a rotating angle of the finishing cutter and coordinates of the rough cutter in the range of coordinates of the rough cutter are input; it is discriminated whether a cutting edge of the rough cutter is disposed in an area of a cross section in parallel to an axial direction of the finishing cutter and in a cutting area surrounded by a shape of the finishing cutter and a work profile shape; a cutting force is made 0 when the cutting edge is disposed outside the cutting area, and a cutting force is calculated over an overall length of the cutting edge of the finishing cutter when the cutting edge is disposed in the cutting area.
[0037] A time-invariant cutting force is calculated from a total value of a cutting force when the finishing cutter makes one revolution; a processing of discrimination of positive and negative of an eigenvalue obtained by substituting the time-invariant cutting force into a characteristic equation is performed; when the eigenvalue is negative, an efficiency of cutting performed by the use of the finishing cutter is calculated and then coordinates of the rough cutter are corrected in the coordinates range of the rough cutter and the cutting force calculating process is repeated; when the eigenvalue is positive, coordinates of the rough cutter are corrected in the coordinate range of the rough cutter and the cutting force calculating process is again repeated.
[0038] Also, the calculation of a cutting force is performed by changing a rotating angle of the finishing cutter until the finishing cutter makes one revolution.
[0039] Further, a cutting area at the time of finishing cut, which cutting area is surrounded by a shape of the finishing cutter, the work profile shape, and a profile shape of the rough cutter, is divided into minute elements, and the time-invariant cutting force is calculated by repeating a process, in which cutting forces acting on respective elements being different in an entry angle Φst and an exit angle Φex are calculated over a whole cutting edge to find a total value, until the finishing cutter makes one revolution, and finding a cutting force acting on the finishing cutter in a period, during which the finishing cutter makes one revolution.
[0040] Thereby, in a shoulder cutting to a work having a L-shaped cross section, it is possible to appropriately find coordinates of a rough cutter at cutting work completion, in which self-excited vibration of a milling cutter in a finishing cut is suppressed and a stable cutting is made possible.
[0041] As described above, first, given a diameter D′ of a rough cutter, a position O′ (y′, z′) in a rough cutting, a diameter D of a finishing cutter, an upper limit zq of a cutting area, a work end yq in a diametrical direction, a matrix [Φ0 (iω)] of a compliance transfer function of the cutters, the number of cutting edges of the finishing cutter, and cutting constants Kt, Kr, it is possible to predict the presence of generation of self-excited vibration under the given condition, thus enabling finding a position at the time of the rough cutting, in which self-excited vibration is not generated and the working efficiency is made maximum.
[0042] Other objects, features, and advantages of the invention will become apparent from the following description of an embodiment of the invention with respect to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a schematic drawing illustrating a state, in which a milling cutter cuts a work while the milling cutter vibrates (case of a single-degree-of-freedom analytic model in the regenerative theory);
[0044] FIGS. 2 a and 2 b are views illustrating a state, in which a cutting of a groove is performed by the use of a milling cutter, FIG. 2 a being a cross sectional view taken along a rotational axis of the milling cutter, and FIG. 2 b being a top view as viewed in a direction along the rotational axis;
[0045] FIG. 3 is a view illustrating the case where a grooving work is performed by the use of a milling cutter and a groove width is larger than a diameter of the milling cutter;
[0046] FIGS. 4 a and 4 b are cross sectional views illustrating a shoulder cutting of a work with the use of a milling cutter, FIG. 4 a showing a finishing cut of a side surface of a L-shaped worked portion, and FIG. 4 b showing a finishing cut of a bottom surface of the L-shaped worked portion;
[0047] FIG. 5 is a schematic drawing illustrating a state, in which a milling cutter cuts a work while the milling cutter vibrates (case of a two-degree-of-freedom analytic model in the regenerative theory);
[0048] FIG. 6 is an analysis flowchart for calculating those positions of coordinates of a rough cutter at cutting work completion, which prevents a milling cutter from generating self-excited vibration;
[0049] FIGS. 7 a and 7 b are views illustrating the relationship between a rough cutter and a finishing cutter and parameters required for analysis shown in FIG. 6 , FIG. 7 a being a cross sectional view taken along a rotational axis of a milling cutter, and FIG. 7 b being a top view viewed in a direction along the rotational axis;
[0050] FIG. 8 is a view showing a position of a rough cutter when a cutting area in a finishing cut becomes the minimum in the present invention;
[0051] FIG. 9 is a view showing a position of a rough cutter when a cutting area in a finishing cut becomes the maximum in the present invention;
[0052] FIG. 10 is a view showing an example of an analysis result obtained according to the flowchart shown in FIG. 6 ; and
[0053] FIGS. 11 a and 11 b show test results for illustrating an example of a shoulder cutting of a work, FIG. 11 a illustrating a case of cutting under that condition, in which self-excited vibration of a milling cutter is generated, and FIG. 11 b illustrating a case of cutting under that condition, in which generation of self-excited vibration can be suppressed.
DETAILED DESCRIPTION OF THE INVENTION
[0054] A method of finding coordinates of a rough cutter at cutting completion, the coordinates enabling stable finishing cut by a milling cutter, in which self-excited vibration of the milling cutter can be suppressed and high work efficiency can be provided, in the case where a cutting area of a work has a L-shaped cross section as shown in FIGS. 4 a and 4 b will be described in detail below with reference to the drawings.
[0055] FIG. 6 shows an analysis flowchart in the invention. There are first given parameters required for analysis, that is, a cutting constant determined by a combination of a cutting edge shape of a milling cutter and a work material, a tool diameter of and a number of edges of a finishing cutter, a compliance transfer function, a tool diameter of and a number of edges of a rough cutter, tool coordinates of the rough cutter, and a coordinate range, in which the rough cutter can be made present.
[0056] Subsequently, the input values and a rotating angle of the finishing cutter are input, and coordinates of a cutting edge of the finishing cutter corresponding to the rotating angle are calculated every minute element when a cutting area is divided into the minute elements. It is discriminated on the basis of the cutting edge coordinates whether a cutting edge of the rough cutter is disposed in the cutting area surrounded by a shape of the finishing cutter and a work profile shape, and when the cutting edge is disposed in the cutting area, a cutting force acting over an overall length of the cutting edge of the finishing cutter is calculated. Of course, when the cutting edge of the rough cutter is disposed outside the cutting area, cutting force acting on the cutting edge of the finishing cutter is defined to be 0.
[0057] Here, in the cutting force of the finishing cutter calculating process, the procedure from a step of calculating coordinates, in which the cutting edge of the finishing cutter is positioned, to a step of calculating a cutting force acting on the overall cutting edge is repeated every rotating angle of the finishing cutter, a cutting force acting on the finishing cutter in a period, during which the finishing cutter makes one revolution, is calculated for one revolution of the finishing cutter, and a time-invariant cutting force of the finishing cutter is found from a total value thereof.
[0058] Subsequently, a value of the time-invariant cutting force thus found is substituted into a characteristic equation and a stability discrimination process of cutting to discriminate positive and negative of an eigenvalue thus obtained is performed. At this time, in the case where a real number part of the eigenvalue thus obtained is positive, self-excited vibration of the milling cutter is generated with the result that it is determined that the cutting with the use of the finishing cutter is not performed stably on the L-shaped cross section portion, and returning to the cutting force calculating process, coordinate values of the rough cutter are again changed to repeatedly calculate cutting force acting on the cutting edge of the finishing cutter.
[0059] On the other hand, in the case where a real number part of the eigenvalue is negative, it is determined that self-excited vibration is not generated during cutting and stable cutting is performed, and the efficiency in the cutting is calculated. Consecutively, returning to the cutting force calculating process described above, coordinate values of the rough cutter are again changed to calculate a cutting force acting on the cutting edge of the finishing cutter, and the stability discrimination process of an eigenvalue obtained from the characteristic equation and besides the efficiency calculating process are repeatedly carried out.
[0060] Contents of processes in the flowchart shown in FIG. 6 , in particular, a method of calculating a cutting force acting on the milling cutter and discriminating whether the milling cutter generates self-excited vibration, and a method of calculating the efficiency in a finishing cutter will be described in detail below with reference to the drawings.
[0061] FIGS. 7 a and 7 b schematically show a situation when a rough cutter is used to cut a shoulder of a work 2 shown in FIGS. 4 a and 4 b and then a finishing cutter is used to perform cutting on a bottom surface and a side surface of the work 2 formed on the shoulder. FIG. 7 a is a cross sectional taken along a rotational axis of a milling cutter and FIG. 7 b is a top view viewed in a direction along the rotational axis of the milling cutter.
[0062] In FIG. 7 a , assuming that finishing cutting is completed, D indicates a diameter of a finishing cutter 100 and O (0, 0) in a Y-Z plane indicates a central position. D′ indicates a diameter of a rough cutter 101 in a rough cutting process performed prior thereto and O′ (y′, z′) indicates a position in a rough cutting.
[0063] Subsequently, a length zq of a cutting edge of the finishing cutter 100 is divided into minute elements Δz. At this time, 1 indicates a minute element disposed on a most bottom surface side and cutting areas 31 , 32 are divided into M minute elements. However, the cutting areas 31 , 32 , respectively, indicate cutting areas having a rectangular cross section on a bottom surface side and a rectangular cross section on a side surface side, which define a cutting area having a non-rectangular cross section (L-shaped cross section).
[0064] Accordingly, for a cutting edge length zq in FIG. 7 a , a length Δz of a minute element is represented by the equation (28).
[0000]
Δ
z
=
zq
M
(
28
)
[0065] Also, assuming that N indicates the number of cutting edges and ω indicates a rotating angular speed of the cutter for a k-th minute element of a j-th cutting edge, a rotating angle Φjk of the cutting edge in the cutting area 31 of FIG. 7 b is represented at a point of time t by the equation (29). Also, a cutting edge angle Φjk in the cutting area 32 is represented in the same manner as the equation (29).
[0000] φ jk =ωt (29)
[0066] For the rotating angle Φjk with Y axis being 0°, coordinates Pjk (Px, Py, Pz) of the cutting edge is represented by the following equation (30) as shown in FIG. 7 b .
[0000]
[
Px
Py
Pz
]
=
[
D
2
sin
φ
jk
D
2
cos
φ
jk
k
Δ
z
]
(
30
)
[0000] Here, a range, in which Pz changes in the cutting area 31 and the cutting area 32 of the work 2 , establishes kΔz≦z′ in the cutting area 31 on the bottom surface side and kΔz>z′ in the cutting area 32 on the side surface side as shown in FIG. 7 a.
[0067] Further, a range, in which Py is in contact with the work, is represented by −yq≦Py≦D/2 in the cutting area 31 and D′/2−y′≦Py≦D/2 in the cutting area 32 where yq indicates a distance from a center of the finishing cutter 100 to a work end surface.
[0068] From the above, ranges, in which coordinates Pz and Py of a cutting edge can be made present, are represented by the equations (31) and (32).
[0000]
k
Δ
z
≤
z
′
and
yq
≤
Py
≤
D
2
(
31
)
k
Δ
z
>
z
′
and
D
′
2
-
y
′
≤
Py
≤
D
2
(
32
)
[0069] Accordingly, in the case where a k-th minute element Pjk out of M minute elements, into which a j-th cutting edge is divided, meets the equation (31) or (32), it is possible to discriminate that a cutting edge Pjk is disposed inside the cutting area.
[0070] According to the discriminating method, in the case where a cutting edge of the finishing cutter is disposed in the cutting area, cutting forces Fx′ and Fy′, in x direction and in y direction, acting on a whole cutting edge at an any cutter rotating angle Φjk can be represented by the equation (33), in which (a) in the equation (5) is replaced by Δz. Here, cutting constants axx, axy, ayx, ayy in x, xy, yx, y directions are represented by the equations (34) to (37), respectively.
[0000]
[
F
x
′
F
y
′
]
=
∑
k
=
1
M
1
2
Δ
z
·
Kt
·
[
a
kxx
a
kxy
a
kyx
a
kyy
]
[
Δ
x
Δ
y
]
(
33
)
a
kxx
=
∑
j
=
0
N
-
1
-
g
(
φ
j
)
[
sin
2
φ
j
+
Kr
(
1
-
cos
2
φ
j
)
]
(
34
)
a
kxy
=
∑
j
=
0
N
-
1
-
g
(
φ
j
)
[
(
1
+
cos
2
φ
j
)
+
Kr
sin
2
φ
j
]
(
35
)
a
kyx
=
∑
j
=
0
N
-
1
g
(
φ
j
)
[
(
1
-
cos
2
φ
j
)
-
Kr
sin
2
φ
j
]
(
36
)
a
kyy
=
∑
j
=
0
N
-
1
g
(
φ
j
)
[
sin
2
φ
j
-
Kr
(
1
+
cos
2
φ
j
)
]
(
37
)
[0000] However, g(Φj) is represented by the equation (38), in which the equations (31) and (32) are used to represent a range of Φj in the equation (10).
[0000]
g
(
φ
jk
)
=
1
←
k
Δ
z
≤
z
′
,
yq
≤
Py
≤
D
2
or
,
k
Δ
z
>
z
′
,
D
′
2
-
y
′
≤
Py
≤
D
2
g
(
φ
jk
)
=
0
←
k
Δ
z
≤
z
′
,
Py
<
yq
or
,
k
Δ
z
>
z
′
,
Py
<
D
′
2
-
y
′
(
38
)
[0000] Here, it suffices to calculate cutting forces Fx′ and Fy′, which act on the cutting edge while determining whether the equations (34) to (37) are inside the cutting area by the equation (38) and while changing Φj every minute angle ΔΦj obtained by dividing one revolution of the tool, that is, 2π (rad) into Q sections, so that cutting forces Fx, Fy of a whole cutting edge acting in a period, during which the finishing cutter makes one revolution, can be represented by the equation (39). Therefore, the equation (40) represents a time-invariant cutting force in the invention.
[0000]
[
F
x
F
y
]
=
N
2
π
∑
j
=
1
t
Δφ
j
∑
k
=
1
M
1
2
Δ
z
·
Kt
·
[
a
kxx
a
kxy
a
kyx
a
kyy
]
[
Δ
x
Δ
y
]
(
39
)
[
A
1
]
=
N
2
π
∑
j
=
1
t
Δφ
j
∑
k
=
1
M
1
2
Δ
z
·
Kt
·
[
a
kxx
a
kxy
a
kyx
a
kyy
]
(
40
)
[0071] Also, since Loop Transfer Function is represented by the equation (41), the characteristic equation is given by the equation (42).
[0000] F ( i ω)=(1 −e iωT )[ A 1 I Φ( i ω)]· F ( i ω) (41)
[0000] det└[I ]−(1 −e −iωT )[ A 1 I Φ( i ω)]┘ (42)
[0000] Here, the equation (45) is deduced by substituting the equations (43) and (44) into the equation (42), an eigenvalue Λ of a matrix [(Φ0 (iω)] is found, and when a real number part of the eigenvalue Λ is negative, it is meant that self-excited vibration of the finishing cutter 100 is not generated and the finishing cut is stably performed. On the other hand, in the case where a real number part of the eigenvalue Λ is positive, the finishing cutter 100 generates self-excited vibration during the finishing cut and so it is not possible to perform a stable cutting.
[0000] [Φ 0 ]=[A 1 I Φ( i ω)] (43)
[0000] Λ=1 −e −iωT (44)
[0000] det[[I]+Λ[Φ 0 ( i ω)]]=0 (45)
[0072] Subsequently, an explanation will be given to a method of calculating the efficiency by a finishing cutter.
[0073] As described above, in the case where the cutting is stably performed, the efficiency therefor is calculated. The magnitude correlation in the efficiency can be determined by comparison of an area of the cutting area projected in a feed direction of the milling cutter.
[0074] As shown in FIG. 7 a , a range, in which coordinates of the rough cutter can be made present, in a z direction is given by the equation (46).
[0000] 0<z′<zq (46)
[0075] Also, as apparent from the arrangement of the milling cutters shown in FIG. 8 , a case where the cutting area in Y direction becomes minimum is the time when the finishing cutter 100 and the rough cutter 101 agree with each other on a side surface portion of the cutting area of the work 2 , and a range thereof is given by the equation (47).
[0000]
y
′
=
D
2
-
D
′
2
(
47
)
[0076] On the other hand, from the arrangement of the milling cutters shown in FIG. 9 , a case where the cutting area becomes maximum is the time when an edge point of the rough cutter 101 is positioned at an end of the work 2 and a range thereof is given by the equation (48).
[0000]
y
′
=
yq
+
D
′
2
(
48
)
[0077] Accordingly, an area S (area represented by the sum of the cutting areas 31 , 32 and indicated by hatched portions in FIG. 7 a ) composed of the cutting area 31 and the cutting area 32 shown in FIG. 7 a and projected in a feed direction of the finishing cutter 100 is found in a coordinate range of the rough cutter of the equations (46) to (48) by the equation (49) in FIG. 7 a . Accordingly, the larger the projected area S, the larger metal removal rate of the milling cutter in a finishing cut, so that a high efficiency results.
[0000]
S
=
zq
·
(
D
2
+
yq
)
-
(
zq
-
z
′
)
(
D
′
2
+
yq
-
y
′
)
(
49
)
[0078] In this manner, coordinates z′, y′ of a center of rotation of the rough cutter are changed in a range, which is set in the manner described above and in which coordinates of the rough cutter can be changed in the rough cutting, and calculation is repeated. Then z′, y′, in which the efficiency becomes maximum in the set range under all stable conditions, are represented.
[0079] As described above, by first using the diameter D′ of the rough cutter 101 , the position O′ (y′, z′) in a rough cutting, the diameter D of the finishing cutter 100 , an upper limit zq of the cutting area, a work end yq in a diametrical direction, the matrix [Φ0 (iω)] of a compliance transfer function of the cutter, the number of cutting edges of the finishing cutter, and cutting constants Kt, Kr, a matrix [A1] of a time-invariant cutting force of the finishing cutter 100 is calculated from the equation (40), a matrix [Φ0 (iω)] is obtained by substituting the results of the equation (40) into the equation (43), and on the basis of a numeric value of the eigenvalue Λ obtained as a result thereof, it becomes possible to determine the presence of self-excited vibration of the finishing cutter 100 during cutting.
[0080] By changing the position O′ of the rough cutter in a set range, repeating the procedure from the calculation of the cutting edge coordinates to the calculation of the eigenvalue, and further repeating the process of determining whether self-excited vibration of the finishing cutter occurs, it is possible to find those coordinates of the rough cutter at cutting completion in a process of a rough cutting, in which self-excited vibration does not occur and the efficiency becomes maximum. In other words, it is possible to estimate a cutting termination position of the rough cutter for a finished shape, that is, a cutting region, in which a finishing cutting is stably and efficiently performed.
[0081] FIG. 10 shows an example indicating coordinates y′, z′ of the rough cutter at cutting work completion, which are calculated according to the flowchart shown in FIG. 6 , the presence of self-excited vibration of the finishing cutter at this time, and an area of a cutting area as efficiency with no occurrence of vibration.
[0082] A shoulder cutting of aluminum alloy was performed under that cutting condition, in which the diameter D′ of the rough cutter and the diameter D of the finishing cutter were 25 mm and the cutters were of two edge structure. As apparent from the results thereof, y′=7 (mm) and z′=4 (mm) for coordinates of the rough cutter at cutting work completion are selected as that condition, in which the efficiency by the finishing cutter becomes maximum, and the condition is represented as being surrounded by a frame. Also, while the example indicates the case where y′>z′, it is possible to obtain that analysis result, in which the efficiency in case of y′<z′ becomes maximum, in the same manner.
[0083] FIG. 11 shows an example of actual cutting. A work (aluminum alloy) was cut to have a L-shaped cross section being 20 mm in width and 17 mm in length and FIG. 11 a shows an example of cutting under that condition, in which a finishing cutter generates self-excited vibration, and a cut surface has the surface roughness of Rmax=23 μm.
[0084] On the other hand, FIG. 11( b ) shows results of cutting under the condition surrounded by a frame in FIG. 10 , that is, that condition, in which self-excited vibration of a finishing cutter is not generated. As a result, a surface subjected to the cutting and being very excellent in flatness to have the surface roughness of Rmax=7.8 μm could be realized.
[0085] As described above, in case of a shoulder cutting of a work, which is free in one part, through a process of rough cutting and finishing cutting with accuracy, the analysis method according to the invention is used to define positions of coordinates of a rough cutter at cutting work completion whereby a finishing cut being a next process can be performed efficiently in a stable state without occurrence of self-excited vibration of a milling cutter. Further, when that cutting condition, in which self-excited vibration of a milling cutter is not occurred, can be beforehand known, a period of time required for correction of a NC program, etc. can be shortened and a great effect is produced on an improvement in productivity in the field of cutting work.
[0086] While the embodiment has been described, it is apparent to those skilled in the art that the invention is not limited thereto but various modifications and corrections can be made within the spirit of the invention and a scope of the appended claims. | Using parameters such as diameters of a rough cutter and a finishing cutter, a position of a tool at cutting work completion in a rough work, a finishing cutting area, specifications of a rotating tool (the number of cutting edges, a cutting force eigenvalue, a compliance transfer function), etc., a cutting force acting on a cutting edge of the rotating tool is found, and results thereof are made use of to analyze a characteristic equation being a loop transfer function of a vibration system composed of the rotating tool and a work, whereby it is possible to predict presence of generation of self-excited vibration of the finishing cutter performed after a rough work in a shoulder cutting work. Thereby, the rotating tool operates stably in a finishing work and besides shoulder cutting of a work can be performed in a high work efficiency. | 1 |
CROSS-REFERENCE TO A RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 60/565,917, filed Apr. 28, 2004, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The subject invention relates to the field of optoelectronics.
BACKGROUND OF THE INVENTION
In the development of solutions for reducing the radiation risks associated with manned space flight, radiation shielding materials have been developed to protect personnel and equipment from the damaging effects of radiation, including galactic cosmic radiation (GCR). Polyethylene (PE) is a favorable material because it exhibits many high performance properties (i.e., strength, thermal, and optical). However, the use of PE is limited to low temperature applications and to those applications wherein visibility through the polymer is not required, because PE is an opaque polymer.
The incorporation of carbon nanotubes (CNTs) into polymer matrices has resulted in composites that exhibit increased thermal stability, modulus, strength, electrical and optical properties (Shaffer et al. 1999; Jin et al. 2001; Haggenmueller et al. 2000; Jia et. al 1999; Ounaies et al. 2003, Park et al. 2005, Tatro et al. 2004; Siochi et al. 2003; Clayton et al. 2005). Several investigations have concluded that carbon nanotubes can also act as a nucleating agents for polymer crystallization (Ryan et al. 2004; Cadek et al. 2004, Ruan et al. 2003).
Various processing techniques have been employed to uniformly disperse the nanotubes in an attempt to increase interaction at the polymer/nanotube interface (Shaffer et al. 1999; Jin et al. 2001; Haggenmueller et al. 2000; Ounaies et al. 2003, Park et al. 2005, Tatro et al. 2004; Siochi et al. 2003; Clayton et al. 2005).
SUMMARY OF THE INVENTION
In the embodiment, the subject invention provides a transparent polymer composites with radiation resistant qualities. Another embodiment of the subject invention provides methods of fabrication of radiation resistant polymer composite. Yet other embodiments of the subject invention provide methods of using the polymer composites as a deep space shielding material, and the subject methods can also include methods of using the polymer composite in various radiation prone environments on Earth, and in space, including service on other planets or moons. In certain embodiments, the subject invention provides composites with improved optical properties. Specifically, certain composites of the subject invention maintain transparency when exposed to radiation and, accordingly, are useful in applications wherein visibility is paramount.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the UV-VIS data of the neat 4-methyl-1-pentene (PMP) and a PMP/CNT composite.
FIG. 2 depicts optical photographs of transparent PMP/CNT films.
FIG. 3 is a scanning electron microscope (SEM) image of a PMP/CNT composite.
FIG. 4 is a scanning electron microscope (SEM) image of a PMP/CNT composite.
FIG. 5 is another SEM image showing that although the films are transparent and nanotube agglomerates are not visible to the naked eye, nanotubes are present within the matrix.
FIG. 6 is yet another SEM image showing that although the films are transparent and nanotube agglomerates are not visible to the naked eye, nanotubes are present within the matrix.
FIG. 7( a ) illustrates carbon nanotubes sonicated in 1-chlorohexane. The carbon nanotubes were pretreated with DMF. The 1-chlorohexane did not dissolve PMP, nor did it effectively disperse the pretreated carbon nanotubes.
FIG. 7( b ) illustrates carbon nanotubes sonicated in cyclohexyl chloride. The carbon nanotubes were pretreated with DMF.
FIG. 7( c ) illustrates a uniformed mixture of cyclohexyl chloride, PMP, and carbon nanotube.
FIG. 8( a ) illustrates an optical micrograph of neat PMP. The magnification is 10×0.3.
FIG. 8( b ) illustrates an optical micrograph of a 0.5% PMP/single wall carbon nanotube composite. The magnification is 10×0.3.
FIG. 9 illustrates DSC Plot of neat PMP.
FIG. 10 illustrates DSC Plot of neat PMP/SWNT.
FIG. 11 illustrates Loss Modulus (E″) plotted against temperature for neat PMP and PMP/SWNT.
FIG. 12 illustrates DMA data at 60 Hz of E′ and E″.
FIG. 13 illustrates Arrhenius plot for neat PMP from 1 Hz to 100 Hz.
FIG. 14 illustrates an Arrhenius plot for 0.5% PMP/SWNT from 1 Hz to 100 Hz.
FIG. 15 illustrates a master curve of neat PMP and PMP/SWNT composite from 3×10 −6 Hz to 1000 Hz.
FIG. 16 illustrates master curve of reported T g region for PMP using WLF shift constants.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of various embodiments, reference is made to the accompanying drawings, which form a part hereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention.
One aspect of the subject invention is directed to a unique polymer nanocomposite technology. Polymers exhibiting high potential for shielding galactic cosmic radiation (GCR) were processed into composites while enabling a high level of processability for integrating the composites into apparatus exposed to ionizing radiation, including GCR, when in use. Thus, the composites can be processed into, for example and without limitation, spacecraft, manned space vehicles, spacesuits, and manned planetary terrestrial living quarters.
The composites of the subject invention comprise carbon nanotubes, which are incorporated into the matrix of a polymer. Specifically, the carbon nanotubes are single wall carbon nanotubes. Carbon nanotubes are 100 times stronger than steel, exhibit excellent electrical and mechanical strength, and are light in weight. Due to their weight, CNTs are thought to be ideal fillers in the PMP matrix in order to produce a composite with GCR resistant properties, as well as with enhanced electrical and mechanical properties. Materials that are light in weight are better in resisting GCR and limiting secondary radiation.
The nanotube concentration in the polymer is between about 0.1% and about 10%. More preferably, the nanotube concentration is between about 0.1% and about 5%. Most preferably, the nanotube concentration is about 0.5%. The nanotube concentration can be adjusted by mixing heat melted polymer with the polymer/CNT composite in a mixer.
In one embodiment, the polymer consists of carbon and hydrogen only. The polymer also exhibits solubility in organic solvents. Preferably, the solvents are cyclohexane and cyclohexene. The melting point temperatures of the polymer are preferably within the range of 200° C. and 400° C. Preferably, the temperature range is within about 225° C. and about 275° C. Also, to obtain transparent composites, the polymer should be transparent in the visible region of the Electromagnetic Spectrum. FIG. 2 illustrates the transparency of one embodiment of the transparent polymer/SWNT composite.
FIGS. 1-6 all illustrate various properties of the PMP/single wall carbon nanotube specific embodiment.
Advantageously, PMP, a linear hydrocarbon, exhibits superior strength, thermal, and optical properties when compared to polyethylene (PE), a polymer commonly used in current space applications. The isotatic form of this polymer is highly crystalline, yet is optically transparent as a result of having a crystalline phase with a lower density (0.828 g/cm 3 ) than the amorphous phase (0.838 g/cm 3 ) (Lopez et. al 1992). Specifically, PMP dissolves in a variety of solvents including cyclohexyl chloride, cyclohexane and cyclohexene. PMP has a much broader temperature use range than PE because it has a melt temperature, T m , of around 235° C.-245° C. as compared to that of 136° C. for PE. Accordingly, the thermal properties of PMP extend the temperature range for shielding materials. The tensile strength of high density PE is 21-38 MPa, while that of PMP is 23-28 MPa. The tensile modulus of high density PE is 0.41-1.24 GPa. For PMP tensile moduli are reported in the range from 0.8 to 1.2 GPa. The skilled artisan would understand that these are representative values under similar test conditions. Sample preparation, annealing, and any additives will affect these properties. Advantageously, PMP is transparent in the visible region of Electromagnetic Spectrum; PE is not.
The polymers of the subject invention can be modifying by doping with an organic dye, which has at least one phenyl ring.
The field of optoelectronics could also benefit from the incorporation of carbon nanotubes in PMP. The fabrication of a polymer-nanotube composite with enhanced electrical properties while limiting the loss of transparency would serve many applications where these properties are needed, such as electrostatic charge dissipation (ESD) (static control) in which the goal is to increase electrical conductivity while limiting the loss of transparency. ESD is beneficial in clean rooms, offices and laboratories, assembly processes, and much more. GE also custom designs plastics where ESD is needed.
Another aspect of the subject invention is directed to methods of preparing the polymer/CNT composites. The composites can be prepared by dissolving the polymer in a solvent and sonicating the CNTs in a separate sample of a second solvent. Preferably, the first solvent and the second solvent are the same. Preferably, the solvent is a halogenated hydrocarbon. More preferably, the halogenated hydrocarbon is cyclohexyl chloride. Optionally, the CNTs can be pretreated with polar solvent, for example, N,N-dimethyl formamide (DMF) or chlorobenzene. To disperse the CNTs throughout the polymer, the sonicated CNT solution is mixed with the polymer solution and sonicated. If the polymer falls out of solution at room temperature, it may be necessary to perform these steps with the solvent heated to and maintained at an elevated temperature. Preferably, the elevated temperature is within the range of about 70° C. and 110° C. More preferably, the elevated temperature is at about 90° C. The resulting polymer/CNT solution can be spun coated onto a device to apply a radiation resistant coating. Optionally, the resulting polymer/CNT solution can be heated and molded into a device that is used in an environment that is exposed to ionizing radiation.
Yet another aspect of the subject invention is directed to methods of using the composites. Because of the composites' ability to resist ionizing radiation, an apparatus that is exposed to radiation when in use can be composed at sufficient amount of the composite to resist radiation. Preferably, the composite is found on the surface of the apparatus. The subject composites can be applied as a coating on the outer surface of the apparatus. The composite optionally can be molded into an end-use equipment, for example, where it would become a structural part of the apparatus.
As noted above, the polymer can be doped with an organic dye having at least one phenyl ring. Composites prepared with doped polymers are useful in thermoluminescent detection. High energy particles and radiation excite π electrons in the phenyl rings of the organic dyes; photons are emitted when the electronics relax to the ground state. These photons can be transported to photodetecters and counted. In this way, the radiation environment of the shielding materials can be continuously monitored. Thus, the composites of the subject invention can be used to monitor ionizing radiation.
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a composite” includes more than one such composite, a reference to “the method” can include more than one method, and the like.
The terms “comprising”, “consisting of”, and “consisting essentially of” are defined according to their standard meaning and may be substituted for one another throughout the instant application in order to attach the specific meaning associated with each term.
As used herein, the term “CNT” refers to carbon nanotubes or a carbon nanotube.
As used herein, the term “SWNT” refers to a single wall carbon nanotube or single wall carbon nanotubes.
As used herein, the term “PMP” refers to the polymer poly(4-methyl-1-pentene) and is interchangeably with “P4M1P”.
Materials and Methods
The poly (4 methyl-1-pentene) and cyclohexyl chloride solvent were purchased from Sigma Aldrich (Milwaukee, Wis.). The N,N-dimethylformamide solvent was obtained from Fisher Scientific (Pittsburgh, Pa.). Purified laser ablated single-walled carbon nanotubes (SWNT) were provided by the Center for Nanotechnology/NASA Ames Corporation (Moffett Field, Calif.).
Dynamic Mechanical Analysis
The viscoelastic properties were collected on a TA Instruments 2980 Dynamic Mechanical Analyzer (DMA). The mode was set to measure a tension film from frequencies ranging from 1 to 100 Hz with an amplitude of 5 microns. The average sample size was 14.4×5.8×1.3 mm. Because measurements are time, temperature and frequency dependent a temperature range was taken from −150° C. to 300° C.
Microhardness
The Vickers hardness number (HV) for each sample was determined with a Leica VMHT MOT with a Vickers indenter. The values were taken from the average of four indents. A horizontal and a vertical reading were taken on each indent. A load of 500 g and a dwell time of 20 s were used. HV values were expressed in MPa by multiplying by 9.807.
Differential Scanning Calorimetry
Melt temperatures (T m ) and percent crystallinity were obtained on a TA Instruments 2920 DSC. A sample amount between 2-10 mg was obtained from the compression molded sample. The samples were heated to 300° C. at a rate of 5° C. per minute to insure that all samples had the same thermal history. The sample was cooled with liquid nitrogen to room temperature and reheated to 300° C. The T m and percent crystallinity values were taken from the second heat. Percent crystallinity values were calculated based on a 100% crystalline polymer with a heat of fusion of 61.7 J/g (Zoller et al. 1986; Miyoshi et al. 2004; Reddy et al. 1997).
a) Differential Scanning Calorimetry (DSC): A TA Instruments 2920 DSC is used to scan 5 mg samples at a rate of 3° C./min. Glass transition temperatures and melting points are determined.
b) Dynamic Mechanical Analysis (DMA): Rectangular samples 3.0 cm×0.5 cm×0.1 cm is compression molded. Shear and tensile moduli is recorded on a TA Instruments DMA 2980 at different frequencies from −150° C. to temperatures at which the samples are unable to bear loads. This defines the use temperature for the materials. An increase in moduli and glass transitions temperatures accompanies SWNT incorporation.
c) Dielectric Analysis (DEA): Disks are compression molded and scanned in a TA Instruments 2970 DEA. The real and imaginary components of the dielectric constant are determined. A standard analysis of viscoelastic properties ensues. Neat PMP and neat PE are not dielectrically active. Composites are tested via DEA.
d) UV Visible Spectroscopy and Transparency: Samples are compression molded in 1 cm diameter disk molds with a thickness of 0.5 cm. Ferrotyping plates will be used on each side of the mold to ensure optical surfaces. Transmission spectra are recorded with an 8452A Hewlett-Packard UV/Visible Spectrophotometer. Neat PMP and low concentration SWNT composites are studied. PE is opaque.
e) Refractive Index: An Abbè Refractometer equipped with a solid sample assembly will be used to determine the refractive indexes of any transparent samples. The incorporation of nanotubes should increase the refractive index of the systems due to incorporation of aromatic moieties.
f) Conductivity: Thin films of the polymer/nanotube composite are spun coat using a Chemat Tech Spin Coater, KW-4A. A four point probe is used to measure the conductivity of the thin films.
g) Tensile Modulus and Tensile Strength: Dog-bone shaped samples are compression molded. A Q-Test Universal Tester is used to determine the modulus and strength of the samples. Samples are deformed at a cross head speed of 0.5 inch/min.
h) Microhardness: A Leica VMHT MOT with a Vickers indenter is used to determine the Vickers hardness number (HV). Four indentations are made on each sample using a load of 500 g and a dwell time of 20 s. The Vickers hardness number is based on the average diagonal length of an imprint made from the indentor. Both the horizontal and vertical diagonal lengths are measured for each indentation. The values reported are an average of these eight measurements.
i) Fourier Transform Infrared Spectroscopy (FTIR): A Nicolet Magna 500 FTIR is used to characterize the PMP synthesized in-house and by Phillips. The symmetric stretching in carbon nanotubes does not give rise to IR absorption bands.
j) Nuclear Magnetic Resonance is used to monitor PMP purity and stereoregularity via a Bruker DPX 250 instrument.
k) Scanning Electron Microscopy (SEM): A Hitachi S-800 Field Emission HRSEM is used to characterize the molded surfaces and fracture surfaces of the nanotube/polymer composites in order to monitor dispersion.
l) Transmission Electron Microscopy (TEM): Phillips FEI Transmission Electron Microscope is used to characterize dispersion of the nanotubes at higher magnifications than those obtained with SEM.
EXAMPLE 1
Single-Walled Carbon Nanotube Preparation
Raw laser ablation material provided by NASA Johnson Space Center was purified as described elsewhere (Liu, J. et al. (1998) “Fullerene Pipes”, Science. 280(5367):1253-1256.). The raw nanotubes were refluxed in 2.6 M nitric acid for approximately 160 hours and then diluted with double distilled water. This solution was then centrifuged (4000 rpm), the solvent mixture decanted, and the sample was again suspended in double distilled water. This step was repeated two more times in order to remove the acid from the nanotubes. Finally, the solution was filtered through a cellulose nitrate filter and died at 60° C. in a vacuum oven to form a buckypaper.
Polymer/Nanotube Composite Synthesis
Commercial low molecular weight poly (4-methyl-1-pentene) with a measured T m of 235° C. was dissolved in cyclohexyl chloride at 110° C. to make a 3.5% solution. Laser ablated SWNTs were sonicated in N,N-dimethylformamide (DMF) using a Branson Sonifer 450 for 1 hour. The nanotube/DMF dispersion was placed in a vacuum oven at 80° C. to remove the solvent. The DMF treated nanotube paper was then dispersed in cyclohexyl chloride via sonication for 6 hours. The nanotube/solvent mixture was added to the polymer solution and sonicated together for 1 hour. The polymer/nanotube/cyclohexyl chloride mixture was placed in a warm beaker lined with teflon film and the solvent was allowed to evaporate at room temperature for 12 hours, and then placed in a vacuum oven at 80° C. to remove any residual solvent. The dried composite with 0.5% (by wt) of SWNTs was compression molded for analysis. Pieces were placed between KAPTON film and stainless steel plates and pressed for 5 minutes at 5000 pounds of pressure at a temperature of 246° C. Neat PMP was prepared in the same manner. After processing, the measured T m for the neat and composite sample was 235° C.
Sample Characterization
Ultraviolet-visible spectra were recorded with an Agilent Technologies 8453 UV-VIS Diode Array spectrophotometer. A glass slide served as the blank. FIG. 1 shows the UV-VIS data of the neat 4-methyl-1-pentene (PMP) and PMP/CNT composite.
FIGS. 3 and 4 are scanning electron microscope images of the PMP/CNT composite. The image evidences the presence of a carbon nanotube coated by the polymer matrix. FIGS. 5 and 6 are more SEM images. SEM images prove that although the films are transparent and nanotube agglomerates are not visible to the naked eye, nanotubes are present within the matrix.
Carbon nanotubes in the powder form may be used instead of the buckypaper. This will allow for better yield and dispersion. Nanotube concentrations ranging form 0.10%-20% are also within the scope of this invention.
1-chlorohexane did not dissolve the polymer nor was it efficient at dispersing the nanotubes ( FIG. 7( a )). Cyclohexyl chloride was found to create a uniformed solvent/nanotube mixture ( FIG. 7( b )) as well as a uniformed solvent/polymer/nanotube mixture ( FIG. 7( c )). FIG. 8(B) is an optical micrograph of the P4M1P thin film. FIG. 8( a ) is that of the neat.
Dynamic Mechanical Analysis
PMP has three reported mechanical relaxations: the α a also referred to as β(α a ) ranging from 20° C.-67° C. (Woodward et al. 1961; Miyoshi et al. 2004; Reddy et al. 1997), a broad high temperature relaxation (α c ) ranging from 105° C.-135° C. (Lopez et al. 1992; Reddy et al. 1997; Choy et al. 1981; Miyoshi et al. 2004) and a low temperature peak (γ or β sc ) was also observed at −123° C. (Woodard et al. 1961) and −140° C. (Choy et al. 1981). The low temperature relaxation (γ) was not seen in the frequency range used for this study. It is defined as the rotation of the side groups and depends on the amount of amorphous character present (Lopez et al. 1986). The α a transition is the glass transition region associated with the segmental motion of the polymer main chain (Penn 1966; Choy et al. 1981). The nature of the α c transition is associated with motions within the crystalline phase and is believed to be an expansion of the unit cell parameter a (Lopez et al. 1992, Penn 1986, Ranby et al. 1962).
FIG. 11 is a plot of the loss modulus (E″) plotted against temperature for the neat and composite samples from −150° C. to 250° C. and 1 Hz to 60 Hz. The loss modulus of the composite sample increases with the addition of the carbon nanotubes. The high temperature relaxation (α c ) is more pronounced in the composite sample as compared to the neat. The percent crystallinity, as determined from DSC plots, ( FIGS. 9 and 10 ) for the neat and composite samples was 68% and 74%, respectively. The elastic modulus (E′) represents the material's stiffness. The stiffness of the composite at 60 Hz and −50° C., 25° C., and 50° C. is higher than that of the neat as indicated in Table 1, with the highest modulus existing at temperatures below the T g region ( FIG. 12 ). Further, an increase in stiffness should correlate to an increase in the percent crystallinity of the polymer (Gedde 1999). To further support the increase in viscoelastic properties, the composite had a Vickers hardness number of 97 MPa as compared to 82 MPa for the neat.
TABLE 1
Storage Modulus (E') values at 60 Hz.
E' (MPa) @ 60 Hz
−50° C.
25° C.
50° C.
Neat PMP
2409
1710
918
0.5% PMP/CNT
3716
2713
1494
The enhanced relaxation intensity of the crystalline region (α c ) is indicative of increased interaction between the carbon nanotubes and polymer matrix. Studies have shown that carbon nanotubes can act as nucleating agents (Ryan et al. 2004; Cadek et al. 2004, Ruan et al. 2003; Bhattacharyya 2003). It was shown that uniform dispersion and good interfacial bonding between CNTs and polyethylene resulted in secondary crystal growth, thus enhancing the ductility of the composite (Ruan et al. 2003). Further, a crystalline layer formed on MWNTs, contributed to the enhanced mechanical properties of polyvinylalcohol/MWNT composites (Cadek et al. 2004).
In semi-crystalline polymers, the glass transition region is restricted by crystals and exhibit broader relaxations than in the T g region of fully amorphous polymers (Gedde 1999). Thus, glass transition temperatures are difficult to decipher in differential scanning calorimetry plots. However, DMA is a useful tool in determining these values. Moreover, being that relaxations are time, temperature and frequency dependent, T g values reported from DMA must specify the frequency in which the temperature is reported. The glass transition temperatures for the neat and composite samples taken at 60 Hz were found to be 37° C. and 43° C.
The maximum loss peak height obtained from DMA will shift to higher temperatures. In a narrow temperature range, the shift or frequency is linear (Gedde 1999). Temperature dependency of semi-crystalline polymers conforms to Arrhenius behavior (McCrum 1967). FIGS. 13 and 14 are Arrhenius plots of neat PMP and the composite. Activation energies were obtained by multiplying the slope of the line by the gas constant (1.987 cal/mol K). The neat had an activation energy of 59 kcal/mol with that of the composite being 76 kcal/mol. The energy needed to induce flow in the composite was higher. The reason for this increase is two-fold: (1) the presence of the nanotubes hindering chain movement and (2) the presence of a crystal layer on the CNTs, thus increasing the crystallinity in this region which in turn restricts the mobility of the amorphous region. Activation energies associated with viscous flow are large due to the cooperative behavior present in this region (Starkweather 1981). Lee and Hiltz (1984) obtained an activation energy of 106 kcal/mol and Choy et al. (1981) reported 60 kcal/mol. Activation energies vary depending on the method used for testing, thus they are only approximations.
The Williams, Landel and Ferry equation (1) accounts for curvature present in the Arrhenius plot (Gedde 1999; Starkweather 1981). In this study, the values for C 1 , C 2 , and the reference temperature T o (T g ) were obtained from a curve fitting program (Gao 1997); a T represents the shift factor or frequency and T is the given temperature. Table 2 lists the values reported by Penn (1966) and Lee and Hiltz (1984). Deviations from the universal constants are typical due to variations in the glass transition temperatures and the methods used to obtain these values (McCrum 1967).
log
a
T
=
-
C
1
(
T
-
T
o
)
C
2
+
(
T
-
T
o
)
(
EQ
1
)
TABLE 2
WLF shift constants for poly (4-methyl-1-pentene)
Sample
T o
C 1
C 2
Universal constants
—
17.4
51.6
Neat PMP
32.6
9.90
56.3
0.5% PMP/CNT
37.7
10.2
48.1
Lee and Hiltz*
—
20.7
37.0
Penn*
25.0
17.3
40.4
The WLF shift constants, C 1 and C 2 , can be used to predict mechanical behavior of a polymer over a wide range of frequencies. In this study, 1 Hz, 3 Hz, 6 Hz, 10 Hz, 30 Hz, 60 Hz, and 100 Hz were used to obtain mechanical data. To further understand the behavior of PMP as a function of time and temperature over a wide range of frequencies a master curve was generated utilizing the WLF shift constants. FIG. 15 is a plot of master curves for the neat and composite samples. It is clear that over a wide range of frequencies and temperatures, PMP conforms to WLF. FIG. 16 is a plot of the glass transition region of PMP using the WLF shift constants. These results are comparable to WLF treatment of PMP previously published (Penn 1966; Lee and Hiltz 1984).
The WLF constants can also be used to calculate the fractional free volume (f g ) and the thermal expansion coefficient (α f ) (Table 3) of a polymer (Aklonis et al. 1972; Emran 2000). Equations 2 and 3 were used to calculate f g and α f , where B is equal to 1.
f g = B ( 2.303 ) C 1 ( EQ 2 ) α f = f g C 2 ( EQ 3 )
f g defines the amount of unoccupied space between chain segments as a result of chain segment packing (Aklonis et al. 1972). Conclusions can not be made based on the calculated fractional free volume and coefficient of thermal expansion for the neat and composite sample due to the small loading of carbon nanotubes; however, it can be stated that the composite can be used in applications in which the pure polymer is desired.
TABLE 3 WLF constants and calculated fractional free volume and expansion of thermal coefficient values. Sample T o C 1 C 2 f g a f Neat PMP 32.6 9.90 56.3 0.0439 0.779 0.5% PMP/CNT 37.7 10.2 48.1 0.0430 0.884
Conclusions
Carbon nanotubes were successfully incorporated into poly(4-methyl-1-pentene). The processing technique employed was found to be effective in dispersing the nanotubes in the polymer. Further, analysis of the composite confirmed that the nanotubes did in fact serve as a good reinforcement agent for the polymer. The composite sample exhibited an increase in modulus and glass transition temperature. The crystalline region as noted in the loss modulus data was found to enhance with the addition of carbon nanotubes, indicating good interaction between the polymer-nanotube interface.
Experimental data for the composite sample was fitted to WLF parameters and found to be consistent with values obtained for neat poly (4-methyl-1-pentene) in this study and previously published results (Penn 1966; Lee and Hiltz 1984); thus characterization techniques can be extended to polymer-nanotube composites.
EXAMPLE 2
Studies Using Commercial PMP as Neat Polymer (No Nanotubes) and in USF Processed PMP/Carbon Nanotube Composites with PE Controls
PMP is purchased from Phillips; PE is purchased as recommended by NASA. SWCTs are purchased from Carbon Nanotube Technologies Inc. (CNI). Neat PMP, PE and PMP composites are compression molded in a Carver hot press according to sample dimension specified by NASA. The composites are prepared by sonicating SWNT in cyclohexane at temperatures below the boiling point of the solvent. PMP is added (5% polymer to solvent by weight). Nanotube concentrations vary from 0.1 to 10% based on nanotube to polymer weight. Solutions with the lower concentrations of nanotubes are cast into films of various thickness using doctor blades. The films are dried in a vacuum over at 80° C. for 12 hours. These films are stacked and compression molded to yield samples of the appropriate thicknesses required for testing. 10% nanotube solutions are dried under vacuum for 25 hours. These are used as masterbatches and diluted with PMP in a melt mixer (Banbury mixer) to produce samples with concentrations from 0.1-5% SWNT. PE nanotube composites are prepared by melt mixing 50% SWNT with 50% PE in the Banbury. This is used as a masterbatch and diluted in the Banbury with pure PE to concentration from 0.1-5% SWNT. This procedure is repeated with PMP for comparison. PMP has the advantage of being able to undergo the sonication process described above using cyclohexane. It is expected that use of the solvent will greatly improve dispersion.
EXAMPLE 3
Studies Using Synthesized PMP and PMP Carbon Nanotube Composites
The synthesis of neat PMP polymer is a low risk experimental plan; well tested, explicit procedures are at hand (Tait, P. J. T. et al. “Polymerization of 4-Methylpentene-1 with Magnesium-Chloride-Supported Catalysts”, Advances in Polyolefins 309 (R. B. Seymour and T. Cheng, eds. Plenum Press) (1987)). This synthesis involves the use of MgCl 2 -supported titanium catalyst systems. The reactions are carried out in heptane or toluene solvents. Since PMP is commercially available, the reason for undertaking in-house synthesis is to take advantage of the fact that the synthesis starts out with an ultra low viscosity system, monomer in solvent. Once the in-house synthesis of neat polymer is optimized the synthesis is adapted to include the addition of carbon nanotubes-solvent systems, which have been sonicated prior to addition to the monomer catalyst system. However, carbon nanotubes may interfere with the catalyst system and impede the polymerization, or alter the stereoregularity of the polymer. All materials are available from Aldrich. The synthesis scheme used in this research is described by Tait et. al. A typical recipe is as follows:
a) Preparation of the catalyst: Dried MgCl 2 is treated with thionyl chloride while ball milling at MgCl 2 :SOCl 2 mole ratios of 1.0:0.05. Ethyl benzoate, EB, is added 1 to 10 mole ration based EB:MgCl 2 . Milling continues for 72 hours. Siloxane oil is added at 0.08 moles of silicon to 1 mole of MgCl 2 and the system is milled for 5 hours. Neat TiCl 4 is added, and the system is heated to 115° C. for 1.5 hours. The system is then filtered.
b) Polymerization: Glassware is dried at 150° C. and stored under vacuum until use. The order of addition is: solvent/catalyst slurry/alkyl aluminum (triethyl aluminum)/monomer. The polymerization proceeds for 30 hours at 10° C. Concentrations are: Ti=0.028 mmole dm −3 , Al=18 mmole dm −3 monomer=2 mmole dm −3 , solvent=excess. Neat polymers are extracted with boiling hexane. Composites are isolated by distilling of excess solvent followed by drying them in a vacuum over at 80° C. for 12 hours. Samples are molded to appropriate dimensions using a Carver hot press.
EXAMPLE 4
Ground Testing: Brookhaven National Lab (BNL)
Dosimetry is used to characterize the uniformity of the applied GCR field, and the flux of the applied radiation field (Isodose Region). The size and uniformity of the field determines the sample size. Dosimetry of the applied field and the dose behind each shielding configuration are measured to determine the shielding efficiency. Several witness dosimeters are required for each trial to ensure consistency of the applied field from trial run to trial run. Each DOE test configuration is performed in triplicate. The three factors selected includes thickness (250 mils and 25 mils), composite concentration (no nanotubes vs. fully loaded) and resin composition (polyethylene vs. PMP).
This DOE test matrix provides an evaluation that validates the test conditions are accurate if the baseline value for shielding effectiveness established by NASA-Langley. The test matrix also examines the value of densely-packed carbon atoms for determining if the cross-sectional density of the shield has been realized. Finally the linearity of the shielding efficiency can be inferred by the thickness study (non-linearity inferring limits in stopping power or secondary radiation effects). The results will advance the understanding of material behavior and particle physics for hydrocarbon-based polymeric shields.
It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application. | Novel transparent composites composed of single wall carbon nanotubes incorporated into the matrix of a polymer are utilized in services wherein the composites are exposed to ionizing radiation, including galactic cosmic radiation. Accordingly, the composites are useful in deep space applications like space vehicles, space stations, personal equipment as well as applications in the biomedical arts and atom splitting research. The composites can be modified with organic dyes containing at least one phenyl ring and the resulting doped composite is useful as a radiation detector. The preferred polymer is poly(4-methyl-1-pentene). | 2 |
FIELD OF THE INVENTION
The present invention relates to automatic transmissions, and more particularly to an eight-speed automatic transmission for use in a motor vehicle.
BACKGROUND OF THE INVENTION
A typical automatic transmission in a motor vehicle has two or three planetary gear sets, one of which receives a torque input from an engine, another one of which is coupled to a drive shaft for providing a torque output. During operation, a set of frictional units couple the torque input from the engine to one or more members of the planetary gear sets. Simultaneously, another set of frictional units holds stationary one or more members of the planetary gear sets. These frictional units provide different ratios of input-to-output torque to the vehicle. It is desirable to provide an automatic transmission for a vehicle that includes a wider range and a larger number of transmission ratios.
Automatic transmissions are typically controlled by a hydraulic control system. These hydraulic control systems are used to engage and disengage the frictional units of the transmission according to the ratio of torque needed. A typical hydraulic control system is disclosed in U.S. Pat. No. 6,159,124 to Redinger et al., herein incorporated by reference. The typical hydraulic control system is composed of various valves that direct and regulate hydraulic pressure to the frictional units via various fluid passages.
SUMMARY OF THE INVENTION
The eight-speed automatic transmission according to the principles of the present invention has a compound planetary gear set, a second planetary gear set, and a third planetary gear set. The compound planetary gear set has a small sun gear, a large sun gear, a first carrier, and a first ring gear. The second planetary gear set has a second sun gear drivingly engaged with the first carrier, a second carrier drivingly engaged with the large sun gear, and a second ring gear. The third planetary gear set has a third sun gear, a third carrier drivingly engaged with the second ring gear and drivingly engaged with an output shaft, and a third ring gear drivingly engaged with the second carrier.
The eight-speed automatic transmission further includes a first clutch selectively receiving an input from an engine and drivingly engaged with the third sun gear, a second clutch selectively receiving an input from the engine and drivingly engaged with the large sun gear and the second carrier, and a third clutch selectively receiving an input from the engine and drivingly engaged with the small sun gear. A first brake is engaged with the third ring gear and the second carrier for selectively fixing the third ring gear and the second carrier from rotation. A second brake is engaged with the first ring gear for selectively fixing the first ring gear from rotation. A third brake is engaged with the first carrier for selectively fixing the first carrier from rotation. A fourth brake is engaged with the small sun gear for selectively fixing the small sun gear from rotation. Selectively engaging one of the clutches and one of the brakes provides an input-to-output torque ratio corresponding to one of eight forward gear speeds and at least one reverse speed.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood the detailed description and the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of an eight-speed automatic transmission according to the principles of the present invention;
FIG. 2 is a table showing the combination of clutches and brakes to be applied to achieve specific torque ratios according to the principles of the present invention; and
FIG. 3 is a detailed view of the eight-speed automatic transmission according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to FIGS. 1 and 3, an eight-speed automatic transmission for use in a motor vehicle is generally indicated by reference numeral 10 . The eight-speed automatic transmission 10 is linked to an engine, not shown, through an engine output shaft 2 . Rotational output from the engine output shaft 2 is received by the eight-speed automatic transmission 10 through a torque converter assembly 4 . The torque converter assembly 4 then transfers the rotational output through a gear set 6 , as will be described in greater detail below, to a transmission output shaft 8 and then on to the drivetrain of the motor vehicle.
The gear set 6 of the eight-speed automatic transmission 10 comprises a compound planetary gear set 12 , a second planetary gear set 14 , and a third planetary gear set 16 . In the preferred embodiment, the compound planetary gear set 12 is a Ravigneaux Planetary Gear Set as is well known in the art. However, various other gear set types may be employed. The compound planetary gear set 12 includes a small sun gear 18 engaged with a plurality of first pinions 20 (one of which is shown), and a large sun gear 22 engaged with a plurality of second pinions 24 (one of which is shown). The first and second pinions 20 , 24 are rotatably supported on a carrier 26 and the plurality of first pinions 20 are engaged with a ring gear 28 . The large sun gear is provided with a splined connection to a first intermediate shaft 29 .
The second planetary gear set 14 includes a second sun gear 30 engaged with a plurality of pinions 32 (one of which is shown). The plurality of pinions 32 are rotatably supported on a second carrier 34 and engaged with a second ring gear 36 . The second sun gear 30 is drivingly engaged with the carrier 26 of the compound gear set 12 . The second carrier 34 is drivingly connected to the first intermediate shaft 29 .
The third planetary gear set 16 includes a third sun gear 38 engaged with a plurality of pinions 40 . The plurality of pinions 40 are rotatably supported on a third carrier 42 and engaged with a third ring gear 44 . The third carrier 42 is drivingly engaged with the second ring gear 36 of the second planetary gear set 14 . The third ring gear 44 is drivingly engaged with the second carrier 34 of the second planetary gear set 14 . The third carrier 42 rotates to produce a torque output to the transmission output shaft 8 . The third sun gear 38 is provided with a splined connection to a second intermediate shaft 45 concentrically disposed with said first intermediate shaft 29 .
The eight-speed automatic transmission 10 further includes a first clutch 46 , a second clutch 48 , and a third clutch 50 . Clutches 46 , 48 , and 50 are each selectively engagable to receive the torque input from the torque converter assembly 4 via a transmission input shaft 51 . The first clutch 46 is drivingly connected to the third sun gear 38 of the third planetary gear set 16 via shaft 45 . The second clutch 48 is drivingly connected to the large sun gear 22 of the compound planetary gear set 12 as well as to the second carrier 34 of the second planetary gear set 14 via shaft 29 . The third clutch 50 is drivingly connected to the small sun gear 18 of the compound planetary gear set 12 via a third intermediate shaft 53 .
The eight-speed automatic transmission 10 further includes a first brake 52 , a second brake 54 , a third brake 56 , and a fourth brake 58 . The first brake 52 is drivingly connected to the third ring gear 44 of the third planetary gear set 16 , the second carrier 34 of the second planetary gear set 14 , as well as the first intermediate shaft 29 . The second brake 54 is drivingly connected to the ring gear 28 of the compound planetary gear set 12 . The third brake 56 is drivingly connected to the carrier 26 of the compound planetary gear set 12 , as well as the second sun gear 30 of the second planetary gear set 14 . The fourth brake 58 is drivingly connected to the small sun gear 18 of the compound planetary gear set 12 via the third intermediate shaft 53 . Each of the brakes 52 , 54 , 56 , 58 is selectively fixable such that the brakes 52 , 54 , 56 , 58 prevent rotation of corresponding attached planetary gear set components.
During operation of the eight-speed automatic transmission 10 , the torque input from the input shaft 51 is transferred through one of the clutches 46 , 48 , 50 to the planetary gear sets 12 , 14 , 16 and on to the third carrier 42 providing the torque output to output shaft 8 . The third carrier 42 is connected to the transmission output shaft 8 which transmits the rotational output of the engine to the drivetrain of the motor vehicle. To achieve specific torque input-to-output ratios, one or more of the clutches 46 , 48 , 50 and brakes 52 , 54 , 56 , 58 are engaged to receive torque input from the engine and/or to prevent rotation of attached gears and/or carriers. There is shown in FIG. 2 a table illustrating the combination of clutches and brakes engagable to achieve specific torque input-to-output ratios. Each clutch and brake combination corresponds to one of eight forward gear speeds, two reverse speeds, and two neutral speeds, each of which correspond to a torque input-to-output ratio.
The above description of the invention is merely exemplary in nature and, thus, variations that do not depart from the general scheme of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An eight-speed automatic transmission having a compound planetary gear set, a second planetary gear set, and a third planetary gear set each driven by three clutches and fixed to four brakes is provided. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/875,072, filed on Oct. 19, 2007, and titled “CERVICAL PLATE LOCKING MECHANISM AND ASSOCIATED SURGICAL METHOD”, which is a continuation-in-part of U.S. patent application Ser. No. 11/804,545, filed on May 18, 2007, and titled “CERVICAL PLATE LOCKING MECHANISM AND ASSOCIATED SURGICAL METHOD.” Both of the foregoing applications are hereby incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] Some embodiments disclosed herein relate generally to locking and/or anti-backout mechanisms for various medical devices and/or implants, and related methods. For example, various features and/or components of embodiments disclosed herein may be incorporated into and/or used in conjunction with various implants, including cervical plates, thoracolumbar fixation plates, anterior lumbar fixation plates, standalone interbody devices, bone fracture fixation plates, pedicle screw couplers, such as pedicle screw tulips, and the like.
[0003] Some embodiments may comprise one or more novel locking screws and a novel plate that works cooperatively therewith. The locking mechanism, the one or more novel locking screws, and/or a novel plate or other such implants may be used for the fixation/stabilization of the spine, such as the cervical spine. Alternatively, some embodiments may be configured for the fixation/stabilization of the lumbar spine, the sacral spine, and/or the placement of bone grafts, biocompatible inserts, and the like. Still other embodiments may be used for the fixation/stabilization of other anatomical structures and/or non-anatomical structures.
BACKGROUND OF THE INVENTION
[0004] The vertebrae of the human spine are generally arranged in a column, with an intervertebral disc disposed between each. These intervertebral discs transmit forces and perform a “cushioning” function. As a result of the stresses and strains continuously applied to the intervertebral discs, as well as disease, degeneration and/or deformity is relatively common. Typically, diseased, degenerated, and/or deformed intervertebral discs are treated by removal and the insertion of an implant, anatomical (i.e., a bone graft) or mechanical (i.e., a biocompatible insert), in the associated intervertebral space. The adjacent vertebrae are preferably immobilized using a plate, such as a cervical plate, during bone graft or biocompatible insert placement and subsequently until they fuse, for example.
[0005] Conventional cervical plates typically include a plurality of screw holes and one or more access holes, through which one or more bone grafts or other biocompatible inserts are placed. These cervical plates may span one or multiple levels, with a level defined by the presence of an intervertebral space, and may be secured to the vertebrae of the spine using a plurality of bone screws. Absent some sort of locking mechanism, these bone screws tend to reverse thread, or back out, over time. This reverse threading or backing out is obviously problematic. Various locking mechanisms exist in the art for preventing reverse threading or backing out, and typically involve the use of polymeric bushings, securing caps, securing cover plates, novel thread designs, and the like that prevent the bone screws from disengaging the vertebrae and/or cervical plate subsequent to installation. Many of these locking mechanisms are ineffective, overly complicated, cumbersome to implement, and/or unnecessarily expensive. Thus, what is still needed in the art is a robust, simple, and inexpensive locking mechanism for cervical plates or other medical devices or implants incorporating screws or other fasteners.
SUMMARY
[0006] In various exemplary embodiments, the present invention provides such a robust, simple, and inexpensive locking and/or anti-backout mechanism for a screw and/or other fastener of a plate or other medical implant or device. Various embodiments may be elegant in design and effective in performance. Some embodiments may utilize a plate with holes one or more of which may comprise a locking lip structure and/or receiving well, and locking screws that may incorporate a head portion having petal structures that are outwardly biased prior to insertion via an internally-disposed c-ring or another similar biasing member. Advantageously, in some embodiments, the lead-in torque of each of the locking screws is less than the lead-out torque of each of the locking screws. Thus, reverse threading or backing out is prevented.
[0007] In a specific example of an embodiment of a fastener locking system for a medical device, such as, for example, a cervical plate, a thoracolumbar fixation plate, an anterior lumbar fixation plate, an intervertebral device, a bone fracture fixation plate, or a pedicle screw coupler, the system may comprise an outer surface defining at least one fastener opening in the outer surface configured for receiving a fastener. The at least one fastener opening may comprise a lip structure positioned adjacent to the outer surface.
[0008] The system may further comprise at least one fastener, such as a locking screw, configured to be received in the at least one fastener opening. The at least one fastener may comprise a head portion comprising a plurality of petal structures configured to expand and contract to expand and contract a size of the head portion.
[0009] The system may further comprise a biasing member, such as a c-ring, configured to be positioned within the plurality of petal structures to expand a size of the head portion. The at least one fastener may be configured to contract to extend past the lip structure and then be expanded by the biasing member within the head portion such that the petal structures engage the lip structure to inhibit the at least one fastener from being removed from the at least one fastener opening.
[0010] In some embodiments, an upper portion of the lip structure may be angled inward towards a central axis of the at least one fastener opening such that the plurality of petal structures contracts as the head portion is inserted into the at least one fastener opening.
[0011] In another specific example of an embodiment of a fastener locking system for a medical device, the system may comprise a medical device comprising an outer surface defining at least one fastener opening in the outer surface configured for receiving a fastener. The at least one fastener opening may be defined at least in part by a plurality of petal structures configured to expand and contract.
[0012] The system may comprise a biasing member configured to be positioned around the plurality of petal structures to provide an inward bias to the plurality of petal structures and contract a size of the at least one fastener opening.
[0013] The system may further comprise at least one fastener configured to be received in the at least one fastener opening. The at least one fastener may comprise a head portion configured to be retained in the at least one fastener opening by the plurality of petal structures and the biasing member.
[0014] In some embodiments, the head portion may comprise an upper surface, and the plurality of petal structures may be configured to engage the upper surface after the biasing member has been positioned around the plurality of petal structures with the at least one fastener in the at least one fastener opening.
[0015] In some embodiments, the biasing member may be configured to be positioned concentrically around the plurality of petal structures.
[0016] In still another specific example of a fastener locking system for a medical device, the system may comprise a medical device comprising an outer surface defining one or more fastener openings configured for receiving a fastener. The system may comprise at least one fastener configured to be received in the at least one fastener opening. The at least one fastener may comprise a head portion comprising an upper surface.
[0017] The system may further comprise a plurality of petal structures configured to be selectively expanded or contracted to engage the head portion and retain the at least one fastener within the at least one fastener opening to inhibit the fastener from backing out of the at least one fastener opening. A biasing member may be configured to selectively engage the plurality of petal structures to either expand or contract the plurality of petal structures between an open configuration in which the at least one fastener is able to be removed from the at least one fastener opening and a closed configuration in which the at least one fastener is at least inhibited from being removed from the at least one fastener opening. The plurality of petal structures may be configured to engage the upper surface of the at least one fastener in the closed configuration.
[0018] In some embodiments, the plurality of petal structures may be part (in some embodiments an integral part) of the head portion. In some such embodiments, the biasing member may be configured to be positioned within the plurality of petal structures to expand a size of the head portion.
[0019] In some embodiments, the plurality of petal structures may together define a central driver bore configured to be engaged by a keyed tool. In some such embodiments, the central driver bore may comprise a polygonal shape.
[0020] In some embodiments, at least a subset of the plurality of petal structures may comprise an inner groove configured to receive the biasing member therein. In some such embodiments, each of the plurality of petal structures may comprise an inner groove configured to receive the biasing member therein.
[0021] In some embodiments, the plurality of petal structures may at least partially define the at least one fastener opening, and the biasing member may be configured to be positioned around the plurality of petal structures to provide an inward bias to the plurality of petal structures.
[0022] In some embodiments, the at least one fastener opening may comprise a lip structure positioned adjacent to the outer surface. As mentioned elsewhere herein, in some such embodiments, the petal structures may be configured to retain the fastener within the fastener opening beneath the lip structure such that the lip structure contacts an upper surface of a head portion of the fastener.
[0023] The features, structures, steps, or characteristics disclosed herein in connection with one embodiment may be combined in any suitable manner in one or more alternative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Various embodiments are illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like system components and/or method steps, as appropriate, and in which:
[0025] FIG. 1 is an exploded perspective view of one exemplary embodiment of the cervical plate locking mechanism of the present invention (being installed using a keyed screwdriver or the like), the cervical plate locking mechanism including both novel plate and novel locking screw designs;
[0026] FIG. 2 is an exploded perspective view of one exemplary embodiment of the novel locking screw design of FIG. 1 , the locking screw including a head portion that incorporates a plurality of petal structures that are outwardly biased by an internally-disposed c-ring or the like;
[0027] FIG. 3 is a perspective view of the novel locking screw design of FIGS. 1 and 2 , the locking screw being in its “as inserted” state, with the c-ring being installed and the head portion being compressed;
[0028] FIG. 4 is a partial cross-sectional view of the cervical plate locking mechanism of FIG. 1 , the novel locking screw of FIGS. 1-3 in the process of being inserted into the novel plate of FIG. 1 ;
[0029] FIG. 5 is a partial cross-sectional view of the cervical plate locking mechanism and locking screw of FIGS. 1-4 being fully inserted into the novel plate of FIGS. 1 and 4 ;
[0030] FIG. 6 is a partial cross-sectional view of the cervical plate locking mechanism and locking screw of FIGS. 1-5 after the locking screw has been fully inserted into the locking plate and allowed to expand therein;
[0031] FIG. 7 is a partial cross-sectional view of the cervical plate locking mechanism of FIGS. 1 , 4 , and 5 , the novel locking screws of FIGS. 1-5 being inserted into the novel plate of FIGS. 1 , 4 , and 5 at various exemplary angles;
[0032] FIG. 8 is a perspective view of another exemplary embodiment of the cervical plate locking mechanism of the present invention, the cervical plate locking mechanism again including both novel locking plate and novel screw (not illustrated) designs;
[0033] FIG. 9 is a partial perspective view of the cervical plate locking mechanism of FIG. 7 , the novel locking plate incorporating one or more screw-receiving holes each including a plurality of petal structures configured to engage and retain the novel screws (not illustrated);
[0034] FIG. 10 is an exploded perspective view of the cervical plate locking mechanism of FIGS. 7 and 8 , a novel screw being inserted into a screw-receiving hole of the novel locking plate;
[0035] FIG. 11 is a perspective view of the cervical plate locking mechanism of FIGS. 7-9 , novel screws fully inserted into all of the screw-receiving holes of the novel locking plate;
[0036] FIG. 12 is a partial perspective view of the cervical plate locking mechanism of FIGS. 7-10 , novel screws fully inserted into all of the screw-receiving holes of the novel locking plate; and
[0037] FIG. 13 is a partial cross-sectional view of the cervical plate locking mechanism of FIGS. 7-11 , a novel screws fully inserted into a screw-receiving holes of the novel locking plate.
DETAILED DESCRIPTION OF THE INVENTION
[0038] As described above, in various exemplary embodiments, the present invention provides a robust, simple, and inexpensive locking and/or anti-backout mechanism. Some embodiments may be elegant in design and effective in performance, and may utilize a plate with holes that each incorporate a locking lip structure and/or receiving well. Associated locking screws may each incorporate a head portion having petal structures that are outwardly biased prior to insertion via an internally-disposed c-ring or the like. Advantageously, in some embodiments, the lead-in torque of each of the locking screws is less than the lead-out torque of each of the locking screws. Thus, reverse threading or backing out may be prevented.
[0039] FIG. 1 is an exploded perspective view of one exemplary embodiment of a cervical plate locking mechanism 10 of the present invention (being installed using a keyed tool, such as a keyed screwdriver 18 or the like), the cervical plate locking mechanism 10 including both novel plate and novel locking screw designs, as are described in greater detail herein below. Specifically, the cervical plate locking mechanism 10 comprises a plate 12 that is configured to be securely fixed to adjacent vertebrae of the cervical spine or the like via one or more locking screws 14 and one or more c-rings 16 . The keyed screwdriver 18 may be used to drive the one or more locking screws 14 through the plate 12 and into the adjacent vertebrae.
[0040] The plate 12 may comprise one or more screw-receiving holes 13 and, optionally, one or more access holes 15 for the placement of one or more bone grafts, biocompatible inserts, or the like. Preferably, the plate 12 is manufactured from a biocompatible material and is sized such that it achieves its intended purpose. Material, shape, and size selection may be selected according to the knowledge of those of ordinary skill in the art. Each of the one or more locking screws 14 may comprise a threaded portion 17 and a head portion 19 . The threaded portion 17 of each of the one or more locking screws 14 may be configured to pass through the one or more screw-receiving holes 13 of the plate 12 and securely fix the plate 12 to the adjacent vertebrae. Thread selection is well known to those of ordinary skill in the art.
[0041] The head portion 19 of each of the one or more locking screws 14 may be configured to securely engage each of the one or more locking screws 14 with the plate 12 . As described in greater detail herein below, the head portion 19 of each of the one or more locking screws 14 may be outwardly biased by the c-ring 16 , or by another similar biasing member or other mechanism or feature. Such mechanism or feature may be inserted and/or compressed into the head portion 19 of a given locking screw 14 . In some embodiments, the head portion 19 may expand automatically upon insertion of the c-ring 16 .
[0042] The c-ring 16 , or another comparable mechanism, and the head portion 19 of the given locking screw 14 may be again compressed and subsequently allowed to expand as they are inserted into a given screw-receiving hole 13 of the plate 12 . More specifically, in some embodiments, the head portion 19 of a given locking screw 14 may be allowed to expand in the receiving well of the given screw-receiving hole 13 . This insertion may be accomplished using, for example, a matching flat, triangle, square, star, hexagon, octagon, or other keyed screwdriver 18 , as appropriate. Preferably, the shape of the outside of the head portion 19 of each of the locking screws 14 substantially corresponds to the shape of the inside of the associated receiving well, although this is not a requirement.
[0043] FIG. 2 is an exploded perspective view of one exemplary embodiment of the novel locking screw design of FIG. 1 , the locking screw 14 including a head portion 19 that incorporates a plurality of petal structures 20 that are outwardly biased by the internally-disposed c-ring 16 or the like. Locking screw 14 and/or its accompanying locking features may be incorporated into and/or used in conjunction with various implants, such as cervical plates, thoracolumbar fixation plates, anterior lumbar fixation plates, standalone interbody devices, bone fracture fixation plates, pedicle screw couplers, such as pedicle screw tulips, and the like.
[0044] As described above, c-ring 16 , or other comparable mechanism, may be selectively inserted and/or compressed into the head portion 19 of a given locking screw 14 , and then allowed to expand. The c-ring 16 , or other comparable mechanism, and the head portion 19 of the given locking screw 14 may then be compressed again and subsequently allowed to expand as they are inserted into a given screw-receiving hole 13 ( FIG. 1 ) of plate 12 ( FIG. 1 ), or of another screw-receiving hole of another plate or other implant or medical device.
[0045] More specifically, the head portion 19 of the given locking screw 14 may be allowed to expand in a receiving well of the given screw-receiving hole 13 . This insertion may be accomplished using a matching flat, triangle, square, star, hexagon, octagon, or other keyed screwdriver 18 (as shown in FIG. 1 ), as appropriate.
[0046] Preferably, the shape of the outside of the head portion 19 of each of the locking screws 14 at least substantially corresponds to the shape of the inside of the associated receiving well, although this is not a requirement. Accordingly, the head portion 19 of each of the locking screws 14 may comprise a plurality of concentrically-arranged petal structures 20 that are disposed around a central driver bore 21 , which may have a shape corresponding to that of the keyed screwdriver 18 . In one exemplary embodiment, the plurality of petal structures 20 may be formed by cutting concentrically-arranged slots into the head portion 19 of the locking screw 14 . Thus, the plurality of petal structures 20 may, in some embodiments and implementations, be integrally formed with the head portion 19 of the locking screw 14 . Alternatively, the plurality of petal structures 20 may be formed separately and then joined to the head portion 19 of the locking screw 14 .
[0047] The material characteristics and/or configuration of the plurality of petal structures 20 may, in some embodiments, impart the plurality of petal structures 20 with an inherent outward bias, which bias in some embodiments may be independent of the c-ring 16 or other comparable mechanism, although this is not required.
[0048] In some embodiments, the plurality of petal structures 20 may define an inner groove 22 extending around an inner perimeter of head portion 19 , such as around an exterior perimeter of central driver bore 21 , as shown in FIG. 2 . Inner groove 22 may be configured to receive and retain the c-ring 16 or other comparable mechanism within the head portion 19 of the locking screw 14 . FIG. 2 illustrates the head portion 19 of the locking screw 14 in an “unlocked” configuration, with the plurality of petal structures 20 being “open,” either due to the eventual insertion of the c-ring 16 or other comparable mechanism, or inherently. FIG. 3 illustrates the head portion 19 of the locking screw 14 in a “locked” configuration, with the plurality of petal structures 20 being “closed,” either inherently or due to the eventual insertion of the head portion 19 of the locking screw 14 into a receiving well. Thus, in some embodiments, the plurality of petal structures 20 may be configured to be flexibly biased towards a locked/closed configuration such that the petals 20 can be flexed open to an unlocked/open configuration to receive c-ring 16 and then automatically revert to a locked/closed configuration with c-ring 16 therein. In some embodiments, the presence of c-ring 16 within head portion 19 may partially flex petals 20 towards an unlocked/open configuration (but not fully) so as to enlarge the diameter of head portion 19 and retain head portion 19 within a locking hole of a device, such as cervical plate 12 .
[0049] It can also be seen in FIGS. 2 and 3 that petal structures 20 each partially defines an upper surface of head portion 19 of locking screw 14 . In the depicted embodiment, this upper surface is flat. In this manner, the upper surface of head portion 19 may be engaged with a lip structure of a locking hole of a device, such as cervical plate 12 , as discussed in greater detail below. FIGS. 2 and 3 further depict that petal structures 20 together define central driver bore 21 (as shown in FIG. 3 ) comprising a polygonal opening, and can be expanded by flexing petal structures 20 (as shown in FIG. 2 ) such that petal structures 20 no longer define the same bore opening. In this manner, a keyed tool, such as keyed screwdriver 18 , may be used to expand central driver bore 21 by inserting the keyed tool and rotating it. This may allow for the c-ring 16 to be inserted into inner groove 22 . FIG. 3 also illustrates that, in a closed configuration, petal structures 20 at least substantially enclose c-ring 16 within head portion 19 to prevent inadvertent removal of c-ring 16 after a locking screw 14 has been fully engaged within a corresponding receiving hole 13 .
[0050] FIG. 4 is a partial cross-sectional view of the cervical plate locking mechanism 10 of FIG. 1 , the novel locking screw 14 of FIGS. 1-3 in the process of being inserted into the novel plate 12 of FIG. 1 . It should be noted that the head portion 19 of the locking screw 14 , and specifically the lower, outer portion of each of the plurality of petal structures 20 , optionally incorporates a recessed or otherwise weakened area 24 , or flexure, in order to facilitate the flexibility and/or outward biasing of the plurality of petal structures 20 by the c-ring 16 or other comparable mechanism, after it is inserted into the inner groove 22 that is manufactured into the middle, inner portion of each of the plurality of petal structures 20 .
[0051] One or more of the one or more screw-receiving holes 13 of the plate 12 or other such device may comprise an annular lip structure 26 through which the head portions 19 of the locking screws 14 may be inserted (with a compression/expansion action). This annular lip structure 26 may serve to retain the head portion 19 of the given locking screw 14 once it is fully inserted and expanded, thereby preventing the reverse threading or backing out of the locking screw 14 .
[0052] Optionally, the inner annular surface 28 of each of the screw-receiving holes 13 of the plate 12 may be curved in a generally concave manner, as shown in FIGS. 4-6 , but shaped such that the lead-in torque of a given locking screw 14 is less than the lead-out torque or the locking screw 14 , i.e., the inner annular surface angles adjacent to the outer surface 29 of the plate 12 (at the “top” and “bottom” of the lip structure 26 ) vary as experienced by an inserted locking screw 14 versus a removed locking screw 14 , with the “top” angle being greater (more vertical or steep) and the “bottom” angle being smaller (more horizontal or shallow), for example.
[0053] As also shown in FIGS. 4-6 , the portion of the lip structure 26 immediately adjacent to the upper surface of petal structures 20 is preferably angled slightly inward towards a center axis of central driver bore 21 to facilitate desirable feel and function of head portion 19 of the locking screw 14 fitting into screw-receiving hole 13 and preventing backout of locking screw 14 thereafter.
[0054] FIG. 5 is a partial cross-sectional view of the cervical plate locking mechanism 10 of FIGS. 1 and 4 , the novel locking screw 14 of FIGS. 1-4 being fully inserted into the novel plate 12 of FIGS. 1 and 4 . Again, it should be noted that the head portion 19 of the locking screw 14 , and specifically the lower, outer portion of each of the plurality of petal structures 20 , optionally incorporates a recessed or otherwise weakened area 24 , or flexure, in order to facilitate the flexibility and/or outward biasing of the plurality of petal structures 20 by the c-ring 16 or other comparable mechanism, after it is inserted into the inner groove 22 that is manufactured into the middle, inner portion of each of the plurality of petal structures 20 . Each of the one or more screw-receiving holes 13 of the plate 12 may comprise an annular lip structure 26 through which the head portions 19 of the locking screws 14 are inserted (with a compression-expansion action).
[0055] This annular lip structure 26 serves to retain the head portion 19 of the given locking screw 14 once it is fully inserted and expanded, as illustrated, thereby preventing the reverse threading or backing out of the locking screw 14 . As described above, optionally, the inner annular surface 28 of each of the screw-receiving holes 13 of the plate 12 is curved in a generally concave manner, but shaped such that the lead-in torque of a given locking screw 14 is less than the lead-out torque or the locking screw 14 , i.e. the inner annular surface angles adjacent to the outer surface 29 of the plate 12 (at the “top” and “bottom” of the lip structure 26 ) vary as experienced by an inserted locking screw 14 versus a removed locking screw 14 , with the “top” angle being greater (more vertical or steep) and the “bottom” angle being smaller (more horizontal or shallow), for example.
[0056] FIG. 6 depicts head portion 19 of locking screw 14 after it has been allowed to expand within receiving hole 13 by the expansion of c-ring 16 . As depicted in this figure, once this expansion takes place, an upper surface of head portion 19 of locking screw 14 contacts a lower surface of lip structure 26 to retain locking screw 14 in place and prevent, or at least reduce the possibility of, backup.
[0057] Thus, some embodiments may be configured to have a first, fully open configuration in which the petal structures 20 are fully open to receive c-ring 16 , a second, partially open configuration in which c-ring 16 flexes petal structures 20 partially open, and a third, fully-closed configuration in which c-ring 16 is absent and petal structures 20 are able to fully compress together.
[0058] FIG. 7 is a partial cross-sectional view of the cervical plate locking mechanism 10 of FIGS. 1 , 4 , 5 , and 6 the novel locking screws 14 of FIGS. 1-5 being inserted into the novel plate 12 of FIGS. 1 , 4 , 5 , and 6 at various exemplary angles relative to both the plate 12 and the underlying vertebrae. In this embodiment, each of the receiving wells may be asymmetrical in shape such that the head portion 19 of each of the locking screws 14 snugly and securely engages the receiving well, although this is not necessarily illustrated. In other words, each of the receiving wells may be appropriately angled in the plate 12 in order to receive each of the angled locking screws 14 .
[0059] Referring to FIGS. 8-13 , in another exemplary embodiment of a locking mechanism 100 of the present invention, the locking mechanism 100 again comprises both novel locking plate and novel screw designs, as are described in greater detail herein below. Locking mechanism 100 also comprises a cervical plate locking mechanism although, as mentioned above, this locking mechanism may be applied to a wide variety of other devices and implants, such as thoracolumbar fixation plates, anterior lumbar fixation plates, standalone interbody devices, bone fracture fixation plates, pedicle screw couplers, such as pedicle screw tulips, and the like.
[0060] More specifically, the cervical plate locking mechanism 100 comprises a locking plate 102 that is configured to be securely fixed to adjacent vertebrae of the cervical spine or the like via one or more screws 104 and one or more c-rings 106 . The keyed screwdriver (not illustrated) is used to drive the one or more screws 104 through the locking plate 102 and into the adjacent vertebrae. The locking plate 102 comprises one or more screw-receiving holes 103 and, optionally, one or more access holes 105 for the placement of one or more bone grafts, biocompatible inserts, or the like.
[0061] In some embodiments, the locking plate 102 may be manufactured from a biocompatible material and may be sized such that it achieves its intended purpose. Material, shape, and size selection may be selected by those of ordinary skill in the art. Each of the one or more screws 104 may comprise a threaded portion 107 and a head portion 109 . The threaded portion 107 of each of the one or more screws 104 may be configured to pass through the one or more screw-receiving holes 103 of the locking plate 102 and securely fix the locking plate 102 to the adjacent vertebrae. Thread selection may be as desired to those of ordinary skill in the art.
[0062] The head portion 109 of each of the one or more screws 104 is configured to securely engage each of the one or more screws 104 with the locking plate 102 . As described in greater detail herein below, a plurality of petal structures 120 disposed about each of the screw-receiving holes 103 may be inwardly biased by the c-ring 106 . Petal structures 120 may be incorporated into plate 102 , or into another implant or device comprising screw-receiving holes. A c-ring 106 , or another comparable mechanism may be expanded and subsequently allowed to contract around the petal structures 120 as the head portion 109 of a screw 104 is disposed in the receiving well of the given screw-receiving hole 103 . This insertion may be accomplished using a matching flat, triangle, square, star, hexagon, octagon, or other keyed screwdriver, as appropriate. Preferably, the shape of the outside of the head portion 109 of each of the screws 104 substantially corresponds to the shape of the inside of the associated receiving well, although this is not a requirement. Thus, in this exemplary embodiment, the plurality of petal structures 120 and the c-ring 106 have been shifted from the one or more screws 104 to the locking plate 102 , accomplishing the same purposes.
[0063] It can be best seen in FIG. 13 that, once screw 104 is positioned in the receiving well/hole 103 and c-ring 106 has been positioned about the plurality of petal structures 120 , at least a portion of the locking mechanism (namely, a portion of the petal structures 120 ) extends above a top surface of screw 104 to secure screw 104 within hole 103 and prevent, or at least inhibit, backout of screw 104 .
[0064] Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims. | Medical device locking mechanisms and related methods and systems. In some embodiments, the medical device may comprise an outer surface defining one or more fastener openings configured for receiving one or more fasteners. The one or more fasteners may comprise an upper surface configured to be engaged by a component of the locking system to prevent fastener backout. A plurality of petal structures may be configured to be selectively expanded or contracted to engage the head portion and retain the at least one fastener within the fastener opening to prevent the fastener from backing out of the fastener opening. A biasing member may selectively engage the plurality of petal structures to either expand or contract the plurality of petal structures to facilitate locking the fastener(s) in place within the device. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a camera with a self-contained electrical flash unit and shutter release and in particular to a camera of the character described which has a high energy efficiency.
Conventionally, cameras having a self-contained flash unit are provided with manually operable ON-OFF power switch for selectively providing electrical power from an electrical battery mounted in the camera housing to power the flash unit. Such conventional cameras are provided with a flash firing capacitor for storing electrical charge, which, upon actuation of the shutter release, is applied to the flash lamp to create the required burst of light to illuminate the target being photographed. When it is desired to operate the flash unit, the above-mentioned power switch is turned ON whereby electrical current flows from the battery to the firing capacitor to charge the latter to the required charge level. After the stored electrical charge on the firing capacitor has been applied to the flash lamp, the capacitor charge is substantially depleted and the electrical circuitry immediately causes the battery to recharge the firing capacitor in readiness for a subsequent operation of the flash lamp. Such recharging takes place automatically, i.e. even if no further use of the flash lamp is contemplated thereby causing unnecessary power drain on the battery and resulting in reduction of battery life and waste of energy.
Furthermore, in such conventional cameras in which the firing capacitor is automatically recharged immediately after discharge, the user may put the camera in storage forgetting to disconnect the flash unit from the battery. In such cases, the prolonged power drain on the battery will cause the latter to discharge completely. Such complete discharge of the battery will render the same useless and will require replacement thereof. In the case of rechargeable batteries significant replacements cost causes unnecessary and substantial additional expense.
Accordingly, the present invention provides a camera having a self-contained electrical flash unit which avoids the above-described disadvantages of the prior art. Also, the present invention provides a camera having a self-contained electrical flash unit which is highly efficient in the utilization of electrical battery energy.
Furthermore, the present invention provides a camera of the character described in which operation of the flash is controlled by the camera shutter release as a function of existing ambient light conditions, and the supply of current from the battery to the flash capacitor is discontinued immediately after the charge on the capacitor reaches a predetermined level of charge.
The present invention also provides a camera system of the character described in which operation of the flash and camera by the user is greatly simplified and reduced and wherein actuation of the flash is enabled by means of the shutter release member as a function of existing light conditions. When the flash unit reaches a predetermined charge level it is automatically disconnected from the power source and operation of the shutter release member cause either the shutter itself to be released or the charging of the flash unit to take place.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the present invention, there is provided a photographic camera system having a shutter and a flash unit for providing momentary artificial illumination of the photographic subject including means adaptable for connection of the camera system to a D.C. power source, and a shutter release member movable from a rest position through an intermediate position to a fully depressed position. Also provided is a pivotally mounted holder member mounting an electromagnet which is movable in response to the aforesaid movement of the shutter release member from a rest position through an intermediate position to a fully extended position, respectively; an armature pivotally mounted on the holder member, operative to move into first and second positions into and out of contact with the elctromagnet in response to the energization and deenergization of the electromagnet, respectively, and latching means for latching and releasing the shutter in response to the movement of the armature into and out of contact with the electromagnet whereby when the holder member is in the intermediate position and the armature is in the second position the shutter is released.
In another feature of the present invention, the position of the armature is varied in accordance with the level of light on the photographic subject.
In a further feature of the present invention the electromagnet and armature are locked in contact with each other in the ON position until the charge on the flash unit reaches a predetermined level and thereafter the armature is moved out of contact with the electromagnet by the action of a return spring.
In yet another feature of the present invention the armature will under all circumstances move out of contact with the electromagnet when the charge on the flash unit reaches a predetermined level.
Still other objects and advantages of the invention will in part be obvious and will in part become apparent from the specification.
The invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a fragmentary sectional view of a camera in accordance with the present invention showing the condition thereof with the shutter release button in a first or rest position;
FIG. 2 is a sectional view similar to that of FIG. 1 showing the condition of the camera with the shutter release button in a second or intermediately depressed condition;
FIG. 3 is a sectional view similar to that of FIG. 2 showing the condition of the camera with the shutter release button in a third or fully depressed condition while the shutter remains unreleased; and
FIG. 4 is an electrical schematic diagram of the electrical circuitry employed in the embodiment of FIGS. 1-3.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, the embodiment depicted in FIGS. 1-3 includes a manually depressable cylindrical shutter release button 30 slidably movable in a slot 40 formed in the top wall 41 of camera housing 42 between a first rest position depicted in FIG. 1, through a second intermediate position shown in FIG. 2, to a third limit position depicted in FIG. 3.
Pivotally mounted in housing 42 on pivot 46 is a holder 28 carrying an electromagnet M1, which is normally biased in the rest position of FIG. 1 by the restraining force of holder return spring 25. Shutter release button 30 is provided with an enlarged spherical head portion 30b for camming engagement with the smooth linear upper wall 28a of holder 28. A return pin 30a extending transversely from head 30b forces the movable contact arms 44 and 45 of normally closed switches S1 and S4 upwardly for maintaining switches S1 and S4 open when release button 30 is in the rest position of FIG. 1. Only switch S1 is visible in FIGS. 1-3.
Pivotally mounted at pivot 48 on holder 28 is a magnet armature 27 which is magnetically acted upon by electromagnet M1, when the latter is energized. Also acting upon armature 27 is a tension return spring 26 having one end thereof anchored to holder 28 and the other end thereof fixedly secured to the upper arm 27b of armature 27. Armature 27 is also provided with a nose portion 27a which bears against stop pin 29 to limit upward movement of holder 28 when armature 27 is attracted to electromagnet M1. A tooth extension portion 27c extending from the lower end of armature 27 limits the downward movement of holder 28.
Pivotally mounted on pivot 50 is a pawl 33 provided with a first tooth 336 for latching engagement with the tensioning lever 34 of shutter 52 and an oppositely disposed second tooth 33a for engagement with shoulder 27b of armature 27. Mounted on the bottom wall 54 of camera housing 42 is a spring loaded holding pawl 31 which is provided with a tooth extension located in proximity to a pair of normally open spring switches S2 and S3 mounted side by side on bottom wall 54, only switch S2 being visible in FIGS. 1-3.
Referring now to FIG. 4, the flash circuit in the embodiment of FIGS. 1-3, includes a flash lamp 12 energizable by a firing electrode 13, a high voltage transformer 7 having associated therewith a firing capacitor in series arrangement with the primary winding 7a of transformer 7, a resistor 8, and a charging capacitor 14. Also provided is a photoresistor 1 operative to detect light conditions and whose electrical resistance varies inversely with the amount of light impinging thereon; and indicator lamp 4 for indicating that ambient light conditions require use of the flash lamp 12 and a glow lamp 24 which when lit indicates that sufficient charge has accumulated on charging capacitor 14 to permit operation of flash lamp 12. The circuitry includes a pair of input terminals 60 and 62 for connection thereto of a D.C. power source such as an electrical battery (not shown).
In operation, when shutter release button 30 is manually depressed out of the position shown in FIG. 1, return pin 30a releases contact arms 44 of switches S1 and S4 allowing the same to close simultaneously. At this point, the operation of the camera system will be described for the case where the ambient light level renders the use of flash lamp 12 unnecessary. Referring to FIG. 4, photoresistor 1 and resistor 2 form a variable voltage divider the output of which is applied to a threshold circuit which may take the form of a Schmitt trigger circuit 3. Under the assumed light conditions which do not require the use of flash lamp 12, the resistance of photoresistor 1 is low and consequently the proportion of the battery voltage applied to Schmitt trigger circuit 3 is small. As a result, no current flows to either ambient light indicator lamp 4 or electromagnet M1.
Further depression of release button 30 to the intermediate position shown in FIG. 2, causes button head 30b to bear downwardly on the top wall of holder 28 causing the latter to pivot in the direction of arrow 68. As a result of such pivoting motion by holder 28, armature nose portion 27a is released from stop pin 29 causing armature 27 to pivot under the force of return spring 26 in the direction of arrow 70 whereby armature shoulder portion 27b engages pawl tooth 33a causing shutter release pawl 33 to rotate in the direction of arrow 72. Such rotation of pawl 33 causes its upper tooth position 33b to disengage from shutter tensioning level 34, permitting shutter 52 to rotate in the direction of arrow 74 and snap into the position shown in FIG. 2.
The operation of the camera system will now be described for the case where light conditions require the use of flash lamp 12 and where it is accordingly desired that shutter 54 not be released from its position of FIG. 1 until sufficient charge has been accumulated on charging capacitor 14 to permit firing of flash lamp 12.
As previously suggested, under conditions of low ambient light levels the resistance of photoresistor 1 will be high relative to the fixed resistance of resistor 2, whereby the voltage drop across photoresistor 1 which is applied to Schmitt trigger circuit 3 via leads 64 and 66 will be sufficiently high to actuate trigger circuit 3 causing currect flow both to light indicator lamp 4, causing the latter to light, and to electromagnet M1 which is in parallel with trigger 3. Such current flow through electromagnet M1 causes the latter to energize, thus attracting armature 28 into contact therewith.
When button 30 is further depressed to its lower limit position, depicted in FIG. 3, the underside of armature tooth 27c simultaneously bears downwardly against the contact arms 76 and 78 of switches S2 and S3 to close said switches while the upper hook portion of tooth 27c engages spring loaded pawl 31. Closure of switch S3 permits current flow through electromagnet M1 from battery terminal 62 through leads 80, 82, switch S3, conductive transistor T2, leads 86 and 90, closed switch S1 and lead 92 battery terminal 60. It is thus evident that such current flow through electromagnet M1 will be maintained even if light conditions cause the resistance of photoresistor 1 to drop and Schmitt trigger 3 to deactivate.
The process of charging capacitor 14 initiated by closure of switch S2 will now be described. It will be noted that resistors 17, 18, 19 and 20 form a variable voltage divider circuit in which resistor 20 is shunted when transistor T3 is conductive and is part of the voltage divider circuit when transistor T3 is non-conductive. When a predetermined level of charge is accumulated on charging capacitor 14, the voltage on capacitor 14 will cause indicator glow lamp 24 to fire thus signalling a "flash ready" condition. Transistor T4 becomes conductive in this condition thereby applying a negative potential from negative battery terminal 62 to the base of transistor T1 rendering the same conductive whereby the positive potential from battery lead 60 through switch S1, lead 90 and conductive transistor T1 renders the base of transistor T2 positive causing the latter to become non-conductive and thereby interrupting the current flow to electromagnet M1. As a result of this deenergization of electromagnet M1, armature 27 is released therefrom allowing return spring 26 to pivot armature 27 in the direction of arrow 70. Furthermore, return spring 25 pivots holder 27 in a direction opposite to that of arrow 68, i.e. upwardly, moving release button 30 upwardly to its rest position of FIG. 1 wherein armature nose portion 27a abuts limit stop pin 29.
Shortly before release button 30 reaches its upper limit rest position of FIG. 1, return pin 30a in its upward motion simultaneously opens contract arms 44 and 45 of switches S1 and S4. The opening of switch S4 removes the load imposed on capacitor 14 by the various components is eliminated thus conserving the charge on capacitor 14 and prolonging the charge level on capacitor 14 necessary for energizing flash lamp 12. The readiness for flash is indicated both by the illumination of indicator glow lamp 24 and the snap of release button 30 into its rest position of FIG. 1, thus providing both a visual and audible indication of flash readiness. When release button 30 is depressed again from its rest position of FIG. 1, and capacitor 14 is at full charge level, the downward motion of return pin 30a causes both switches S1 and S4 to close, causing transistor T1 to become conductive and thereby causing transistor T2 to become non-conductive. When transistor T2 is thus rendered non-conductive it blocks current flow to electromagnet M1 and indicator lamp 4 whereby the latter is extinguished. However, when transistor T1 is conductive it provides current flow to electromagnet M2 which energizes and thus switches the diaphragm of the camera into the proper position for a flash photograph.
The above-mentioned interruption of current to electromagnet M1 causes armature 27 to pivot in the direction of arrow 68 into the position depicted in FIG. 2 and the shutter release operation is then similar to that described above for the case when ambient light conditions are sufficient and do not require the use of a flash. When button 30 is released, synchronous contacts 15 and 16 are bypassed in the usual manner causing lamp 12 to flash.
In the event that flashing does not occur promptly after capacitor 14 is charged to the flash level, it will maintain its charge for a certain period of time in readiness for flash. Opening of switch S2 causes transistor T3 to be rendered non-conductive thereby placing resistor 20 into the above-described voltage divider circuit including resistors 17, 18 and 19. The resultant deenergization, i.e. turning OFF of glow lamp 24, occurs at a substantially lower voltage than the turn ON voltage, i.e. the voltage necessary to cause lamp 24 to ignite, thus forming an artificial hysteresis.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A camera system has a self-contained flash unit where the supply of current from a battery to the flash unit charging capacitor is discontinued immediately after the level of charge on the capacitor reaches a predetermined full charge level and charging of the capacitor is controlled as a function of existing light conditions. The shutter release member is movable from a rest position through an intermediate position to a fully depressed position. A pivotally mounted holder member which is movable in response to the movement of the shutter release member carries an electromagnet and a pivotally mounted magnet armature which moves into and out of contact with the electromagnet in response to the energization and deenergization of the electromagnet to latch and release the shutter. | 6 |
This is a division of application Ser. No. 08/716,215 filed Nov. 6, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to a patterning unit of a warp knitting machine and more particularly to a patterning unit which is controls the position of a guide point provided on a holding member individually by means of a linear pulse motor and to control methods thereof.
Hitherto, patterning of a warp knitting machine has been carried out by lapping patterning reeds in which guide points are mounted in a direction of a row of needles of the patterning reed based on means for lapping the patterning reeds such as a chain drum and an electronic patterning unit. However, because only the same quantity of lapping can be obtained for all the guide points mounted on one patterning reed, the superiority of patterning effect caused by a number of patterning reeds is proportional to the number of patterning reeds.
In view of the prior art problem described above, the present applicant proposed a new patterning unit previously in Japanese Patent Application No. 06-200750 (PCT/JP95/00032). This patterning unit is arranged such that guide points are provided individually as part of moving elements in a fixed guide path which corresponds to the patterning reed so as to be movable individually within the guide path.
However, even though the above-mentioned patterning unit patterns through the control of the movement of the moving elements on which the guide points are provided by utilizing linear pulse motors, it has left room for improvement in the following points:
(1) When a number of holding members increases, it is necessary to deal with it by thinning the linear pulse motor further;
(2) It is necessary to solve the problem of short life of a bearing caused by a large attraction force generated between a stator and a moving element of the linear pulse motor;
(3) It is necessary to take measures for preventing erroneous operation due to step-out, to power failure and external noise in the positioning control;
(4) With the increase of numbers of the holding members and of moving elements, it is necessary to improve a wiring method for wiring connection cables to the moving elements to realize a range in which the moving elements can be moved freely. This is a problem in mounting to the warp knitting machine
(5) With the increase of numbers of the holding members and moving elements, it is necessary to simplify the assembly and adjustment of the unit. This is a problem in mounting to the warp knitting machine;
(6) It is necessary to correct a pitch error which might be caused by the difference in working precision of pitches of poles of a stator assembled to the holding member, in working precision of pitches of knitting needles and in expansion coefficient of the holding members due to environmental temperature changes;
(7) In operation, because a plurality of layers of patterning reeds, i.e. the holding members, are disposed, it is necessary to simplify the replacement of the guide point and its alignment with a knitting needle of each moving element which is located behind another; and
(8) With the increase of the number of moving elements to be mounted, a control method is required which allows each moving element to be positioned at high-speed in synchronism with the rapid rotation of the warp knitting machine while maintaining the free movable range of each moving element and which can realize the above-mentioned points (3) through (7) at low cost.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a patterning unit of a warp knitting machine and control methods thereof which are arranged so as to solve each of the problems described above.
The present invention is arranged such that in a patterning unit of a warp knitting machine in which a stator of a linear pulse motor is assembled in a holding member functioning as a guide path and a plurality of moving elements are provided at arbitrary intervals on the same path, part of the moving element is constructed as a guide point or a guide bar, and poles of the moving element are disposed so as to face to poles on both sides of the stator.
Thereby, attraction forces generated between the stator and the moving element cancel each other and the burden placed on a bearing section is reduced as a result. Therefore, the thickness of the poles of the moving element may be reduced to about a half without dropping a thrust of the moving element. Accordingly, an increased number of the holding members is made possible by thinning the linear pulse motor.
The present invention is also arranged such that in the patterning unit described above, coils of the poles of the moving element, i.e. moving element driving coils, NS directions of two field magnets within the moving elements facing the poles on the both sides of the stator and teeth of the stator are set so that a magnetic path of the field magnets runs in the same direction.
Thereby, a leakage magnetic flux is reduced and the magnetic flux generated by both field magnets and excited coils pass through each pole, so that the thrust may be uniform and the guide point is positioned stably.
Further, the present invention solves the aforementioned problems in the patterning unit of the warp knitting machine in which a stator of a linear pulse motor is assembled in a holding member, functioning as a guide path and a plurality of moving elements are provided at arbitrary intervals on the same path and part of the moving element is constructed as a guide point or a guide bar, by adopting the following control methods.
A first inventive method for controlling the patterning unit of the warp knitting machine described above is to control the acceleration or deceleration of the linear pulse motor by providing a position sensor in connection with the poles of the stator and the poles of the moving element and by confirming by the position sensor that the poles of the moving element have moved a unit of one pulse with respect to a positioning command to generate a next positioning pulse.
Thereby, information for positioning the moving element is logically incorporated as moving conditions in the positioning control commands, so that the moving element follows reliably in accordance with the command values and is positioned accurately. At this time, the correction of position and the like may be readily made, thus guaranteeing more accurate positioning control by controlling the positioning by setting a number of pulses per gage at a plurality of pulses.
A second inventive method for controlling the patterning unit of the warp knitting machine described above is to provide absolute position detecting means whose span is adjusted according to the pitch of the pole of the stator disposed in the holding member to control the relationship between a position detected value detected by the position detecting means and the excitation of the moving element driving coils.
Thereby, the position of the moving element is always detected so that the moving element is caused to follow in accordance with the position control command values, it thus becomes unnecessary to return to the reference position by performing a zero return operation even if power is turned on again after power failure and the machine will not step out due to electrical noise and external noise such as a difference in tension of patterning yarns and in yarn feeding methods.
A third inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element by carrying out optimum positioning acceleration or deceleration by finding current control and excitation switching timings of the moving element driving coil from the position detected value. Thereby, it becomes possible to carry out the positioning reliably in a short time, to execute a stop at the accurate position and to prevent step-out.
A fourth inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element freely by way of wireless control by supplying electric power and transmitting signals to the moving element by using a non-contact method utilizing a magnetic coupling of a power receiving coil of the moving element and an induction coil attached to the holding member or a contact method in which a conductive portion is provided on a part of the holding member and a slip ring is contacted. Thereby, it becomes possible to realize the small and light-weight machine, to increase the thrust and to increase the speed.
A fifth inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element by mounting a microcomputer or a logic circuit on the moving element to reduce an amount of control signals transmitted to the induction coil for the correction of position and the like.
In this case, even if the amount of information to be transmitted by the induction line increases and the processing capacity of the moving element positioning control computer increases, the positioning of the moving element may be controlled individually by the microcomputer or the logic circuit mounted on the moving element without being restricted by the amount of information of the control signals. Then, it allows the load of the moving element positioning control computer to be reduced significantly, the positioning to be accommodated with the high speed rotation and to be controlled accurately at high speed, thus allowing the machine to be put into more practical use.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic perspective view of a warp knitting machine to which one embodiment of an inventive patterning unit and a control method thereof is applied;
FIG. 2 is a section view of a holding member, including a guide point, showing a structural example in which two sets of poles of a stator are disposed on the both sides of the holding member in the patterning unit in FIG. 1;
FIG. 3 is a partly cutaway perspective view showing the embodiment in which a linear pulse motor in which poles of a moving element are disposed so as to face to the poles of the stator on both sides and a magnetostrictive sensor, used for detecting the position of the moving elemnt, are mounted in the patterning unit in FIG. 1;
FIG. 4 is a structural view showing a relationship between the poles of the moving elements and the poles of the stator of the linear pulse motor in the patterning unit in FIG. 1;
FIG. 5 is a block diagram showing one example of a control mechanism for controlling the patterning unit by the linear pulse motor in the patterning unit in FIG. 1;
FIG. 6 is a signal waveform chart of output signals of the magnetostrictive absolute sensor for detecting the position of the poles of the moving element and the position of the pole of the stator in the patterning unit in FIG. 1;
FIG. 7 is a graph showing a relationship among position control parameters of the linear pulse motor in the patterning unit in FIG. 1;
FIG. 8 is a partly cutaway perspective view an embodiment of a patterning unit without connection cables;
FIG. 9 is a block diagram showing one example of a control mechanism of a unit according to an embodiment in which power is supplied and control signals are transmitted by a non-contact method in the patterning unit in FIG. 8;
FIG. 10 is a block diagram showing one example of a control mechanism of the moving element, an induction coil and a receiving coil in the patterning unit in FIG. 8;
FIG. 11 is a signal waveform chart showing an example of signals of a power supplying oscillation section of the moving element in the patterning unit in FIG. 8;
FIG. 12 is a partly cutaway perspective view of an embodiment in which the poles of the moving element are disposed so as to face only to one side of the poles of the stator;
FIG. 13 is a block diagram showing one example of a positioning control mechanism using microcomputers mounted to the moving element;
FIG. 14 is a signal waveform chart showing an example of signals of the power supplying oscillation section of the moving element in the patterning unit in the embodiment shown in FIG. 13;
FIG. 15 is an explanatory diagram of an exemplary data array of the control signal transmitted by a control signal induction coil;
FIG. 16 is a block diagram showing one example of a control mechanism according to an embodiment in which two lines consisting of a power supplying induction coil and the contr ol signal induction coil are applied; and
FIG. 17 is a partly cutaway perspective view of a part of the moving element showing an embodiment in which a moving element per holding member is constructed by attaching a guide bar.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained below with reference to the drawings.
FIG. 1 is a schematic perspective view of a warp knitting machine to which one embodiment of a patterning unit and a control method thereof of the present invention is applied. The reference numeral (1) denotes a traverse which is part of a machine frame, (2) hangers suspended from and fixed to the traverse 1 at intervals of a certain distance, (3) holding members in each of which a stator of a linear pulse motor extends in a direction of width of the knitting machine and a certain number of which are fixed to the hanger 2 in parallel, and (4) moving elements which reciprocate linearly on the holding number 3 and to each of which a guide point 5 (5a-1, 5a-2, 5a-3) is attached. Normally, several to ten-odd moving elements 4 are mounted to the holding member 3 which constitutes, at least partly, the stator of the linear pulse motor across the width of the knitting machine so as to be movable in accordance to a patterning program.
Provided within a control section 6 are known control units, i.e. a position control circuit, a linear pulse motor driving circuit, a position detecting circuit and a patterning computer with a memory. Because their structure is well known, an explanation thereof is omitted. A position controlling method of the linear pulse motor is explained below in detail with reference to FIGS. 4, 5, 6 and 7 because it is an essential part of the present invention.
Each holding member 3 has a signal cable 7 as one of means for transmitting signals to each moving element 4 at one end thereof. The reference numeral (8) denotes knitting needles, (9) a trick plate, and (10, 11) a lever and an aim for driving the trick plate 9 which are mounted to a supporting shaft 12. The trick plate 9 is oscillated together with the knitting needles 8 in a direction of A. Any type of knitting needles beside those conventionally used such as a composite needle, a latch needle, a beard needle and the like may be used for the knitting needle 8 so long as it has a similar function.
Next, a structure of a driving section containing the stator of the linear pulse motor incorporated in the holding member 3 and the moving element 4 will be explained.
FIG. 2 is a longitudinal section view of an embodiment in which the moving elements 4 are attached to both sides of the holding member 3 provided on a holder 13 and FIG. 3 is a partly cutaway perspective view of one side thereof. The stator 18 on which toothed poles are formed on both sides thereof is provided in the holding member 3 across the whole length of the knitting width so that the moving elements 4 may be moved throughout the knitting width. Normally, several to ten-odd moving elements 4 (4-1, 4-2, . . . 4-n) are mounted to the holding member 3. A moving element bearing 14 holds the moving element 4 and the guide point 5 attached to the moving element 4.
The moving element 4 of the linear pulse motor is constructed as follows. In the figure, the reference numerals (15: 15a, 15b) denote field magnets (magnets), (16: 16a-1, 16a-2, 16b-1, 16b-2) poles of the moving element, and (17: 17a-1, 17a-2, 17b-1, 17b-2) moving element driving coils. The poles 16a-1 and 16a-2 of the moving element, the moving element driving coils 17a-1 and 17a-2, the poles 16b-1 and 16b-2 and the moving element driving coils 17b-1 and 17b-2 are disposed so as to face to the poles of the stator 18 in order to cancel out large attraction forces generated between the poles 16 of the moving elements 4 and the poles of the stator 18. Thereby, because a load placed on the moving element bearing 14 as well as the gap between the both poles may be reduced, a thrust is maintained, heat generated is reduced, the miniaturization of the bearing and the prolongation of its life is realized by reducing an exciting current applied to the moving element driving coils 17. Further, the whole moving element 4 may be thinned by miniaturizing the moving element driving coils 17 and the moving element electrodes 16.
A magnetostrictive absolute sensor probe 19 is mounted across the whole range of the knitting width of the holding member 3. A position detecting sensor magnet 20 is mounted on each moving element 4 (4-1, 4-2, . . . 4-n) (See FIG. 5). The magnetostrictive absolute sensor probe 19 detects the position of each moving element 4 by detecting the position of the sensor magnet 20 of the moving element 4 on the holding member 3 to create data for controlling the position. A flexible cable is used as a signal cable 7a connecting a linear pulse motor driving circuit provided in the control unit with the moving element driving coil 17 of the moving element 4 to allow the moving element 4 to move freely. The signal cable 7a is explained below with respect to an embodiment in which the cable is eliminated.
FIG. 4 is a structural diagram showing a relationship between the poles of the moving element and the poles of the stator of the linear pulse motor of the patterning unit of the present invention. Because its basic structure is known, a detailed explanation of its basic operation is omitted and its operational principle is explained only about the part related to the present invention.
Several problems are solved by disposing two sets of the poles 16 of the moving elements and the moving element driving coils 17 so as to face to the poles on the both sides of the stator 18, by arranging phases of the upper and lower teeth, i.e. the poles of the stator 18, so as to be opposite, and by configuring directions of NS of the upper and lower field magnets 15a and 15b to be also opposite.
While it has been described with respect to the explanation of FIGS. 2 and 3 that the load placed on the moving element bearing 14 can be reduced significantly by adopting the structure in which the attraction forces generated between the upper and lower poles are canceled, it is also a solution for the biggest problem of the linear pulse motor used in the inventive unit. Further, because the gap between the poles is minimized by solving the problem of the attraction force, the thrust is increased. While it has been also described before, a difference in magnetic flux density is caused between the inner poles close to the field magnets 15a and 15b and the outer poles due to a difference in resistance of magnetic paths and leakage flux from the prior art structure, causing a dispersion of the thrust among the inner and outer poles. This problem is solvable in the present invention by configuring the two sets of upper and lower linear pulse motors by assorting the inner poles with the outer poles, by arranging (alternating) the upper and lower teeth of the poles of the stator 18 so as to be opposite and by arranging the NS directions of the field magnets 15a and 15b so as to be also opposite.
Further, the dispersion of the thrust is minimized and the performance of position control is improved by connecting the upper and lower moving element driving coils 17a-1 and 17b-1 for A phase to the same phase and connecting the upper and lower moving element driving coils 17a-2 and 17b-2 for B phase to the same phase in the same manner to set the pole Nos. 1p, 2p, 3p and 4p of the moving elements shown in FIG. 4 so that when the upper side ones are positioned outside, the lower side ones are positioned inside and when the upper side ones are positioned inside, the lower side ones are position outside.
As shown by a broken line in FIG. 4, the path φ of the magnetic flux generated when the field magnets 15a and 15b and the moving element driving coils 17a-1 and 17b-1 are excited always passes through both the upper field magnet 15a and the lower field magnet 15b, thus providing a highly efficient thrust. The highly efficient thrust is obtained also when the moving element driving coils 17a-2 and 17b-2 are excited by the same reason.
In the present embodiment, a pitch Pd of the pole of the stator 18 is set at four times a gage pitch (1/18 inch=1.411 mm) of the guide point. In the structure shown in FIG. 4, the movement per pulse is 1.411 mm in the case of one-phase excitation or two-phase excitation as it is known. The movement per pulse is 0.705 mm in the case of the one-two-phase excitation method. In the present embodiment, a combined method of the one-phase excitation and the one-two-phase excitation is adopted in order to carry out the position control per 1.411 nm pitch. The position control method is described below with reference to FIGS. 5, 6 and 7.
Next, an exemplary control method of the patterning unit of the above-mentioned embodiment of the present invention is explained with reference to FIG. 5.
The reference numeral (30) denotes a computer for pattern control. A pattern data disk 31 prepared beforehand based on lace pattern structures is read into an internal memory of the pattern control computer 30. This pattern data which is to be decomposed per holding member by a moving element positioning control computer 23 of each holding member, is transmitted as a pattern data signal S8a and is stored in the memory in the moving element positioning control computer 23. When the knitting machine is driven, periodic signals S5 and S6 are sent from a proximity sensor 25 and a disk 26 for the proximity sensor 25 for an underlap starting signal provided on a main shaft 24 of the knitting machine and from a proximity sensor 27 and a disk 28, for the proximity sensor 27 for an overlap starting signal, respectively, to the moving element positioning control computer 23.
Each of the pattern guide point moving elements 4-1, 4-2, . . . 4-n disposed on the holding member 3 contains the linear pulse motor and its position is controlled by exciting the moving element driving coils. The reference numerals (20-1, 20-2, . . . 20-n) denote magnets for sensors for detecting the position of the moving elements, (19) the magnetostrictive absolute sensor probe for detecting the position of the moving elements, (19a) a sensor amplifier, (19b) a circuit for detecting the position of each moving element by counting an output signal S1 of the sensor amplifier 19a, and (21-1, 21-2, . . . 21-n) pulse motor driving circuits for sending signals S4-1, S4-2, . . . S4-n for exciting the moving element driving coils of the linear pulse motor, to each of the moving elements 4-1, 4-2, . . . 4-n to position them.
The moving element positioning control computer 23 controls the position of each of the guide points 5a-1, 5a-2, . . . 5a-n attached to the moving elements 4-1, 4-2, . . . 4-n in accordance to the pattern data based on positional elements 4-1, 4-2, . . . 4-n stored therein and moving element position detected signals S2 and signals generated by commands S3-1, S3-2, . . . S3-n for positioning the moving elements 4-1, 4-2, . . . 4-n which are synchronized with the periodic signals S5 and S6 of the main shaft of the knitting machine, are transmitted by the pulse motor driving circuits 21-1, 21-2, . . . 21-n.
Further, as a known method for controlling the position of the pulse motor, there is a method of guaranteeing the prevention of step-out during startup and positioning to a target position by generating slow-up and slow-down pulses. However, this slow-up and slow-down method cannot guarantee it 100% accuracy due to the fluctuation of load and external noise even if a safety factor is increased.
The present embodiment is adapted to carry out the positioning reliably in the shortest time using a control method explained in detail below referencing FIGS. 6 and 7.
FIG. 6 shows a relationship between the output signals of the magnetostrictive absolute sensor and the poles of the stator 18. In the present embodiment, the pitch of the pole of the stator 18 corresponds to four gages and there are four ways of positioning positions of GA1, GA2, GA3 and GA4.
In the present embodiment, the position detecting circuit is designed so as to detect the position in unit of 1/8 of the movement of one gage (1.411 mm) from GA1 to GA2. When the span of the knitting width of the holding member 3 is adjusted and positioned so that the output signals of the magnetostrictive absolute sensor agree with the pitch of the pole of the stator 18, the relationship shown in FIG. 6 is obtained as a result.
Position detection values are represented by binary numbers like S2-0 (20), S2-1 (21), S2-2 (22), S2-3 (23) . . . Although S2-4 and above are omitted, they are detected by values of 16 bits. Accordingly, as for a guide address, the unit of S2-3 (23) becomes a guide address detection value of the guide point (moving element). Three bits S2-0, S2-1 and S2-2 below that are information on movement required for the positioning control of the linear pulse motor.
FIG. 7 represents a relationship among positioning control parameters of the linear pulse motor. The reference symbol (Pc) denotes a position detected value of the moving element 4, (S2) a signal for exciting the moving element driving coil 17 of the linear pulse motor, (i0, i1, i2, i3, i4, i5, i6, i7) exciting current parameters of the moving element driving coil 17, and (ΔP0, ΔP1) the movement per pulse of the linear pulse motor. That is (ΔP0) is the movement in case of the one-two-phase excitation and (ΔP1) is the movement in case of the one-phase excitation. (Sn) of the horizontal axis represents a number of times of sampling for detecting the position. The sampling period is 1.6 msec. in the present embodiment. (ts) denotes time (msec). (Δf) represents a speed of the moving element 4 and indicates a varied movement of a detected value in one sampling period. (d0, d1, d2) denote control parameters indicating distances to positioning target values. (Δd) denotes a parameter of an allowance between a position detected position and a position for exciting the moving element driving coil of the linear pulse motor. Δd is important as a parameter for preventing step-out and is set as Δd≦12 in the detected value. It is set as Δd≦12 in the present embodiment considering the safety factor because the step-out condition is brought about when Δd≦16 as is well known.
An embodiment concerning to each parameter and the positioning control method will be explained below.
A positioning time of the moving element synchronized with a number of revolutions of the knitting machine of 400 rpm to 450 rpm is within 50 msec. in the underlap positioning and within 18 msec. in the overlap positioning. While there is a fluctuation of the allowance more or less on a number of the holding members, the reliable positioning is guaranteed in a short time in any case. The lapping illustrated in FIG. 7 presents the movement of 12 gages. Positioning is started by the underlap starting signal and, at the startup for the start dash, the rise time is minimized by charging the current of i7 and i6 fully for the performance of the driving circuit. It is accelerated by adding ΔP1=8 when the position detected value approaches to a difference with the exciting position Δd=4 to move the exciting position. While it turns out as Δd=12 at that moment, the exciting position is moved further when the detected position of the moving element approaches to Δd=4, thus repeating this process sequentially until reaching to the target position. This method represents the shortest startup of the moving element conforming to a time constant of inertia thereof. This control is performed with the period of the position detecting sampling of 1.6 msec.
Control parameters and a control method for stopping at the next target value will be explained. While the stopping control starts at the point of time when the position of the signal S2 for exciting the moving element driving coil of the linear pulse motor reaches to the target position as described above, the moving element is at the position distant from the target position by 1.5 gage at the point of time when the signal S2 reaches to the target because Δd≦12. Then, a moving velocity Δf at that time is found. The operation of FIG. 7 is then carried out in accordance to d0, d1 and d2 and the exciting currents of i1, i2 and i3 set in advance by the value of Δf, as follows.
At first, when the position approaches to d2 with respect to the target value, the exciting position is returned by ΔP1 to excite the point one gage before the target value. Assume the exciting current at this time as i3. That is, it acts as a brake for stopping at the target position. Next, the exciting position is approached to the target position by ΔP0 at the point of time when it approaches to the position of d1. The exciting current at this time is i2. Then, when the exciting position is advanced by ΔP0 at the point of time when it approaches to the position of d0, the exciting position reaches to the positioning target. The exciting current at this time is i1.
The above control method allows the moving element to be stopped at the target position in the shortest time by optimally setting the parameters Δf, d0, d1, d2, i1, i2 and i3. i0 is the exciting current after the stop and a current value conforming to a torque for holding the stop is selected.
The method of the present embodiment allows the positioning in the shortest time by controlling the position detected position of the moving element and the exciting position of the moving element driving coil, i.e. the command value, always at intervals of the period of the position detecting sampling of 1.6 msec. and by controlling always so as to prevent the step-out which is the biggest problem of the linear pulse motor.
The control parameters may be applied to all the moving elements so long as they have the same structure by setting the optimal values once.
The performance of the patterning unit may be improved further by minmizing the dispersion of thrust by constructing the linear pulse motor as shown in FIG. 4 as described above and by reducing the thickness and weight of the moving element and by increasing the thrust.
Next, an embodiment in which power is supplied and control signals are transmitted in a non-contact manner without using cables, will be explained as a method for controlling each driving coil of the moving elements 4-1, 4-2, . . . 4-n for the guide points disposed on the holding member 3. This embodiment solves the problems of the restricted movement range of the moving element and the short life of the cables as well as the problem in mounting and realizes free patterning by eliminating the connection cables to the moving elements.
FIG. 8 shows one example of the patterning unit from which the connection cables are removed. The parts structurally common with those in FIG. 3 are designated with the same reference numerals and an explanation thereof is omitted. Only parts added to the upper edge portion are explained below.
A unit is formed by assembling a ferrite plate 40 secured to the holding member 3, an induction coil 34 secured in parallel with the ferrite plate 40 in the longitudinal direction, a power receiving coil 35 provided in correspondence with the induction coil 34 at the upper part of the moving element 4, a rectifier circuit 36, a driving circuit 37 and a signal detecting circuit 38.
A control method using the above-mentioned unit is explained referencing FIGS. 9, 10 and 11. It is noted that the explanation of the control method common with that in the previous embodiment shown in FIG. 5 is omitted and only the additional control method is explained.
Commands S3-1, S3-2, . . . S3-n for positioning the moving elements 4-1, 4-2, . . . 4-n generated by the moving element positioning control computer 23 in FIG. 9 are input to a signal converter circuit 32 to be converted into a serial pulse signal S10 which is input to a power supplying and oscillating section 33. The power supplying and oscillating section 33 outputs a power signal S11 whose oscillation frequency is modulated by the serial pulse signal S10 for positioning the moving element and excites the induction coil 34 attached on the holding member 3.
The moving elements 4-1, 4-2, . . . 4-n can obtain induced power caused by the magnetic coupling between the power receiving coils 35-1, 35-2, . . . 35-n and the induction coil 34 and in the same time, receive the control signal.
A method for controlling the moving elements 4-1, 4-2, . . . 4-n will be explained with reference to FIG. 10. The induced power S12 generated in the power receiving coil 35 is input to the control signal detecting circuit 38 and the rectifier circuit 36 and a control signal S13 and a DC voltage signal S14 are input to the linear pulse motor driving circuit 37. Then, control signals S15 and S16 excite the moving element driving coils 17a-1 and 17a-2. Thus, the position of each moving element is controlled in the same manner with above.
FIG. 11 shows exemplary signal waveforms of a basic oscillation signal CL of the power supplying and oscillating section 33 and the power signal S11 which has been pulse-width modulated by the positioning command serial pulse signal S10.
While the embodiment in which the power is supplied together with the control signal is explained above, it is conceivable to adopt a method of supplying the power and transmitting the control signal by two line systems described below. In any case, the more the number of moving elements disposed on the same holding member, the greater the effect of removing the connection cables becomes. While the weight of the moving element increases by adding the power receiving coil 35, the power receiving coil ferrite core 39, the control signal detecting circuit 38, the rectifier circuit 36 and the linear pulse motor driving circuit 37, a light-weight, thin and high-thrust patterning unit may be realized and be put into practical use due to the effect of the patterning unit an opposing pole structure.
It is noted that beside the non-contact method described above, positioning control by way of wireless control similar to one described above may be implemented by a contact method of supplying signals and power by providing a conductive portion on a part of the holding member and by contacting it with a slip ring provided on the moving element.
FIG. 12 shows an embodiment in which poles of the moving element 4 are disposed so as to face poles at one side of an upper or lower side (upper side in case of the figure) of the stator 18 provided in the knitting width direction in the holding member (not shown).
In the figure, the reference numeral (15) denotes a field magnet, (16a-1, 16a-2) poles of the moving element, and (17a-1, 17a-2) moving element driving coils. Moving rollers 41 are provided before and after the both poles 16a-1 and 16a-2 and are placed on the stator 18 formed so that the moving rollers 41 function also as a guide so as to be able to move the moving element in the knitting width direction. Because an induced power is obtained by the magnetic coupling of the induction coil 34 and the power receiving coil 35, a necessary power is supplied by it. This point is the same with the case in the embodiment in FIG. 8.
FIG. 12 also shows a case in which a microcomputer or a logic circuit is mounted on the moving element 4 to control the moving element 4 thereby reducing the control signals of the induction coil 34 for the correction of position and the like. Accordingly, the figure shows microcomputer chips attached on a substrate PB.
That is, although the case in which the control is made by setting the movement per pulse of the linear pulse motor at the gage pitch (1.411 mm) has been shown in the embodiment of the control method described above, it is desirable to select a control method in which the movement per pulse is set at one-several of 1.411 mm per pulse described above, e.g. one quarter in order to solve the problems of the working precision of the stator, the working precision of the pitch of the knitting needles, the correction of the pitch error, the simplification of the alignment and the increase of the speed. More desirably, the one-two-phase exciting method is adopted to correct the position of the moving element, temperature and individual guide position in unit of 0.176 mm per pulse.
However, if it is set at a plurality of pulses per move of one gage, an amount of information to be transmitted by the induction lines increases four times and in the same time, the processing capacity of the moving element positioning control computer 23 has to be increased four times or more. Further, carrier frequency of the induction line becomes high frequency of more than four times and it becomes difficult to realize it because of the high cost in the aspects of the mounting and processing capacity.
It is preferable, therefore, to adopt the following control method after setting a number of pulses for moving one gage at a plurality of pulses, e.g. four pulses or eight pulses, as shown in the embodiment.
Firstly, the microcomputer is mounted on the moving element 4 to carry out the positioning control individually in order to significantly reduce the amount of information carried by the control signal induction line. Secondly, two lines consisting of the power supplying induction line and the control signal induction line are provided so that resonance frequency can be set in accordance to an inductance of the power supplying induction line without being restricted by the amount of information of the control signal.
The processing capacity is dispersed and the load of the moving element positioning control computer 23 is significantly reduced by adopting this control method.
FIG. 13 shows one example of a control mechanism controlled by the computer mounted on the moving element 4.
It comprises the power receiving coil 35 provided corresponding to the power supplying induction coil 34 secured to the holding member and a signal receiving coil 53 provided corresponding to the control signal induction coil 52 secured to the same holding member together with the power supplying induction coil. An output signal S21 of the power receiving coil 35 is input to a power receiving section 55 to output a controlling power source V5 and a power source Vc for the pulse motor driving circuit 58. Further, an output signal S22 of the control signal receiving coil 53 for shaping the output signal S21 of the power receiving coil 53 and for outputting a control signal synchronizing signal CL is input to the control signal receiving section 56 to be shaped as a serial control signal S23.
FIG. 14 shows each exemplary signal. The serial control signal S23 is output as a sequence consisting of 0 and 1 with respect to the control signal synchronizing signal CL. The signals CL and S23 are input to a positioning control microcomputer section 57. Receiving information necessary for positioning each moving element sent from the pattern controlling and moving element positioning control computer 23, the positioning control microcomputer section 57 develops an exciting signal S24 for the linear pulse motor and a current signal S25 to be output to the pulse motor driving circuit 58. Then, the pulse motor is positioned by means of an A-phase exciting signal S15 and a B-phase exciting signal S16.
FIG. 15 shows an embodiment of the serial control signal S23 transmitted by the control signal induction coil 52. While the method for transmitting and receiving the serial signal is known and its explanation is omitted here, the content of the signal is explained below.
Control codes listed in the lower fields of FIG. 15 are control commands for the moving element and are common to all the moving elements.
The control commands can be roughly divided into two kinds of commands of transmitting control data and of starting the control. The control codes will be explained below briefly.
05H Transmit command values: Transmit a movement for positioning, direction, and presence or absence of overlapping to each moving element from pattern data. Transmit once per turn
01H Start underlap positioning: Execute command of transmitting command value. It is a synchronizing
02H Start overlap positioning: Execute command of transmitting command value. It is a synchronizing signal for starting.
06H Transmit return command value: Used primarily for recovering operation after occurrence of error. Command a movement to be returned.
03H Start positioning of return: Execute command in accordance to return command value.
04H Start adjustment of span: It is a command for starting to control excitation of pulse motor when the position of the stator of the pulse motor is to be adjusted with absolute position detected value. Present position of each moving element is updated.
07H Transmit correction value: Transmit correction value to each moving element. Positioning position is corrected by correcting zero offset values.
08H Transmit control data: Transmit control parameters.
0FH-51H Transmit positioning parameters: Transmit positioning control time with respect to move pulse and current value.
60H-62H Transmit present position of moving element: Transmit absolute detected value to update internal data of moving element.
Mounting the microcomputer in the moving element positioning control section as described above allows the positioning control section and the distributed processing to be realized and the problems to be solved, thus allowing to accommodate with the multi-function of the future, in view of its accommodation to the multiple pulses, to the position correcting function and cordless control and to the multiple moving elements.
FIG. 16 is a block diagram of a control mechanism of the embodiment in which two lines consisting of the power supplying induction coil 34 and the control signal induction coil 52 are provided.
As compared to one described before in FIG. 9, the oscillating section for exciting the induction coil 34 is divided into an oscillating section 51 for exciting the control signal induction coil and an oscillating section 50 for exciting the power supplying induction coil and a control signal S19 output from the moving element positioning control computer 23 is input to the oscillating section 51 to output an oscillating section output signal S20 to be supplied to the control signal induction coil 52. Similarly, a control signal S17 is input to the power supplying oscillating section 50 and an oscillating section output signal S18 which is output as ON and OFF signals is supplied to the power supplying induction coil 34.
Microcomputer positioning control substrates PB-1, PB-2, . . . PB-n are mounted on the moving elements 4-1, 4-2, . . . 4-detecting a temperature of the holding member portion on which the moving elements are mounted and a correction control panel 61 are provided to realize the optimum patterning and positioning control by inputting temperature data S30 and a correction control signal S31 to the moving element positioning control computer 23 to give commands of correction values for the correction of position necessary due to temperature changes and for the adjustment necessary for each individual moving element to the aforementioned moving element correction functions.
FIG. 17 shows one example of a patterning unit constructed by attaching guide bars having a plurality of guide points to the moving elements moved and positioned as described above.
The basic structure of this embodiment is common with the embodiment shown in FIG. 3, so that the same components are designated with the same reference characters and their detailed explanation is omitted. The stator 18 of the linear pulse motor is assembled in the holding member 3 as a guide path and a plurality of moving elements 4 (4-1, 4-2, 4-2, 4-4, . . .) are disposed on the same path so that poles 16a and 16b of each moving element face to the poles on both sides of the stator 18 provided in the holding member 3 as the guide path so as to be movable individually in the knitting width direction. Then, guide bars 70 (70-1, 70-2, 70-3, . . . ) on which a plurality of guide points 5 (5-1, 5-2, 5-3, . . . ) are provided are attached to the arbitrary, plural number of moving elements 4 by screw clamp means 71. Each guide point 5 is attached to a desirable position of the guide bar 70 by screws 72.
The moving elements 4 hold the guide bar 70 at least at two points close edge thereof for each guide bar, though it depends on a length of the guide bar 70, i.e. the knitting machine width. The moving elements 4 for holding the guide bar 70 at several points may be provided at adequate intervals depending on the length of the guide bar 70.
When the plurality of guide bars 70 are provided so as to be movable respectively by the moving elements by shifting the attaching positions in the direction of the front and back of the knitting machine, the displacement of each guide bar 70 may be individually controlled readily and quickly. Further, because the plurality of guide bars may be provided individually displaceable within the same guide path, a space margin is created for installing the guide bars and a structure in which a number of guide bars are provided in parallel may be readily realized.
It is noted that although the linear pulse motor driving circuit of the control unit and the moving element driving coils are connected by the signal cables 7 in FIG. 17, it is possible to remove the signal cables like those in FIGS. 9 and 12 to control by way of wireless control also in this embodiment. In this case, it is necessary to provide a unit in which an induction coil, a power receiving coil and current circuit, a driving circuit and a signal detecting circuit are assembled on the upper part of the moving element 4. Further, the embodiment is possible to implement it by disposing the poles of the moving element so as to face to the poles on one side of the stator as in FIG. 12.
Further, beside setting a number of pulses for moving one gage to one pulse, it may be set at a plurality of pulses also in this embodiment. It is also possible to mount a microcomputer on the moving element to position individually and to construct using two lines consisting of the power supplying induction line and the control signal induction line.
According to the inventive patterning unit of the warp knitting machine, a load placed on the moving element bearing is reduced and the thickness of the motor is reduced without reducing a thrust of the linear pulse motor, so that the number of the holding members, which corresponds to a thread guiding reed of the prior art machine, may be increased and the assemble thereof and adjustment, like an alignment with knitting needles, may be made readily.
Further, a leakage magnetic flux may be reduced and the thrust may be uniformed by arranging so that a magnetic path of the magnets runs in the same direction, so that guide points may be positioned stably.
Information for positioning the moving element is incorporated logically in the circuit as moving conditions of positioning control commands by the first control method of the inventive patterning unit, so that it becomes unnecessary to return to the reference position in restarting after power failure, step-out caused by various external noise sources is eliminated and no erroneous operation occurs. Further, it becomes possible to guarantee a short-time and reliable positioning by controlling the exciting position, exciting current and excitation switching timing by parameters given above.
Further, because the restriction on the moving range of the moving element is eliminated in creating a pattern by removing the signal cables connected with the moving elements and by positioning the moving elements by way of wireless control, pattern yarns may be run freely and fully in the knitting machine width, allowing knitting of lace fabrics having a new pattern structure which has been impossible in the past. Further, it allows the machine to be miniaturized, its weight to be reduced and the high thrust to be realized, thus contributing to the increase of the speed.
Further, the moving element may be positioned without being restricted by an amount of information of the control signals and the load of the moving element positioning control computer may be reduced, putting the machine into more practical use, by mounting the microcomputer or the logic circuit on the moving element to reduce the control signals transmitted to the induction coil for the correction of the position and the like.
Thus, the patterning unit of the warp knitting machine and the control methods thereof of the present invention allow the problems (1) through (8) described above to be solved and readily enable the patterning and knitting carried out by controlling the move of the moving elements provided with the guide points by utilizing the linear pulse motor. | The present invention provides a patterning unit of a warp knitting machine having a holding member with a stator of a linear pulse motor disposed thereon and a plurality of moving elements provided at arbitrary intervals on the holding member with parts of the moving elements being constructed as guide points. A control method increases reliability and accuracy of positioning the moving elements and eliminates erroneous operation such as step-out by providing a position sensor related to poles of the stator and by exciting movement of the moving elements on a step by step basis based upon positions of the moving elements. The control method includes providing the moving elements each with a linear motor coil assembly for functioning in conjunction with the stator, defining the poles, to move the moving elements along the holding member. | 3 |
Benefit of U.S. Provisional Application 61/011,084, filed Jan. 14, 2008 is claimed.
RELATED APPLICATION
PCT/US2005/043755, published as WO2006/065563, Method and Apparatus for Determining Position and Rotational Orientation of an Object.
BACKGROUND OF THE INVENTION
Determining the position and rotational orientation of an object within a defined space is a practical problem that has brought many solutions. For example, Global Positioning Systems (GPS) is a widely recognized position determination technology, but it lacks rotational orientation determination capability for stationary objects. GPS operability suffers indoors from signal attenuation and reflections, so it is not a good choice for indoor applications. Ultrasonic methods that operate well indoors have been designed to replicate GPS capability, but they, too, lack rotational orientation determination. In prior art optical position location systems various markers are used.
PRIOR ART
U.S. Pat. No. 6,556,722 discloses a method, wherein circular barcodes are utilized to indicate reference positions within a television studio. In this optically based method, a television studio camera is equipped with a secondary camera which views position markers set onto the studio ceiling in known locations. The markers are constructed of concentric ring barcodes which are developed specifically for that purpose. Camera position is determined by capturing an image of at least three markers and performing geometric analysis in a digital computer to determine accurate location within the three-dimensional studio space. The invention discloses proprietary circular ring barcodes, which cannot be read by commercial machine vision systems, and requires a multiplicity of markers to be within view.
U.S. Pat. No. 5,832,139 discloses a method and apparatus for determining up to six degrees of freedom of a camera relative to a reference frame which comprises an optically modulated target with a camera and processing the camera's output video signal with a digital computer. The target may have a single pattern, multiple patterns, or patterns of varying size, and multiple targets may be used. The invention analyzes the parallax, or “warping” of square target patterns into non-square quadrilaterals within the field of view in order to determine six degrees of freedom of the camera. It does not present common barcode symbols as a choice for passively modulated targets, and does not use the inherent identity of barcode symbols for both automated means and non-automated position determination means.
A number of machine vision-based systems exist, especially for vehicle and robot guidance, however, most analyze physical surroundings by viewing downward toward floor markings, or horizontally toward local scenery or reflective markers. For example, U.S. Pat. No. 6,728,582 provides a system and method for estimating the position of an object in three dimensions using two machine vision cameras interconnected with a machine vision search tool. A nominal position for each camera's acquired image of the object is determined and a set of uncertainty vectors along each of the degrees of freedom is generated. This method requires viewing multiple objects with multiple cameras in order to make the weighted estimation of the position of the object.
In view of the foregoing, there is a need for a simple, easy to install, optical position marker apparatus useful with image acquisition systems such as machine vision and navigation systems.
SUMMARY OF THE INVENTION
An apparatus for marking predetermined known overhead positional locations within a coordinate space, for viewing by an image acquisition system, is disclosed. The apparatus comprises a plurality of marker tags, the marker tags being grouped in one or more rows, each row having an axis, the marker tags in a row being supported by a row support. Each marker tag comprises an optically opaque, dark colored corrugated substrate, substantially rectangular in shape. An adhesive-backed label having a unique machine-readable barcode symbology printed thereon is positioned centrally on the substrate so that a dark colored border of the substrate surrounds the label. Each row support comprises a first support cord and a second support cord. The first support cord supports a first lateral edge of the marker tags in a row group in a fixed, spaced-apart positional arrangement. The second support cord supports the second lateral edge of the marker tags in the row in a slidable support arrangement. The first support cord is attached to an overhead support structure at each end with a tensioning device and the first support cord is drawn to a predetermined tension, thus establishing a substantially straight first lateral row edge. The tensioning devices on the first support cord permit precise positioning of the marker tag group along the row axis. The second support cord is also attached to the support structure at each end with a tensioning device and the second support cord is drawn to substantially the same tension of the first cord, so that the marker tags are supported in a substantially horizontal plane. The slidable support of the second edge allows the marker tags of a row group to align along the first lateral edge and eliminates any skewing of the marker tags due to unequal tensions in the support cords. A spreader bar is provided at each end of the support cords to establish a fixed spacing of the support cords corresponding to the spacing of the first and second lateral edges of the marker tags, thus preventing the application of lateral forces to the substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an arrangement of a position marker apparatus having multiple row groups of overhead optical position marker tags in accordance with the present invention;
FIG. 2 is a plan view of a row group of marker tags showing the support cords supporting the row group of marker tags, the ends of the support cords having loops through which cable ties pass to attach the row group to a support structure and to adjust the support cord tension;
FIG. 3 is an enlarged plan view of a marker tag;
FIG. 4A is a perspective view showing a first attachment arrangement of a marker tag to two support cords, also illustrating the support cords being fed through holes in a spreader bar; and
FIG. 4B shows a second attachment arrangement of a marker tag to two support cords.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an improved optical position marker apparatus usable with the system of the related application, PCT/US2005/043755 WO2006/065563, incorporated herein by reference, for the tracking of vehicles and stored goods within a warehouse or factory setting which requires a plurality of individually unique position markers, arranged at predetermined known positional locations. As described in the related application, in a factory or warehouse setting, the object to be located is typically on the floor, and the position markers are placed overhead. The overhead support structure, such as a roof truss support, is sufficiently high above the working area so as not to interfere with operations.
FIG. 1 illustrates the apparatus 10 of the present invention in use in the system of the related application. The optical position marker apparatus 10 described herein allows light to pass from overhead light fixtures to the work area, and air to flow freely for heating and ventilation. Suspension of the optical position marker apparatus 10 is provided by mechanical supports, such as overhead beams or trusses of a building structure. The apparatus 10 comprises one or more row groups 20 , illustrated as row groups 20 - 1 , 20 - 2 , 20 - 3 in FIG. 1 .
As described in the related application, an image acquisition system is mounted on an object, such as an industrial materials handling vehicle, typically a forklift. The field of view FOV of the image acquisition system is shown in dashed lines as an inverted pyramid. The image acquisition system acquires an image of one or more position markers within view and the image is then decoded by commercially available machine vision equipment to determine the identity of the one or more position markers. The location of a position marker with the acquired image is then used to determine the position and rotational orientation of the object. Each position marker 30 (best seen in FIG. 3 ) bears a unique barcode symbol 40 B that contains a rotational orientation feature 40 R, thereby identifying both the position coordinate and rotational orientation of the position marker within the predefined coordinate space. The position and rotational orientation in “real” space are them computed from machine vision data using a series of programmed instructions which translate the relative positional and rotational orientation data to coordinates expressed in usable units such as feet or meters relative to a know datum. Results are stored, displayed, and/or transmitted to another system, such as an inventory control system, where data may be used to record object location, to direct vehicle guidance, or for other navigation or control purposes.
Although only one position marker must be within view of the object, if more than one position marker is within view (as seen in FIG. 1 ) the position and rotational orientation of the object may be calculated from each position marker within view to verify and improve the precision of the position and rotational determination.
A marker tag 30 is created by affixing a label 40 ( FIG. 3 ) to a substantially stiff substrate 50 to add mechanical strength. A corrugated plastic substrate, such as black polypropylene corrugated sheeting, four millimeters thick, available under the trade name Coroplast, from Coroplast Corporation of Dallas, Tex., is preferred since it provides for easy attachment of the support system. The corrugated plastic substrate is sized larger than the barcode label to provide a dark border 50 D ( FIG. 3 ), termed an “optical quiet zone”, around each barcode symbol 40 B. For clarity of illustration, in FIG. 3 the substrate 50 is cross hatched, so that the individual elements, i.e. the label 40 , the barcode symbol 40 B and the rotational orientation feature 40 R may best be seen.
The dimensions of a marker tag substrate 50 and the barcode symbol 40 B are selected according to the desired field of view for the camera of an image acquisition system and the distance between the camera and the elevation of the position marker apparatus 10 . Barcode symbols ranging from about three centimeters square to about twenty-four centimeters square have been used. Barcode symbols, each containing a unique identification encoded in two-dimensional barcode symbology are printed on label stock. Retro reflective barcode labels are preferred to improve the contrast of the image and thus the signal-to-noise ratio and the quality of the signal output from the machine vision camera. A retro reflective material sold under the trade name Scotchlite™ from 3M Corporation of St. Paul, Minn. is preferred, although other label stocks available from many suppliers, such as Duratran II thermal transfer label stock, Part No. E06175 available from Intermec Corporation of Seattle, Wash., are suitable. Barcode labels may be printed using a common barcode label printer such as Intermec model 3800 thermal transfer barcode label printer or a commercial inkjet printer such as Roland XC-540 model printer.
As may be seen in FIG. 2 the marker tags 30 are attached to a first and second support cords 60 A, 60 B of a supporting cord or cable assembly 60 , known as a row support, in a fixed, spaced-apart positional arrangement to create row groups 20 of marker tags. The support cords 60 A, 60 B of the support cord assembly 60 should have substantially no stretch. A cord material, such as one eighth inch diameter antenna cable, having a diamond braided polyester outer jacket with a Kevlar® core used for radio antenna support, available from Erin Rope Corporation of Blue Island, Ill., has been found suitable.
In a preferred embodiment as seen in FIG. 4A (also FIG. 3 ) a corrugated substrate 50 is used and each support cord 60 A, 60 B is threaded through a corresponding corrugation channel 50 C, 50 D adjacent to each lateral edge 50 L 1 , 50 L 2 of the substrate 50 . The first support cord 60 B is threaded through a corrugation channel 50 C adjacent to the first lateral edge 50 L 1 of the substrate 50 . Two fasteners 62 , 63 such as a nylon cable ties, also known as a zip ties, available from NELCO Products Incorporated of Pembroke, Mass., are cinched down tightly on the first support cord 60 A, one at each side of the marker tag 30 to hold the marker tag in place on the cord 60 A, thus establishing a fixed, spaced-apart positional arrangement (best seen in FIG. 2 ) for the marker tags 30 in a row group 20 . The second support cord 60 B is threaded through a corrugation channel 50 D adjacent to the second lateral edge 50 L 2 of the substrate 50 to support the edge in a slidable manner.
Alternatively, as shown in FIG. 4B , the first lateral edge 50 L 1 of each marker tag 30 may be fastened tightly to the first support cord 60 A using two or more fasteners 64 , 65 , such as nylon cable ties, to establish the fixed, spaced-apart positional arrangement for the marker tags 30 in a row group 20 . The second lateral edge 50 L 2 is attached loosely to the second support cord 60 B with two additional fasteners 66 , 67 , such as the nylon cable ties shown, to establish support of the marker tag 30 in a slidable manner, so that the marker tag 30 can move freely on the second support cord 60 B.
In both embodiments of FIGS. 4A and 4B , the second support cord 60 B supports the second lateral edge 50 L 2 of each marker tag 30 in a slidable manner. This slidable support of the second lateral edge insures that the marker tags 30 will be aligned along the first lateral edge 50 L 1 , and thus along the row group axis 20 A ( FIGS. 1 and 2 ). This slidable support of the second lateral edge thus prevents any skewing tension on the marker tags 30 .
As seen in FIGS. 2 and 4A a stiff bar, termed a spreader bar 70 , is used at each end 20 E 1 , 20 E 2 of each row group 20 of marker tags to maintain the support cords 60 A, 60 B at the proper separation, thus preventing the application of lateral forces to the substrates 50 . The spreader bar 70 can be made of any suitable material such as fiberglass composite, metal or plastic. Holes 70 H 1 , 70 H 2 formed adjacent to each end of the spreader bar 70 receive the corresponding support cords 60 A, 60 B to establish the support cord spacing.
As best seen in FIGS. 2 and 4A , a loop 60 L is created at each end of each support cord 60 A, 60 B such as by tying a bowline knot, so that the loop will not slip or close up when tension is applied. Tensioning fasteners 72 , 74 , such as heavy duty cable ties, are then inserted through each loop 60 L at the end of each support cord 60 A, 60 B to serve as tensioning devices. A twenty centimeter (fourteen inch) long heavy duty nylon cable tie available from NELCO Products Incorporated is the preferred tensioning device to attach the support cords to an overhead support structure S. It may be appreciated that by adjusting each fastener 72 , 74 , the positions of the marker tags 30 of a row group 20 may be precisely established.
As may be appreciated from FIG. 2 , the barcode labels 40 B of all marker tags 30 in a row group 20 are typically oriented in the same direction relative to the row axis 20 A and the substrates 50 are supported with the barcode labels facing downward ( FIG. 1 ) so they may be viewed by an image acquisition system adjacent the floor below. Each row group 20 - 1 , 20 - 2 , 20 - 3 , etc. of marker tags is supported in a straight line along the row axis 20 A and the row axes, such as 20 A- 1 and 20 A- 2 ( FIG. 1 ), of adjacent rows 20 - 1 , 20 - 2 are typically parallel to each other.
Those skilled in the art, having benefit of the teachings of the present invention asset forth herein, may effect modifications thereto. Such modifications are to be construed as lying within the contemplation of the present invention, as defined by the appended claims. | An apparatus for marking predetermined known overhead positional locations within a coordinate space, for viewing by an image acquisition system. The apparatus comprises a plurality of marker tags, grouped in one or more rows, each row having an axis, each row being supported by a row support. Each marker tag comprises an optically opaque, dark colored corrugated substrate, substantially rectangular in shape. A label having a unique machine-readable barcode symbology printed thereon is positioned centrally on the substrate so that a dark colored border of the substrate surrounds the label. Each row support comprises a first support cord and a second support cord. The first support cord supports a first lateral edge of the marker tags in a row group in a fixed, spaced-apart positional arrangement. The second support cord supports the second lateral edge of the marker tags in the row in a slidable support arrangement. | 6 |
This application is a continuation-in-part of application Ser. No. 895,000 filed Aug. 7, 1986, now abandoned.
BACKGROUND OF THE INVENTION
In large patio doors or doors which are held in a large frame and adapted to slide sideways in the door opening, the door is quite often left open, and in insect-infected areas it is necessary to have a sliding screen arranged to close the opening after the sliding door has been opened.
A number of inventors have directed their attention to solving the problem of keeping the door closed, and I refer particularly to U.S. Pat. Nos. 3,160,250; 4,003,102; 4,004,372; 4,126,912; 4,301,623; and 4,300,960; as well as the German Offenlegungsschrift No. 2 001 678.
In all of these door-closing devices (some of which were adapted automatically to close a thick, heavy safety door or a fire door in an industrial installation), the closing mechanism operates on either the top or the bottom of the screen or door to be automatically closed. In large and heavy doors, this presents no problem, but in lightweight screens constructed primarily for use in patio doors or similar doors in private homes or non-institutional areas, if the screen or closing member is not pulled directly at the approximate vertical center of the door, it tends to "cock" in the frame and resists the easy sliding or closing thereof.
All of the inventions of the prior art are thus defective or impractical for use in lightweight screens or patio doors, or the like, and my invention has overcome this problem, inasmuch as the operating forces all act upon the center portion of the door, and thus permit easy sliding of the door back and forth in the horizontal upper and lower tracks which guide and hold the screen in place.
SUMMARY OF THE INVENTION
The screen closure of the present invention includes a hollow, tubular holder which is mounted on the in-board, vertical portion of the frame of the door, with a spring-loaded cord which can be pulled horizontally therefrom and attached to the inboard edge of the screen or sliding portion, which is to be automatically pulled across the opening of the doorway. The assembly of the cord, spring and pulleys provides a block-and-tackle arrangement within the holder, and affords a cord of sufficient length to reach completely to the distant inboard edge of the screen when the screen is in fully open position. When the pushing force on the screen (created by the person opening the screen) is released, the tension of the spring, block-and-tackle, and cord acts directly on the center of the vertical inboard edge of the screen and pulls the screen across the opening of the door.
None of the devices of the prior art would be effective in this manner, because if they were mounted on the outboard frame of the door opening, the cord which draws the screen into the closed position would pass directly across the middle portion of the open doorway and prevent passage therethrough.
Thus, for the first time, there is provided a closing mechanism which properly operates and applies its forces at the centerline of a doorway, without obstructing the opening with its own mechanism, and which permits the easy and proper sliding-action of the door and prevents the "cocking" and "jamming" of the frame of the screen within the doorway.
Therefore, a principal purpose of the present invention is to provide a screen closer constructed and arranged to act upon the vertical centerline of a sliding screen or door.
A further purpose of the present invention is to provide a mechanism for easy closing of a lightweight screen in a doorway or similar opening.
Still another object of the present invention is to provide a screen-closer which is easy to mount on existing doorways, and which does not obstruct entrance to the doorway when the screen is open.
An additional object of the present invention is to provide an adjusting feature which permits the closing device to operate at different speeds and thus provide for either fast or slow closing of the screen door.
Further objects of the present invention are to provide a mechanism which automatically closes a screen door, fits a variety of door sizes, is adjustable in tension, stabilizes flimsy screens, extends the life of frame and screen, locks in open position, and can be easily installed.
With the above and other objects in view, more information and a better understanding of the present invention may be achieved by reference to the following detailed description.
DETAILED DESCRIPTION
For the purpose of illustrating the invention, there is shown in the accompanying drawings forms thereof which are at present preferred, although it is to be understood that the several instrumentalities of which the invention consists can be variously arranged and organized and that the invention is not limited to the precise arrangements and organizations of the instrumentalities as herein shown and described.
In the drawings, wherein like reference characters indicate like parts:
FIG. 1. is a perspective view of the screen closer of the present invention mounted on a sliding screen in a patio door.
FIG. 2 is a perspective view of the door closer shown in section so as to illustrate the internal mechanism thereof.
FIG. 3 is a perspective view of the fragmentary upper portion of another modification of the door closer of the present invention.
FIG. 4 is a vertical cross-sectional view taken generally along line 4--4 of FIG. 3.
In FIG. 1, I have shown a patio door 10 which has a fixed portion 11 and a sliding portion 12. The sliding portion 12 is adapted to be moved sideways so as to provide an opening 13 in the doorway.
A screen 14 is constructed and arranged to travel in a pair of tracks, one being the upper track 15 and the other being the lower track 16, so as to slide across the opening 13 when the door 12 is both open and closed, but also to slide across the fixed portion 11 when moved sideways by a person desiring to pass through the door.
The non-moving vertical portion 17 of the fixed member 11 provides the in-board edge of the doorway opening, and it is to this portion 17 that the closer 18 of the present invention is attached.
A cord 19 which extends from the closer 18 has a hook 20 at its outer end, and this hook is intended to be secured to the inboard vertical edge 21 of the screen 14.
Tension on the cord 19, created by the spring 22 in the closure 18, causes a drawing force on the cord 19 to exert a closing force on the vertical edge 21 of the screen 14, and to move it in the tracks 15 and 16 across the opening 13 when the pushing force created by the person passing through the door is released.
Thus the tension in the cord 19 acts on the vertical center of the screen and prevents the screen from "cocking" or jamming in the tracks 15 and 16.
More importantly, the positioning of the closer 18 on the identical member 17 puts it out of the way of the opening 13 and eliminates any closing mechanism from obstructing the opening 13.
The closer 18 is a generally tubular member which can be either circular or rectangular in cross section, and which has disposed therein a spring 22 fastened at its bottom 23 to the housing 24.
The upper end 25 of the spring 22 is secured to a pulley 26 which is fastened through the block and tackle arrangement 27 to the upper pulley 28.
The cord 19 of the block and tackle 27 extends horizontally through the opening 29 so that it can be pulled horizontally to enable the hook 20 to be connected to the inboard vertical edge 21 of the screen 14.
A separate chain 30 having a hook 31 at its end may be provided on the outside of the body member 24 so that the hook 31 may be placed around the outboard vertical edge 32 of the screen 14, when the screen is in open position so as to hold the screen in open position against the tensioning forces on the cord 19 if it is desired to hold the screen permanently in open position.
The cord 19 is made of long-life material, such as dacron, and the housing of the closer can be made of aluminum or plastic with stainless steel parts, if desired, so that the device is weather-resistant and long-lasting.
If desired, a knot 33 can be tied in the cord 19 so as to adjust the tension of the cord 19 to the requirements of the sliding screen to which the closer is attached.
The closer body 24 can be fastened to the vertical portion 19 of the non-movable frame, either with double-sided adhesive tape or appropriate bolts, or screws, or in any other manner well-known in the art.
In FIGS. 3 and 4, I have shown a modification of the closer of the present invention which includes a tubular housing 46 which can be mounted by the screw 40 on the bracket 41. The bracket 41 is intended to be secured to the inboard vertical edge 17 of the fixed member 11.
In FIG. 3 I have shown the tube 46 mounted by the screw 40 in the inner-most hole 43 of the bracket portion 42. Additional holes 44 and 45 may be positioned in the bracket 42 if it is desired to mount the tube 46 at some distance from the surface of the vertical portion 17.
As can be seen particularly in FIG. 3, the opening 29 in the tube 46 has a grommet 47 fitted within the opening, and the cord 19 is drawn through the grommet by the hook 48.
When the tube 46 is fastened securely by the screw 40 in the hole 43 of the bracket 42 in the angular position shown in FIG. 4, the cord 19 can be drawn easily through the grommet to its extended position at the outboard end of the screen (as is shown in FIG. 2 or in FIG. 4).
Then when the opening force on the screen is released, the tension on the spring 22 easily pulls the cord back through the grommet 47 into the tube 46 and the screen door is rather rapidly returned to its closed position.
However, if the tube 46 is rotated in the direction of the arrow 49, as shown in FIG. 4, (approximately 90 degrees or more) the cord is caused to pass through the grommet 47 at a sharp angle, and this causes friction between the grommet 47 and the cord 19, and the spring-loaded forces within the tube 46 cannot as effectively draw the cord inward. Therefore, the action on the screen door is less forceful and the door is returned to its closed position more slowly than if the grommet 47 were in the original position shown in solid lines in FIG. 4.
When mounting the tube 46 on the bracket 42, the screw 40 is tightened sufficiently to prevent the tube from rotating in relation to the bracket 42. However, this force can be overcome manually by twisting the tube 46 against the restraining action of the screw 40 and bracket 42.
This single adjustment of the friction forces acting on the cord 19 make it easy to change the speed with which the screen door will be closed. This is particularly critical if, for instance, the people passing through the door are of different ages. If there are a lot of children in the house and the door is opened and closed often, it is desirable to have the fast-acting effect on the door so that the door closes quickly. Thus it is desirable to have the tube adjusted to the position shown in solid lines in FIG. 4.
On the other hand, if elderly people often use the passageway, it is desirable that the screen door does not close so quickly, and a simple turning of the tube 46 against the action of the screw 40 and bracket 42 increases the friction on the cord and prevents the door closing faster than is desirable when an elderly person is passing therethrough.
It is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes hereof, and it is therefore desired that the present embodiments be considered in all respects as illustrative, and therefore not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A door closer for a sliding screen or door which can be vertically mounted on the vertical non-movable frame of a doorway. A tension cord extends inwardly from the door-opening to be secured to the inboard end of a sliding screen or door whereby automatically to pull the screen or door across said opening. The closer does not obstruct the opening when said screen or door is in open position. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to the manufacture of rosettes of the kind widely used at agricultural shows, dog shows, horse shows and the like, that is to say being awarded in competition as an indication of merit, and also as used to indicate for example, allegiance to a particular political party.
Rosettes of the kind referred to are made of several radiating rings or bands of pleated ribbon attached to a particular carrier, the innermost rings or bands each partly overlapping the next larger ring or band. The ribbon may be pre-pleated and attached to the carrier or pleated and attached to the carrier in one operation. The ribbon may be attached to the carrier for example by stitching, stapling or by the use of an adhesive, the rosette being completed by the attachment of a distinctive center, the latter conveniently being attached by means of an adhesive, and by the attachment of ribbons and a clip, tape, safety pin or the like by means of which the rosette may be secured in position when in use. Rosettes of this kind may be of flat form using a two dimensional circular or oval carrier or may be of three dimensional form using a three dimensional carrier. A three dimensional carrier may, for example, be of frusto-conical form. Rosettes made in the manner described have been known for many years and are of an attractive appearance.
SUMMARY OF THE INVENTION
The object of the invention is to provide a method of making a rosette of either two dimensional or three dimensional form by means of which the resulting rosette will be equally as attractive as hitherto but which is produced at a much reduced cost.
It is another object of the invention to provide a method of making a rosette by means of which a three dimensional rosette of an unusual shape can very easily be made, for example a rosette of three dimensional horse-shoe shape.
In this invention, a method of making a rosette includes the steps of making a body part or carrier with a plurality of resilient clips, pre-pleating lengths of ribbon and securing the ribbon as radiating rings or bands on the body part or carrier by means of said resilient clips. The method may include the initial step of moulding the body part or carrier, integrally with the resilient clips, in a synthetic plastic material and may also include the step of moulding a rim element and the attachment of a distinctive center and of ribbon tails by the snap fitting of said rim element to the body part or carrier. The opposite ends of the pre-pleated lengths of ribbon on being secured to the body part or carrier by means of the resilient clips, may be connected together by staples or by an adhesive.
The body part or carrier may be made of thin-walled form, the lengths of ribbon being secured on one side of the thin wall of said body part or carrier by being engaged beneath the resilient clips which have been pressed outwards from the plane of the thin wall; if preferred, the method may include the step of spreading an adhesive on the other side of the thin wall of the body part where portions of the ribbons are there exposed.
The body part or carrier may be made in a three dimensional form, that is to say of frusto-conical form, of a three dimensional oval shape, or a three dimensional horse-shoe shape, or of some other three dimensional shape.
The method of making the rosette may include the final step of attaching a clip, tape or safety pin to the body part or carrier.
In another aspect of the invention, there is provided a rosette including a body part or carrier with a plurality of resilient clips, and a plurality of rings or bands of pleated ribbon secured to the body part or carrier by said clips. The rosette may include a distinctive center attached to the body part or carrier by a rim element snap fitted in position, and the rim element may be slotted for the fitment of ribbon tails. The body part or carrier may be provided with a clip, tape or safety pin by means of which the rosette can be attached, for example, to a horse's harness or to the wearer's person, as the case may be. The rosette may be of a three dimensional form, that is to say a frusto-conical form, or a three dimensional oval shape, or of some other three dimensional shape, or may be of two dimensional form.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rosette which has been made by a method embodying the invention,
FIG. 2 is an exploded view,
FIG. 3 is an enlarged view shown in section of a part of the rosette shown in exploded view in FIG. 2,
FIG. 4 is a view similar to FIG. 2 of a modified construction of rosette,
FIG. 5 is a view in section similar to FIG. 3 of a part of the rosette shown in FIG. 4,
FIG. 6 is a part sectional view of a further modified construction of rosette which will presently be referred to, and
FIGS. 7 and 8 are views which will be referred to when describing the method of manufacture of the rosette illustrated in FIG. 6.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIGS. 1 to 3 of the drawings, the three-dimensional rosette there illustrated is constituted by six elements, that is to say a moulded three-dimensional plastic body part or carrier generally indicated 10 (in this case of frusto-conical form), a set of three pre-pleated ribbons 12, a center piece 14 of printed paper, a pair of ribbon tails 16, a rim element 18, and a backing piece 20 which can be clipped into position within the wider end of the frusto-conical body part or carrier. A length of tape 22 is secured to the backing piece by means of which the rosette can be attached, for example, to a horse's harness or to the wearer's person, as the case may be. (The manner in which the tape is secured to the backing piece is not shown but can take one of several forms. For example, it may be riveted thereto or trapped beneath a specially moulded clip configuration of the backing piece).
As shown in FIG. 3, the body part or carrier has been moulded integrally with a plurality of resilient clips 24, arranged in circumferential rows, and the pre-pleated ribbons 12 are secured on said body part or carrier by means of said clips. That is to say, a marginal edge of each pre-pleated ribbon is secured to the body part or carrier, the arrangement being such that when the rosette has been fully assembled the clips securing the radially inner pre-pleated ribbon in position are masked by the rim element 18 and the clips securing the other pre-pleated ribbons in position are masked by the respectively overlapping areas of pre-pleated ribbon radially within them. The pre-pleated lengths of ribbon can be secured very quickly and conveniently to the body part or carrier by means of the resilient clips. As each pre-pleated length of ribbon is secured in position, its opposite ends are connected together by staples (not shown) but of course they could equally well be connected together by means of a suitable adhesive if preferred. The radially innermost row of resilient clips serve the dual purpose of retaining the rim element in position on the body part or carrier, the rim element having an inturned lip which snaps over the resilient clips. It will be seen that the rim element also has a slot 26 through which the ribbon tails can be threaded to extend, as shown by the chain-dotted line in FIG. 3, beneath the center piece 14 before the rim element is snap fitted in position.
Also as shown in FIG. 3, the backing piece 20 is capable of being clipped into position within the wider end of the frusto-conical body part or carrier, that is to say into a groove 28 extending around its inside surface.
It will be understood that by reason of the very simple "clip in" attachment of the lengths of pre-pleated ribbon to the body part or carrier, and the subsequent snap on attachment of the rim element 18, a rosette embodying the invention can be produced very quickly and therefore at a relatively low manufacturing cost. However, various modifications may be made. For example, the rosette need not necessarily be provided with the length of tape 22. On the contrary, a spring clip or a safety pin could be secured to the backing piece 20 so that the rosette could be attached, for example, to a horse's harness or to the wearer's person, as the case may be.
In FIG. 4 of the drawings, there is illustrated a construction of rosette basically similar to that described above in that a set of three pre-pleated ribbons 12 are secured on the body part or carrier by a plurality of resilient clips 24 moulded integrally with said body part or carrier. However, in this case the body part or carrier has been made in the form of a thin-walled shell, the resilient clips 24 being defined by a pattern of slots in the shell. The arrangement is such that the resilient clips can be pressed outwards from within the body part or carrier as shown in FIG. 5 to facilitate the engagement of the pre-pleated ribbons beneath them. A further advantage of this form of body part or carrier is that, as shown in FIG. 4, when the pre-pleated ribbons have been secured thereon, the portions of said ribbons beneath the clips are exposed as indicated at 13 within the body part or carrier (the backing piece 20 not yet having been clipped in position). Consequently, if preferred, a suitable adhesive, for example a so-called hot melt adhesive, can be spread within the body part or carrier so that when set it retains the ribbons very securely beneath the resilient clips.
A further variation which will be observed in this modified construction of rosette is the fact that the rim element 18 is not provided with an inturned lip which snaps over the radially innermost row of resilient clips but is provided with a plurality of axially extending pins 42 which are a push fit in respective holes 43 which have been moulded in the body part or carrier around the outer edge of its narrower end face. In addition, the end face of the body part or carrier is provided with a narrow slot 44 through which the ends of the ribbon tails 16 can be passed before being masked by the center piece 14 and secured in position by the rim element 18 (through the slot 26 in which said ribbon tails also extend) being secured on the body part or carrier.
The backing piece 20 is again capable of being clipped in position within the wider end of the frusto-conical body part or carrier, that is to say into the groove 28 which extends around the inside surface of the latter, but in this case the backing piece is shown to be provided with a clip element 46 instead of with the length of tape of the first described embodiment. As shown, the backing piece has been specially designed for securing the clip element 46 in position. This has involved the forming of the backing piece with a hole 48 through which part of the clip element visible when in use has been caused to project and the moulding of a central spigot formation 50 on what is to be the inside surface of the backing piece. A ring-like root portion 52 of the clip element can be forced over said spigot formation 50 of the backing piece to secure the clip element in position.
Referring now to FIG. 6 of the drawings, in a further modified construction of rosette, the set of three pre-pleated ribbons 12 are secured on a carrier 30, the latter having the form of a frusto-conical sleeve secured on a generally plain frusto-conical body part 32. However, although the body part 32 is generally plain it is provided with an upturned lip 34 at its wider end, forming a shallow channel in which the sleeve-like carrier 30 is engaged, and at its narrower end it is provided with a stepped ridge 36 on which the rim element 18 can be snap fitted in position to make captive the sleeve-like carrier 30 and to secure the center piece 14 and ribbon tails 16 in position as in the first described embodiment.
Referring now in particular to FIGS. 7 and 8, it will be seen that the carrier 30 has been formed from an arcuate length of card or thin plastic material 38, the opposite ends of which have been secured together by a strip 40 of self-adhesive material. The arcuate length of material has been provided with a plurality of resilient clips 24 by means of which the pre-pleated ribbons have been secured in position either before or after the arcuate length of material has been formed into the frusto-conical carrier. As in the case of the first described embodiment, when the rosette has been fully assembled the clips securing the radially inner pre-pleated ribbon in position are masked by the rim element 18 and the clips securing the other pre-pleated ribbons in position are masked by the respectively overlapping areas of pre-pleated ribbon radially within them.
Various modifications may be made to the method of manufacture just described. For example, instead of the opposite ends of the arcuate length of card or thin plastics material 38 being secured together by a strip of self-adhesive material they could for example be stapled together or be provided with interlocking formations.
Although the illustrated examples are of rosettes of frusto-conical form it will be understood that the invention may be used for the making of other three dimensional forms of rosette, for example by using a body part or carrier of a three dimensional oval form or of some other three dimensional shape such as a horse-shoe shape. Indeed, the invention may be applied to the making of a two dimensional rosette, that is to say a rosette of flat form, in which case the body part or carrier may be of flat disc or oval shape, or of some other two-dimensional shape, with resilient clips. | A rosette includes a number of pre-pleated lengths of ribbon secured as radiating rings on a body part or carrier, the body part or carrier having a plurality of resilient clips which can be used for the securement of the ribbons. The rosette will preferably include a distinctive center and ribbon tails secured in position by a snap fitted rim element. Preferably, the body part or carrier is of thin-walled form, the resilient clips being pressed outwards from the plane of the thin wall. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of reflector antennas, and more particularly, to a reflector antenna which includes frequency selective or polarization sensitive zones to provide a plurality of antenna patterns having different polarizations or frequencies from a single reflector.
2. Description of the Prior Art
Reflector antennas are frequently used on spacecraft to provide multiple uplink and downlink communication links between the spacecraft and the ground. The downlinks operate at one frequency, typically around 20 GHz, and the uplinks operate at a second higher frequency, typically around 30 or 44 GHz. It is typically desirable for a single spacecraft to have multiple uplink and downlink antennas where each antenna provides a separate antenna pattern covering a predetermined coverage zone on the earth. It is also typically desirable to provide both an uplink and downlink antenna pattern having the same beamwidth so that users can both receive and transmit to the same spacecraft. For example, a single spacecraft may have one uplink antenna which provides a 3°×6° antenna beam at 30 GHz for uplink communications from the continental United States (CONUS), and, one downlink antenna at a frequency of 20 GHz which provides a 30°×6° beam for downlink communications to CONUS. The method typically used to provide multiple uplink and downlink antenna patterns from a single spacecraft is to provide separate reflectors for each uplink and downlink antenna. This requires a large amount of space on a spacecraft, is expensive and extracts a weight penalty.
One method attempted to save weight is to couple one uplink and one downlink antenna together in a single reflector body. To do so, an illumination source is configured to illuminate the reflector body with two RF signals, one having a frequency of 20 GHz and the other having a frequency of 30 GHz. The reflector is typically fabricated of a composite or honeycombed material coated with a reflective material, typically aluminum, which is reflective to RF signals of all frequencies. The disadvantage with this system is that it is difficult to provide antenna patterns having predetermined beamwidths at different frequencies from the typical reflector. The beamwidth of an antenna beam is inversely proportional to the size of the reflector and the frequency of illumination. From the same sized reflector, the uplink antenna pattern at 30 GHz would have a smaller beamwidth than the downlink antenna pattern at 20 GHz thereby covering a smaller coverage zone than the downlink antenna pattern. To address this problem, conventional reflector antennas have used specially designed feed horns configured to under illuminate the reflector at 30 GHz, the higher frequency, thereby generating an antenna pattern at 30 GHz having a wider beamwidth. This is inefficient and often difficult to do since feed horns are extremely sensitive to tolerance and bandwidth limitations.
A need exists to have a single reflector which provides a plurality of antenna patterns each having a predetermined beamwidth allowing a single spacecraft to carry the weight and expense of only one reflector while having the ability to provide multiple uplink and downlink antenna patterns.
SUMMARY OF THE INVENTION
The aforementioned need in the prior art is satisfied by this invention, which provides a reflector antenna having frequency selective or polarization sensitive zones to provide a plurality of antenna patterns from a single reflector body. A reflector antenna, in accord with the invention, comprises a single concave reflector body having a plurality of zones with each zone configured as a frequency selective or polarization sensitive zone. The zones can be partially, completely or not overlapping. An illumination source is configured to illuminate the reflector body with a plurality of RF signals with each zone reflecting one or more of the RF signals. The reflector body generates a plurality of antenna patterns from the reflected RF signals with the shape & beamwidth of the antenna patterns being determined by the shape and dimensions of each zone. The shape and dimensions of each zone is thus preselected to provide an antenna pattern having a desired shape and beamwidth.
For the preferred embodiment of the invention, the reflector body has two concentric zones comprised of an inner zone and an outer zone encompassing the inner zone. The two zones are illuminated with the RF signals having frequencies of approximately 20 GHz and 30 GHz. The inner zone is comprised of a material which is reflective to RF signals of all frequencies, and, the outer zone is comprised of a material which reflects RF signals of a 20 GHz frequency and passes RF signals having a frequency of 30 GHz. The 30 GHz signal is reflected only by the inner zone and is not reflected by the second zone. Antenna patterns are generated at 20 and 30 GHz from the 20 and 30 GHz reflected signals respectively with the size and shape of only the inner zone determining the shape and beamwidth of the 30 GHz antenna pattern and the shape and beamwidth of both zones determining the shape and beamwidth of the 20 GHz antenna pattern. The dimensions of the inner and first zone are preselected to generate 20 and 30 GHz antenna patterns having approximately equal shapes and beamwidth.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the detailed description of the preferred embodiments illustrated in the accompanying drawings, in which:
FIG. 1 a is a top plane view of a reflector body in accordance with one embodiment of the invention;
FIG. 1 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 1 a;
FIG. 1 c shows antenna patterns generated by the reflector antenna shown in FIG. 1 b;
FIG. 2 a is a top plane view of a reflector body in accordance with a second embodiment of the invention;
FIG. 2 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 2 a;
FIG. 2 c shows antenna patterns generated by the reflector antenna shown in FIG. 2 b;
FIG. 3 a is a top plane view of circular loop frequency selective elements in accordance with a third embodiment of the invention;
FIGS. 3 b and 3 c are top plane views of nested circular loop frequency selective elements in accordance with a fourth embodiment of the invention;
FIG. 4 a is a top plane view of a reflector body in accordance with a fifth embodiment of the invention;
FIG. 4 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 4 a;
FIGS. 4 c and 4 d show the x and y axis principle plane antenna patterns respectively generated by the reflector antenna shown in FIG. 4 b.
FIG. 5 a is a top plane view of a reflector body in accordance with a sixth embodiment of the invention;
FIG. 5 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 5 a;
FIG. 5 c shows antenna patterns generated by the reflector antenna shown in FIG. 5 b;
FIG. 6 a is a top plane view of a reflector body in accordance with a seventh embodiment of the invention;
FIG. 6 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 6 a;
FIG. 6 c shows antenna patterns generated by the reflector antenna shown in FIG. 6 b;
FIG. 7 a is a side plane view of a reflector body in accordance with a eighth embodiment of the invention;
FIG. 7 b is a side plane view of a reflector antenna having the reflector body shown in FIG. 7 a ; and,
FIG. 7 c shows antenna patterns generated by the reflector antenna shown in FIG. 7 b.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 a - 1 c, a reflector antenna 10 for providing multiple antenna patterns 12 - 16 is illustrated. The reflector antenna 10 can be configured as a prime focus feed reflector, an offset reflector, a cassegrain reflector or the like. The reflector antenna 10 includes a reflector body 18 and an illumination source 20 . The reflector body 18 is comprised of a plurality of zones 22 - 26 with each zone 22 - 26 configured to be a frequency selective or polarization sensitive zone. The illumination source 20 is configured to illuminate the reflector body 18 with a plurality of RF signals depicted by the lines marked 28 - 32 with each RF signal 28 - 32 being of a preselected frequency or polarization. Each zone 22 - 26 is configured to selectively reflect, pass or absorb selected RF signals 28 - 32 having preselected frequencies or polarizations. Antenna patterns 12 - 16 are generated from each reflected RF signal 34 - 38 with the characteristics of each antenna pattern 12 - 16 , including the shape and beamwidth, being determined by the shape and dimensions of the zones 22 - 28 . The size and shape of each zone 22 - 28 is preselected so that antenna patterns 12 - 16 are generated having desired shapes and beamwidths. By configuring a single reflector body 18 to comprise one or more frequency selective or polarization sensitive zones 22 - 26 , a plurality of antenna patterns 12 - 16 , each being of a preselected shape and beamwidth, can be generated from a single reflector antenna 10 .
For one embodiment of the invention shown in FIGS. 2 a - 2 c, the reflector body 40 is comprised of three concentric zones 42 - 46 . The first zone 42 is configured to reflect RF signals having frequencies of f 1 -f 3 ; the second zone 44 is configured to reflect RF signals having frequencies f 2 and f 3 and pass RF signals having a frequency of f 1 . The third zone 46 is configured to reflect RF signals having frequencies of f 3 and pass RF signals having frequencies of f 1 and f 2 . The illumination source 48 is configured to generate three RF signals depicted by the lines marked 50 - 54 where each RF signal 50 - 54 is of a different frequency f 1 -f 3 respectively.
The first RF signal 50 is incident on the reflector body 40 with the portion of the first RF signal 50 which is incident upon the first zone 42 being reflected by the first zone 42 . However, the portion of the first RF signal 50 which is incident on the second 44 and third 46 zones is not reflected and pass through the second 44 and third 46 zones. Thus, only the first zone 42 reflects the first RF signal 50 to provide a first reflected signal 56 which will form a first antenna pattern 58 having characteristics including shape and beamwidth which are substantially determined by the shape and dimensions of only the first zone 42 . The shape and dimensions of the first zone 42 is thus preselected to provide a first antenna pattern 58 having predetermined pattern characteristics such as shape and beamwidth.
The first zone 42 is preferably formed of a light weight core 60 fabricated from a material such as Graphite, Kevlar™, Nomex™, aluminum honeycomb, or the like which are all commercially available materials with Kevlar™ being fabricated by Hexcel Corporation located in Huntington Beach, Calif. and Nomex™ being fabricated by Hexcel Corporation located in Huntington Beach, Calif. A highly reflective coating 62 such as aluminum is typically applied to the top surface 64 of the light weight core 60 preferably by a vapor deposition or sputtering process to provide a surface which is highly reflective to RF signals 50 - 54 of a plurality of frequencies. A more detailed description of processes such as vapor deposition or sputtering used to apply materials can be found in Microelectronic Processing and Device Design, by Roy A Colclaser, 1980.
The second RF signal 52 is incident on the reflector body 40 with the portion of the second RF signal 52 which is incident upon the first 42 and second 44 zones being reflected 66 by the first 42 and second 44 zones. However, the portion of the second RF signal 52 which is incident on the third 46 zone is not reflected and passes through the third 46 zone. Thus, only the first 42 and second 44 zones reflect the second RF signal 52 to provide a second reflected signal 66 which will form a second antenna pattern 68 having characteristics which are substantially determined by the shape and dimensions of both the first 42 and second 44 zones combined.
The third RF signal 54 is incident on the reflector body 40 and is reflected 70 by the all three zones 50 - 54 . A third antenna pattern 72 is generated from the third reflected RF signal 70 with characteristics associated with the dimensions of all three zones 42 - 46 combined.
Each frequency selective zone 44 & 46 is typically comprised of a patterned metallic top layer 74 or 76 over a dielectric core 78 or 80 respectively. The dielectric cores 78 and 80 are fabricated of materials such as Kevlar™, Nomex™, Ceramic Foam, Rohacell foam™ or the like which are commercially available materials known in the art to pass RF signals with Rohacell foam™ being fabricated by Richmond Corporation located in Norwalk, Calif. For simplicity in manufacturing, all three cores 60 , 78 and 80 are typically fabricated of the same materials. To produce the patterned metallic top layers 74 and 76 , a metallic top layer is first applied to the dielectric cores 78 and 80 using a vapor depositing or sputtering process and portions of the metallic top layer are removed by an etching technique thereby forming the patterned metallic top layers 78 and 80 . A more detailed discussion of vapor depositing, sputtering and etching processes can be found in the reference cited above. Alternatively, the patterned top layers 74 and 76 can be formed on separate sheets of material and then bonded to the cores 78 and 80 respectively. The patterned layers 74 and 76 typically include crosses, squares, circles, “Y's” or the like with the exact design and dimensions of the patterned top layers 74 and 76 being determined by experimental data coupled with design equations and computer analysis tools such as those found in the book Frequency Selective Surface and Grid Array, by T. K. Wu, published by John Wiley and Sons, Inc. The design and dimensions of the first patterned top layer 74 covering the second core 78 is selected to reflect RF signals having frequencies f 2 and f 3 and pass RF signals having a frequency of f 1 , whereas, the patterned top layer 76 covering the third core 80 is selected to reflect RF signals having a frequency of f 3 and pass RF signals having frequencies f 1 & f 2 .
For example, referring to FIGS. 2 a, 2 b, and 3 a, 3 b and 3 c, the first patterned metallic top layer 74 could consist of a plurality of singular circular loops 81 each of which having a diameter of D 1 and a width of W 1 . Alternatively, the first patterned metallic top layer 74 could consist of a plurality of nested circular loops 82 where each nested circular loop 82 is comprised of an inner loop 83 and an outer loop 84 . Each inner loop 83 has a diameter D 2 and a width W 2 , and, each outer loop 84 has a diameter D 3 and width W 3 where D 2 <D 3 and W 2 <W 3 . Both the singular circular loops 81 and the nested circular loops 82 will pass RF signals having a frequency of 44 GHz and reflect RF signals having frequencies of 29 and 30 GHz. Nested circular loops 82 are preferred for embodiments which pass and reflect RF signals which are closely spaced in frequency.
The second metallic top layer 76 could also consist of a plurality of nested circular loops 85 where each nested circular loop 85 is comprised of an inner loop 86 and an outer loop 87 . Each inner loop 86 has a diameter D 4 and a width W 4 , and, each outer loop 87 has a diameter D 5 and width W 5 where D 4 <D 5 and W 4 <W 5 . These nested circular loops 85 will pass RF signals having frequencies of 30 and 44 GHz but will reflect RF signals having a frequency of 20 GHz.
Alternatively, frequency selective zones 44 & 46 can be fabricated from RF absorbing materials which absorb RF signals of preselected frequencies and reflect RF signals of other preselected frequencies. One such material is a carbon loaded urethane material manufactured by The Lockheed-Martin Corporation located in Sunnyvale Calif.
For the embodiment of the invention shown in FIGS. 4 a - 4 d, the reflector antenna 86 is comprised of an offset reflector body 88 having four zones 90 - 96 with each zone 90 - 96 configured to pass or reflect RF signals, depicted by the lines marked 98 - 104 of preselected frequencies f 1 -f 4 . The illumination source 106 is comprised of four feed horns 108 - 114 with each feed horn 108 - 114 generating one of the RF signals 98 - 104 respectively. The first zone 90 is configured to be reflective to RF signals of all frequencies such that all four RF signals 98 - 104 are reflected 116 - 122 by the first zone 90 . The second zone 92 is configured to be reflective to RF signals 100 - 104 having frequencies of f 2 -f 4 and pass RF signals 98 having a frequency of f 1 such that the second 100 through fourth 104 RF signals are reflected 118 - 122 by the second zone 92 and the first RF signal 98 passes through the second zone 92 . The third zone 94 is configured to be reflective to RF signals 102 and 104 having frequencies of f 3 & f 4 and pass RF signals 98 and 100 having frequencies of f 1 & f 2 such that the third 102 and fourth 104 RF signals are reflected 120 and 122 by the third zone 94 and the first 98 and second 100 RF signals pass through the third zone 94 . The fourth zone 96 is configured to reflect an RF signal 104 having a frequency of f 4 and pass RF signals 98 - 102 having frequencies of f 1 -f 3 such that the fourth 104 RF signal is reflected 122 by all from zones 90 - 96 .
The dimensions of each zone 90 - 96 determines the characteristics of the antenna patterns 124 - 130 generated therefrom. FIGS. 4 c and 4 d shows the principal plane cuts of the antenna patterns generated by the antenna 86 in the x and y planes (FIG. 4 a ) respectively. The first 90 and third 94 zones are configured in elliptical shapes, and, the second 92 and fourth 96 zones are configured in circular shapes. Thus, the antenna patterns 130 and 126 generated from the first 116 and third 120 reflected signals will have elliptical pattern shapes and the antenna patterns 128 and 124 generated from the second 118 and fourth 122 reflected signals will have circular pattern shapes. This embodiment of the invention generates four antenna patterns 124 - 130 from a single reflector antenna 86 with each antenna pattern having a predetermined shape and being of a different frequency f 1 -f 4 respectively.
Referring to FIGS. 5 a - 5 c, for a second embodiment of the invention, the first zone 132 reflects all RF signals, the second zone 134 is a polarization sensitive zone; and, the third zone 136 is both a frequency selective and polarization sensitive zone.
Polarization sensitive zones will pass RF signals having one sense of polarization and reflect orthogonally polarized signals. For example, a polarization sensitive zone will either pass horizontally polarized RF signals and reflect vertically polarized RF signals or pass vertically polarized RF signals and reflect horizontally polarized RF signals. Like the frequency selective zones described in the embodiments above, polarization sensitive zone are typically comprised of a patterned metallic top layer over a dielectric core. For horizontally or vertically polarized RF signals, the patterned top layer typically includes metallic parallel lines oriented such that an RF signal having one sense of polarization is passed through and an orthogonally polarized RF signal is reflected. Using polarization sensitive zones enables two oppositely polarized RF signals operating at the same frequency to be coupled in a single reflector with each reflected RF signal providing a separate antenna pattern having a desired shape and beamwidth.
For example, the first zone 132 is configured to reflect all RF signals. The second zone 134 is configured as a polarization sensitive zone 134 designed to reflect all vertically polarized RF signals regardless of the frequency. The third zone 136 is configured to be both a frequency selective and polarization sensitive zone 136 which is designed to reflect only vertically polarized RF signals having a frequency of f 2 .
The reflector 138 is illuminated by three RF signals, depicted by the lines marked 140 - 144 . The first RF signal 140 is at a first frequency f 1 and is horizontally polarized. This RF signal 140 will be reflected 146 by the first zone 132 but will pass through the second 134 and third 136 zones. A horizontally polarized antenna pattern 152 , having a frequency of f 1 , and having characteristics determined by the dimensions of the first zone 132 will be generated from the first reflected signal 146 .
The second RF signal 142 is also at a frequency of f 1 but is vertically polarized. This second RF signal 142 will be reflected 148 by both the first 132 and second 134 zones but will pass through the third zone 136 . A vertically polarized antenna pattern 154 , having a frequency of f 1 , and having characteristics determined by the characteristics of both the first 132 and second 134 zones will be generated from the second reflected signal 148 .
The third RF signal 144 is also vertically polarized but is at a different frequency f 2 . The third zone 136 is both a frequency selective and a polarization sensitive zone 136 configured to pass all horizontally polarized RF signals regardless of frequency but reflect vertically polarized RF signals of a frequency f 2 . The third RF signal 144 will be reflected 150 by all three zones 132 - 136 . A vertically polarized antenna pattern 156 , having a frequency of f 2 , and having characteristics determined by the characteristics of the entire reflector 138 will be generated from the third reflected signal 150 .
For the embodiment of the invention shown in FIGS. 6 a - 6 c, the reflector antenna 158 generates two antenna patterns 160 and 162 each having approximately the same shape and beamwidth with the first antenna pattern 160 being at a frequency of approximately 20 GHz and the second antenna pattern 162 being at a frequency of approximately 30 GHz. The reflector antenna 158 includes an illumination source 164 and a reflector body 166 . The illumination source 164 is configured to illuminate the reflector body 166 with two RF signals, depicted by the lines marked 168 and 170 . The first 168 and second 170 RF signals have frequencies of 20 & 30 GHz respectively. The first zone 172 of the reflector body 166 is configured to be reflective to RF signals having frequencies of 20 and 30 GHz and the second zone 174 is a frequency selective zone 174 which is configured to be reflective to RF signals having a frequency of 20 GHz and pass RF signals having a frequency of 30 GHz signal. The first 172 and second 174 zones of the reflector body 166 are dimensioned to generate antenna patterns 160 and 162 having equal beamwidths at frequencies of 20 and 30 GHz respectively. Since the beamwidth of an antenna pattern 160 and 162 is inversely proportional to both the frequency and the diameter d 1 or d 2 of the reflective zones 172 and 174 , generating the antenna pattern 160 and 162 respectively, to generate antenna patterns at both 20 and 30 GHz which have the same beamwidth, the diameter d 1 of the first zone 172 should be approximately two thirds the diameter d 2 of the second zone 174 .
Referring to FIGS. 7 a - 7 c, the present invention is not limited to antenna reflectors having concentric zones but may be implemented with a reflector body 176 having a plurality of zones 178 - 184 located within the reflector body 176 , with each zone 178 - 184 being of a preselected shape and dimension. For this embodiment, the illumination source 186 is configured to generate three RF signals, depicted by the lines marked 188 - 192 . The first and second zones 178 and 180 are configured to reflect the first RF signal 188 generating a first antenna pattern 194 therefrom whereas the third 182 and fourth 184 zones are configured to pass the first RF signal 188 . The second 180 and third 182 zones are configured to reflect the second RF signal 190 generating a second antenna pattern 196 therefrom whereas the first 178 and fourth 184 zones are configured to pass the second RF signal 190 . All four zones 178 - 184 are configured to reflect the third RF signal 192 and generate a third antenna pattern 198 therefrom.
The portions of the first 188 and second 190 RF signals which pass through zones 178 - 184 of the reflector body 176 can create problems in other electronic components (not shown) being in a close proximity to the reflector body 176 . RF absorbing material 200 can be attached to the bottom side 202 of the reflector body 176 and absorb the passed through RF signals 188 - 190 .
It is typically desirable for the antenna patterns 196 - 198 generated from a reflector body 176 to have low sidelobe levels 204 - 208 . To do so, a ring of resistive material 210 , such as R-card™ manufactured by Southwall Technologies Corporation located in Palo Alto, Calif. can be coupled to the reflector body 176 . Analysis has shown that the sidelobe levels 204 - 208 of an antenna pattern 194 - 198 generated by a reflector body 176 is decreased when resistive material 210 is coupled to the edge of a reflector body 176 .
The present invention utilizes a preselected plurality of frequency selective and/or polarization sensitive zones to provide multiple antenna patterns from a single reflector antenna. By configuring each zone to a preselected shape and dimension, the present invention generates a plurality of antenna patterns from a single reflector body with each antenna pattern having a desired shape and beamwidth. In this manner, a single reflector can replace multiple reflector antennas saving weight, cost and real estate.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been shown and described hereinabove. The scope of the invention is limited solely by the claims which follow. | A multi-pattern antenna for providing a plurality of antenna patterns at different frequencies or polarizations from a single reflector body eliminates the need for multiple reflector antennas on a single spacecraft. The reflector antenna comprises a reflector body and an illumination source. The illumination source illuminates the reflector with a plurality of RF signals each of a preselected frequency or polarization. The reflector comprises a plurality of zones with each zone reflecting preselected RF signals. A plurality of antenna patterns are generated from the reflected RF signals. Each zone is sized to a preselected shape such that the antenna patterns have a desired shape or beamwidth characteristic. | 7 |
This application claims priority to United States Provisional Application No. 60/083,422, filed Apr. 29, 1998.
BACKGROUND OF THE INVENTION
This invention relates generally to furniture, and more particularly to furniture used in an office, or home office environment.
Today's businesses rely heavily upon a variety of different electrical apparatus as the primary means by which information is received and disseminated. Thus, it is almost invariable that every desk encountered in a business environment supports one or more of these electronic apparatus. Common to most every office desk is at least a computer and a telephone. However, there are a variety of other devices that are normally positioned atop a business desk. Such other apparatus includes dictation/recorders, computer printers, computer scanners, telephone answering machines, facsimile machines, paper copiers and image scanners. Each of these office tools contain at least one electrical cable and may include additional cables permitting electrical communication with other devices. For example, such additional cables include the cable connecting the computer to the computer printer, the telephone cable between the facsimile machine and the telephone outlet and the connection between an image scanner and a computer.
Depending upon the particular arrangement of devices on the desk, these cables are often strewn in a haphazard arrangement on the top of the desk. This arrangement is unacceptable because it decreases the effective area in which a person can work. Also, many of these cables are positioned such that they partially hang over the back of the desk. This arrangement produces a visually unpleasant work environment. Moreover, if the particular desk is in a common area through which people frequently pass, there exists the potential for inadvertent contact with the cables which can damage the cables. In addition, a passing individual may become entangled in these cables and, as a result, pull the dedicated electrical apparatus from the desk causing irreparable damage to the electrical apparatus and personal injury.
Additionally, in order to provide maximum space utilization, many offices are arranged such that the individual desks are positioned in an open area. As a result, persons working in this environment do not enjoy a sense of privacy. Furthermore, the typical office desk does not afford the worker any appreciable degree of modesty, i.e. privacy for the area existing below the worksurface of the desk.
Another shortcoming with respect to present day office furniture is in the area of conference tables. Normal conference tables comprise a substantially rectangular, horizontal worksurface with a series of legs depending therefrom. During meetings, presentations, and seminars, one or more electrical apparatus are often used to convey information. In this context, such electrical devices include overhead projectors, slide projectors, film projectors, and phone teleconferencing equipment. To use these devices, one must normally attach the electrical cable to the electrical outlet positioned in the wall adjacent to the conference table. Thus, the cable hangs over a side of the conference table and prevents individuals from moving freely about the conference room.
Therefore, there exists a need for an office furniture system which effectively eliminate the problems extant in the prior art and is cost effective to manufacture.
SUMMARY OF THE INVENTION
Accordingly the present invention advances a new and unique office furniture system which successfully eliminates problems unaddressed by the prior art. According to one preferred aspect of the invention, the office furniture system is embodied in a utility desk having a cable channel depending from the back of the worksurface. This cable channel is dimensioned to accept the electrical cables connected to the electrical apparatus positioned on the worksurface. In accepting these electrical cables, the cable channel improves the visual appearance of the work area and prevents inadvertent contact between individuals and the electrical cables. In addition, placement of the electrical cables within the channel increases the effective workspace area. Moreover, the cable channel depends a preselected distance below the worksurface and thereby provides the worker with a degree of modesty.
According to another preferred aspect of the invention, the desk includes a vertical back extending from the cable channel. The top of the back may contain a horizontal shelf extending therefrom, thereby providing an additional worksurface. Also, the vertical back may be formed with a window having an adjustable shade positioned thereover. This vertical back in combination with the window provides the worker with a degree of privacy.
According to another aspect of the invention, the pair of legs positioned proximate to the back of the worksurface are equipped with rollers. These rollers facilitate movement of the desk when rearrangement of the work area is required.
According to still another aspect of the invention, the desk includes a return rotatably attached to a front leg of the desk. The return is equipped with a pair of legs having rollers attached thereto, permitting the return to be rotated about the leg of the desk. Thus, the return provides an additional work surface and can be positioned under the worksurface of the desk when not in use.
According to yet another aspect of the invention, a conference table is provided having a generally rectangular worksurface with four legs depending therefrom. The front of the worksurface is formed with a cutout section while the pair of legs positioned proximate to the front of the worksurface are fitted with rollers to thereby provide mobility. In a preferred embodiment, two individual conference tables are juxtaposed such that the front surfaces of the adjacent conference tables are in abutting contact, with the cutout sections of the respective tables in registration. When so positioned, these conference tables create an enlarged cutout section dimensioned to enable electrical cables to extend therethrough.
These and other advantages, benefits and objects will be understood by one skilled in the art from the drawings, description and claims which follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a utility desk according to the present invention;
FIG. 2 a is a rear perspective view of the desk illustrated in FIG. 1;
FIG. 2 b is a side view of the desk illustrated in FIGS. 1 and 2 a shown supporting a computer depicted in phantom;
FIG. 3 is a front exploded view of the desk shown in FIGS. 1, 2 a and 2 b;
FIG. 4 is a rear exploded view of the desk shown in FIG. 3;
FIG. 5 is a front view of a utility desk according to the invention illustrating both a return and a window shade;
FIG. 6 is a front view of the utility desk of FIG. 5 with the shade shown in the drawn position;
FIG. 7 is a front perspective view of a utility desk according to an alternative preferred embodiment of the present invention;
FIG. 8 is a rear perspective view of the utility desk illustrated in FIG. 7;
FIG. 9 is a front perspective view of a utility desk according to another alternative embodiment of the invention;
FIG. 10 is a rear perspective view of the utility desk illustrated in FIG. 9;
FIG. 11 is a perspective view of a utility desk according to the invention illustrated attached to a return;
FIG. 12 is a top view of the return illustrated in FIG. 11;
FIG. 13 is a perspective view of a conference table according to the invention;
FIG. 14 is a top view illustrating a pair of conference tables according to the invention shown in the juxtaposed position;
FIG. 15 is a front view of the conference tables illustrated in FIG. 14;
FIG. 16 is a side view of a utility desk according to an alternative preferred embodiment of the present invention;
FIG. 17 is a detailed side view of the cable channel of the utility desk illustrated in FIG. 16;
FIG. 18 is a partial cross-sectional front view of a utility desk according to another alternative preferred embodiment of the invention; and
FIG. 19 is a cross-sectional side view taken along line I—I of FIG. 18 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is embodied in a unique desk particularly suited for office or home use. Turning now to FIGS. 1, 2 a and 2 b, there is shown a desk according to a preferred embodiment of the present invention, and generally designated by reference numeral 10 . Desk 10 contains a worksurface 20 and a plurality of legs 60 depending from bottom surface 22 of worksurface 20 . Legs 60 support worksurface 20 a preselected distance above the floor. Worksurface 20 is of a generally rectangular shape having a front 24 , opposing sides 26 , 28 and a rear 30 . Depending from rear 30 of worksurface 20 is a cable channel 32 . Cable channel 32 spans from side 26 to side 28 and depends a preselected distance from rear 30 of worksurface 20 . Cable channel 32 includes a vertical member 34 attached to rear 30 of worksurface 20 and a vertical back 36 . Vertical member 34 and back 36 are joined by a horizontal bridge member 35 and hence defines an interior 37 between vertical member 34 and back 36 . As shown in FIG. 2 b, interior 37 is dimensioned to receive one or more electrical cables 152 attached to an electrical apparatus 150 positioned on top 21 of worksurface 20 . As illustrated, electrical device 150 is a computer, however, it will be recognized by those with ordinary skill in the art that electrical device 150 may be any electrical device commonly used in a home or business office environment. As shown in FIGS. 9 and 10, top 38 of back 36 may be approximately coplanar with top 21 of work surface 20 .
In an alternative preferred embodiment as shown in FIGS. 7 and 8, back 36 may extend above the plane defined by top 21 of work surface 20 . A shelf 38 extends substantially horizontally from top 37 of back 36 . Preferably, shelf 38 extends in a direction towards work surface 20 .
In the most preferred embodiment, as shown in FIGS. 1, 2 a and 2 b, back 36 extends a greater distance above the plane defined by top 21 of work surface 20 than back 36 of FIGS. 7 and 8. In this embodiment, back 36 is fitted with a window 40 . As shown in FIGS. 5 and 6, interior surface 41 of back 36 supports a shade 42 which can be adjustably positioned over window 40 . As shown in FIG. 5, shade 42 is illustrated in the open position whereas FIG. 6 illustrates shade 42 in the drawn position, thereby covering window 40 . In the most preferred form, window 40 is approximately thirteen and one quarter inches high and six inches wide, but other dimensions may be acceptably utilized. Alternatively, a plurality of windows 40 may be located in back 36 .
Desk 10 is supported a preselected distance above the floor by a pair of front legs 62 attached proximate to front 24 and a pair of rear legs 64 depending from exterior surface 65 of bridge member 35 . As shown, legs 64 are slightly curved, however it will be appreciated by those with ordinary skill in the art that legs 64 may assume any shape without departing from the spirit and scope of the present invention. Preferably, rear legs 64 are fitted with rollers or casters 63 to facilitate the movement of desk 10 . Additionally, one or both of front legs 62 may be fitted with glides or levelers (not shown) which serve to adjust legs 62 when desk 10 is positioned on a non-level floor.
Turning now to FIGS. 3 and 4, desk 10 is preferably assembled by attaching bottom edge 67 of vertical member 34 to surface 66 of bridge member 35 . Attachment can be accomplished by any means commonly employed in the art including, but not limited to, mechanical fasteners and adhesives. In desk 10 , the positioning and configuration of cable channel 32 provides the lower region of back 36 with the dual function of forming a component of cable channel 32 as well as forming a modesty panel that depends from work surface 20 . Positioning of rear legs 64 on the undersurface of bridge member 35 causes cable channel 32 to also perform a leg support function for a portion of the distance below work surface 20 . This reduces the amount of metal utilized in rear legs 64 and thus desk 10 . In the most preferred form, cable channel 32 has a thickness or spacing between vertical member 34 and back 36 of approximately two inches, and has a depth or spacing between the upper surfaces of bridge member 35 and work surface 20 of approximately ten and one quarter inches. Other dimensions may be utilized which accommodate cabling for equipment such as computers, modems, ISDNs, telephones, dictating machines, monitors, facsimile machines, photocopiers, image scanners and the like.
In a preferred embodiment, as shown in FIGS. 16 and 17, bridge member 35 includes a first pair of vertical uprights 35 ′ and a second pair of uprights 35 ″, dimensioned to receive vertical member 34 and back 36 , respectively. Uprights 35 ′ and 35 ″ are formed with teeth 35 ′″ which removably engage mating recesses 36 ′ found in vertical member 34 and back 36 . Additionally, bridge member 35 is formed with a cable guide clip 39 dimensioned to accept the electrical cables positioned within bridge member 35 . In this embodiment, rear legs 64 are attached to and depend from bridge member 35 . Uprights 35 ′ and 35 ″ of bridge member 35 permit facile and secure attachment between vertical member 34 and back 36 . Furthermore, the detachable feature of bridge member 35 permits quick dissassembly in the event it is desired to store or transport utility desk 10 . In a preferred embodiment, bridge member 35 is made of aluminum.
Turning now to FIGS. 5, 6 , 11 and 12 , desk 10 may also include a rotatable return 70 attached to a leg 62 and extending therefrom below bottom 23 of work surface 20 . Return 70 includes a work surface 72 having a bottom surface 73 . A pair of legs 74 depend from bottom surface 73 of work surface 72 with each leg 74 having a wheel or caster 75 . As shown in FIG. 12, work surface 72 of return 73 is formed with an aperture 76 dimensioned to loosely surround leg 62 . Hence, an individual may utilize return 70 as an additional work surface when needed and when not in use, rotate return 70 such that work surface 72 is positioned under bottom 23 of work surface 20 .
In the most preferred embodiment, legs 62 , 64 and 74 of desk 10 and return 70 are made of tubular steel and are powder coated. Also, in the most preferred embodiment, work surface 20 , vertical member 34 , bridge member 35 and back 36 are made of maple, multi-ply or high grade veneered plywood. However, it will be recognized by one with ordinary skill in the art that other materials can be used without departing from the spirit and scope of the present invention.
Turning now to FIGS. 18 and 19, desk 10 may also include a tower 90 dimensioned to receive and support the central processing unit (CPU) of a computer (not shown). Tower 90 is positioned below bottom 23 of work surface 20 , and is preferably flush against surface 33 of vertical member 34 . As shown in FIG. 18, a vertical shelving unit 94 is positioned against, and preferably attached to, side 28 of work surface 20 . In this embodiment, legs 64 (FIG. 16) of bridge member 35 are replaced by legs 95 (FIG. 18) depending from tower 90 and legs 96 of vertical shelving 94 .
In another aspect, the present invention is embodied in a unique conference table, a preferred embodiment of which is shown in FIGS. 13 through 15, and generally designated by reference numeral 100 . Conference table 100 includes a work surface 102 having a plurality of legs 104 depending therefrom which support work surface 102 a preselected distance above the floor. Work surface 102 includes a front 110 , opposing sides 112 and 114 and a rear 116 . Formed in front 110 of work surface 102 is a cutout section 120 . Preferably, cutout section 120 is in the shape of a half circle. Legs 104 , positioned proximate to front 110 of work surface 102 , are each fitted with a wheel or caster 122 to permit movement of conference table 100 .
As shown in FIGS. 14 and 15, conference table 100 is preferably used in conjunction with a second conference table 100 . In this embodiment, conference tables 100 are juxtaposed such that fronts 110 of work surfaces 102 are placed in abutting contact. When so positioned, cutout sections 120 are positioned in registration, and together form a circular aperture. This circular aperture is dimensioned to permit electrical cables to extend therethrough and thus provides a more convenient method for supporting electrical devices upon top 103 of work surface 102 and subsequently connecting electrical apparatus to an electrical outlet. Alternatively, conference table 100 may be provided with a plurality of circular apertures forming cable access ports through work surfaces 102 . A plurality of cutout sections 120 may be provided along fronts 110 in order to form a plurality of cable access openings when work surfaces 120 are mated. Also alternatively, conference tables 100 may be mated with one or more additional spacing sections that have a planar upper surface and opposing facing sides that abuttingly mate with fronts 110 and opposed side edges that conform to the configuration of sides 112 and 114 . Such spacing sections may be fitted with support legs or alternatively fasteners that connect to work surfaces 102 , and include cutout sections that mate with cutout sections 120 .
In the most preferred embodiment, front 110 of work surface 102 has a length of approximately 44.38 inches, rear 116 has a length of approximately 36.0 inches and opposing sides 112 and 114 have a length of approximately 60.0 inches.
It is to be understood that the foregoing is a description of the preferred embodiments. One skilled in the art will recognize that variations, modifications, and improvements may be made without departing from the spirit and scope of the invention disclosed herein. The scope of protection is to be measured by the claims which follow and the breath of interpretation which the law allows, including the doctrine of equivalents. | A desk providing a work surface and having a top, a bottom, a perimeter edge, and a U-shaped channel disposed below the top of the work surface adjacent the perimeter edge. The U-shaped channel includes a vertical member extending downwardly from the work surface proximate the perimeter edge, a bridge member, and a back member extending upwardly from the bridge member and spaced from the vertical member. A plurality of legs are attached to the bottom of the work surface to support the work surface a predetermined distance above a floor. The desk may be fitted with a return rotatably attached to at least one of the plurality of legs such that the return can be rotated under the work surface when not in use. | 0 |
FIELD OF THE INVENTION
The present application relates to burners and more specifically to side burners for grills.
BACKGROUND INFORMATION
Propane cooking grills often include side burners for providing an auxiliary heating surface in addition to the main grilling surface. Conventional side burner assemblies, however, can be quite complex, often requiring large numbers of components. For example, a typical side burner assembly includes a base, bowl, facia, lid, burner, grid, valve, valve bracket, knob, electrode and a variety of screws, nuts and washers. Parts counts of 25 or more are typical. Such complexity leads to substantial assembly time, cost, lost parts and reduced reliability.
Known side burner designs can also be inefficient, failing to deliver a substantial portion of the heat generated to the cooking surface. The heat not delivered to the cooking surface is typically dissipated in the base, raising the temperature of the base.
SUMMARY OF THE INVENTION
The present invention provides a burner, which can be used as a side burner of a grill, that overcomes many problems of conventional side burners.
An exemplary embodiment of a side burner assembly in accordance with the present invention comprises a burner base sub-assembly, a grid and a valve. The burner base sub-assembly includes a base and a burner, with the base and burner being staked together. An exemplary embodiment of the burner has a generally circular configuration with a substantially oval cross section. A fuel feed channel extends radially from a lower portion of the burner. An upper portion of the burner comprises a plurality of apertures arranged about a generally cylindrical protrusion at the top of the burner.
Both the base and the burner may be composed of stamped sheet metal, the base preferably of stainless steel and the burner preferably of aluminized or stainless steel. A dual spark electrode may also be arranged proximate to the burner for ignition.
The burner of the present invention has a substantially reduced parts count, leading to reduced assembly time, reduced cost and improved reliability over known burners.
In addition, the burner of the present invention includes a novel arrangement of flame ports which provides improved heat delivery and distribution to the cooking surface, thus also improving efficiency. Comparisons to known burner arrangements show a 25-30% improvement in efficiency. Heat dissipated in the base is substantially reduced, resulting in a cooler base.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A and 1B show a perspective view and side view, respectively, of an exemplary embodiment of a side burner assembly in accordance with the present invention.
FIG. 1C shows a perspective view of an exemplary embodiment of a side burner assembly with the grid removed.
FIGS. 2A and 2B show a perspective view and side view, respectively, of an exemplary embodiment of a burner in accordance with the present invention.
FIG. 3 shows a perspective view of an exemplary embodiment of a burner grid in accordance with the present invention.
DETAILED DESCRIPTION
An exemplary embodiment of a side burner assembly 10 in accordance with the present invention is shown in FIG. 1A in perspective view. The assembly 10 comprises a base 20 , a burner 30 , a grid 40 and a fuel valve sub-assembly 50 .
FIG. 1B shows a side view of the burner assembly 10 . The base 20 includes a bowl-like recess 25 with a circular opening in its bottom for receiving a top portion of the burner 30 . This arrangement can also be seen in FIG. 1C which shows a perspective view of a side burner assembly 10 with the grid removed. As shown in FIG. 1C, a dual ignitor sub-assembly may be included with two ignitors 251 and 252 arranged proximate to the burner 30 . When activated, each ignitor 251 , 252 generates a spark between it and the burner 30 . The provision of two arcs improves ignition. Moreover, the inclusion of two ignitors provides redundancy, should one of the ignitors fail to operate.
The fuel valve sub-assembly 50 can be implemented using conventional components and can be attached to the base 20 in a conventional manner.
FIG. 2A shows a perspective view of an exemplary embodiment of a burner 30 as used in the assembly 10 of FIGS. 1A and 1B. FIG. 2B shows a side view of the burner 30 . As shown in FIGS. 2A and 2B, the burner comprises a generally disc-shaped body 300 with a fuel feed channel 310 extending radially from the body 300 . The burner 30 comprises a bottom portion 320 and an upper portion 330 each of which comprises a flange 322 and 332 , respectively, by which the two portions are joined such as by welding, hemming or other appropriate joining techniques.
The lower portion 320 of the burner comprises a dish-like recess 325 from which the fuel feed channel 310 extends. The upper portion 330 comprises a dome-like structure 340 whose perimeter substantially matches that of the recess 325 in the lower portion. When the upper and lower portions 330 , 320 are joined, the dome-like structure 340 and the dish-like recess 325 form a generally disc-shaped compartment with a generally oval cross-section. Furthermore, upon joining the upper and lower burner portions 320 and 330 , the fuel feed channel is enclosed on its top side by the flange of the 332 of the upper portion.
A generally cylindrical projection 345 extends upwards from the top of the dome-like structure 340 of the upper burner portion 330 . Proximate to the base of the projection 345 , a plurality of apertures or ports 355 are arranged on the dome-like structure 340 . The projection 345 helps shield those ports 355 that are downwind from wind that may blow across the burner 30 , thus preventing the flame emitted from the burner from being blown out.
In the exemplary embodiment shown, each port 355 comprises a hood-like projection, or louver 356 . As shown in FIG. 2A, the louvered ports 355 are spaced radially around the dome-like structure 340 with the louvers 356 pointing in a counter-clockwise direction, as seen from above. The plurality of louvered ports 355 create a cyclone effect which helps direct the heat generated by the burner upwards, to the cooking surface. Each of the louvered ports 355 emits a flame at an angle above horizontal so that the flame emitted does not shoot directly at the flame emitted by the adjacent port. This prevents the flames from joining together as one flame which would impede the cyclone effect.
In the exemplary embodiment shown, below the plurality of louvered ports 355 , the dome-like structure 340 comprises a plurality of secondary ports 357 . Below the ports 357 , a further plurality of secondary ports 359 are included on the dome-like structure 340 . The secondary ports 357 and 359 are spaced apart sufficiently to prevent the blending of the individual flames emitted from each port. The secondary ports 357 and 359 provide additional flame-generating capacity for additional heat delivery to the cooking surface. The secondary ports 357 and 359 also act to prevent “lifting” of the flame emitted by the main, louvered ports 355 . Furthermore, by being further shielded from wind, due to their arrangement below the main ports 355 , the secondary ports 357 and 359 help keep the burner 30 lit in windy conditions.
When assembled, the burner 30 is attached via its joined flanges 332 , 322 to the bottom of the recess 25 in the base 20 , as shown in FIG. 1 B. As shown in FIG. 2A, the flanges 322 , 332 comprise mounting holes 383 , arranged around the burner body 300 , by which the burner 30 can be attached to the base 20 , such as by staking, riveting or other appropriate attachment methods. In one such method, the holes 383 receive corresponding embossed cylindrical features (not shown) on the base. Once the burner 30 is seated in the base, the embossed cylindrical features are flattened over the holes 383 , thereby capturing the burner between the base and the flattened features.
The bowl-like recess 25 has a circular opening at its bottom for receiving therein the dome-like structure 340 of the burner. As shown in FIG. 1A, arcuate openings 29 concentrically surround the circular opening of the recess 25 . The openings 29 provide additional secondary air to the burner ports. The openings 29 also allow any water or moisture that may enter the bowl-like recess 25 to drain. Furthermore, when attached to the base 20 , the burner 30 is coupled via the fuel feed channel 310 to a fuel outlet of the valve sub-assembly 50 , as shown in FIG. 1 B.
As shown in FIGS. 2A and 2B, the fuel feed channel 310 preferably comprises a gutter 315 which runs along the length of the channel 310 . The gutter 315 is inclined downward (e.g. 2%) as it extends away from the dish-like recess 325 of the lower portion 320 of the burner. The gutter 315 serves to drain any water or moisture that may be in the burner body 300 .
FIG. 3 shows, in perspective view, an exemplary embodiment of a grid 40 , as used in the exemplary side burner assembly described. The grid 40 is generally in the shape of a truncated cone, with a circular base and a circular top. Tabs 425 are arranged along the perimeter of the base of the grid 40 and are received in corresponding openings in the burner base 20 surrounding the recess 25 . The grid 40 is thereby secured against lateral motion over the burner 30 , as shown in FIG. 1 A. While the grid 40 is thus partially secured to the base, the grid can be readily removed from the base 20 (such as for cleaning) by being lifting upwards. The upper surface of the grid 40 comprises a plurality of spokes 450 extending from a central hub 475 . The spokes 450 and the central hub 475 are preferably cupped on their bottom surfaces to promote the retention of heat and for stiffening the overall grid structure. The side wall of the grid 40 acts primarily as a windscreen but includes a plurality of openings 430 which allow exhaust gasses to escape.
The grid 40 can be advantageously formed by being stamped or embossed from a single piece of sheet metal. The stamped sheet metal can then be coated with porcelain using known techniques. The unitary construction of the grid of the present invention provides a much sturdier construction than known grids that are typically constructed by welding several component parts together. The unitary construction is also better suited to porcelain coating, as distortions caused by welding are avoided. | A grill side burner assembly including a burner having a generally disc-shaped body with an oval cross-section. Louvered main ports are arranged around the upper part of the burner body and create a cyclone-like distribution of heat to the cooking surface thereby improving efficiency. A fuel feed channel is formed integrally into a lower portion of the burner and provides fuel to the interior of the burner body. The burner can be attached to the bottom of a bowl-like recess in a side-burner base and covered with a grid. The side burner assembly can be implemented with a very low parts count. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 10/130,600, filed on May 21, 2002, now U.S. Pat. No. 6,955,466, which is a National Stage of PCT/SE00/02279, filed on Nov. 20, 2000, which claims priority of Swedish Appln. No. 9904210-3 filed on Nov. 21, 1999, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a device for closing and opening a package, and a package, preferably for hazardous samples and the like.
DESCRIPTION OF THE RELATED ART
From the Swedish patent 8304910-6 there is known a package primarily adapted for hazardous samples, comprising an inner compartment for receiving hazardous samples or the like, and an outer compartment enclosing the inner compartment and adapted for placing therein of a document, such as a packing slip or the like. The outer compartment has a slit-like opening adjacent the opening of the inner compartment. Both compartments can be closed with one and the same closure tab, whereby the tab closes the inner compartment in a watertight seal. The outer compartment can be opened with the aid of a tear thread, whereby the inner compartment remains closed.
Packages of this type fulfil their purpose reasonably well but suffer from the disadvantage of not being cheap enough to manufacture in order to be mass produced at a low cost. Furthermore there is a certain risk for inadvertent mix-up, namely in that the hazardous sample is not placed in the compartment adapted therefor but instead in the adjacent compartment. Furthermore, previously there has been a small but nevertheless existing risk that a sample that is soiled on its exterior, when placed in correct compartment will touch the lid tab also on the part that is adapted to close the other compartment—the document compartment—whereby there is a risk of infection at its opening.
In the Swedish patent 9102569-2 is disclosed a package the purpose of which is to prevent such risk of infection from the first compartment to the second compartment in the presence of a possibly leaking sample or sample soiled on its exterior, in particular when opening the second compartment. Furthermore there is suggested a method of manufacturing a package of this kind which allows cheap and simple mass production and which reduces the risk of mix-up between the compartment adapted for the hazardous sample or the like and the second compartment adapted for accompanying documents.
Because the first and the second tab and thereby the openings of both compartments are located on opposite sides of the package, the risk of infection is efficiently prevented when placing a sample possibly soiled on the exterior, in the first compartment and closing of the compartments, or due to leaking samples, when opening the second compartment at a later time. According to a further development the first tab is located outside both compartments of the package. Thereby this tab and the associated compartment will in a natural way be perceived by the user primarily as adapted for placing the hazardous sample therein.
This effect is amplified further if the outer contour of the second tab substantially coincides with the adjacent outer contour of the package, and thus will be perceived as a closure tab only when the first tab already has been closed, and only the second tab still is open. This will further prevent the risk that the sample is placed in the wrong compartment.
Suitably the tabs are provided with a self-adhesive glue, covered with a removable protective layer, the tabs being provided with a slit penetrating through the tab, said slit in its turn on its exterior (i.e. the side that is turned outwards when the package has been closed) is covered with a strip that can be torn off, for opening of the associated compartment. In this way it is achieved in a way known per se that the self-adhesive glue only at the correct occasion and not inadvertently will close the associated compartment, and at the same time opening of the compartments at a later time will be made easier.
It has proven to be suitable that the self-adhesive glue layer on the first glue tab, surrounds the entire associated slit, at a distance, whereby the slit or the glue layer that surrounds it, needs to be positioned accurately with respect to the opening of the compartment, which simplifies production and makes it cheaper, the compartment at the same time being closed in a liquid proof manner, and handling is simplified.
Suitably the self-adhesive layer is positioned on the side of the associated slit in the second tab closest to the outer end edge of the tab, preferably at a certain spacing. This will also make manufacture cheaper and simpler without rendering the package more difficult to handle. A the same time an additional advantage is obtained by minimizing the risk that a document that has not been pushed into the second compartment at a long enough distance inadvertently will be glued stuck when the second tab with the glue layer is fastened over the opening of the document compartment.
Suitably the side of the first compartment that is facing outwards, said compartment being adapted to be closed by the first tab, is made of shock-absorbing material. In this case it may be suitable that at one side of the second compartment, which can be closed by the second tab, also comprises or consists of shock-absorbing material. Alternatively the side facing inwards of the first compartment, said compartment being adapted to be closed by the first tab, comprises or consists of shock-absorbing material.
According to one embodiment a liquid-absorbing member is provided in the first compartment which is adapted to be closed by the first tab. Said absorbing member suitably has the shape of the sheet and is placed between the shock-absorbing layers and is fastened along one of its short sides against the inner side of the outer layer, which is possibly made of shock-absorbing material, near the opening of the document compartment such that it is impossible to position the sample between the absorbent and the outer layer. The absorbent is suitably selected to be opaque, such that it will not be possible to read text that has been applied to the sample. The liquid absorbing layer furthermore has different appearances in dry and wet or moist conditions respectively, whereby the outside of the first compartment suitably is transparent, translucent or opaque in order that it is possible to view the appearance of the liquid absorbing layer from the outside and to note changes in the case of leaking samples.
The inwards and/or outwards facing side of the second compartment, which can be closed by the second tab, can be made of a non-transparent material. The purpose of this is that unauthorised persons must not be able to read or in any other optical way perceive messages, documents or the like that has been positioned inside the second pocket without opening the package. If a package according to the invention and embodiments thereof once has been opened this will be perceivable from the outside.
With the method one obtains the advantage that the package can be mass produced in a cheap and simple way with an efficient utilization of machine time and with high accessibility. Thereby certain large tolerances can be applied regarding material and positioning, and exactness is only required in certain final operations, which simplifies manufacture and makes it cheaper and yields a price worthy product. The process can be performed continuously and efficiently by preferably unwinding the paper web and the shock-absorbing materials from rolls, and the longitudinal sides thereof are adjusted to be positioned edge to edge, which is a fairly simple operation, and also i. a. that the rolling width of the first shock-absorbing material web is selected to be about one tab width narrower than the rolling width of the paper web, but wider than the rolling width of the second shock-absorbing material web.
Suitably a liquid absorbing material is also selected to be provided in the form of rolls with a lesser width than the width of the package, it is cut transversally to be somewhat shorter than the shortest width of the shock-absorbing material, such that also this material can be supplied continuously, whereby the liquid absorbing sheets after being cut, preferably are fastened with or adjacent one of the cut edges, either directly at or adjacent to the nearest edge of the second shock-absorbing material.
Also the tear strips can be supplied from rolls and provided with glue when attaching them over the slits, except for the tear strip edges, whereby gripping tabs are provided at the ends for easy removing by tearing of the tear strips.
Suitably a non-transparent paper is selected, preferably kraft paper, kraft liner or the like, which both yields strength and protection from viewing of the document or referral compartment. This paper web suitably is provided with print regarding instructions for opening, tab and compartment references, preprint of postal address and/or current information with round of the pattern corresponding to the length or width of the package.
As a shock-absorbing material suitably two plastic foils that are welded together and having enclosed there between gas or air cushions is used. Alternatively two plastic foils can be used as a shock-absorbing material, whereby a third plastic foil is provided there between and thereby forming the air cushions. The plastic foils in the layers that are to be welded together with the liquid absorbing material are suitably selected to be translucent. The shock-absorbing material located between the paper web and the liquid absorbing material need not consist of translucent material but can of course do so. One reason to select translucent plastic foils is that they commonly are the cheapest and are available as standard merchandise, which makes manufacture cheaper and thereby the end product cheaper.
A disadvantage package patented in SE-9102569-2 is that is sometimes can be difficult to open the compartment in an optimal way. Further drawbacks with this package is that it can happen that the liquid sample that leaks out of its package, can penetrate through the slit that has been provided in the kraft liner that the package has been made from. The liquid sealing PE-layer has been cut through, and trials have shown that there is a risk that liquids penetrate out through the closure, albeit after relatively long time, i.e. some or few days. However, this can in certain cases be unacceptable.
SUMMARY OF THE INVENTION
The present invention therefore seeks to improve the opening function in a package of the type disclosed in SE-9102569-2.
This is achieved by a package device having self-adhesive closure means, by a closure device having a tear function and which is disclosed below.
Thereby the through slit used in, the known package has been eliminated, and the tear strip has been provided on the inside of the tab instead of on the outside thereof. In a preferred embodiment the tear strip, on its outside, i.e. the side that is not fastened against the tab, is provided with a layer of silicone. Thereby the glue layer that is applied on the tab, and which is to achieve that the tab does not stick at closing, will not adhere appreciably to the tab over the better part thereof. Neither will the tear strip be able to participate in welding for the case where the tear strip is present between two PE-layers that are to be joined, i.e. at an edge weld of a package. Thereby a channel or “tunnel” is formed to be in the siliconized surface of the tear strip and the glue layer, or between the siliconized surface of the tear strip and PE-layer in the side weld. When the tab is glued against the package at the time of closing, the tear strip will therefore adhere poorer against that part of the package against which said glue layer is applied on closing, which makes it very easy to tear the strip through the paper tab, and in this way achieve opening. However, the closure device has a general applicability, and the illustrated use with the previously known bag package is only one possibility.
BRIEF DESCRIPTION OF THE DRAWINGS
By the new invention there is provided a device that enables liquid tight transportation of hazardous samples, and which is tamper proof, i.e. that non-authorized access of the interior of the package cannot happen without it being discovered. The invention will now be described in more detail with reference to an embodiment of a package of the type referred to above, having a closure and opening means according to the invention.
FIG. 1 shows a cross section through a package having a closure and opening means according to the invention;
FIG. 2 shows a view from above one end of the package having the protruding tab.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen of the schematic cross section view according to FIG. 1 the illustrated embodiment of the package consists of a first compartment P, adapted for the sample in question, and which is closable with a first tab H 2 , and a second compartment M, adapted as a document or admission note compartment which is closable with the second tab H 1 . As clearly can be seen in FIG. 1 the first tab H 2 and the second tab H 1 as well as the opening of the first compartment P and the opening of the second compartment M are located on opposite sides of the package. In the first compartment P which is closable with the first tab H 2 , there is provided a liquid absorber A, which at its right end edge (viewed in the figure) is fastened quite close to the opening of the compartment P. A sample R positioned in the compartment P is thus not visible, and due to the non-transparency of the absorber A it is not possible to read what may be written on the sample either.
Furthermore, as is evident from FIGS. 1 and 2 the tab H 2 , which is adapted for closing the sample compartment P in its unclosed condition, is positioned outside both compartments of the package. The tab H 1 of the admission note or document compartment, however, has an outer contour which substantially coincide with the adjacent outer contour of the package. Both tabs H 1 and H 2 are provided with one layer each of self-adhesive glue L 1 and L 2 , covered with one releasable protective layer F 1 , F 2 each, these also being referred to as release layers. These protective layers preferably consist of silicone treated foil material, e.g. silicone treated paper.
The upper restricting wall B of the sample compartment P in FIG. 1 e.g. comprises a double layer bubble foil made of polyethylene, having dimensions 250×200 mm (roll width 200 mm). The absorption layer that is attached at a thereby can have dimensions 230×270 mm (roll width 270 mm). The absorber is attached along one or both of its short edges against the double layer bubble foil. It is of importance that the absorber in its left end (as viewed in FIG. 1 ) does not extend too close to the left end of the layer B, such that there will be room for welding together of layer B with the layer C which is located there underneath, said layer C e.g. can be comprised of a three layer bubble foil of polyethylene, possibly having the dimensions 270×200 mm (roll width 270 mm). Beneath these both layers there is a layer D of polyethylene coated kraft liner, in the present case having the dimension 320×200 mm (roll width 320 mm).
The shock-absorbing layer C has been welded together with the kraft liner D in the weld c 1 quite adjacent the opening edge of the sample compartment P. In addition to layers C and D are also welded together by means of the longitudinally running welds d 1 and d 2 .
The shock-absorbing layer B should be transparent in order to enable the observation of changes in the appearance of the liquid absorbing material A in the case of a leaking sample. The second shock-absorbing layer C can but does not necessarily need to be transparent, translucent or opaque. The layer D which is provided with the tabs should normally not be translucent or transparent, in any case if one wishes that the content of the document pocket M should not be possible to read from the outside. The material for the layer D is selected among known materials having regard to the properties one wishes that the layer D should have. For example the layer D could be shock-absorbing and the layer C could be non-shock-absorbing.
Practical trials with prototypes have shown that it is very easy to close both compartments of the package and also to open them separately.
In accordance with the invention each tab, H 1 , H 2 is provided on the inside, i.e. the side that lies close to the bag when it has been closed, are provided with a self-adhesive tear strip (or tear tape) G 1 , G 2 running in the transverse direction, transversely over respective tab. This tear tape thus is applied on the PE-layer K of the kraft liner D, such that it attaches against the PE-layer with its glue. The tear tape G 1 , G 2 is a self-adhesive tape, e.g. consisting of a polypropylene carrier coated with an adhesive compound L 3 , L 4 and provided with a release layer of silicone R 1 , R 2 . Alternatively it can be a self-adhesive tear tape having a mono-axially polypropylene coated with polyethyelene and adhesive compound, and provided with a release layer of silicone. These tapes can be obtained from Beiersdorf, Germany under the trade names Tesa 4235 and Tesa 51235 respectively.
After the tear tape has been attached to the PE-layer according to the above disclosure, a glue layer is applied on an area around and over the strip, thereby forming a closure means, such as a tab, that can be folded over an opening and thereby close the package. This glue layer L 1 , L 2 will due to the siliconized surface of the tear strip not adhere against the tear tape to any particular degree. However the adhesion is enough to achieve that the strip is held in place. The release paper or protective foil F 1 , F 2 is applied over the glue layer L 1 , L 2 and over the tear strip.
Due to the lesser degree of adhesion between tear strip and glue layer L 1 , L 2 , there is formed a “tunnel” between the tab and the tear strip. This “tunnel” does not have any proper volume, but is rather to be looked upon as an area where the two materials have a capability of being easily separated.
This can be most clearly seen if one touches the glue layer with a finger where the layer in question lies over the tear strip. Since the glue is a very strongly tacky glue, it will immediately stick to the finger. If it then is attempted to remove the finger therefrom, the glue will be lifted from the tear strip and form a blister because it is tough and does not adhere against the tear strip. When the tab has been attached to the package material at the time of closing, this effect will facilitate tearing of the strip through the tab. The tear strip simply releases easier from the package material against which the tab has been glued on closing the package. Possibly it can be required to apply slightly more silicone than what is present on the commercially available tape in order to achieve optimal function.
The tear tape strip G 1 on the smaller of the tabs H 1 is provided such that it will be located within the region where the bag is edgewelded in its longitudinal direction. However it will not participate in the weld because of the silicone layer. Thereby an advantage is achieved the same way as with the other tab, in that it becomes easier to separate the layers and thereby get a grip of the end of the tape in order to tear it through the paper of the closure tab H 1 .
It is also possible to use a glue of the same type as for the glue layers L 1 , L 2 instead of welding the side edges, at d 1 and d 2 of the package together. Thereby one achieves the same effect as with the first embodiment disclosed above, where the tear strip is located on a closure tab, and is covered by a glue layer that does not adhere against the silicone to any significant degree.
In order to improve function further it is possible according to the invention to provide edge cuttings E 11 , E 12 at the strip G 1 , and E 21 , E 22 at the strip G 2 . These edge cuttings are made on either side of the ends of the tapes, and a small distance into the edge area of the bag. Thereby gripping tabs GF are formed, making it easier to get a grip on the tear strip thereby making it easy to open the package. This is most clearly evident from FIG. 2 . Such edge cuttings are suitably made by two parallel knives or industrial blades provided in the manufacturing line. Another way of achieving the edge cutting is by punching. Punching can be preferable in that it is possible to shape the gripping tabs according to desire, e.g. by making cuttings wider, and the gripping tabs can be given a rounded shape in order to make them grip friendlier. A skilled man will easily realise how such an operation is implemented in a plant. | A closure device for packages having at least one self-adhesive closure element is disclosed. It comprises a self-adhesive glue layer (L 1 , L 2 ) on the closure element, arranged for closing of the package. A release layer (F 1 , F 2 ) covers the glue layer (L 1 , L 2 ). At least one tear strip (G 1 , G 2 ) is provided such that it can be torn through the package when the package is closed to form an opening. The tear strip (G 1 , G 2 ) is provided on a part of the package forming the closure element, and on one side thereof that is facing inwards when the package is closed. Finally, the tear strip (G 1 , G 2 ) is provided with a silicone layer on the side thereof facing the material of the package when the package is in a closed condition. | 1 |
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/041,253, filed Apr. 1, 2008, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Outdoor decorative lighting of the type that is typically hung during the holidays has typically been comprised of light strings which when hung do not provide uniform lighting unless each bulb is individually secured using clips or other means. Individually securing each bulb is a time-consuming effort.
[0003] This purpose of this invention is to provide a lighting system that can be quickly and easily installed to provide uniform, direct, decorative lighting without having to secure each bulb individually. Furthermore, the invention solves the problem of tangled wires as the wiring is embodied within rigid or semi-rigid components.
DETAILED DESCRIPTION OF THE INVENTION
[0004] A system of interlocking components, end caps, plugs, sockets, mounting brackets, connectors, light bulbs and etcetera, as defined below, together comprising a simplified means of hanging direct, decorative lighting. Each interlocking component is of varying or uniform length to be hung on various surfaces—each component having an internal cavity through which an electrical conduit is run. Each component has a pair of prongs, or other male conductors on one end and a matching pair of female receptacles on the other end. Each component has a series of decorative lighting sockets (such as, but not limited to C7 or C9, etc) that are connected via the internal electrical conduit. Additionally, on each end of the components is a mechanism for snapping, hooking, or otherwise connecting the component to another component in such a manner as to allow the continuation of the electrical conduit from component to component. Also specified are end caps and for terminating each component facilitating the completion of the electrical circuit. Also included are pairs of end caps connected by a wire to allow the components to be connected via a flexible wire rather than a fixed, ridged connection to another component—thus allowing the components to connect around corners or at various angles. Furthermore, end caps are included that are connected to a length of cord terminated by an electrical plug for connecting to standard electrical outlets. Also included are various mechanical or magnetic clips to be attached to each component for hanging on various surfaces via varied means. These various clips would allow the components to be hung on eaves, rain gutters, walls, etc. Also specified is mounting hardware for receiving said clips including magnetic or mechanical receptacles. Also included are other components that can be connected to each component, continuing the electrical circuit, and providing decoration such as illuminated or non-illuminated letters or words, illuminated or non-illuminated designs (such as stars, birthday cakes, etc.), motorized gadgets, etc. such that each of these devices can be plugged into the system between any two components (or between a component and an end cap).
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The attached images demonstrate a sample implementation of the invention. Below is a description of the images:
[0006] FIG. 1 : Complete, three dimensional assembly including 2-foot rail, male and female ends, sockets, L-Bracket, and spacer.
[0007] FIG. 2 : Two-dimensional, two-foot rail specifications showing stamp-out for sockets.
[0008] FIG. 3 : Three-dimensional female end which inserts into one end of rail.
[0009] FIG. 4 : Two-dimensional female specifications.
[0010] FIG. 5 : Three-dimensional male end which inserts into opposite end of rail.
[0011] FIG. 6 : Two-dimensional male specifications.
[0012] FIG. 7 : Three-dimensional female end cap for completing electrical circuit.
[0013] FIG. 8 : Two-dimensional female end cap specifications.
[0014] FIG. 9 : Male plug specifications for providing power to one end of assembly.
[0015] FIG. 10 : Base specifications for receiving light bulb.
[0016] FIG. 11 : Three-dimensional permanent mounting bracket.
[0017] FIG. 12 : Two-dimensional mounting bracket specifications.
[0018] FIG. 13 : Three-dimensional “L”-bracket for mounting on flat surfaces such as (but not limited to) the front of a home where no rain-gutter exists.
[0019] FIG. 14 : Two-dimensional “L”-bracket specifications.
[0020] FIG. 15 : Three-dimensional “U”-bracket for mounting on a surface such as (but not limited to) a raingutter.
[0021] FIG. 16 : Two-dimensional “U”-bracket specifications.
[0022] FIG. 17 : Three-dimensional “hinged” bracket for installing on ridged surfaces.
[0023] FIG. 18 : Two-dimensional “hinged” bracket specifications.
[0024] FIG. 19 : Three-dimensional spacer for use when no bracket is necessary. | A system of interlocking, rigid or semi-rigid, components which when connected provide a modular, easy-to-install, direct, decorative, lighting system. | 5 |
REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application Ser. No. 61/473,418, filed Apr. 8, 2011 and entitled “Piping Joint Assembly, System and Method”, and is a continuation-in-part of U.S. application Ser. No. 12/981,855, entitled “Piping Joint Assembly, System and Method”, filed on Dec. 30, 2010, which is a continuation of U.S. patent application Ser. No. 11/807,072 filed May 25, 2007, now U.S. Pat. No. 7,862,089, entitled “Piping Joint Assembly, System and Method” which issued on Jan. 4, 2011. The disclosures of all of the above are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to fluid flow systems, and more particularly to a push-fit piping joint assembly, system and method that facilitates the repair and re-use of piping system parts without coining or threaded end caps.
BACKGROUND OF THE PRESENT INVENTION
Piping systems exist to facilitate the flow of fluids (e.g., liquid, gas (such as air) or plasma). For example, homes, schools, medical facilities, commercial buildings and other occupied structures generally require integrated piping systems so that water and/or other fluids can be circulated for a variety of uses. Liquids and/or gases such as cold and hot water, breathable air, glycol, compressed air, inert gases, cleaning chemicals, waste water, plant cooling water and paint and coatings are just some examples of the types of fluids and gases that can be deployed through piping systems. Tubing/piping types can include, for example, copper, stainless steel, CPVC (chlorinated polyvinyl chloride) and PEX (cross-linked polyethylene). For purposes of the present disclosure, the term “pipe” or “piping” will be understood to encompass one or more pipes, tubes, piping elements and/or tubing elements.
Piping connections are necessary to join various pieces of pipe and must be versatile in order to adapt to changes of pipe direction required in particular piping system implementations. For example, fittings and valves may be employed at the ends of open pieces of pipe that enable two pieces of pipe to fit together in a particular configuration. Among fitting types there are elbows, “tees”, couplings adapted for various purposes such as pipe size changes, ends, ball valves, stop valves, and partial angle connectors, for example.
In the past, pipe elements have been traditionally connected by welding and/or soldering them together using a torch. Soldering pipe fittings can be time-consuming, unsafe, and labor intensive. Soldering also requires employing numerous materials, such as copper pipes and fittings, emery cloths or pipe-cleaning brushes, flux, silver solder, a soldering torch and striker, a tubing cutter and safety glasses. The process for soldering pipes can proceed by first preparing the pipe to be soldered, as the copper surface must be clean in order to form a good joint. The end of the pipe can be cleaned on the outside with emery cloth or a specially made wire brush. The inside of the fitting must be cleaned as well. Next, flux (a type of paste) can be applied to remove oxides and draw molten solder into the joint where the surfaces will be joined. The brush can be used to coat the inside of the fitting and the outside of the pipe with the flux. Next, the two pipes are pushed together firmly into place so that they “bottom out”—i.e., meet flush inside the fitting. The tip of the solder can be bent to the size of the pipe in order to avoid over soldering. With the pipes and fitting in place, the torch is then ignited with the striker or by an auto-strike mechanism to initiate soldering. After heating for a few moments, if the copper surface is hot enough such that it melts when touched by the end of the solder, the solder can then be applied to the joint seam so that it runs around the joint and bonds the pipe and fitting together.
In recent years, push-fit technology has been employed with piping systems to reduce the dangers and time involved in soldering joints, Push-fit methods require minimal knowledge of pipe fitting and involve far fewer materials than soldering. For example, one may only need the pipes, quick-connect fittings, a chamfer/de-burring tool and tubing cutter in order to connect pipes using push-fit technology.
The steps involved in connecting piping systems using push-fit technology can be outlined as follows. First, the pipe is cut to the appropriate length and the end of the pipe is cleaned with the de-burring tool. Then the pipe and fitting are pushed together for connection, The fitting is provided with a fastening ring (also called a collet, grip ring or grab ring) having teeth that grip the pipe as it is inserted. The fastening ring device is employed to provide opposing energy, preventing the device from disconnection while creating a positive seal. Accordingly, no wrenches, clamping, gluing or soldering is involved. Push-fit and/or quick-connect technology for piping systems can be obtained, for example, through Quick Fitting, Inc. of East Providence, Rhode island, USA, suppliers of the CoPro® line of pipe fittings and related products. Also, such technology is described, for example, in U.S. Pat. No. 7,862,089, the disclosure of which is incorporated herein by reference in its entirety.
In past pipe coupling technology, the fastening ring is inserted into the fitting body along with a plastic grip ring support that typically fails under extensive tensile testing. Further, the coupling must then be either coin rolled, glued or receive a threaded cap member to retain the fastening ring inside the fitting body. In addition to the added steps for the manufacture and assembly of the coupling, the strength of the plumbing joint is determined by the retaining cap member. The additional steps and components add significant labor and manufacturing costs to the final product cost and reduce the overall production capability due to the extensive time required for proper assembly.
In addition to the above, when using a threaded retaining cap method, the process of cutting threads into the fitting body and the retaining cap elevates the cost of machining the fitting components. Further, the threaded end cap method requires mechanical assembly as well as the added cost and application of a thread sealant to the threads. In prior efforts that employ a coined retaining cap method, the process of coining the fitting body as the retaining cap significantly increases the cost of final assembly of the fitting. Additionally, the coining process permanently encapsulates the fastening ring inside the fitting, whereby the fastening ring cannot be removed without complete destruction of the ring and fitting.
Along with additional assembly steps and increased manufacturing costs, past pipe fittings and connection methods do not allow repair for various reasons. In some cases, this is because they are factory sealed, for example. In other cases, it is because the separation of the fitting from the pipe can damage or induce wear on the parts. For example, some push-fit pipe fittings provide permanently fixed demounting rings for removing the fittings. The demounting rings can be depressed axially to lift the fastening ring teeth off of the surface of the inserted pipe, such that the pipe can then be withdrawn. This arrangement, however, can subject the pipe fittings to tampering and shorter life. In addition, while fastening ring devices work effectively as an opposing retaining member, their functionality makes them nearly impossible to dismount, remove or detach for re-use. The fastening rings are thus permanently affixed unless they are cut and removed, which then destroys the fastening ring.
Whether connected by traditional soldering methods or with push-fit methods, past efforts have been specifically provided for the connection of like materials and lack the ability to connect two unlike materials, such as copper with CPVC, PEX or stainless steel, or any other combination of unlike materials. Past methods further invariably require the replacement of fittings and valves, and do not allow re-use of the fittings or valves in instances where only a small internal component needs to be repaired or replaced.
SUMMARY OF THE PRESENT INVENTION
The present invention provides, in part, a pipe fitting assembly package as well as a removal method allowing one to re-use push-fit piping fittings without damage to the fitting elements or the pipe. The present invention connects tubing/piping using no tools, clamps, solder or glues, while creating a leak-free seal at the connected joining area. Further, unlike prior methods, the present invention can join both like and unlike piping elements in any combination, and without coining or threading the elements into place.
The quick connection pipe joint assembly package provided as part of the present invention employs a one-piece retaining ring and pusher that, when removed, exposes the clamping, sealing and fastening mechanisms of the fitting. The retaining ring and pusher member (“release pusher” for purposes of this disclosure) moves axially and can push the fastening ring of the present invention in order to facilitate the release of a cylindrical object such as a piping element held within the fitting.
For purposes of the present disclosure, a fitting (also referred to as a body member) can encompass a valve member and other piping elements including, but not limited to: a coupling joint, an elbow joint, a tee joint, a stop end, a ball valve member, tubing and other objects having cylindrical openings. In one embodiment of the present invention, a dual seal is provided with sealing member gasket inserts (e.g., O-ring members) that fit side-by-side within a first radial housing element defined in the interior wall of the fitting. In addition, at each pipe receiving end of the fitting, a second radial housing element is machined into the interior wall to retain the edges of the fastening ring. The interior housing elements provide integrated support for the sealing members and fastening ring when opposing force is applied to piping elements that have been inserted into the fitting pipe. In one embodiment, a flexible metal support snap ring gland member is employed to provide additional support for the fastening ring.
In one aspect of the present invention, once the fastening ring is inserted into the fitting, the fastening ring does not require any additional method or device to retain it under opposing force. The integrated radial housing element provides for a more stable fastening ring connection with the ability to withstand significantly higher tensile pulling forces than the prior art. As a result, the stability of the quick fitting fastening connection is not determined or co-dependent on a plastic retainer, threaded end cap or machined coined retainer.
The release pusher provided as part of the present invention is primarily employed to facilitate the release of tubing, piping and other cylindrical objects inserted into a fitting. The release pusher is manually pushed into the fitting body and tapered edges of the release pusher generally or nearly abut the installed fastening ring. When it is desired to release an inserted pipe, for example, from the fitting, the release pusher can be forced in the direction of the fastening ring such that its angular surfaces depress the fastening ring teeth off of the surface of the inserted pipe, thereby allowing the pipe to be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded front perspective view of the piping joint assembly package of the present invention.
FIG. 2 is an exploded front perspective cross-sectional view of the piping joint assembly package of FIG. 1 .
FIG. 3 is a front cross-sectional view of a portion of the present invention according to FIG. 1 .
FIG. 4 is a detailed cross-sectional view of encircled portion 4 - 4 of FIG. 3 .
FIG. 5 is a cross-sectional view of one embodiment of the fitting of the present invention.
FIGS. 6 and 7 are detailed cross-sectional views of encircled portions 6 - 6 and 7 - 7 of FIG. 5 , respectively.
FIG. 8 is a cross-sectional view of the release pusher of the present invention.
FIG. 9 is a left side view of one embodiment of the fastening ring of the present invention.
FIG. 10 is a front view of the fastening ring of FIG. 9 .
FIG. 11 is a right side cross-sectional view of the fastening ring taken along line 11 - 11 of FIG. 10 .
FIG. 12 is an exploded front perspective view of an alternative embodiment of the piping joint assembly package of the present invention.
FIG. 13 is a front cross-sectional view of a portion of the present invention according to FIG. 12 .
FIG. 14 is a detailed cross-sectional view of encircled portion 14 - 14 of FIG. 13 ,
FIG. 15 is a cross-sectional view of one embodiment of the fitting of the present invention.
FIG. 16 is a detailed cross-sectional view of encircled portions 16 - 16 of FIG. 15 .
FIG. 17 is a front view of the flexible support snap ring gland member of the present invention.
FIG. 18 is a right side cross-sectional view of the snap ring gland member taken along line 18 - 18 of FIG. 17 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the push-fit piping joint assembly 10 as shown in FIGS. 1 and 2 , elements of the joint assembly as shown include: a fitting (i.e., fitting body member) 12 having an inner wall 13 and outer wall 15 , a fastening ring 18 , two substantially identical sealing members 14 , 16 (which can be optionally lubricated) and a release pusher 20 . The fastening ring and sealing members together provide one embodiment of a packing arrangement for the present invention, and each has an internal diameter that allows for smooth and snug engagement of a piping or tubing element external surface 24 . The fitting 12 is substantially hollow with a pipe receiving opening 100 therein. In one embodiment, the interior diameters of the fastening ring 18 (as measured to the teeth 19 and not the ring cylindrical base) and sealing members 14 , 16 are substantially the same, and the interior diameters of the fitting 12 and the release pusher 20 are substantially the same. Further, the interior diameters of the fastening ring 18 and sealing members 14 , 16 are slightly less than that of the fitting 12 and release pusher 20 so as to facilitate proper operation of the present invention. The release pusher 20 is substantially cylindrical and includes an external tip 21 at the fastening ring engaging end thereof.
In one embodiment, the fitting 12 can be forged CW617N brass, with full porting and full flow fitting, for example. The lubricant for the sealing members 14 , 16 can be a food grade lubricant, for example. It will be appreciated that the sealing members can comprise a flat ring or washer-type seal member in addition or as an alternative to a circular member of substantially circular cross-section. The fastening ring 18 can comprise a spring steel formulation, for example, that enables the fastening ring to be malformed during installation, while springing back into its originally manufactured position once installed. The fastening ring is capable of grabbing an inserted pipe's surface via two or more teeth 19 to ensure connections cannot be pulled apart. The fastening ring teeth are angled downward from the perimeter of the ring, toward the fitting and away from the cap, such that when the pipe is inserted, the teeth exert a pressure against the pipe to discourage the pipe from slipping or moving back out of the fitting. No wrenches, solder, welding, glue and/or twisting and turning the elements are required to form a connection.
As shown in FIGS. 3 , 4 and 8 , for example, the release pusher 20 includes a radially outer ledge 26 , the external tip 21 and outer wall segments 25 , 27 . The release pusher can comprise an injection-molded plastic material or a metal material such as brass, for example. When pressure is applied on the back side 30 of the release pusher 20 , the external tip 21 can engage the inside surface 32 of the fastening ring teeth 19 as will be described in more detail below, and the ledge back wall 29 can removeably engage a retaining lip 34 extending radially inwardly of the fitting inner wall 13 at the axially outermost position of the fitting, as shown in FIG. 3 .
In one embodiment of the release pusher of the present invention, the outer wall segments 25 , 27 comprise a single linear segment from the radially outer ledge to the external tip. In another embodiment of the present invention, as shown in FIG. 8 , the first outer wall segment 25 extends linearly at a first angle C from the radially outer ledge 26 to an outer wall intermediate point 36 , and the second outer wall segment 27 extends linearly from the outer wall intermediate point 36 to the external tip 21 at a second angle D.
During removal, a tool such as a specially adapted wrench, for example, can be applied to the outer top surface of the release pusher so as to exert a pushing and lifting force that causes the release pusher outer ledge to disengage the retaining lip 34 . Once the release pusher is removed, the internal packing arrangement components are exposed for removal and/or replacement.
As shown in FIGS. 2 through 7 , the fitting 12 is formed with first 40 and second 42 radial housing elements. The first radial housing element 40 houses sealing members 14 , 16 , and the second radial housing element 42 houses the fastening ring 18 . The sealing members can be housed so as to substantially abut one another within the first radial housing element 40 . Further, the sealing members 14 , 16 are shown axially inward of the fastening ring 18 , when in position within the fitting 12 . In the embodiment shown in FIGS. 12 through 14 , the second radial housing element 42 also houses a support snap ring gland member 90 , described in more detail below.
The first radial housing element 40 is formed by a first housing back wall segment 44 , the fitting inner wall 13 and a housing separator segment 46 . The second radial housing element 42 is formed by the housing separator segment 46 , the fitting inner wall 13 and a second housing front wall segment 48 . The inner wall 13 is not labeled within the recesses of the housing elements 40 , 42 . As shown in FIG. 7 , the second housing front wall segment 48 has a top angled guiding surface 50 , which permits sliding engagement with the fastening ring circumferential base 52 (shown in FIG. 10 ) when the fastening ring 18 is either being inserted or removed. The top angled guiding surface 50 of the second housing front wall segment 48 extends from the fitting inner wall 13 at an axially outer position 53 thereof to a front wall segment tip 54 at an axially inner position 55 of the fitting inner wall 13 .
As shown in FIG. 6 , the housing separator segment 46 has a plateau surface 58 and a front wall 60 with a front tip 62 . The housing separator segment also includes a top angled backing surface 64 that extends from the front wall tip 62 to the plateau surface 58 . In one embodiment of the present invention, the distance E from the fitting inner wall 13 to the separator segment front tip 62 is approximately the same as the distance from the fitting inner wail 13 to the second housing front wall segment tip 54 . In another embodiment of the present invention, as shown in FIG. 5 , the distance E from the fitting inner wall 13 to the separator segment front tip 62 is less than the distance from the fitting inner wall 13 to the second housing front wall segment tip 54 . This distance E can be changed as necessary to facilitate engagement and movement of the fastening ring 18 within the second radial housing element, as desired. As shown in FIG. 7 , the top angled guiding surface 50 of the second housing front wall segment 48 can extend at an angle A measured from the fitting inner wall. Further, as shown in FIG. 6 , the top angled backing surface 64 can extend at an angle B measured from the fitting inner wall. In one embodiment of the present invention, angles A and B are substantially the same. In one embodiment of the present invention, angle B can range from approximately 9 degrees to approximately 52 degrees, and angle A can range from approximately 6.5 degrees to approximately 50 degrees. Further, in one embodiment of the present invention, angle B is greater than angle D of the release pusher 20 (see FIG. 8 ) so as to facilitate proper operation of the present invention as described below.
As shown in FIGS. 1 and 9 through 11 , the fastening ring 18 can be a split ring member having a circumferential base 52 and two circumferential end points 66 that do not connect. The fastening ring can further include fixture points 68 for handling and compressing the fastening ring. In one embodiment of the present invention, the fixture points 68 are provided at the split end so that a tool designed to hold the fastening ring at the fixture points can more easily handle and compress the fastening ring in order to assist with assembly or disassembly. Once compressed, the fastening ring is easily insertable into the second radial housing element 42 of the fitting 12 by releasing the hold on the fixture points 68 , thereby allowing the fastening ring to expand such that the circumferential base engages the walls of the second radial housing element. The fastening can be removed from the second radial housing element in similar manner. No wrenches, solder, welding, glue and/or twisting and turning the elements are required to form or disengage a connection. As shown in FIG. 9 , the teeth 19 of the fastening ring 18 can extend at an angle F from the horizontal axis G, wherein F ranges from approximately 39 degrees to approximately 68 degrees. In one embodiment of the present invention, angle F is approximately 56 degrees.
Operation
In operation, the fitting 12 of the present invention is provided and one or more sealing members 14 , 16 are inserted into the first radial housing element 40 , as shown in FIG. 3 . Next, the fastening ring 18 is inserted into the second radial housing element 42 , and release pusher 20 is snapped into engagement with the retaining lip 34 of the fitting 12 . When a pipe 70 is inserted, it travels through the release pusher 20 into the pipe receiving cavity 100 of the fitting 12 , engaging the fastening ring 18 and the one or more sealing members 14 , 16 . The sealing members provide a strong, leak-free seal and the fastening ring prohibits any inclination the pipe may have to slide out of position adjacent the pipe end point lip 71 (see FIG. 3 ) inside the pipe fitting 12 .
FIGS. 12-18 illustrate an alternative embodiment of the present invention. In this embodiment, the first radial housing element 40 of the pipe fitting 12 is substantially the same as described above. Further, as shown in FIG. 12 , the fitting 12 , sealing members 14 , 16 , release pusher 20 and fastening ring 18 are similarly present. However, the second radial housing element 42 includes a front wall segment 72 that does not have a top angled guiding surface. Rather, the front wall segment 72 of the second radial housing element 42 extends radially outwardly and into the fitting inner wall 13 . As such, the second radial housing element 42 includes the inner wall surface 13 for engaging the circumferential base 52 of the fastening ring 18 , as well as a surface 74 for engaging the circumferential base 92 of a snap ring 90 . Surface 75 provides a guiding surface for the release pusher 20 as it is pushed axially inwardly of the fitting in order to depress the fastening ring teeth so as to allow removal of an inserted pipe member, for example. As shown in FIGS. 17 and 18 , the snap ring 90 includes a fastening ring-engaging surface 94 and a release pusher engaging surface 96 , and is positioned in place in the fitting when the release pusher 20 is snapped or popped into engagement with the retaining lip 34 of the fitting 12 . The snap ring 90 can comprise a spring steel formulation. Further, circumferential base 92 can extend from the horizontal axis H of the snap ring 90 at an angle I of between approximately 6.5 degrees and approximately 50 degrees. In a particular embodiment of the present invention, angle I is approximately 40 degrees.
While the fastening ring 18 is shown in FIG. 12 as being a split ring, the fastening ring in this embodiment of the present invention can also be an integral ring that is not split. As such, and given the lower profile of the front wall segment 72 of the second radial housing element 42 , the fastening ring can be more easily inserted into the second radial housing element without as much initial deformation as that associated with the embodiment of the present invention shown in FIGS. 1-5 , for example.
In the embodiment of the present invention with the snap ring 90 , the snap ring can be provided with a split similar to that provided in fastening ring 18 in FIG. 1 . After placing the fastening ring into the second radial housing element, the support snap ring gland 90 can be compressed with a tool using fixture points (not shown) similar to that shown for the fastening ring 18 of FIG. 10 , and then positioned within the second radial housing element 42 . The compression of the supporting snap ring gland is released, and the ring returns to its original manufactured size, thereby acting to retain the fastening ring in position. Next, the release pusher 20 can be pushed into place such that the ledge back wall 29 removably engages the lip member 34 of the fitting 12 .
The angles described herein will be understood to be exemplary and provided as embodiments associated with proper working operation of the present invention. For example, the angles of the top surfaces of members 46 and 48 contribute to the stability of the present invention as well as the easy manipulation of its component parts.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A pipe fitting and associated piping joint assembly package allow re-use and repair of push-fit piping fittings and valves without damage to the fitting or valve elements or the pipe, and without coining, gluing or threaded engagement of parts. In one embodiment, the present invention includes a pipe fitting having first and second radial housing elements for receiving one or more sealing members and a fastening ring, respectively. The fastening ring can be a split fastening ring. The split fastening ring and the sealing members provided as part of the present invention are capable of being removed and/or replaced. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor integrated circuit for data processing in synchronization with a clock signal.
2. Description of the Related Art
With the realization of large-sized semiconductor integrated circuits, functional blocks (hard macros) already developed are reused as circuit patterns for labor savings of designing the semiconductor integrated circuits. Particularly, system vendors in the fields of consumer products, information, and communications provide a common interface specification standard for allowing the use of not only the hard macros self-designed but also the hard macros designed by other venders. The hard macros following the standard are called IP (Intellectual Property) or VC (Virtual Component) for registration. The IP or VC is utilized to allow the realization of combined hard macros supplied from various venders in the development of system LSIs. As examples of the hard macro, digital signal processors, A/D converters, and various memories are named.
Patent Document 1 (JP-A-2000-113025) describes the configuration and fabrication method of such the hard macro.
In the hard macro, its data input end is connected to a data input end of a flip flop (hereafter, it is called FF) on the input side and a data output end of an FF on the output side is connected to an output end of the hard macro through delay cells. Then, delay time of the delay cells is set so as to match data timing given to the FF on the input side from the data input end and data timing outputted to the data output end from the FF on the output side with timing of clock signals. Accordingly, the results of the hard macro are sequentially given to the subsequent hard macros in synchronization with the clock signals for assured processing.
SUMMARY OF THE INVENTION
However, the traditional semiconductor integrated circuit has problems below.
Since the clock signals in the hard macro are given to each of the FFs in phase, the maximum processing time allowed for internal circuits is fixed to a value that the setup time of the FF is subtracted from one cycle of a clock signal. On this account, in the case where delay in data paths between the hard macro and the external FFs is large, timing conditions cannot be satisfied, the cycle of the clock signal needs to be extended, and the processing speed is likely to be reduced. In addition, in the case where the processing time of a part of the internal circuits is long even though the processing time of most of the internal circuits is short, the cycle of the clock signal needs to be matched with the processing time of the internal circuit having a long processing time. Thus, it is difficult to shorten the processing time.
In a semiconductor integrated circuit including: a hard macro having a plurality of combinational circuits for performing predetermined logic processing and a plurality of flip flops for performing data transfer, the hard macro being registered as a circuit pattern beforehand; an input flip flop for taking input data in synchronization with a clock signal; an output flip flop for outputting output data in synchronization with the clock signal; a first data path for giving the input data taken in the input flip flop to the hard macro; and a second data path for giving data outputted from the hard macro to the output flip flop, the had macro is configured as below.
More specifically, the hard macro has a first flip flop for holding data given from the first data path at timing delayed from the clock signal, a second flip flop for performing data transfer between the plurality of the combinational circuits in synchronization with the clock signal, and a third flip flop for holding data outputted to the second data path at timing advanced from the clock signal for output.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIGS. 1A and 1B are explanatory drawings of a semiconductor integrated circuit illustrating a first embodiment according to the invention;
FIG. 2 is a schematic block diagram of a semiconductor integrated circuit illustrating a second embodiment according to the invention;
FIG. 3 is a schematic block diagram of a semiconductor integrated circuit illustrating a third embodiment according to the invention; and
FIG. 4 is a schematic block diagram of a semiconductor integrated circuit illustrating a fourth embodiment according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
First Embodiment
FIGS. 1A and 1B are explanatory drawings of a semiconductor integrated circuit illustrating a first embodiment according to the invention. FIG. 1A is a schematic block diagram, and FIG. 1B is an operation timing chart.
As shown in FIG. 1A , the semiconductor integrated circuit has a hard macro 10 A, an FF group 1 and a combinational circuit 2 for forming a data path, both disposed on the input side of the hard macro 10 A, and a combinational circuit 3 for forming a data path and an FF group 4 , both disposed on the output side of the hard macro 10 A.
The hard macro 10 A has a plurality of combinational circuits 11 to 17 for forming data paths, FF groups 12 to 16 for connecting the combinational circuits 11 to 17 in between, and nodes 18 a , 18 b and 18 c . The FF group 12 is connected to the node 18 a through a clock wiring line 19 a , the FF group 14 is connected to the node 18 b through a clock wiring line 19 b , and the FF group 16 is connected to the node 18 c through a clock wiring line 19 c.
The input side of the top combinational circuit 11 in the hard macro 10 A is connected to the output side of the combinational circuit 2 , and the output side of the last combinational circuit 17 at the backend is connected to the input side of a combinational circuit 3 .
In addition, clock wiring lines 6 a and 6 c for feeding clock signals CK 1 and CK 3 from clock terminals 5 a and 5 c , respectively, are disposed for the nodes 18 a and 18 c in the hard macro 10 A. Furthermore, for the FF groups 1 and 4 and the node 18 b in the hard macro 10 A, a clock wiring line 6 b for feeding a clock signal CK 2 from a clock terminal 5 b in the same phase is disposed.
Next, the operation of the semiconductor integrated circuit shown in FIG. 1A will be described with reference to FIG. 1B .
As shown in FIG. 1B , the clock signal CK 1 slightly delayed from the clock signal CK 2 given to the clock terminal 5 b is given to the clock terminal 5 a . In the meantime, the clock signal CK 3 slightly advanced from the clock signal CK 2 is given to the clock terminal 5 c.
In the FF group 1 , data D 1 outputted in synchronization with the rise of the clock signal CK 2 reaches the input side of the FF group 12 as data D 11 after processing (delay) time elapsed in the combinational circuits 2 and 11 . In the FF group 12 , the data D 11 reached on the input side is held in synchronization with the rise of the clock signal CK 1 , and outputted as data D 12 . Therefore, the maximum allowable delay time between the FF group 1 and the FF group 12 is T+td−ts, where the cycle of the clock signal CK 2 is T, the delay time of the clock signal CK 1 is d 1 , and the setup time of the FF group 12 is ts.
Similarly, in the FF group 16 , data D 16 outputted in synchronization with the rise of the clock signal CK 3 reaches the input side of the FF group 4 as data D 3 after processing (delay) time elapsed in the combinational circuits 17 and 3 . In the FF group 4 , the data D 3 reached on the input side is taken in synchronization with the rise of the clock signal CK 2 . Therefore, the maximum allowable delay time between the FF group 16 and the FF group 4 is T+tl−ts, where the cycle of the clock signal CK 2 is T, the lead time of the clock signal CK 3 is tl, and the setup time of the FF group 4 is ts.
As described above, the semiconductor integrated circuit of the first embodiment has the clock terminals 5 a to 5 c for feeding the different clock signals CK 1 to CK 3 to the FF groups 12 to 16 in the hard macro 10 A, and the clock wiring lines 6 a to 6 c corresponding to the clock terminals 5 a to 5 c . Therefore, the clock signals fed to the FF groups 12 and 4 to take the data D 11 and D 3 can be delayed more than those fed to the FF groups 1 and 16 to output the data D 1 and D 16 . Accordingly, there are advantages that the time allowed for data transfer can be prolonged, timing conditions are satisfied even in the same clock frequencies, and processing time can be shortened.
Second Embodiment
FIG. 2 is a schematic block diagram illustrating a semiconductor integrated circuit of a second embodiment according to the invention. The same components as those shown in FIG. 1 are designated the same numerals and signs.
The semiconductor integrated circuit has a hard macro 10 B, an FF group 1 and a combinational circuit 2 , both disposed on the input side of the hard macro 10 B, and a combinational circuit 3 and an FF group 4 , both disposed on the output side of the hard macro 10 B.
The hard macro 10 B has a plurality of combinational circuits 11 to 17 , FF groups 12 to 16 for connecting the combinational circuits 11 to 17 in between, a node 18 fed with clock signal CLK, and a clock wiring line 19 for feeding clock signals to the FF groups 12 to 16 from the node 18 . A clock signal CLK delayed by delay devices 21 and 22 for forming a unit for adjusting timing from the clock wiring line 19 is given to the FF groups 12 and 14 as clock signals CK 1 and CK 2 . In addition, the clock signal CLK on the clock wiring line 19 is given to the FF group 16 as a clock signal CK 3 .
In the meantime, the clock signal CLK from a clock terminal 5 is fed to the FF groups 1 and 4 through delay devices 7 a and 7 b as the clock signal CK 2 in phase with that fed to the FF group 14 . Furthermore, the delay devices 22 , 7 a and 7 b are that even numbered inverters are cascade-connected, for example. The delay amounts of the delay devices 22 , 7 a and 7 b are set similarly, and the delay amount of a delay device 21 is set greater than those.
The operation of the semiconductor integrated circuit is the same as the operation of the semiconductor integrated circuit shown in FIG. 1 , except that the clock signals CK 1 and CK 2 in the hard macro 10 B are generated by the delay devices 21 and 22 .
As described above, the semiconductor integrated circuit of the second embodiment has the delay devices 21 and 22 for generating the different clock signals CK 1 to CK 3 in the hard macro 10 B. Accordingly, the semiconductor integrated circuit can generate the proper clock signals CK 1 to CK 3 in the hard macro 10 B in accordance with the function of the hard macro 10 B, having an advantage to allow a highly accurate operation, in addition to the advantage of the first embodiment.
Third Embodiment
FIG. 3 is a schematic block diagram of a semiconductor integrated circuit illustrating a third embodiment according to the invention. The same components as those in FIG. 1 are designated the same numerals and signs.
The semiconductor integrated circuit has a hard macro 10 C having a slightly different function instead of the hard macro 10 A. More specifically, three kinds of clock signals CK 1 to CK 3 are fed to FF groups 12 C and 16 C in the hard macro 10 C from nodes 18 a to 18 c through clock wiring lines 19 a to 19 c , and proper clock signals in the clock signals CK 1 to CK 3 are separately given. The other configurations are the same as those shown in FIG. 1 .
The operation of the semiconductor integrated circuit is basically the same as the operation of the semiconductor integrated circuit shown in FIG. 1 . However, since the proper clock signals among the clock signals CK 1 to CK 3 are fed to each FF in the FF groups 12 c and 16 C, the operation is performed at the best timing in accordance with the delay time of the signal.
As described above, the semiconductor integrated circuit of the third embodiment gives a plurality of the clock signals CK 1 to CK 3 having different timing to the FF groups 12 C and 16 C in the hard macro 10 C, and feeds the clock signals having proper timing to each FF in the FF groups 12 B and 16 B. Accordingly, the semiconductor integrated circuit has an advantage that the clock signals having proper timing are given to each FF in the hard macro 10 C and high-speed processing can be performed further highly accurately, in addition to the advantage of the first embodiment.
Fourth Embodiment
FIG. 4 is a schematic block diagram of a semiconductor integrated circuit illustrating a fourth embodiment according to the invention, in which timing of clock signals fed to a synchronous RAM (Random Access Memory) incorporated therein is controlled to intend that limited processing (delay) time is relaxed and processing time is shortened.
The semiconductor integrated circuit has FFs 31 and 35 , combinational circuits (LOGIC) 32 and 34 , a synchronous RAM 33 , a clock terminal 36 , delay devices 37 a , 37 b and 38 , and a selector (SEL) 39 for forming a timing supplying unit. In addition, the delay times of the delay devices 37 a and 37 b are set nearly equal, and the delay time of the delay device 38 is set longer than them.
The FF 31 is that holds input data in synchronization with a clock signal CK 2 . A clock signal CLK given to the clock terminal 36 is delayed by the delay device 37 a and fed the clock signal CK 2 . The combinational circuit 32 is connected to an output side of the FF 31 , and an output side of the combinational circuit 32 is connected to an input terminal DI of the RAM 33 .
The RAM 33 is that reads and writes data in synchronization with clock signals given to a clock terminal C. An address signal AD for an object to be accessed is given to an address terminal A, and a write control signal WE and a read control signal RE are given to control terminals W and R. The combinational circuit 34 is connected to an output terminal DO of the RAM 33 , and the FF 35 is connected to an output side of the combinational circuit 34 .
The FF 35 is that holds output data from the combinational circuit 34 in synchronization with the clock signal CK 2 . The clock signal CLK given to the clock terminal 36 is delayed by the delay device 37 b , and fed as the clock signal CK 2 .
Furthermore, the clock signal CLK given to the clock terminal 36 is delayed by the delay device 38 , and fed to a first input side of the selector 39 as clock signal CK 1 . It is also given to a second input side of the selector 39 as the clock signal CK 3 as it is. In the selector 39 , the second input side is selected when the read control signal RE is high (enable), and the first input side is selected when the signal is low (disable). An output side of the selector 39 is connected to the clock terminal C of the RAM 33 .
Next, the operation will be described.
When data is written into the RAM 33 , the read control signal RE is turned low, the selector 39 selects and gives the clock signal CK 1 to the clock terminal C of the RAM 33 . On the other hand, input data held by the FF 31 is given to the input side of the combinational circuit 32 in synchronization with the clock signal CK 2 . Since the clock signal CK 1 has a delay amount greater than that of the clock signal CK 2 , delay (processing) time allowed for the combinational circuit 32 is longer than the cycle of the clock signal CLK.
When data is read out of the RAM 33 , the read control signal RE is turned high, the selector 39 selects and gives the clock signal CK 3 to the clock terminal C of the RAM 33 . On the other hand, the clock signal CK 2 is given to the FF 35 on the output side of the combinational circuit 34 . Since the clock signal CK 2 has a delay amount greater than that of the clock signal CK 3 , delay (processing) time allowed for the combinational circuit 34 is longer than the cycle of the clock signal CLK.
As described above, the semiconductor integrated circuit of the fourth embodiment uses the clock signal CK 1 having delay longer than that of the clock signal CK 2 fed to the FFs 31 and 35 when data is written in the RAM 33 . In addition, the semiconductor integrated circuit uses the clock signal CK 3 having delay shorter than that of the clock signal CK 2 fed to the FFs 31 and 35 when data is readout of the RAM 33 . Accordingly, the delay (processing) time allowed for the combinational circuit 32 and 34 is longer, and a reliable operation is feasible. Furthermore, the clock speed is increased, and the operating speed can be improved.
Moreover, the invention is not limited to the embodiments, which can be modified variously. As the modified example, the following are named.
(a) Three types of the clock signals CK 1 to CK 3 are used to adjust timing, but it is acceptable that a plurality of clock signals having different delay time is used.
(b) The numbers of the combinational circuits and the FF groups are not defined. They can be set freely in accordance with the function and scale of a semiconductor integrated circuit applied.
As described above, according to a first aspect of invention, the hard macro has the first FF for holding data given from the first data path at timing delayed from the clock signals, and the third FF for holding data to be outputted at timing advanced from the clock signals. Accordingly, limits on the delay time of data paths on the input and output sides are relaxed, and the processing time can be shortened.
According to a second aspect of the invention, the semiconductor integrated circuit has the delay devices for generating the clock signals for the input and output FFs, and the adjusting unit for adjusting the timing of the clock signals to be fed to each of the first to third FF groups in the hard macro. Accordingly, the timing of the clock signals does not need to be adjusted outside, and the hard macro can be operated at proper timing.
According to a third aspect of the invention, the semiconductor integrated circuit has the clock terminals and the clock wiring lines for inputting the clock signals from outside, the clock signals are given to the first to third FF groups in the hard macro. Accordingly, the clock signals can be given at any given timing, and the optimum time control can be totally performed.
According to a fourth aspect of the invention, the semiconductor integrated circuit has the timing supplying unit for giving a timing signal at timing delayed from the clock signal when data is written in the storage part and a timing signal at timing advanced from the clock signal when data is read out of the storage part. Accordingly, a limit on the delay time of the first data path is relaxed by the delay time of the timing signal when written, and a limit on the delay time of the second data path is relaxed by the lead time of the timing signal when read out. | A semiconductor integrated circuit includes first and second data paths, first to third flip flops and logic circuits. The first data path transfers input data. The first flip flop is coupled to the first data path for temporally storing data received from the first data path in response to a first clock signal that is delayed from a reference clock signal. One of the logic circuits receives data from the first flip flop and another logic circuit outputs output data. The second flip flop is connected between the logic circuits for transferring signal between them in response to the reference clock signal. The third flip flop is connected to another logic circuit for outputting the output data in response to a second clock signal that is advanced from the reference clock signal. The second data path transfers data received from the third flip flop. | 6 |
RELATED APPLICATIONS
[0001] This application claims priority of provisional patent application No. 60/323,240, filed on Sep. 19, 2001, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention pertains fasteners, and more particularly fasteners which attach one object to another object, with special emphasis to objects in the Automotive Industry.
BACKGROUND OF THE INVENTION
[0003] In the original conventional technology of fasteners employed to securely attach one object to another, such as for example one part to another in the case of an automobile or an appliance, has utilized a nut on one of the two objects, usually welded or glued to the back of said object, and a bolt passing through a hole on the second object in a manner to be engaged by the nut, thereby securing the two objects together.
[0004] This arrangement presents many problems, among which, one of the most important is that in the case that one object is hollow, the nut has to be in place at the back of the hollow object before assembling the two objects together. If for any reason the nut is misplaced, and/or if it becomes desirable to introduce a new fastening connection between the two objects, the task of achieving such connection becomes very difficult if not impossible for all practical purposes.
[0005] The so-called “quick nuts” have also been used to connect two objects. In addition, vibration during the operation of a device, such as an automobile or appliance for example, containing the two objects results very often in loosening of the bolt or “quick nut” and in either full disassembling of the objects from each other, or in a vibration noise which is most annoying and often of unacceptable levels.
[0006] Fasteners of the type described in U.S. Pat. No. 4,500,238 (Vassiliou) have been utilized to reduce considerably the potential of bolt or screw loosening and vibration. They have also eliminated the problem of having to place one member of the fastener at the back portion of the hollow object. These fasteners are placed through a slot from the front part of the hollow object. An expanding member, being usually a bolt or a screw, supports the second object by forcing the legs of the fastener (as described for example in U.S. Pat. No. 4,500,238) to open or expand, thereby securing the two objects together. The legs of the fasteners are supported by a double-layered head having an upper side and a lower side joined by side bents. The fasteners of this type have greatly improved the prevailing torque, as well as the pulling force of the system. Prevailing torque is the torque required to render a screw loose. Pulling force is the pulling force applied on the screw to the point of failure, which usually occurs at the bents.
[0007] Other references representing the state of the art at this point are disclosed in U.S. Pat. Nos. 6,179,366 B1, 6,095,734, 5,919,019, 5,873,690, 5 , 759 , 004 , 5 , 725 , 343 , 5 , 636 , 891 , 5 , 632 , 584 , 5 , 336 , 125 , 5 , 314 , 280 , 5 , 249 , 900 , 5 , 129 , 768 , 4 , 610 , 588 , 4 , 595 , 325 , 4 , 495 , 380 , 3 , 505 , 922 , 3 , 486 , 158 , 3 , 426 , 817 , 2 , 707 , 013 , 2 , 430 , 555 , 2 , 376 , 167 and 2 , 181 , 966 .
SUMMARY OF THE INVENTION
[0008] This invention pertains fasteners, and more particularly fasteners which attach one object to another object, with special emphasis to objects in the Automotive Industry. More particularly, this invention pertains a spring fastener comprising:
[0009] a head portion having an upper side, and a lower side, the upper side having an engageable hole on which a securing member can engage and pass through;
[0010] an elastic body disposed at least under the lower side of the head portion; and
[0011] a body portion extending from the lower side of the head portion at a substantially right angle with respect to the head portion, the body portion comprising
[0012] a front body portion and a back body portion, the front body portion and the back body portion being at least partially in proximity with each other;
[0013] a front opening on the front body portion and a back opening on the back body portion, each of the openings having a respective opening bottom a respective opening top, a first opening side and a second opening side;
[0014] a side body portion on each opening side;
[0015] a front snapping segment connected to the front body portion in the vicinity of the opening bottom, and having a front free engagement end; and
[0016] a back snapping segment connected to the back portion in the vicinity of the opening bottom, and having a back free engagement end.
[0017] The presence of the elastic body at least under the lower side of the head of the fastener is of extreme importance, since, unexpectedly, in addition to its excellent sealing properties allows the snapping segments to freely pass through the slot of an object, and then to snuggly contact the lower surface of said object, a necessary requirement to prevent unacceptable rattling.
[0018] The lower side of the head may have a secondary engagement section, and at least one of the side body portions may have a tertiary engagement section.
[0019] At least one of the free engagement ends may comprise a section selected from anti-sliding section, anti-opening section, and a combination thereof.
[0020] At least one snapping segment may be disposed at least partially along the respective side body portion and/or the respective opening.
[0021] Vehicles comprising the spring fasteners of this invention, connecting two parts, one of the parts comprising a slot in which the fastener is secured by the snapping segment, are also included within the scope of the instant invention. Thus, automobiles or other vehicles may be made, comprising one or more of the fasteners of the instant invention, providing substantial improvements regarding safety, performance and comfort.
BRIEF DESCRIPTION OF THE DRAWING
[0022] The reader's understanding of this invention will be enhanced by reference to the following detailed description taken in combination with the drawing figures, wherein:
[0023] [0023]FIG. 1 illustrates a perspective view of a spring fastener in the absence of the elastic body according to a preferred embodiment of the present invention.
[0024] [0024]FIG. 2 illustrates a fragmental perspective view of the back body portion and part of the lower side of the head portion of the fastener of FIG. 1 in the absence of the elastic body.
[0025] [0025]FIG. 3 illustrates a front view of the side body portions comprising threading teeth according to another preferred embodiment of the instant invention.
[0026] [0026]FIG. 4 illustrates a front view of a spring fastener of the instant invention, illustrating the elastic body in the region of the head portion.
[0027] [0027]FIG. 5 illustrates the operation of the fasteners of the instant invention.
[0028] [0028]FIG. 6 illustrates a spring fastener according to another embodiment of the present invention in the absence of the elastic body.
[0029] [0029]FIG. 7 illustrates a spring fastener according to still another embodiment of the present invention in the absence of the elastic body.
[0030] [0030]FIG. 8 illustrates a cross section of a straight snapping segment configuration according to another embodiment of the instant invention.
[0031] [0031]FIG. 9 illustrates a cross section of a snapping segment configuration involving an anti-opening front engagement end according to another embodiment of the instant invention.
[0032] [0032]FIG. 10 illustrates a cross section of a snapping segment configuration involving an anti-sliding front engagement end according to another embodiment of the instant invention.
[0033] [0033]FIG. 11 illustrates a cross section of a snapping segment configuration involving an anti-sliding front engagement end according to still another embodiment of the instant invention.
[0034] [0034]FIG. 12 illustrates a perspective view of a snapping segment configuration involving an anti-sliding front engagement end according to still another embodiment of the instant invention.
[0035] [0035]FIG. 13 illustrates a perspective view of a snapping segment configuration involving an anti-sliding front engagement end according to still another embodiment of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] As aforementioned, this invention pertains fasteners, and more particularly fasteners which attach one object to another object, with special emphasis to objects in the Automotive Industry.
[0037] As also mentioned earlier, there is a need to have one or more fasteners attached to a large first object, such as a headliner or roof-rack of a car for example, and then attach this large first object to second object, such as the inside or outside of the roof of a car, respectively, for example, by inserting at least part of the fastener into the second object, through a slot for example. An additional requirement many times is to use a rather light force for the insertion, but to require an extraordinarily high force to separate the two objects, if the fastener is not first removed, by unthreading for example a bolt or a screw which attaches the fastener to the first object. A further requirement in many occasions is that after unthreading the bolt or screw, the fastener remains attached to the second object. In other occasions, however, it is required that the two objects are separated by pulling one object away from the other object, without performing other action, such as unthreading a screw or a bolt. Another requirement in a plurality of application is that the fastener has to be attached to a specified position on the first object, and not allowed to turn. The configuration should be such that the screw or bolt could hold additional object(s), such as a car handle for example.
[0038] This invention provides fasteners which have the configurations required to satisfy the above need.
[0039] Referring now to FIG. 1, there is depicted, in a perspective view, a spring fastener 10 according to a preferred embodiment of the instant invention. The fastener 10 comprises a head portion 12 having an upper side 14 , and a lower side 16 . The upper side has an engageable hole 18 on which a securing member 20 (shown in FIG. 5) can engage and pass-through.
[0040] An elastic body 44 (illustrated in FIGS. 4 and 5), necessary for this invention has been omitted from the rest of the Figures for clarity purposes.
[0041] The elastic body 44 of this invention, better shown in FIG. 4, is disposed at least under the lower side 16 of the head portion 12 . Such elastic bodies are preferably integrally molded at least at the lower side of the head portion 12 , and preferably around the whole head 12 . These elastic bodies are for example disclosed in U.S. Pat. Nos. 5,725,343, and 6,379,092, both of which are incorporated herein by reference.
[0042] In FIG. 2, there is depicted a fragmental view of a back lower body 22 b as well as portion of the lower head side 16 of the fastener 10 , as explained hereinbelow.
[0043] The spring fastener 10 comprises a body portion 22 , which extends from the lower side 16 of the head portion 12 at a substantially right angle with respect to the head portion 12 .
[0044] The body portion 22 has a front body portion 22 a (better shown in FIG. 1) and the back body portion 22 b (better shown inn FIG. 2). The front body portion 22 a and the back body portion 22 b are at least partially in proximity with each other.
[0045] For purposes of clarity, in the following discussion and in the Figures, numerals followed by the letter “a” refer to the front body portion 22 a of the body portion 22 , and numerals followed by the letter “b” refer to the back body portion 22 b of the body portion 22 . The two elements corresponding to the body portion 22 are referred to collectively as the respective numeral without the letter.
[0046] The front body portion 22 a has a front opening 24 a , and the back body portion 22 b has back opening 24 b . Each of the openings 24 a and 24 b has a respective opening bottom 26 a and 26 b , and a respective opening top 28 a and 28 b . Each of the openings 24 a and 24 b also has a respective first opening side 30 a and 30 b and a respective second opening side 32 a and 32 b.
[0047] The front body portion 22 a has side body portions 34 a , while the back body portion 22 b has side body portions 34 b.
[0048] The body portion 22 further comprises a front snapping segment 36 a connected to the front body portion 22 a in the vicinity of the opening bottom 26 a , and having a front free engagement end 38 a . The body portion 22 also comprises a back snapping segment 36 b connected to the back body portion 22 b in the vicinity of the opening bottom 26 b , and having a back free engagement end 38 b.
[0049] The spring fasteners of the present invention may have a secondary engagement section at the lower side 16 of the head portion 12 . The secondary engagement section 40 comprises two arcs, 40 a and 40 b , which are capable to engage to the securing member 20 (FIG. 5), such as a screw or bolt for example. This arrangement provides increased pulling force, which is the force required to remove the securing member 20 from the spring fastener by pulling them apart.
[0050] At least part of the side body portions 34 a and 34 b may comprise threading teeth 42 , which create a tertiary engagement section, as better shown in FIG. 3. The threading teeth 42 engage the securing member 20 (FIG. 5), thus also providing increased pulling force. The threading teeth may be on the same plane as the respective side body portions 34 a and 34 b or bent to a certain degree in a manner to nest better the threads of the securing member 20 . Further, the angles of the front and the back sides of the teeth may be such as to favor easy insertion and difficult removal of the fastener, in a similar manner as the bent teeth 64 (FIG. 13, and applications incorporated by reference) discussed at a later point.
[0051] Complementary engagement mechanisms which may be used in the present invention, if so desired, are described in provisional application 60/167,080 (filed Nov. 23, 1999), 60/169,447 (filed Dec. 7, 1999), 60/170,611 (filed Dec. 14, 1999), and 60/179,834 (filed Feb. 2, 2000), and non-provisional application Ser. No. 09/699,760 (filed Oct. 30, 2000), all of which are incorporated herein by reference.
[0052] The fastener 10 also has an insertion region 23 ( 23 a and 23 b ), which may be covered by a soft material, such as a plastic for example, in order to avoid scratching the surface of a part, such as the second object 52 for example shown in FIG. 5.
[0053] The operation of the above embodiments is better illustrated in FIG. 5.
[0054] The fastener 10 is secured on a first object 46 , such as a roof-rack or headliner for example, by passing a securing member, such as a screw or bolt 20 , for example, through hole 48 of the first object 46 , and threading said screw or bolt 20 on the engageable hole 18 . If the secondary and/or tertiary and/or other engagement sections are present, as for example described above, the securing member is engaged on these engagement sections, too.
[0055] The first object 46 has preferably a recessed region 50 under the hole 48 , which serves to align and/or nest partially or totally the head portion 12 and/or the elastic body 44 . A deeper recessed region 50 allows the distance between the upper side 14 and the lower side 16 of the head portion to be large enough so that the curved regions joining the two sides are adequately gradual, thus providing considerably higher structural strength.
[0056] One or more additional objects, such as a handle (not shown) for example, may also be secured by the same securing member 20 by passing said securing member through a hole (not shown) belonging to the additional object(s). More than one fasteners may be secured in a similar manner on the first object 46 . Such combinations may form an assembly, such as a roof-rack or headliner assembly for example.
[0057] It is important that the length of the securing member is long enough for any desired engagements, but have a shorter length than a length which would exceed the opening bottom 26 , and thus cause any appreciable opening of the body portions 22 a and 22 b.
[0058] The assembly, such as a roof-rack or headliner assembly for example, which usually comprises more than one secured and aligned fasteners 10 in predetermined positions, is pushed by the operator against a second object, such as for example metal sheet 52 , which can be in the form of a framework in the vicinity of the roof or ceiling of the outside or inside region of a vehicle for example, having properly arranged slots 54 to accept body portion 22 of the fattener 10 . Other material may replace, however, the metal, and it should be understood throughout this disclosure that when referring to metal sheet, any other suitable material may replace the metal, or any other object or combination of objects may replace the sheet.
[0059] As the body portion 22 of the fastener 10 is being pushed through the slot 54 , the snapping segments 36 a and 36 b are inwardly pushed until they reach a position at which the body portion is allowed to pass through the slot 54 , at which point the elastic body 44 has been compressed to a desired degree. When the body portion 22 of the fastener 10 has reached its final position, the snapping segments 36 a and 36 b snap back. In sequence, the insertion force is released, allowing the elastic body 44 to expand to a desired degree, and thus, the fastener 10 , as well as the whole assembly, are secured onto the metal sheet 52 .
[0060] The elastic body serves also as an excellent insulator for gases and liquids, and as a noise damper.
[0061] A number of parameters determine the force needed to insert the assembly into the slot 54 . These include but are not limited to the thickness, hardness and spring characteristics of the folded sheet metal from which the fastener is made, the shape and dimensions of the fastener, the length and width of the snapping segments, the angle formed by the left and right sections with the respective snapping segments, the dimensions of the slot 62 , the thickness and elasticity of the elastic body, etc. For each particular application, these parameters may be determined experimentally, or by engineering calculations, or a combination thereof without undue effort.
[0062] The force to separate the assembly from the metal sheet 52 is manifold higher than the insertion force, due to the critical configurations of the instant invention, and it depends on the above parameters, but also on the characteristics of the screw or bolt 48 , the characteristics of the engageable hole or sections or other engageable elements of the fastener, etc. The multiplicity of engageable features of the fastener of the present invention, are critical in considerably increasing the ratio of the separating force to the insertion force.
[0063] The utilization of more than one engageable sections is important not only for adequately strong attachment of the fastener 10 to the first object, directly or indirectly, in a manner to form an assembly, but also to combine very easy insertion of the fastener into the slot 54 of the metal sheet 52 with extremely difficult separation of the assembly from the metal sheet after the easy insertion has taken place. The importance of adequately strong attachment, despite the easy insertion, becomes even more important when a larger number of objects, and/or more demanding objects have to be supported by the fastener 10 . This is especially so in the case that a given additional object (not shown for purposes of clarity), such as an air-bag system for example, has to be attached to the upper side 56 of the first object 46 .
[0064] If service is needed, and partial or total removal of the assembly of elements from the metal sheet 52 is needed, the screw(s) or bolt(s) 20 are unthreaded, and the assembly is freed from the metal sheet 52 , with the fastener, however, attached now to the metal sheet 52 . After the service, the elements may be attached in their initial position by using the screw or bolt 20 as shown in FIG. 5.
[0065] In a different embodiment of the instant invention, better shown in FIG. 6, the snapping segments 36 a and 36 b are disposed along the side body portions 34 a and 34 b , respectively. The fastener 10 , in this case also, may have secondary and tertiary engagement sections as well as other additional engagement sections (not shown).
[0066] The operation of this embodiment is substantially the same as the operation of the above embodiments, with the difference that the snapping segments 36 a and 36 b are disposed along the side body portions 34 a and 34 b instead along the opening 24 .
[0067] In still a different embodiment of the instant invention, better shown in FIG. 7, the snapping segments 36 a and 36 b are disposed not only along the side body portions 34 a and 34 b , but also along the opening 24 in a continuous manner.
[0068] The operation of this embodiment is substantially the same as the operation of the above embodiments, with the difference that the snapping segments 36 a and 36 b are disposed along the side body portions 34 a and 34 b , as well as along the opening 24 in a continuous manner.
[0069] The snapping segments of this invention may have different configurations, including but not limited to straight and curved.
[0070] One example is shown in FIG. 8, wherein the snapping segment 36 has a substantially linear configuration with a free engagement end 38 as being a linear extension of the snapping segment 36 .
[0071] In order to provide anti-opening properties to the snapping segment 36 , an anti-opening configuration can be used, such as the one shown in FIG. 9, for example. When the snapping segment tends to open, the prong 58 , which resides within the slot 54 (FIG. 5) during the operation, prevents such opening. This particular configuration is preferable when the failure is due to the snapping segments 36 having a tendency to open (move away from the slot on and parallel to the lower surface 60 of the sheet metal 52 ) when a separation force is applied between the first object 46 and the metal sheet 52 (see FIG. 5)
[0072] Anti-sliding properties (preventing the snapping segments 36 from sliding through the slot 54 when a separation force is applied between the first object 46 and the metal sheet 52 —see FIG. 5) may be provided, especially in the case that the free engagement end 38 forms an angle with the rest of the engagement segment 36 , as illustrated for example in FIG. 11, for multi-position engagement on the slot 54 . Perspective views of examples of anti-sliding configurations are shown in FIG. 12 (ripples 62 on the free engagement end 38 ) and in FIG. 13 (bent teeth 64 on the free engagement end 38 ).
[0073] It is important to note that even in the case that the free engagement end 38 is parallel to the side body portions 34 when it resides in the slot 54 (not completely passed through the slot in its final position), it can hold the first object and the metal sheet together in the case of presence of ripples 62 and/or bent teeth 38 .
[0074] Further, the securing member 20 itself hinders the sliding of the snapping segments out of the slot 54 .
[0075] Other examples of anti-opening and anti-sliding configurations, and more details regarding their structure, as well as other types of spring fasteners having snapping segments are disclosed in non-provisional application Ser. No. 09/969,563 (Publication No. 2002/0054808;
[0076] Publication date: May 9, 2002) and provisional application 60/246,634 (filed Nov. 8, 2000), 60/249,996 (filed Nov. 20, 2000), 60/267,281 (filed Feb. 8, 2001), 60/283,266 (filed Apr. 12, 2001), 60/289,343 (filed May 7, 2001), 60/302,194 (filed Jun. 29, 2001), 60/301,164 (filed Jun. 25, 2001), 60/308,921 (filed Jul. 31, 2001), 60/310,343 (filed Aug. 6, 2001), and 60/312,867 (filed Aug. 16, 2001), all of which are incorporated herein by reference.
[0077] Vehicles comprising the spring fasteners of this invention, connecting two parts, one of the parts comprising a slot in which the fastener is secured by the snapping segment, are also included within the scope of the instant invention. Thus, automobiles or other vehicles may be made, comprising one or more of the fasteners of the instant invention, providing substantial improvements regarding safety, performance and comfort.
[0078] Examples of embodiments demonstrating the operation of the instant invention, have now been given for illustration purposes only, and should not be construed as restricting the scope or limits of this invention in any way.
[0079] Any feature(s) described in one of the exemplary embodiments may be combined with any features incorporated in any other exemplary embodiment according to this invention.
[0080] Any explanations given are speculative and should not restrict the scope of the claims. | This invention pertains fasteners which are characterized by easy insertion and extraordinarily difficult separation of items that they attach together. This is achieved by a combination of snapping segments with an elastic body disposed at least under the head of the fastener. The snapping segments may comprise anti-opening and/or anti-sliding portions, which immensely increase the strength with which the fasteners hold the objects together. The elastic body in the vicinity of the bottom section of the fasteners also provides water and gas proof properties, as well as elimination of squeaking noises. Vehicles comprising objects connected together by the fastening devices described and claimed herein are part of the instant invention. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to collapsible structures, and in particular, to collapsible sunshades that can be used for multiple purposes.
[0003] 2. Description of the Prior Art
[0004] Collapsible sunshades have been well-known for some time, as illustrated by the sunshades shown and described in U.S. Pat. Nos. 5,024,262 (Huang), 4,815,784 (Zheng), 5,732,759 (Wan) and 5,553,908 (Shink), among others. All of these sunshades are provided solely for the purpose of blocking sunlight at a window or windshield when the vehicle is parked. None of these sunshades are capable of being used when the vehicle is in motion.
[0005] There are other sunshades that are adapted for use when the vehicle is in motion. While these sunshades can provide partial shade to the occupants inside a vehicle, these sunshades are not effective in blocking heat and sunlight.
SUMMARY OF THE DISCLOSURE
[0006] It is an object of the present invention to provide a collapsible sunshade that can be deployed for different uses in an automobile.
[0007] It is another object of the present invention to provide a collapsible sunshade that can be deployed for use in different environments, including use in the house or locations other than inside an automobile.
[0008] In order to accomplish the objects of the present invention, the collapsible sunshade according to the present invention has a panel comprising a foldable frame member having a folded and an unfolded orientation, the frame member defining a periphery for the panel with an interior space inside of the peiphery, a meshed material covering the interior space defined by the frame member to form the panel when the frame member is in the unfolded orientation, and a shade fabric having at least a portion thereof removably attached to the panel so that the shade fabric can assume a first position in which the shade fabric completely overlies, in a planar manner, the meshed material, and a second position where the portion of the shade fabric that is removably attached to the panel is disengaged from the panel to expose a portion of the meshed material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a collapsible sunshade according to one embodiment of the present invention.
[0010] FIG. 2 illustrates a modification that can be made to the sunshade of FIG. 1 .
[0011] FIGS. 3A-3D illustrate the two different uses for the sunshade of FIG. 1 .
[0012] FIGS. 4A through 4C illustrate how the sunshade of FIG. 1 may be twisted and folded for compact storage.
[0013] FIG. 5 is a partial cut-away view of the section A of the structure of FIG. 1 illustrating a frame member retained within a sleeve.
[0014] FIGS. 6A and 6B illustrate a modification that can be made to the sunshade of FIG. 1
[0015] FIG. 7 illustrates another embodiment of the sunshade of the present invention.
[0016] FIG. 8 is a cross-sectional view of the section 8 - 8 in FIG. 7 .
[0017] FIGS. 9-15 illustrate other embodiments of sunshades according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] 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.
[0019] As shown in FIGS. 1 and 5 , the sunshade 20 is comprised of a single panel 22 . The panel 22 can have four sides, such as a left side 30 , a bottom side 32 , a right side 34 and a top side 36 , although the panel 22 can assume any configuration and have any number of sides (e.g., square, rectangular, oval). The panel 22 has a frame retaining sleeve 38 provided along and traversing the four edges of its four sides. A frame member 40 is retained or held within each respective frame retaining sleeve 38 to support the panel 22 .
[0020] The frame member 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 member 40 is preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame member 40 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 40 is collapsed into a size which is much smaller than its open position (see FIG. 4C ). The frame member 40 may be merely retained within the frame retaining sleeve 38 without being connected thereto. Alternatively, the frame retaining sleeve 38 may be mechanically fastened, stitched, fused, or glued to the frame member 40 to retain it in position.
[0021] A meshed material 42 extends across the panel 22 , and is held taut by the frame member 40 when in its open position. The meshed material is made from strong, lightweight materials and may include woven fabrics or nylons. The meshed material 42 defines a plurality of small uniform openings 24 so that a person can see through the meshed material 42 through these openings 24 . The meshed material 42 should be water-resistant and durable to withstand the wear and tear associated with rough treatment.
[0022] In addition, a shade fabric 26 is provided to extend across the meshed material 42 in the interior space defined by the sides of the panel 22 . The shade fabric 26 can be provided in the form of a fabric material that has a reflective surface that is adapted to reflect sunlight and heat. The shade fabric 26 is preferably made from strong, lightweight materials that are adapted to withstand sunlight and heat, such as nylons, thick fabrics, and the like. In the embodiment shown in FIG. 1 , the shade fabric 26 has a lower edge 44 that is permanently attached (e.g., by stitching) to the bottom side 32 of the panel 22 . Lower portions 46 and 48 of the left edge 50 and right edge 52 , respectively, of the shade fabric 26 are permanently attached (e.g., by stitching) to the lower portions of the left and right sides 30 and 34 , respectively, of the panel 22 . The permanent attachment of the lower edge 44 and lower portions 46 , 48 to the meshed material 42 defines a pocket 28 . The rest of the left and right edges 50 , 52 of the shade fabric 26 are not permanently attached to the left and right sides 30 and 34 , respectively, of the panel 22 , but are instead adapted to be removably attached to the left and right sides 30 and 34 , respectively, of the panel 22 . The removable attachment can be accomplished by a number of different mechanisms. For example, in FIG. 1 , the mechanism can be a zipper 56 provided along the edges 50 , 52 and the top edge 54 of the shade fabric 26 and the left, right and top sides 30 , 34 and 36 of the panel 22 .
[0023] FIG. 2 illustrates the use of opposing VELCRO™ pads 60 instead of the zipper 56 . These pads 60 can be provided in spaced-apart manner along the edges 50 , 52 , 54 of the shade fabric 26 and the sides 30 , 34 and 36 of the panel 22 to facilitate removable engagement thereof.
[0024] The shade fabric 26 is adapted to be folded (or rolled) and tucked into the pocket 28 . This allows the sunshade 20 to be used in two different ways: a first use where the shade fabric 26 is attached to the rest of the panel 22 in a manner such that the shade fabric 26 overlies the meshed material 42 , and a second use where enough of the periphery of shade fabric 26 is detached from the panel 22 so that the detached portion of the shade fabric 26 is tucked into the pocket 28 , thereby exposing a portion of the meshed material 42 . In the first use, the sunshade 20 can be deployed against a window or windshield for use when the vehicle is parked, and in the second use, the sunshade 20 can be deployed against a window or windshield while the vehicle is in motion. In the second use, the exposed portion of the meshed material 42 allows the occupants of the vehicle to see through the exposed portion of the meshed material 42 to the outside of the vehicle. Referring to FIGS. 3A-3D , FIG. 3A shows the sunshade 20 configured to be deployed against a window or windshield when the vehicle is parked, with the shade fabric 26 overlying the meshed material 42 . To convert the sunshade 20 to the second use, the shade fabric 26 is detached from the meshed material 42 by detaching the VELCRO™ pads 60 (or the zipper 56 ) (see FIG. 3B ), and then rolling (or folding) the shade fabric 26 (see FIG. 3C ) and tucking the rolled (or folded) shade fabric 26 into the pocket 28 (see FIG. 3D ).
[0025] Suction cups 58 can be attached to the meshed material 42 and/or the shade fabric 26 at the location of the pocket 28 . The suction cups 58 allow for the sunshade 20 to be removably attached to the inner surface of a window or windshield.
[0026] FIGS. 4A through 4C describe the various steps for folding and collapsing the sunshade 20 of FIG. 1 for storage. The first step consists of twisting and folding to collapse the frame member 40 and panel 22 into a smaller shape. In particular, the opposite border of the panel 22 is folded in (see arrow 2 in FIG. 4A ) upon the previous fold to further collapse the frame member 40 with the panel 22 . As shown in FIG. 4B , the folding is continued so that the initial size of the sunshade 20 is reduced until the frame member 40 and panel 22 are collapsed on each other (see FIG. 4C ) to provide for a small essentially compact configuration having a plurality of concentric frame members 40 and layers of the panel 22 so that the collapsed sunshade 20 has a size which is a fraction of the size of the initial structure.
[0027] FIGS. 6A and 6B illustrate another modification that can be made to the sunshade 20 of FIG. 1 . The lower portions 46 and 48 of the left edge 50 and right edge 52 , respectively, of the shade fabric 26 that are permanently attached to the lower portions of the left and right sides 30 and 34 , respectively, of the panel 22 can be lengthened, with a stitch line 59 provided across the top of the pocket 28 to attach the shade fabric 26 to the mesh material 42 along the stitch line 59 . Removable attachment mechanisms (e.g., VELCRO™ pads 61 ) can be provided along the periphery of the outer surface of the shade fabric 26 so that the upper unattached portion of the shade fabric 26 can be folded over about the stitch line 59 , and opposing pads 61 removably attached to each other (see FIG. 6B ) to secure the upper portion of the shade fabric 26 to the pocket 28 . The embodiment in FIGS. 6A and 6B provides a larger lower portion of the shade fabric 26 .
[0028] FIG. 7 illustrates another embodiment of the present invention, where the sunshade now includes a first panel 22 a and a second panel 22 b positioned such that the two panels 22 a and 22 b are hingedly connected to each other along adjacent sides 32 a and 36 b, respectively. The two panels 22 a, 22 b can be identical in construction to the panel 22 in FIG. 1 , except that both panels 22 a, 22 b now share the shade fabric 26 . FIG. 8 illustrates one possible connection for connecting adjacent sides 32 a, 36 b. The meshed materials 42 a, 42 b are stitched at their edges by a stitching 45 to the respective sleeves 38 . Each sleeve 38 may be formed by folding a piece of fabric. The stitching 45 also acts as a hinge for the panels 22 a and 22 b to be folded upon each other, as explained below.
[0029] A single shade fabric 26 a is provided, and has one edge 44 a stitched to the hinged connection shown in FIG. 8 . The shade fabric 26 a can be removably attached to either meshed material 42 a or 42 b via the same removable attachment mechanisms described above. To fold and collapse the two panels 22 a, 22 b, one panel 22 a is folded on top of the other panel 22 b, with the shade fabric 26 a between the two panels 22 a, 22 b, and then the combined panels 22 a, 22 b can be twisted and folded according to the method shown in FIGS. 4A-4C .
[0030] In the embodiments described above, the shade fabric 26 does not need to be permanently attached to the panel 22 . It is possible to provide the shade fabric 26 as a separate piece of fabric that can be completely removably attached to the panel 22 . For example, FIG. 9 illustrates the embodiment of FIG. 1 with the zipper 56 extending completely around the peripheries of the shade fabric 26 and the panel 22 . FIG. 10 illustrates the embodiment of FIG. 2 with the VELCRO™ pads 60 extending around the peripheries of the shade fabric 26 and the panel 22 . Referring to FIG. 11 , the separate shade fabric 26 can be rolled up and tied to a side 32 of the panel 22 via tie members 64 provided along the side 32 .
[0031] FIG. 12 illustrates yet another modification that can be made to the sunshade in FIGS. 10-11 . The shade fabric 26 can be replaced by two separate shade fabrics 26 c, 26 d that can be completely detached from the panel 22 . The provision of two separate shade fabrics 26 c, 26 d allows the user to completely cover selected portions of the panel 22 , thereby providing additional flexibility in use.
[0032] FIG. 13 combines the principles of FIGS. 1 , 7 and 8 . The sunshade in FIG. 13 comprises three of the sunshades 20 shown in FIG. 1 , but hingedly connected to each other using the hinged connection shown in FIGS. 7 and 8 . The embodiment of FIG. 13 provides a larger overall sunshade that can be used with larger windows, such as in recreational vehicles or inside buildings.
[0033] FIG. 14 illustrates a modification to the embodiment of FIG. 13 . In FIG. 14 , the sunshade is made up of three smaller panels that are different in size and/or shape. In FIG. 14 , the panels 22 f and 22 g are the same size and shape, but the panel 22 h is smaller and has a different shape. This embodiment is best suited for use with the windshield W, with the smaller panel 22 h accomodating the location of the rear-view mirror RV. Additional fabric material 70 can be provided between the panels 22 f, 22 g, and above and below the panel 22 h, to fill out the surface area of the windshield W.
[0034] FIG. 15 extends the principles of FIG. 14 even further by illustrating the provision of another smaller panel 22 j. The smaller panels 22 h and 22 j are provided one above the other, and between the larger panels 22 f, 22 g. As shown in these embodiments, a sunshade according to the present invention can be provided with one or more panels 22 arranged in any desired configuration so that the sunshade can be adapted for use in almost any desired location or environment.
[0035] 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 collapsible sunshade according to the present invention has a panel comprising a foldable frame member having a folded and an unfolded orientation, the frame member defining a periphery for the panel with an interior space inside of the peiphery, a meshed material covering the interior space defined by the frame member to form the panel when the frame member is in the unfolded orientation, and a shade fabric having at least a portion thereof removably attached to the panel so that the shade fabric can assume a first position in which the shade fabric completely overlies, in a planar manner, the meshed material, and a second position where the portion of the shade fabric that is removably attached to the panel is disengaged from the panel to expose a portion of the meshed material. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of Nonprovisional patent application Ser. No. 10/944,287, filed Oct. 21, 2008 (now U.S. Pat. No. 7,440,992) which claims priority from co-pending U.S. Provisional Patent Application No. 60/503,759 filed Sep. 16, 2003 entitled “Self-Contained, Mobile, Autonomous Software Agent”, which is hereby incorporated by reference, as if set forth in full in this document, for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention is generally related to distributed computing environments and in particular to secure operation of agents accessing services as components of the distributed computing environment.
[0004] 2. The Prior State of the Art
[0005] Distributed computing environments allow for dispersal of tasks performed by an application. As distributed computing environments become more prevalent and well understood, many monolithic programming efforts are being replaced with modular computing efforts.
[0006] In a modular view of the computing, modules have their own identities, which are separate from descriptive attributes. A module can be a collection of programmable interfaces. Modules typically have well-defined programmable interfaces at both the source code level and the run-time executable code level. The interfaces are uniquely identified by name or some unique key value, often called a globally unique identifier (GUID). The uniqueness of a module name provides a mechanism such that the module's visibility within a containing process, application, archive, or another module is clear. For example, two spell checking processes may exist on a computing device; however without a way to distinguish between the two, an application could make use of the one of the spell checkers with unpredictable results.
[0007] One driving factor in modular-based development and run-time systems has been the need to control and reduce the increased technical complexity of software development. Goals of modular-based software development include producing software that is fully scalable to small or large computing environments and producing it faster than is possible with monolithic programming.
[0008] A typical application today using conventional monolithic programming might have an event-driven graphical user interface (GUI), network interfaces to both a local area network and the Internet, and include a multi-tiered architecture for use within client-server environments. In contrast, modules allow for a level of abstraction at design time when modeling applications and systems, so that systems can then be assembled at run-time with modules viewed as “black boxes” resulting in a known and understood behavior.
[0009] Modules that have been well tested and perform well can be used within an application with a level of trust that they will perform as expected. Modules that are buggy or do not perform well can be refactored and worked on in isolation from more stable modules. While not altogether eliminating the technical complexity of software development, applications and systems built using modules can be assembled more quickly and offer a level of trust that could not be realized in a monolithic architecture.
[0010] Several well-known frameworks support module-based computing, including Microsoft's COM, COM+, and .Net frameworks, Sun's JavaBeans framework, and OMG's CORBA environment. Using these frameworks, a developer can build modules that interact with other modules on local machines and across networks. The most common method of module interaction and communication in these environments is through a remote procedure call (RPC) mechanism, where a remote module's interface is made to be seen the same as calling a module's internal interface. Although the level of interoperability provided by RPC mechanisms between heterogeneous modules is limited, current frameworks do offer a good way to build module-based applications and systems. The frameworks also do a fair job of hiding the complexity of using modules that are distributed across the network, particularly within a local, secured network, but they present more of a challenge with unsecured networks such as the Internet.
[0011] An agent is a modular software component that has a level of autonomous behavior and acts on behalf of an application or process often referred to as the agent's “client”. An agent is designed to carry out one or more specific functions for its client.
[0012] Mobile software agents are agents that can move from one environment to another environment, with their execution in the one environment able to continue in the other environment. Mobile agents can solve problems with network bandwidth utilization. If a computing process needs to sift through a large volume of remote data, having the computing process run on a local computer and access the data over a network would use considerable network bandwidth. A more bandwidth efficient method would be to have the computing process provide or invoke an agent to move near the data and perform its operations locally.
[0013] Mobile agents are also useful for overcoming problems of intermittent network connectivity. For example, if a local computer is executing a long-running process that requires processing data across the network and the local computer can become disconnected from the network, the process may fail. A better solution is to allow an agent to move near the data and perform its processing operations, then have the agent (or its data) return to the local computer when the local computer is ready to receive the results of the agent's operations.
[0014] Agents using complex programming logic can sometimes exhibit seemingly intelligent behavior. These agents are often referred to as “intelligent agents”. Some intelligent agents perform a directed sequence of actions to achieve a processing goal. Some use a knowledge base. Some use artificial intelligence (AI) methods, such as neural networks to provide problem solving processing.
[0015] IBM's recently open sourced Aglets framework allows for the building and deployment of Java-based mobile agents, but their uses are limited and do not provide the container control or interaction that might be needed.
[0016] Jade is a Java-based development environment that claims Foundation for Intelligent Physical Agents (FIPA) compliance. FIPA is a non-profit organization that promotes and provides specification for the interoperability of agents. Jade code, and similar approaches, has a default mode of running without security. A security manager can be used to protect machine resources, but this must be used throughout a system to ensure full security.
[0017] A service, as used herein, is a software component that provides computer processing through a clearly defined interface. For example, an application using the information provided by the clearly defined interface could execute a “stock quote” service, and a “weather” service, possibly provided by different vendors, and combine the results into an application that provides a graphical user interface (GUI) to show how weather affects stocks. This application could provide, as an adjunct to the GUI, a service that would supply the results to other applications in a raw form as data.
[0018] A service-oriented architecture (SOA) is used to describe applications and systems built primarily using services that are made available. An example of a service is a web service. Web services might interoperate with other services and applications using a wire-level standard protocol such as the Simple Object Access Protocol (SOAP) that uses Extensible Markup Language (XML) to describe a service interface and data elements that will be sent by the invoker of the web service. SOAP is also the protocol of the returned results.
[0019] Unlike the more common Remote Procedure Call (RPC), web services use a self-describing interface to communicate. The interface fully describes the method by which the service is accessed. The contents of a SOAP message include the service interface description and data. By using self-describing interfaces and a wire-level protocol like SOAP, heterogeneous components can communicate. For example, a C++ based module can interoperate with a JavaScript web service.
[0020] The scripting of various service processes is called orchestration or workflow. Microsoft's BizTalk Server is a well-known product that provides for the orchestration of services and XML messages. There is also work being done to provide standard specifications for how web services are orchestrated. For example, Business Process Execution Language for Web Services (BPEL4WS) is one proposed standard. There are also proposed standards to address how a web service might provide support for transactional processing. Transactions are popular in database systems, where transactions provide a method to insure that a set of operations applied to the database either succeed in their entirety or fail in their entirety, leaving the database system in the same state as prior to the start of the transaction.
[0021] Some agent frameworks support services, such as web services (JADE is one example). The World Wide Web Consortium (W3C) is working on standards for agents to understand services and the functionality they offer, with Ontology Web Language for Services (OWL-S). While the generalized interaction of agents with services may make design of distributed computing environments easier, it comes at a price in terms of increased complexity and greater security concerns.
[0022] Some risks stem from the fact that untrusted (or only partially trusted) code is often allowed to execute on a machine often without the machine's owner's explicit knowledge, as is the case with mobile agents and downloaded services. The code that executes can have a cascade effect, where it modifies behavior or code that previously ran correctly but now runs poorly. An example is the application of a software patch or update that seemly installs acceptably, but after the update, the system is left operating poorly. Because the user is often unaware of the complex processing that takes place “under the covers” on the computing device, it can be extremely difficult to undo the changes caused by running mobile code.
[0023] Other security concerns with the use of mobile code are access to sensitive information that could be inadvertently used without the user's knowledge. The concerns described above are present with non-malicious code and the security concerns are greatly heightened if the mobile code has malicious intent.
[0024] One approach to maintaining security is the use of the “container” concept, wherein code runs on a platform that prevents the code from accessing other resources (software, hardware, etc.) of the platform other than through well-defined and controlled openings in the container. Examples are the Java Virtual Machine (JVM), the Java 2 Enterprise Edition (J2EE) Servlet Specification, and the Globus Toolkit. These typically require a developer to provide a significant amount of code to achieve the level of control and manageability required by automated applications.
[0025] What is needed is a system that can efficiently and securely manage service and agent interaction in a controlled environment.
SUMMARY AND OBJECTS OF THE INVENTION
[0026] The invention presented herein relates to a system and method in which the interaction between service components and agents that will make use of the service's computer processing are managed and controlled in a cell construct. The cells discover published services and load those services into the cells for later use by agents, or just make them available and load them as needed. By providing discrete processing, applications and other processes can match and negotiate for available services from those provided that best meet their application requirements and computing needs.
[0027] A service can be loaded into a cell by locating executable program code from a published service description and physically transferring the executable program code to the computer device or distributed devices operating the cell. Applications that deploy agents, as well as agents themselves, find services by looking up the services that a cell has published and made available. If an agent wants to use a service, then the agent makes a request to the cell providing the service and asks to be loaded, run and hooked up to the desired service. Agents can be loaded into the cell in the same manner as services, except the executable program code location might be contained in the agent's service request. If the cell accepts the agent's request, the agent is loaded and the service made available.
[0028] To provide a secure environment for the execution of service processes by agents, the cell does not provide a direct hook up between services and agents, but rather acts as a secure service interface to ensure that malicious or poorly performing services or agents do not harm the system or systems providing the environment. If the operations of a service or agent are found to cause system harm or instability, the cell can apply to a journal that captures all service and agent operations and return the system to a previous stable state.
[0029] A cell can act as a transaction manager for services that support transaction processing when agents choose to access those services using transaction support. Transactions allow a group of agent tasks to be executed as a single entity under control of the cell's transaction manager and either succeed or fail depending on the success or failure of all tasks in the group.
[0030] In some variations, cells form communities of cells. In some variations, cells can vote on which cell to first try a service or service upgrade (e.g., patch, new functionality) and monitor the results, thereby minimizing possible negative results on other cells.
[0031] The invention further provides for the operation of cell systems that exist behind firewalls. A bridging mechanism that uses a shared computer outside the firewall is polled by the cell system and messages, and possibly code, is forwarded to the correct cell or group of cells.
[0032] A further understanding of the nature and the advantages of the inventions disclosed herein may be realized by reference to the remaining portions of the specification and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a schematic diagram of a cell system including cells, cell service registry, agent service registry, service pool, and applications and agents according to one embodiment of the present invention.
[0034] FIG. 2 illustrates example data structures; FIG. 2A illustrates an example data structure representing a cell service description and FIG. 2B illustrates an example data structure representing an agent service description.
[0035] FIG. 3 is a schematic diagram of a proxy agent and the communication channels between the proxy agent and a cell based agent and service.
[0036] FIG. 4 illustrates an example data structure representing an agent invoke service description.
[0037] FIG. 5 is a schematic diagram illustrating a cell system and relationships between a system, cell, services, and agents.
[0038] FIG. 6 is a schematic diagram illustrating cell communication from behind firewalls.
[0039] FIG. 7 is a flow chart illustrating a cell start up process including loading services.
[0040] FIG. 8 is a flow chart illustrating a process of migration and using agents; FIG. 8 comprises FIGS. 8A and 8B ; FIG. 8A shows steps of an agent requesting to be migrated to a cell and creation of a proxy agent; FIG. 8B shows steps of the agent using a service by processing tasks.
[0041] FIG. 9 illustrates an example data structure representing a cell-to-cell interprocess communication description.
[0042] FIG. 10 is a block diagram illustrating an agent's use of a group of services by processing tasks under control of the cell's transaction processing manager.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] The present invention will be described using the diagrams contained herein. The diagrams provide an illustration of the process flow, and possible embodiments, but should not be taken to be the extent and entirety of this invention.
[0044] Those skilled in the art will recognize that the present invention may be practiced in networked computing environments comprising many types of devices including personal computers, personal digital assistants, mobile phones, mini computers, main frames, dedicated embedded devices, and so on. The invention also may be practiced on a standalone computer device that has not been networked. The invention does not target a particular operating system or programming language. The invention could be implemented using C++, C#, Java and/or other programming languages.
[0045] As used herein, a cell is a structure that containerizes agents and service interactions with those agents. Typically, a cell executes in a platform of one or more computers and/or computing devices, wherein the cell is executed and controlled by the entity that controls the platform. A cell provides a computing boundary and that boundary can encompass one computing device, one portion or division of a computing device, or span multiple computing devices, such as a networked computer system, cluster, RAID, etc.
[0046] As an example, a home PC owner might have one or more cells running on their local PC. While not required, it can be assumed that the entity (the PC owner, in this example) that controls the platform does not fully trust the agents that might be executed within the cell and might not trust services that are provided by the cell to those agents. A cell can provide a set of constraints pertaining to a service or group of services, to be made available to an agent or a group of agents.
[0047] Constraints can be of one or more form, where generally constraints are provided to protect the equipment, operation and/or interests of the entity owning or controlling the platform and/or data and/or code with which a cell would operate. For example, a set of cells might be set up to perform actions deemed desirable by users of a network or computing devices coupled to the network and the entity operating or controlling the network (the network operator) could desire constraints that prevent users from accessing others' data without permission, from inadvertently or intentionally setting something in motion to interfere with the operation of the network, etc.
[0048] Examples of constraints include constraints that involve physical attributes of a computing device, such as memory, whereby the cell prevents services or agents from executing if the agent or service is found to require more memory than is available. Constraints could also involve communication with other cells. A service or agent deemed harmful could be flagged such that the cell (and other cells receiving input from the cell) would not load or execute the harmful service or agent. Cells can be physically based on some particular hardware or virtually situated and span multiple physical devices.
[0049] Cell System
[0050] FIG. 1 illustrates an environment in which a cell system might operate. A cell system 5 is shown as a box and it should be understood that various systems and components operate on a physical system, such as a computer having a processor, memory, I/O, networking interfaces, etc. However, as much of the present invention can operate on conventional hardware, some details of the underlying execution hardware are omitted here for clarity as the details of the present invention.
[0051] As shown in FIG. 1 , a cell system might comprise cell service provider-publishers and/or their corresponding computing systems, a cell service registry, cells, reporting systems, agent repositories, agent finders, agent service registries, a transaction manager and other components described herein. Each of these components might comprise software, firmware, logic and/or instructions running or stored on hardware devices (not all of which are explicitly shown herein) as needed to allow for the execution, storage, recall, etc. of such components.
[0052] A cell system 5 is shown in FIG. 1 comprising a provider-publisher 10 of cell services (or apparatus for providing and/or publishing), a cell service registry 16 , executable code for various services (shown as code 14 A- 14 C in the figure), a service finder 24 , and a cell 12 . The provider-publisher 10 makes services available by making an entry in cell service registry 16 that describes the service. Provider-publisher 10 could be a person or an automated process.
[0053] FIG. 2A illustrates an example data structure representing a cell service description, as might appear in cell service registry 16 . The entries each describe a service and contain a pointer to the actual service code 14 A- 14 C that will be executed by an agent described herein. The service code may or may not be contained in the cell service registry 16 . There can be any number of service entries in the cell service registry 16 and service code available. Each provider-publisher 10 preferably maintains the code pointed to in the service descriptions provided-published by it (shown in FIG. 2A ) and is responsible for publishing the availability of the services by making an entry into cell service registry 16 . The service description entries could exist in a number of computer systems. For example, the entries could exist in a local database 18 , in a database available over a network such as the Internet 22 or, in a simple case, as files in a locally available file system 20 .
[0054] Service finder 24 can locate the service descriptions in cell service registry 16 and load them into cell 12 . Service finder 24 can locate cell service registry 16 (or multiple service registries called out as 16 A and 16 B in FIG. 1 ) by using a multicast network request for the entries contained in the registry or by having the cell service registry 16 locations previously configured. For example, if the entries exist in a locally available file system 20 , then the path to a directory holding the service entries could be previously configured for use by the service finder 24 . The path might be a directory “C:/My Documents/Services” with files therein for each service description. Service finder 24 might periodically query cell service registry 16 to locate new service descriptions.
[0055] Service finder 24 can load all the service descriptions it finds in the service registry 16 into the cell system 5 . The loading could be done by making the service descriptions available in process memory of cell 12 or by making entries into a persistent storage area accessible to cell processes. Service finder 24 may exclude some services based on information contained in the service descriptions. For example, if the cell is executing on a computer device that does not match a service description's preferred environment values, service finder 24 might skip that service and not load its service description. Service finder 24 might also be aware of previous bad or poor performance of a service and skip loading it on that basis.
[0056] Services that are not programmed to run in a cell environment, or otherwise not meeting cell service interface requirements of the given cell environment can be run in the given cell environment using a service wrapper. A service wrapper provides, among possibly other features, a programming interface that acts as a front end to the otherwise noncompliant service. This is useful for supporting legacy services in a cell environment. The service wrapper might itself have an entry in cell service registry 16 .
[0057] Cell 12 executes on a computing platform (not shown) and is either controlled by the entity that owns or controls the computing platform or cell 12 executes in such a way that the computing platform is protected against actions of the cell. Cell 12 is shown in FIG. 1 comprising several elements, not all of which need be present in all implementations and cells might contain other elements not shown or described herein.
[0058] Cell 12 is shown comprising a service finder 24 , a service grabber 26 , instantiated services 28 , a service publishing object 32 , and agent service request handler 48 , an agent grabber 50 , instantiated agents 52 , a proxy interface 54 over which instantiated services 28 and instantiated agents 52 interface, and an inter-cell communication object 86 .
[0059] If a service is acceptable to cell finder 24 based on the values contained in the service description or previous knowledge of a service's performance, service publishing object 32 makes an agent service description entry into an agent service registry 34 . An example of the agent service description structure is shown in FIG. 2B . Service publishing object 32 can be implemented to parallel the manner that provider-publisher 10 publishes service availability to cell system 5 . Agent service registry 34 might be constructed from one or more of: a local database 36 , a remote database 38 accessed over a network such as the Internet, or storage on a local network 40 .
[0060] An application 42 (it should be understood that the term application may include agents in their own right, unless otherwise indicated) uses an agent service finder 44 to locate within agent service registry 34 a service or group of services that may satisfy an agent's goal or task. Agent service finder 44 could be embedded in application 42 itself or be provided as module for inclusion in application 42 . Agent service finder 44 , like service finder 24 , may use a multicast network request for the entries contained in agent service registry 34 or by having agent service registry 34 locations previously configured.
[0061] If an appropriate service is discovered (in this example, suppose cell 12 published service availability, then application 42 will make an agent service request to agent service request handler 48 requesting that a specified agent be loaded into cell 12 . Cell 12 can accept or deny the agent service request. If the agent service request is accepted, that fact is communicated to service grabber 26 and agent grabber 50 .
[0062] The service grabber 26 uses the information gathered by service finder 24 and fetches the executable code pointed to by the service descriptions, possibly by moving the code into the cell and instantiating one or more service 28 . Service grabber 26 might operate as a service negotiator. A service may be found acceptable to cell 12 through the values presented in the service description or by instantiating the service and negotiating with the service for loading into cell 12 .
[0063] In a particular embodiment, the executable code is not run immediately and is only instantiated when an agent requests to use the service, but this default can be overridden in that embodiment. An attribute in the service description can override the default implementation by including a flag that indicates that the service is to be pre-loaded when the service is requested, rather than waiting for an agent to actually need the service. Once a service is instantiated, it is ready for use by instantiated agents.
[0064] Agent grabber 50 grabs the accepted agent by moving the accepted agent's executable code 30 A from its location described in an agent invoke service description, such as that shown in FIG. 4 . Agent grabber 50 then instantiates the agent as instantiated agent 52 .
[0065] An instantiated agent 52 is preferably not hooked up directly to instantiated services 28 , but rather through the protective interface of proxy interface 54 . Using proxy interface 54 , an instantiated agent operates as if it is communicating with the requested instantiated services 28 directly, but the instantiated agent is actually communicating with the cell's proxy interface, which forwards requests and responses between the instantiated agent and the instantiated service. This allows for easier tracking and journaling, as explained below. It also allows for greater control over the environment.
Details of Selected Operations
[0066] FIG. 3 illustrates an operation of an application 342 in making a request 310 to a cell 300 to fetch/run an agent 308 . FIG. 4 illustrates one example of an agent invoke service description that is sent to cell 300 , either using a multicast network request sent to a group of cells or by having the cell locations previously configured. Other approaches can be used instead.
[0067] Cell 300 is shown comprising an instantiated service A 302 , an instantiated agent A 304 interfaced via a proxy interface 306 . The process of making a cell service request and the subsequent creation of a proxy agent happen within application environment 318 . Application 342 could have all the required processes to accomplish this task, but most likely there will be processes available to application 342 in application environment 318 to support agent service request 310 , and the creation of agent 308 and/or proxy agent 312 . It should be understood that, while only one cell, one service, one agent and one interface are shown by way of example, multiple cells, services, agents and interfaces might be present.
[0068] If agent service request 310 is accepted by cell 300 , agent 308 's code is moved into cell 300 and is instantiated as agent 304 therein. Then, proxy agent 312 is created within application environment 318 . Proxy agent 312 provides for controlled communication between instantiated agent 304 and application 342 . The communication is via an agent channel 316 . Agent channel 316 might use the globally unique identifiers (GUIDs) to maintain a point-to-point link.
[0069] Once the agent moves to cell 300 , cell 300 uses a reflection mechanism on instantiated service 302 to get a reference to the service interface and the methods offered by service 302 to agent 304 . Cell 300 uses the references acquired through reflection to provide proxy interface 306 to agent 304 . Agent 304 uses the published agent service description held in an agent service registry (such as agent service registry 34 shown in FIG. 1 ) to transact with what it believes is the instantiated service 302 while in actuality it interacts with cell 300 . When the agent completes its tasks, it makes a request for termination, resulting in either disposal by cell 300 or a return to a destination accessible by the application 342 that dispatched the agent. The latter is useful where the agent obtains state during execution that was not present when agent dispatcher 314 dispatched the agent to cell 300 .
[0070] FIG. 4 illustrates an example data structure representing an agent invoke service description, as might be used in the transaction that occurs in agent service request 310 .
[0071] FIG. 5 is an illustration of a system stack 500 illustrating the relationships between the various modules, including a cell 510 , an agent 512 , a service object 514 , a physical/protocol layer 516 and a system application programming interface (API) 518 . Cell 510 contains agent 512 and service object 514 and, at a lower level, includes physical and protocol modules 516 . Where all modules have access to API 518 and both agents and services are migrated to the cell from possibly untrusted sources and run within the cell, security is a key concern.
[0072] To protect the cell (and its execution hardware, data, environment, etc.), various security steps can be taken. For example, the cell might require verified digital signatures for both services and agents before allowing them to execute. If the system supports a low level API to monitor system functions, it may provide for greater control and security. Communications channels within the cell system can use a standards-based encryption mechanism, such as Secure Socket Layer (SSL), to ensure that the contents of communications remain secure.
[0073] Communication between cell systems (such as cell system 5 shown in FIG. 1 ) located on a local network can be done using both unicast (point-to-point delivery) and broadcast network packet delivery, where network packets are sent to all computing devices on a network interested in receiving the broadcast. Referring back to FIG. 1 , service finder 24 , service publishing object 32 , agent service finder 44 and the inter-cell communication channel 86 (described further below) might each use broadcasts or multicast to communicate between cell systems, while service grabber 26 , agent grabber 50 and agent service request handler 48 might use unicast packet delivery methods. The agent channel 216 shown in FIG. 2 for providing communication between instantiated agents and proxy agents might also use unicast packet delivery methods.
[0074] Where cell systems are separated by firewalls, a bridge server might be needed to handle inter-system communications. FIG. 6 shows a bridge server 602 used to connect a local network 610 A behind a firewall 613 A to a local network 610 B behind a firewall 613 B over a network such as Internet 614 . Cell 612 A and cell 612 B use bridges 618 A and 618 B, which are configured to know the network location of bridge server 602 (such as its IP address). Bridges 618 periodically check with bridge server 602 and retrieve or deliver packets between cell module sets 620 A and 620 B. Cell module sets 620 A and 620 B and their modules need not be aware that they are communicating across a firewall.
Cell System Process Flow
[0075] FIG. 7 is a flow chart illustrating a cell start up process including loading services. As shown there, a cell hosted on a computing device starts running (step 710 ) either through an automatic startup mechanism such as UNIX System V (SYSV) initialization or through various other startup processes, including being started manually. At startup, the cell might load previously active services ( 712 ). These previously active services might be loaded from a persistent store or from locations determined using a service finder, such as service finder 24 shown in FIG. 1 . Using a service finder, a cell can locate published services not already active in the cell.
[0076] If a service cannot be loaded for any reason, a log entry is made to that effect ( 714 ). If the service is loaded successfully into the cell, then the cell publishes availability of the service for use by agents ( 716 ). The cell then checks for termination requests ( 718 ), terminating if a request is made, otherwise looping back to step 712 , looking for newly published services that the cell can load.
[0077] FIG. 8 is a flow chart illustrating a process of migration and using agents. FIG. 8 comprises FIGS. 8A and 8B ; FIG. 8A shows steps of an agent requesting to be migrated to a cell and creation of a proxy agent; FIG. 8B shows steps of the agent using a service by processing tasks. Based on a defined goal or task, an application will locate a service that offers results that may satisfy the application's goal or task.
[0078] According to the steps shown in FIG. 8A , once a service has been found in a particular cell, the application makes a request to that cell to load and run an agent ( 810 ) for that application (or the agent itself when the agent is acting as the application). The cell then decides whether to load the agent ( 812 ). If the cell declines, because the cell is too busy, the cell does not trust the agent, the cell cannot support the agent's needs, or for other various reasons, the cell responds to the request with an indication of why the cell will not accept the agent ( 814 ) and the cell returns to processing and/or waiting for further service requests (loping back to step 810 ).
[0079] Once an agent is loaded and running within a cell ( 818 ), the agent can invoke service methods provided by services hosted by the cell to satisfy the agent's goal or task ( 824 ). The cell checks if the task completes successfully ( 826 ) and if not, returns status to the proxy agent ( 828 ), otherwise the cell and returns a result set to the proxy agent ( 830 ). In either case, processing continues at step 832 .
[0080] In step 832 , the cell determines whether more service tasks need to be run. If yes, the process loops back to step 824 , otherwise processing continues with step 834 , wherein return status is provided to the proxy agent. The agent will loop through all tasks that may be satisfied by the services provided within the cell. If there are no more tasks to be run, a status message is returned to the proxy agent and the agent will ether request to be moved to another cell or will shut itself down ( 836 ).
[0081] The cell will continue running until it is shut down ( 838 ).
Inter-Cell Communication
[0082] Inter-cell communication object 86 (shown in FIG. 1 ) can be used to for traffic between cells and between computing devices. Cells can broker the initial loading and instantiation of services and move services to more appropriate devices or environments using object 86 to coordinate such transfers. Object 86 can also provide for encrypted communications if requested by cell 12 .
[0083] FIG. 9 illustrates an example data structure representing a cell-to-cell interprocess communication description.
Journaling
[0084] A journal-reporting system 88 (shown in FIG. 1 ) can be implemented to maintain the state of a cell, provide cell monitoring capabilities to external management processes, and facilitate roll-back if a service or agent corrupts a cell. System 88 might also support a costing/billing capability, where costs and benefits of running services and/or agents are allocated among service providers and agents. Information in a persistent storage area such as might be maintained within journal-reporting system 88 to provide service costing information as reflected in a monetary amount, possibly as reflected in computing device performance metrics. Information in the persistent storage area might also provide a reputation system wherein applications and agents can rate the level of satisfaction had using a service.
[0085] Referring to FIG. 10 , and expanding on journal-reporting system 88 , suppose an agent 952 A desires to use services 928 A, 928 B and 928 C under the control of a transaction manager 990 . Suppose further that agent 952 A also wants to access a service 914 outside of transaction control.
[0086] Before any tasks between the step denoted in 952 A as “Begin Transaction” and the step denoted “End Transaction” are run, transaction manager 990 notifies each service that will be involved in the transaction that they should prepare themselves to run under transaction control. In the case of the example shown in FIG. 10 , the tasks A, B and C of Agent A ( 952 A) require service A 928 A, service B 928 B and service C 928 C, so each service is notified by transaction manager 990 to prepares themselves for the processing that will follow up until a commit or abort notification is sent from transaction manager 990 ending the transaction. The initial preparation often entails making sure the initial state of the service is preserved, as the service may be called on to roll back to this initial state if any service involved in the transaction fails and transaction manager 990 sends an abort and rollback notification to the services involved in the transaction.
[0087] If any service 928 A, 928 B or 928 C is not able to satisfy the agent's request, then the service should update journal-reporting system 88 with information about the failure and transaction manager 990 should notify all services 928 A, 928 B and 928 C that they should roll back their processing as described above. Services that will be involved in transaction need to be designed for transaction support and able to respond appropriately to the messages sent by the transaction manager. In particular, messages might include: 1) prepare for running under transaction support, 2) abort and roll-back to initial service state, 3) commit the state at the end of the transaction.
[0088] Transactional support becomes more complicated when a service involved in a transaction is dependent on the results of another service, as a potential dead lock could occur. One solution is to run the agent task using a proxy interface (such as proxy interface 54 shown in FIG. 1 ) but not immediately return the service results to the agent. Instead, the results are cached within the proxy interface and only at the end of all transaction processing the results are returned to the agent.
[0089] Using the teachings described herein, a cell system can be used to connect up agents and services in a controlled manner, even if the entity controlling a cell system cannot fully trust the providers of agents and services. Using a cell system with services being loaded into the cell and used by agents, an application can be built. Using the cell system, not only can applications be built, but a platform such as an entire an operating system could be built. Furthermore, the platform could be distributed and the services and agents within the cells could offer discrete operations. For example, one cell could offer security on a particular physical platform while another cell may offer network storage.
[0090] As described above, a computing device instantiates a cell, then that cell loads services according to criteria and conditions under which that cell is willing to operate. The cell then advertises the services it has loaded or is willing to load. Agents find cells advertising services that the agents need and send agent load requests to those cells. The cells consider agent load requests and load approved agents. The instantiated agents in a cell interact with the instantiated services in the cell via a sell proxy interface. A journaling system can be provided for tracking, auditing and supporting transaction processing and rollbacks. Intercell system communications might also be provided.
[0091] The above description is illustrative and not restrictive. Many variations of the invention will become apparent to those of skill in the art upon review of this disclosure. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents. | System and method for using cells as a type of managed container to control the operation of mobile software agents and the run-time invocation and use of services within distributed computing environments. The cell process initially starts out empty containing nether agents nor services. The cell discovers and loads published services at run-time through a look up into a distributed service registry. After loading the service, the cell then publishes availability of the service for use by agents. If an application using agents or an agent desires to make use of a service published and provided by a cell, the application or agent makes a request to the cell to fetch an agent that will invoke the service. Prior to migrating to its new cell, the agent creates a proxy agent that provides a communication channel between the agent running within the cell and the originating agent system. Service status and results are returned through the proxy channel. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to power adaptors and, more particularly, to programmable power adaptors.
[0003] 2. Related Art
[0004] Power adaptors are used to provide electrical power to, and/or charge batteries for, a variety of portable electronic devices, such as computers, mobile telephones, handheld personal digital assistants (“PDAs”), smartphones, MP3 players, DVD players, and the like.
[0005] Different portable electronic devices often have different electrical requirements. Different portable electronic devices also typically have physically distinct electrical input ports. As a result, conventional power adaptors are generally designed for particular electronic devices. Although some conventional power adaptors are designed to be interchangeable with multiple electronic devices, conventional power adaptors lack programmability and configurability. Thus, what is needed is a programmable power adaptor.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to methods and systems for programmable power adaptors that can be programmed to adapt electrical power for one or more electronic devices. A programmable power adaptor optionally includes a user interface and/or other user input mechanism(s), which allows users to preset voltage requirements for one or more electronic devices. The pre-settings are stored in memory for future use. The programmable power adaptor is optionally configurable for multiple electronic devices, and/or multiple users. The programmable power adaptor optionally informs users of faults, proper device usage, and/or provides database access.
[0007] Additional features and advantages of the invention will be set forth in the description that follows. Yet further features and advantages will be apparent to a person skilled in the art based on the description set forth herein or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0008] It is to be understood that both the foregoing summary and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0009] The present invention will be described with reference to the accompanying drawings, wherein like reference numbers indicate identical or functionally similar elements. Also, the leftmost digit(s) of the reference numbers identify the drawings in which the associated elements are first introduced.
[0010] FIG. 1 is a block diagram of an example programmable power adaptor 100 .
[0011] FIG. 2 is an example screen display 200 for a user interface 108 for the programmable power adaptor 100 .
[0012] FIG. 3 is an example pop-up display associated with the example screen display 200 .
[0013] FIG. 4 is another example screen display for the user interface 108 .
[0014] FIG. 5 is another example screen display for the user interface 108 .
[0015] FIG. 6 is a front plan view of an example external package design for the programmable power adaptor 100 .
[0016] FIG. 7 is a rear plan view of another example external package design for the programmable power adaptor 100 .
[0017] FIG. 8 is another rear plan view of another external package design for the programmable power adaptor 100 .
DETAILED DESCRIPTION OF THE INVENTION
[0000] I. Programmable Power Adapting
[0018] FIG. 1 is a block diagram of an example programmable power adaptor 100 . The programmable power adaptor 100 includes an input port 102 , for receiving electrical power from an electrical source, such as an electrical wall outlet or an automobile electrical outlet. The electrical source can be an alternating current (“AC”) electrical source and/or a direct current (“DC”) electrical source.
[0019] The programmable power adaptor 100 further includes one or more output ports 104 , which provide electrical power (typically DC) to one or more portable electronic devices 110 .
[0020] The portable electronic devices 110 can be one or more of a variety of types of portable electronic devices. For example, and without limitation, the portable electronic devices 110 can include computers, mobile telephones, handheld personal digital assistants (“PDAs”), smartphones, MP3 players, and DVD players.
[0021] Different portable electronic devices 110 often have physically different electrical input ports 118 . The programmable power adaptor 100 thus optionally includes one or more interchangeable tips 116 that are removably coupled to the one or more output ports 104 , or removably coupled to one or more cables that extend from the one or more output ports 104 . The interchangeable tips 116 allow the programmable power adaptor 100 to be coupled to one or more of a variety of different portable devices 110 .
[0022] During a configuration mode, a user associates a selected portable device 110 with a corresponding set of power supply characteristics. In an embodiment, the association is made by selecting a tip 116 that fits into the input port 118 of the portable device 110 , and by fixing the tip to the output port 104 . The selected tip is then associated in memory with electrical supply characteristics of the electronic device 110 . This is referred to hereinafter as device configuration information. Device configuration information is optionally stored in a database and/or in one or more look-up tables.
[0023] During the configuration mode, the programmable power adaptor 100 identifies the installed tip 116 in one or more of a variety of ways. For example, the programmable power adaptor 100 optionally senses one or more characteristics of the installed tip 116 , and/or receives feedback information from the installed tip 116 . Alternatively, or additionally, the user identifies an installed tip 116 through the user interface 108 .
[0024] During the configuration mode, the user can provide a variety of types of information to the programmable power adaptor 100 . For example, and without limitation, the user identifies the portable device 110 by manufacturer, make, and/or model number. The programmable controller 106 obtains the power requirements for the portable device 110 automatically and/or through manual user input. For example, and without limitation, the programmable power adaptor 100 retrieves the power requirements for the portable device 110 from a look-up table or from a database, which can be internal or external of the programmable power adaptor 100 . As described below, the programmable power adaptor 100 is optionally configured to update the look-up table and/or database through an external port. Alternatively, or additionally, the user manually selects input power characteristics for the portable computer.
[0025] During normal operation, when the tip 116 is installed, the programmable power adaptor 100 retrieves the associated electrical supply characteristics from memory and converts power accordingly. As with the configuration mode, the programmable power adaptor 100 identifies the installed tip 116 automatically and/or through user interface 108 .
[0026] For example, where the portable device 110 is a portable computer, the user selects an appropriate tip 116 for the portable computer, fixes the tip 116 to the output port 104 , and, through menu selections presented on the user interface 108 , the user provides information to the programmable controller that will allow the programmable controller 110 to associate the selected tip 116 with electrical supply needs of the portable computer.
[0027] The programmable power adaptor 100 optionally informs users of faults, proper device usage, and/or provides database access.
[0028] In the example of FIG. 1 , the programmable power adaptor 100 further includes a programmable controller 106 , a user interface 108 , and memory 120 , which are described below.
[0000] II. Programmable Controller
[0029] The programmable controller 106 allows users to configure the programmable power adaptor 100 to power one or more of a variety of portable electronic devices 110 . The programmable controller 106 is optionally fabricated as an application specific integrated circuit (“ASIC”), which is optionally implemented in planar transformer technology. The programmable controller 106 is optionally fabricated with both memory 120 and power conversion circuitry. Alternatively, memory 120 and/or power conversion circuitry, or portions thereof, are provided with other circuitry.
[0030] The programmable controller 106 converts the one or more electrical inputs 102 into one or more of a variety of outputs. For example, and without limitation, the programmable controller 106 is designed to convert a 110 volt AC source to a DC voltage in the range of up to 24 VDC. Alternatively, or additionally, the programmable controller 106 is designed to convert a DC source, such a 12 volt DC source (e.g., from an automobile), to one or more of the output DC voltages above. The invention is not, however, limited to the example voltages above. Based on the description herein, one skilled in the relevant art(s) will understand that invention can be designed for other voltages voltages.
[0000] III. User Interface
[0031] The programmable power adaptor 100 is configured, at least in part, by user commands entered through the user interface 108 . The user interface 108 is optionally a graphical user interface (“GUI”), such as a liquid crystal display (“LCD”). FIGS. 2-5 , which are described below, are example graphical user interface displays for the user interface 108 . Configuration and operation of the programmable power adaptor 100 is described below with reference to FIGS. 2-5 . The invention is not, however, limited to the examples of FIGS. 2-5 . Based on the description herein, one skilled in the relevant art(s) will understand that the invention can be implemented with other user interfaces.
[0000] IV. Configuration
[0032] During a configuration mode, a user configures the programmable power adaptor 100 by identifying a desired portable electronic device for configuration.
[0033] FIG. 2 is an example display 200 for the user interface 108 . The display 200 includes selectable icons for a plurality of device types. In the example of FIG. 2 , the example icons include a Laptop icon 202 , a Cell Phone icon 204 , a PDA icon 206 , and an “Other Devices” icon 208 . The user can select from any of these categories to configure a desired component. The example display 200 also includes a selectable memory icon 210 , which is described below.
[0034] The icons are activated or selected in one or more of a variety of ways. For example, where the user interface 108 includes a touch screen, icons are selected by touching the screen over a desired icon, by finger and/or by wand. Alternatively, or additionally, icons are selected by way of left and right and/or up and down arrow keys.
[0035] When the user selects a desired category from display 200 , one or more subsequent display screens and/or pop-up screens are presented to allow the user to select a particular device within the desired category.
[0036] For example, referring to FIG. 3 , when the user selects the Laptop icon 202 from display 200 , a pop-up display 300 is presented. Pop-up display 300 provides a list of laptop computers. In an embodiment, when a device is listed within the pop-up window 300 , electrical requirements of the device are currently stored within the memory 120 . The device is thus referred to as a supported device.
[0037] Electrical requirements for devices can be loaded into memory 120 during manufacturing. Alternatively, or additionally, electrical requirements for devices are updated periodically, such as through an internet connection. Alternatively, or additionally, electrical requirements for devices are input manually through the user interface 108 .
[0038] In the example of FIG. 3 , a Compaq Evo n800c laptop computer is highlighted in the pop-up display 300 . A box 302 within the pop-up display 300 indicates that a tip A 1 is currently coupled to the output port 104 as tip 116 ( FIG. 1 ). As described above, the programmable power adaptor 100 identifies the installed tip 116 in one or more of a variety of ways. For example, the programmable power adaptor 100 optionally senses one or more characteristics of the installed tip 116 , and/or receives feedback information from the installed tip 116 . Alternatively, or additionally, the user identifies an installed tip 116 , through the user interface 108 , as being the desired tip.
[0039] When the desired device is highlighted in pop-up display 300 , and when the proper tip is indicated in the box 302 , the user saves the configuration by selecting the “save” box 304 . The configuration is then saved in memory 120 for future use.
[0040] The programmable power adaptor 100 is optionally configurable for multiple devices and/or for multiple users.
[0041] Referring back to FIG. 2 , users can view information that is currently stored in memory 120 by selecting the memory icon 210 .
[0000] V. Operation
[0042] During normal operation, the programmable power adaptor 100 provides electrical power to one or more electrical devices 110 . The programmable power adaptor 100 adapts the electrical input 102 to one or more electrical devices 110 , based on each devices' characteristics. The programmable power adaptor 100 optionally senses the presence of one or more installed tips 116 , as described above, and automatically retrieves the electrical requirements that were associated with the tip(s) from memory 120 . The programmable power adaptor 100 then converts electrical input power 102 according to the retrieved electrical requirements.
[0043] During normal operation, the programmable power adaptor 100 optionally provides operational information through the display 108 . For example, and without limitation, FIGS. 4 and 5 are example screen displays for the user interface 108 during operation. The example screen displays of FIG. 4 and/or FIG. 5 are optionally displayed during normal operation, while a tip A 1 is coupled to the programmable power adaptor 100 .
[0044] In the examples of FIGS. 4 and 5 , a display box 400 indicates that the tip A 1 is associated in memory 120 with a Compaq evo laptop computer, model number n 800c. In FIG. 4 , a connection box 402 indicates that the tip A 1 is coupled to the laptop computer. In FIG. 5 , the connection box 402 indicates that the tip A 1 is not coupled to the laptop computer.
[0045] Where multiple portable devices 110 are powered by the programmable power adaptor 100 simultaneously, additional corresponding widows are optionally displayed on the user interface 108 .
[0000] VI. Uploadable Web-Based Database
[0046] The programmable power adaptor 100 optionally updates memory 120 (e.g., database and/or look-up tables) by accessing one or more internet sites or other external database(s). The internet site(s) are optionally dedicated to users of the programmable power adaptor 100 . Alternatively, or additionally, the internet site(s) are associated with one or more manufacturers of the portable device(s) 110 .
[0047] Accordingly, referring back to FIG. 1 , the programmable power adaptor 100 optionally includes a data port 112 , coupled to the programmable controller 106 and/or to the user interface 108 . The optional data port 112 can be coupled to an internet service provider. The data port 112 can be, for example, a mini universal serial bus (“USB”) port that allows the programmable power adaptor 100 to couple to a computer that is coupled to the internet. Alternativley, and/or additionally, the data port 112 is a wireless port that allows the programmable power adaptor 100 to couple wirelessly to the internet. The invention is not, however, limited to USB or wireless ports. Based on the description herein, one skilled in the relevant art(s) will understand that a variety of types of connections are contemplated.
[0000] VII. Battery
[0048] The programmable power adaptor 100 optionally includes an integral and/or externally mounted battery system 114 that, when charged, provides at least temporary back-up power for the user interface 108 and memory 120 , thus allowing active interface activity without input power at input terminal 102 . The optional battery 114 is charged during normal operation of the programmable power adaptor 100 .
[0049] The battery 114 is optionally designed to temporarily provide electrical power to portable electronic device(s) 110 to allow a controlled power down of the portable electronic device(s) 110 .
[0000] VIII. Example Design Packages
[0050] The programmable power adaptor 100 can be implemented in one or more of a variety of packages. FIG. 6 is a front plan view of an example external package design for the programmable power adaptor 100 . FIG. 7 is a rear plan view of another example external package design for the programmable power adaptor 100 . FIG. 8 is another rear plan view of another external package design for the programmable power adaptor 100 . The invention is not, however, limited to the example design packages illustrated in FIGS. 6, 7 , and 8 . Based on the description herein, one skilled in the relevant art(s) will understand that the programmable power adaptor 100 can be implemented in other design packages.
IX. CONCLUSION
[0051] The present invention has been described above with the aid of functional building blocks illustrating the performance of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Any such alternate boundaries are thus within the scope and spirit of the claimed invention. One skilled in the art will recognize that these functional building blocks can be implemented by discrete components, application specific integrated circuits, processors executing appropriate software and the like and combinations thereof.
[0052] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | Methods and systems for programmable power adaptors that can be programmed to adapt electrical power for one or more electronic devices. A programmable power adaptor optionally includes a user interface and/or other user input mechanism(s), which allows users to preset voltage requirements for one or more electronic devices. The pre-settings are stored in memory for future use. The programmable power adaptor is optionally configurable for multiple electronic devices, and/or multiple users. The programmable power adaptor optionally informs users of faults, proper device usage, and/or provides database access. | 8 |
BACKGROUND OF THE INVENTION
This invention relates generally to television high voltage systems and particularly to shutdown circuits used therein.
In a typical color television receiver scansion and display system, a cathode ray tube (CRT) display device includes a trio of electron beam sources which are directed at a tri-color phosphor viewing screen. Horizontal and vertical scansion circuitry within the receiver locally generate scansion signals which are synchronized to reference information within the received signal. The scansion signals are applied to an electromagnetic deflection yoke positioned on the envelope of the CRT producing vertical and horizontal scansion of the viewing screen. The cathode ray tube requires a number of operating potentials the highest of which is an accelerating potential of approximately 25 to 30 kilovolts which is generally referred to as the high voltage. This potential is applied to an electrode within the CRT to accelerate the electrons within the directed beams to an energy level sufficient to cause light emission by impacted phosphor areas and illumination of the viewing screen.
In the great majority of television receivers the horizontal scansion system produces this high voltage in addition to the horizontal scansion signals. Horizontal scansion includes a relatively slow scan deflection of the electron beams followed by a relatively fast retrace deflection in which the beams are deflected back to the "start" of scan position. The scansion signal producing this retrace comprises a short duration high amplitude pulse which is also used to generate CRT high voltage. Most receivers use a tertiary winding on the horizontal transformer together with a rectifier or voltage multiplier to raise the voltage to sufficient level for high voltage production. In the former system the tertiary transformer winding is rectified directly while in the latter a familiar capacitor diode matrix is used to boost the voltage and rectify.
It is generally desirable for purposes of picture sharpness, brightness and color rendition to maintain a relatively high accelerating potential. However, cathode ray tubes have a tendency to produce prohibitive amounts of radiation when excessive high voltage is used. As a result care must be taken to assure that the accelerating potential does not exceed the radiation producing threshold.
It is well known to employ high voltage shutdown circuitry which monitors the accelerating potential or some related voltage and disables or reduces the accelerating potential in the event of excess output. Such circuitry may include threshold circuitry detecting either the high voltage directly or a voltage derived such as that used for CRT focus. Another alternative is to use circuitry detecting the peak or average voltage of the retrace portion of the horizontal scansion signal which, of course, varies in a predictable relationship with CRT high voltage. In either case, the most typical operation provides complete shutdown of the high voltage system in the event of an excess.
In addition to problems of prohibitive radiation produced by excessive high voltage, cathode ray tubes are susceptible to damage by high currents in conjunction with otherwise unobjectionable accelerating potential levels. The energy with which the accelerated electrons impact the CRT parallax barrier as well as the viewing screen is determined largely by the high voltage but the total energy imparted is, of course, also dependent on the number of impacting electrons (e.g., beam current). High beam currents generate heat which if not dissipated may cause damage to the cathode ray tube itself. For example, the parallax barrier may be overheated or the viewing screen phosphors may be burned. Also excessive locallized heat within the tube may produce fracture of the CRT envelope which, of course, usually renders the tube useless.
For these and other reasons most television receivers include beam current limiting circuitry which functions to minimize or avoid prohibitively high beam current. Such circuits are nearly endless in variety but all can be said to perform the common functions of somehow detecting beam current and acting upon signal processing circuitry (which controls beam current) in a negative feedback manner. Such circuits perform satisfactorily under most conditions but frequently do not provide affirmative protection against the types of failures described above and in some cases may themselves have failure modes which result in production of excessive beam current.
The problems of overdissipation and radiation production of the cathode ray tube in modern television receivers are made more difficult by the improvements in regulation of operating supply and high voltage generating circuitry. Modern circuitry is able to sustain great overloads and still maintain high voltage output. Because these improved systems are capable of producing greater power levels they are not in any real sense "self-limiting". Therefore, while providing considerable advantages in picture quality and other performance criteria, such "stronger" high voltage supplies also have a greater capacity for causing CRT damage in the above-described failure modes.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved high voltage shutdown circuit.
It is a more particular object of the present invention to provide an improved, high voltage shutdown circuit which provides greater protection of the cathode ray tube device.
SUMMARY OF THE INVENTION
High voltage shutdown means for use in a television receiver having a cathode ray tube display device in which one or more electron beams are directed to a viewing screen, means causing the beams to scan the screen, and high voltage generating means producing an electron accelerating potential for the cathode ray tube includes high voltage detecting means producing a first error signal when the accelerating potential exceeds a predetermined voltage, beam current detecting means producing a second error signal when electron beam current exceeds a predetermined level and high voltage disabling means, coupled to the high voltage detecting means and the beam current detecting means, rendering the high voltage generating means inoperative in response to either the first or second error signals.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a partial block schematic detail representation of a color television receiver constructed in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The FIGURE shows a partial block diagram, partial schematic representation of a television receiver constructed in accordance with the present invention. A tuner 11 receives an information bearing signal incident upon antenna 10 which is converted to an intermediate frequency signal and coupled to an intermediate frequency amplifier 12 which in turn amplifies the signal to a level sufficient to drive a video detector 13. The modulation components of picture, sound and deflection synchronization information are recovered from the intermediate frequency signal by detector 13 and are applied to a luminance and chrominance processor 14 which in turn drives the cathode electrodes of a conventional tri-color CRT 20.
The output of video detector 13 is also applied to a sound processor 15, which in turn drives a speaker 16, and a sync separator 18. The latter recovers the horizontal and vertical scan synchronization (sync) pulses. Sync separator 18 also separates the horizontal and vertical scansion synchronizing pulses. The former are applied to a vertical scan system 19 which provides a vertical scansion signal driving a vertical deflection yoke 40 situated on CRT 20. The latter are applied to a horizontal sync system 31. Sync separator 18 also drives an automatic gain control (AGC) voltage generator 17 which by conventional amplitude comparison techniques produces a control voltage which is fed back to amplifier 12 and tuner 11 providing a constant output signal level at detector 13.
A horizontal oscillator 32 generates a horizontal rate scansion signal which is coupled to a horizontal output amplifier 33 raising the scan signal to a sufficient level to drive a primary winding 35 of a horizontal deflection transformer 34. The output of horizontal amplifier 33 is also coupled to a horizontal deflection yoke 41 situated on CRT 20.
Secondary winding 36 of transformer 34 is connected to a high voltage rectifier 37 and to ground through a parallel combination of a resistor 38 and a capacitor 39. The output of high voltage rectifier 37 is connected to an accelerating electrode 21 within CRT 20. High voltage transformer 34 and high voltage rectifier 37 are intended to be exemplary of conventional horizontal deflection and high voltage producing circuitry. Transformer 34 is representative of horizontal output transformers commonly used in color television receivers. High voltage rectifier 37 includes the familiar diode capacitive multiplier matrix. Accordingly, secondary winding 36 produces a driving pulse which is "multiplied" through the familiar action of rectifier 37 to produce an appropriate CRT accelerating voltage.
In the alternative, the equally familiar series rectifier may be used in which case secondary winding 36 would be altered to produce an output pulse of greater amplitude directly producing a rectified high voltage appropriate for application to CRT electrode 21. In either case the function of series resistor 38 and capacitor 39 with respect to the present invention is the same and will be discussed in detail below.
A resistive voltage divider comprising the series combination of resistors 43, 44, 45, potentiometer 47, and resistors 48, 69, 68 and 67 is connected between high voltage electrode 21 and ground. In addition a potentiometer 46 is connected in parallel with resistor 45. The voltage divider thus formed provides a source of several operating potentials for CRT 20. The movable contact of potentiometer 46 is connected to a focus electrode 38 of CRT 20 providing a variable source of focus voltage. Similarly, the movable contact of potentiometer 47 is connected to a screen grid electrode 27 of CRT 20.
CRT 20 is a unitized gun type picture tube in which individual cathode electrodes 23, 24 and 25 are connected to luminance and chrominance processor 14. A control grid electrode 26 is common to all three cathodes and is maintained at a constant potential by a voltage divider formed by resistors 29 and 30 connected between +V and ground. It should be clear that the present invention may be used with any of the presently used cathode ray tube types.
A power supply 42 is shown coupled to shutdown circuit 100 (indicated by dashed lines) and horizontal oscillator 32. For clarity power supply connections to the remaining portions of the receiver are not shown. It should be understood, however, that each of the receiver portions (shown in block form) are powered by a source of operating power in accordance with well known receiver fabrication techniques.
The output of power supply 42 is connected to horizontal oscillator 32 and to the cathode electrode of a Zener diode 57 which has its anode electrode connected to ground. Zener 57 performs the power supply regulation function by prohibiting the output voltage of supply 42 from exceeding the reverse breakdown voltage of Zener 57. Shutdown circuit 100 includes a PNP transistor 50 having an emitter electrode 51 connected to the output of power supply 42, a base electrode 52, and a collector electrode 53, and an NPN transistor 60 having an emitter electrode 61 connected to ground by a Zener diode 64, a base electrode 62 connected to collector 53, and a collector electrode 63 connected to base 52. A parallel combination of a resistor 55 and capacitor 54 couples the junction of base 52 and collector 63 to the output of power supply 42. Emitter 61 is also coupled to ground by a capacitor 65 and to the output of power supply 42 by a resistor 66. Base 62 is connected to ground by a capacitor 66 and to the movable contact of potentiometer 68.
A common base amplifier transistor 70 has an emitter electrode 71 coupled to ground by a non-polar electrolytic capacitor 74, a base electrode 72 connected to ground, and a collector electrode 73 connected to the junction of base 52 and collector 63. A resistor 56 is connected between power supply 42 and the junction of resistor 38, transformer secondary winding 36, and capacitor 39. A resistor 75 connects emitter 71 to the junction of resistors 56 and 38 and capacitor 39.
The operation of the horizontal scansion system shown (with the exception of shutdown circuit 100) is conventional in that a locally generated scansion signal produced by oscillator 32 is applied to horizontal amplifier 33 which produces a high energy horizontal scansion signal applied to yoke 41 and to the primary of the horizontal sweep transformer 34. The high amplitude retrace portion of the horizontal scansion signal is coupled to secondary 36 of transformer 34 producing a high voltage AC signal which is converted by high voltage rectifier 37 to an accelerating potential suitable to drive CRT 20.
As is well known, the high voltage system may be considered the "power source" of the CRT. As a result with the exception of certain leakage currents not of significant interest here, it can be said that the average current supplied by the high voltage system must substantially equal that of the average electron beam currents emanating from cathodes 23, 24 and 25. Because the majority of electrons directed toward viewing screen 22 are attracted to accelerating electrode 21 and return to ground through the high voltage circuitry, the current through winding 36 and resistor 38 also equals the average beam current of the CRT. As a result, the average voltage developed across resistor 38 is proportional to CRT beam average current and forms an appropriate input signal for shutdown circuit 100.
As mentioned, the voltage divider coupled between accelerating electrode 21 and ground produces focus and screen electrode voltages. As is known, each point on such a divider changes proportionately with changes in applied potential. Because the CRT accelerating potential may change due to power line variation or beam current loading it is advantageous that the sources of focus and screen electrode voltages "track" with high voltage changes to maintain optimum performance. In a similar manner to focus and screen electrode voltages, the potential at the movable contact of potentiometer 68 also changes in proportion to accelerating potential, and forms the second input signal to shutdown circuit 100.
The operation of circuit 100 is best understood if considered initially in its general function. In response to either an excessive voltage developed across resistor 38 (indicating prohibitive CRT beam currents) or an excessive voltage at the movable contact of potentiometer 68 (indicating prohibitive accelerating potential) a high current shunt path between the output of power supply 42 and ground becomes conductive. The regulation of power supply 42 is overcome and the operating supply available to oscillator 32 is substantially reduced.
In the system shown Zener diode regulation of the output voltage of power supply 42 is employed. As mentioned, such a device regulates voltage due to its avalanche or reverse breakdown characteristic. Once conducting in the reverse direction, the voltage across the Zener will not substantially exceed the breakdown potential. However, the Zener regulator shown will not prohibit reductions of power supply voltage below the breakdown voltage (the mechanism by which shutdown circuit 100 operates). For this reason it is advantageous to use such regulation in the described embodiment. It should be obvious, however, that the use of different regulator construction with corresponding regulation defeating systems can be envisioned without departing from the spirit of the present invention. Regardless of the regulator used the degree of supply reduction during shutdown is selected such that oscillator 32 ceases to produce a horizontal scansion signal which, of course, terminates the production of acceleration potential.
Once activated, the shutdown circuit "latches", that is, maintains the termination of high voltage notwithstanding changes in input signals. This characteristic is important since both accelerating potential and beam current will decrease once the horizontal oscillator is disabled. But for such circuit latching, receiver operation could be restored without removing the failure cause. Or perhaps worse the receiver would vascillate between shutdown which would reduce high voltage and beam current which in turn would turn off the shutdown circuit causing a restoration of high voltage and so on.
Turning now to the operation of circuit 100 in greater detail, the combination of PNP transistor 50 and NPN transistor 60 forms the well known two-transistor analog of a silicon controlled rectifier (SCR). Accordingly, a positive voltage at base 62 which exceeds the voltage at emitter 61 by approximately 0.6 volts causes transistor 60 to conduct. The conduction of transistor 60 produces a current flow through resistor 55 establishing a lower potential at base 52 than that of emitter 51 causing transistor 50 to conduct. The transistor pair forms a regenerative switch in that conduction of transistor 50 drives base 62 more positive causing transistor 60 to conduct heavily further increasing transistor 50 conduction. The conduction of transistors 50 and 60 essentially couples Zener 64 to the output of power supply 42. Zener 64 has a reverse breakdown substantially lower than Zener 57 and when coupled to power supply 42 by way of transistors 50 and 60, it maintains the output voltage of power supply 42 at a substantially reduced voltage. The reduced voltage is, of course, low enough to cause oscillator 32 to cease producing signals.
A similar "triggering" of the transistor pair may be induced by a reduction of the voltage at base 52 in which case transistor 50 initially conducts producing a positive voltage at base 62. Transistor 60 then turns on further reducing the voltage at base 52 and causing the regenerative switching actions described above to proceed.
Once conducting, transistors 50 and 60 remain in saturation despite changes of the voltages applied to bases 52 and 62. Only the removal of the positive voltage applied to emitter 51 will cause the transistor pair to turn off. This characteristic provides the desired latching function of the system.
As mentioned above, the voltage at the movable contact of potentiometer 68 changes in proportion to changes in acceleration potential and determines the voltage at base 62. Emitter 61 is maintained at a substantially constant potential by Zener 64, resistor 66 and capacitor 65. The use of Zener 64 in this manner permits emitter 61 to be maintained at a high enough potential to avoid false triggering by noise energy incident on base 62 or the leads coupled thereto without prohibitive reduction of the gain of transistor 60. Because voltage changes at base 62 directly alter the base-emitter voltage of transistor 60, an increase in accelerating potential sufficient to raise base 62 more than 0.6 volts with respect to emitter 61 overcomes the offset of emitter 61 and turns on transistor 60 and activates the shutdown circuitry. Capacitor 66 filters the voltage at base 62 which improves circuit immunity to "noise" and other "false" triggers.
Turning now to the operation of the shutdown circuitry in response to excessive beam currents, as mentioned above the voltage developed across resistor 38 is substantially proportional to the combined beam currents emanating from cathodes 23, 24 and 25. The negative voltage developed across resistor 38 is filtered to a DC potential by capacitors 39 and 74. Shutdown circuit 100 is intended to respond to beam current changes which exceed the desired maximum. To facilitate this selective operation a threshold is established which must be exceeded to activate the beam current responsive portion of the shutdown circuit. Accordingly, resistor 56 couples an additional current to ground through resistor 38 which opposes the negative voltage developed thereon due to beam current. The current supplied by resistor 56 is constant, that is, it does not vary as a function of beam current. However, the negative voltage developed across resistor 38 due to current in transformer winding 36 bears a direct relationship to beam current. As a result, when the combined beam currents in CRT 20 exceed a predetermined level the voltage at the junctions of resistors 38 and 56 becomes negative notwithstanding the opposing current contributed by resistor 56.
The voltage on resistor 38 is coupled via a resistor 75 to the emitter of common base transistor 70. Because base 72 is at ground potential a negative 0.6 volts at emitter 71 will cause it to conduct. The conduction of transistor 70 produces a voltage drop across resistor 55 which again turns on transistor 50, the conduction of which turns on transistor 60 producing the high current shunt path between the output power supply 42 and Zener diode 64. Capacitor 74 also slows down the operation of transistor 70 for additional rejection of noise and other sources of false triggering.
In addition to the noise and false triggering rejection achieved by the use of capacitors 66, 65 and 74 the switching action of transistors 50 and 60 are degenerated, that is, "slowed down" by the parallel combination of resistor 55 and capacitor 54. In total these safeguards provide excellent false trigger rejection. However, in the event the circuit is falsely triggered, the voltage at emitter 51 may be removed "unlatching" the shutdown circuit by simply turning off the receiver for a moment and then turning it back on.
What has been described is a novel high voltage shutdown system for use in a television receiver. The system simultaneously achieves shutdown protection for fault conditions of excessive accelerating potential and beam current using a transistor pair configured to perform in a similar manner to a silicon controlled rectifier. In addition to the advantages of silicon controlled rectifier switching characteristics, the transistor pair permits control of switching speed and may be triggered at both transistor bases yielding increased performance and flexibility.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A television receiver includes a conventional tri-color cathode ray tube display system having horizontal and vertical scansion systems. Conventional signal receiving and processing circuitry recovers picture, sound and scansion synchronizing information. A high voltage shutdown circuit is responsive to excesses of either high voltage or CRT beam current. The former being detected by a resistance divider coupled between high voltage and ground while the latter is sensed by a resistor placed in series with the secondary winding of the horizontal deflection transformer. A PNP, NPN transistor pair configured to form a switch analogous to a silicon controlled rectifier responds to detected excesses of beam current or high voltage and loads down the operating supply to the horizontal scansion oscillator to terminate high voltage generation. The transistor pair accommodates a degenerating network to reject false triggering. | 7 |
FIELD OF THE INVENTION
The present invention relates to the field of piston rings. More particularly, the invention relates to the field of materials used to manufacture piston rings for automobiles.
BACKGROUND OF THE INVENTION
Piston rings that are used in the automobile industry are commonly nitrided by subjecting the piston rings to a PVD or CVD process, for example. A nitrogen-containing compound coats and/or penetrates the surface of the piston rings. Stainless steel has long been a preferred metal for piston rings as it is highly corrosive resistant and hard. Typically, stainless steel is about 81% iron, and about 18% chromium, with other alloying elements such as carbon, and nickel.
Because stainless steel is not typically highly alloyed, there are depassivation problems associated with a nitriding process, particularly involving a gas nitriding process. Efforts have been made to overcome depassivation problems such as raising the temperatures during nitriding, and prolonging the nitriding cycle. These steps are inefficient and therefore costly, with only limited success. Furthermore, stainless steel is rather difficult to prepare for machining of the piston rings. Coiling stainless steel wire requires a great amount of effort and time.
There is therefore a great need for a piston ring that is made from a strong, corrosion resistant metal that is easily and cheaply nitrided. There is also a need for a more efficient method for manufacturing piston rings.
SUMMARY OF THE INVENTION
The present invention relater to a piston ring that is broadly defined as a ring-shaped, non-stainless steel, iron alloy, sized and formed to accommodate an engine piston. The piston ring is nitrided, and the non-stainless steel enables a nitriding process to be performed in a relatively short interval, at lower temperatures than are required for stainless steel piston rings. The nitriding is most preferably performed using an ionic nitriding process.
The alloy includes between about 1% and about 10% chromium by weight, and preferably includes between about 1% and about 2% chromium by weight. By describing the alloy as a non-stainless steel, iron alloy, it is generally meant that the majority of the alloy is iron instead of, for example, titanium, and that chromium is present at a lower concentration than in stainless steel.
In a preferred embodiment of the invention, additional alloying elements are included. The alloy can further include carbon, manganese, and silicon, for example. Most preferably, chromium is included at no greater than 2% by weight, and carbon, manganese, and silicon are included at concentrations of no greater than about 1% by weight.
The alloy preferably includes even more alloying elements. One embodiment of the invention further includes phosphorus, sulfur, molybdenum, and vanadium, each being present at no greater than about 1% by weight. Another embodiment of the invention further includes aluminum and nickel, instead of phosphorus, sulfur, molybdenum, and vanadium. The aluminum and nickel are each included at no greater than about 1% by weight.
A particular embodiment of the invention includes a non-stainless steel, iron alloy that includes chromium at about 1.4% by weight, manganese at about 1% by weight, molybdenum at about 0.9% by weight, vanadium at about 0.2% by weight, carbon at about 0.2% by weight, silicon at about 0.1% by weight, phosphorus at about 0.02% by weight, and sulfur at about 0.004% by weight. Another particular embodiment of the invention includes a non-stainless steel, iron alloy that includes chromium at about 1.8% by weight, aluminum at about 1% by weight, nickel at about 1% by weight, manganese at about 0.7% by weight, carbon at about 0.3% by weight, and silicon at about 0.3% by weight.
Additional, advantages and novel features of the invention are set forth in the description that follows or may be learned by those skilled in the art through reading these materials or practicing the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the present invention and are a part of the specification.
Together with the following description, the drawings demonstrate and explain the principles of the present invention.
FIG. 1 is a top view of a piston ring according to the present invention.
FIGS. 2 a , 2 b , and 2 c are cross-sections of segments of exemplary piston rings according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Using the drawings, the preferred embodiments of the present invention will now be explained.
FIG. 1 shows the piston ring 100 of the present invention. The ring 100 can be sized for use with any type of internal combustion piston. A cross section of a segment of the ring 100 typically reveals that the ring 100 has a height that is approximately twice its thickness, although it is entirely conceivable that the ring 100 can be dimensioned in any necessary manner. Cross sections of segments of exemplary rings 100 a , 100 b , and 100 c are shown in FIGS. 2 a , 2 b , and 2 c.
The piston ring 100 of the present invention replaces the traditional use of stainless steel with nitriding steel. The term “nitriding steel” is meant to designate a steel alloy that is more adapted to a nitriding process, or has more nitriding potential, than stainless steel. More particularly, the nitriding steel used with the piston ring 100 of present invention is an alloy that has considerably less chromium content that is present in stainless steel. Stainless steel typically has a chromium content of about 15 to 20% by weight, most often about 18% by weight. The nitriding steel used with the piston ring 100 of the present invention can have much less than 10%, and as little as about 1% chromium. Most preferably, the chromium content is between about 1% and about 2% by weight. Other elements should also be included in the steel alloy such as carbon, manganese, and silicon. Also, phosphorus, sulfur, molybdenum, vanadium, aluminum, nickel, and other elements are examples of those that are commonly used in nitriding steel, and can be combined in the alloys that are employed for the piston ring 100 of the present invention. An ideal nitriding steel has relatively high hardness, but can still be deeply nitrided.
In one preferred embodiment of the invention, a nitriding steel alloy wire is used to manufacture a piston ring 100 , and subjected to a nitriding treatment. The wire is made from a nitriding steel alloy, and the alloy is commercially available in either unshaped form or in wire form. The nitriding steel contains about 0.34% C, 1.75% Cr, 1% Al, 1% Ni, 0.7% Mn, 0.27% Si, with the balance being Fe. In Germany, the alloy is equivalent to 1.8550 steel. In France, the alloy is designated by AFNOR (French Norm Office) as ASCO 34CrAlNi7.
The nitriding steel wire is pressed into the shape of a piston ring 100 using common techniques. The corners of the ring 100 are preferably rounded as shown in FIG. 2 . The ring 100 is then subjected to a nitriding process, preferably an ionic nitriding process, in a conventional chemical deposition chamber. With nitriding steel as the substrate, the gas nitriding process can be performed at lower temperatures, and in a shorter time cycle than when the substrate is stainless steel. The ease with which a deep nitriding of the piston ring 100 is performed is increased when the piston ring 100 is made of nitriding steel. This is because the problems of depassivation sometimes associated with stainless steel are not present with the nitriding steel that is part of the invention.
In another preferred embodiment of the invention, a different nitriding steel alloy wire is used to manufacture the piston ring 100 . The wire is again made from a nitriding steel alloy, and the alloy is commercially available in either unshaped form or in wire form. If a suitable alloy is obtained in unshaped form, it is preferable that it be made into a wire or other form that will ease the shaping of the alloy into a piston ring. The nitriding steel in this preferred embodiment of the invention contains about 0.16% C, 1.37% Cr, 0.96% Mn, 0.09% Si, 0.020% P, 0.004% S, 0.934% Mo, and 0.231% V, with the balance being Fe. In France, the alloy is designated by AFNOR (French Norm Office) as ASCO 15CrMoV6. Once the piston ring 100 is formed, it is subjected to a nitriding treatment as described above.
The preceding description has been presented only to illustrate and describe the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
The preferred embodiment was chosen and described to best explain the principles of the invention and its practical application. The preceding descriptions is intended to enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims. | A piston ring is broadly defined as a ring-shaped, non-stainless steel, iron alloy that is nitrided, and includes between about 1% and about 10% chromium by weight, and preferably includes between about 1% and about 2% chromium by weight, with additional alloying elements also included. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/DE00/03321, filed Sep. 25, 2000, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a configuration for making electrical contact with an electric valve, in particular a shift or pressure regulating valve for automatic transmissions of motor vehicles. The system has an electric wiring element wherein the electric valve is equipped with contact spring elements that are arranged outside the valve housing and that, in the assembled state, act on exposed opposing contact elements of the wiring element under spring pressure.
In automatic transmissions, hydraulic devices are driven by electric valves. Since the valves are integrated into the transmission only during final assembly, their fitting is normally carried out by means of plug-in fastenings, which are provided at a suitable point within the transmission.
In a construction of this type, one difficulty consists in achieving a secure and long-term stable electrical contact with the electric valve. The requirements on the contact-making security are extremely high in practice since, firstly, extreme ambient conditions (temperatures between −40° C. and 140° C., vibration accelerations up to 33 g) prevail in the transmission and, secondly, (because of high repair costs and possible danger to persons in the event of a failure) the highest reliability requirements must be complied with.
A further aspect, which is closely connected with making contact with the electric valve, relates to the implementation of the electric feed lines for the electric valve. The object is cost-effective feed line concepts which permit optimum routing and arrangement of individual conductors within the transmission.
U.S. Pat. No. 5,269,490 (German published patent application DE 42 33 783 A1) describes a solenoid valve which, when it is inserted into a fixing element, is connected via a penetration contact arrangement to one end of a wiring element running in the fixing element. At its other end, the wiring element is connected to a contact pin belonging to a plug which is implemented on the upper side of the fixing element. The overall construction is quite complicated and, in addition, the penetration contact arrangement does not always meet the requirements in practice placed on the contact-making security.
U.S. Pat. No. 5,447,288 (German published patent application DE 43 24 781 A1) describes a further plug-in solenoid valve. The electrical connections fitted to the outside of the valve body are configured as spring contacts. Electrical contact is made by way of a contact pin oriented in the plug-in direction and belonging to the spring element and which, with one end, presses on an opposing contact under defined pressure.
U.S. Pat. No. 5,038,125 (German published patent application DE 38 33 474 A) describes a valve block for a controlled-slip hydraulic braking system. A conductor track substrate with an integral ring seal extends into the inner region of the valve body. In order to make contact with the valve coil, a contact spring with a bent bearing area is in contact there with an exposed conductor track belonging to the conductor track substrate.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an electrical contacting configuration for a valve, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which permanently ensures a high degree of contact-making security, on the basis of the contact-making material used.
With the foregoing and other objects in view there is provided, in accordance with the invention, a configuration for making electrical contact between an electric valve, in particular a shift or pressure valve in an automatic transmission of a motor vehicle, and an electric wiring element, such as a printed circuit board. The configuration comprises:
at least one contact spring element disposed outside a valve housing of the electric valve;
the contact spring element having a pressing section with a tinned, rounded bearing surface;
an opposing contact element of the electric wiring element having a tinned opposing bearing surface;
whereby, in an assembled state, the tinned, rounded bearing surface of the contact spring element bears against the tinned opposing bearing surface of the wiring element under spring pressure.
By means of a tinned pressing section of the bearing surface and a tinned opposing surface of the opposing contact element,
a low-wear contact point is implemented, which ensures fault-resistant and reliable functioning of the electric valve. The required contact quality can therefore be maintained for a sufficiently long time period (lifetime of the transmission).
With this material pairing, the best results with respect to the electric contact resistance were obtained during tests.
The bearing surface can be implemented both in the form of a spherical surface and in the form of a cylindrical circumferential surface.
In accordance with an added feature of the invention, the pressing section of the contact spring element is arcuate-shaped. That is, the contact spring element preferably has a pressure section which runs in the shape of an arc and whose outer side forms the bearing surface.
A particularly preferred refinement of the invention is distinguished by the fact that the wiring element is a flexible printed circuit board. Because of the low wear in the region of the contact point, the opposing contact element in this case can be implemented as a simple surface metalization of a conductor track belonging to the printed circuit board. The use of a flexible printed circuit board, made possible by the invention, is advantageous from the point of view of costs and proves to be beneficial in particular when, within the context of a total connection concept internal to a transmission, further mechatronic components (actuators, sensors, control electronics and so on) are to be attached electrically by means of the flexible printed circuit board.
Particularly good contact properties are achieved with a radius of curvature of the rounded bearing surface of approximately 1.2 to 1.7 mm.
A beneficial range for the spring force exerted on the opposing contact element lies between 12 and 15 N. A force lying in this range is firstly sufficiently high to make secure contact and secondly does not yet lead to relevant damage to the opposing contact element.
By means of structuring the bearing surface and/or by means of providing hooking elements projecting beyond the bearing surface, rubbing movement of the bearing surface on the opposing bearing surface can effectively be prevented.
In accordance with an additional feature of the invention, the contact spring element is formed with an S-shaped segment.
In accordance with another feature of the invention, the pressing section has a width of approximately 3 to 5 mm measured parallel to an axis of an arc defined by the arcuate shape.
In accordance with a further feature of the invention, the bearing surface of the pressing section is a structured surface.
In accordance with again an added feature of the invention, there are provided hooking elements formed on the pressing section and projecting beyond the bearing surface.
In accordance with a concomitant feature of the invention, the contact spring element is formed of copper-tin alloy, such as CuSn 6 , and a copper-tin-nickel alloy, such as CuNi 9 Sn 2 .
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a configuration for making electrical contact with a valve, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a solenoid valve inserted in a fixing element and having a contact spring element making contact with a flexible printed circuit board;
FIG. 2A is a longitudinal sectional illustration of a further contact spring element according to the invention, modified slightly as compared with the contact spring element illustrated in FIG. 1;
FIG. 2B is a side view of the contact spring element illustrated in FIG. 2A; and
FIG. 2C is an enlarged detail from FIG. 2 B.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a solenoid valve 1 with a cylindrical valve body 2 which, via a plug-in fixing attachment not specifically illustrated in the bottom region, is coupled to a fixing element 3 of a subassembly located in the transmission. In the solenoid valve 1 there is provided an axially oriented magnetic coil, and a magnetic armature that penetrates a hole in the coil. The magnetic armature is connected in terms of movement to a piston element 4 , which leaves the valve element 2 on the bottom side and is accommodated such that it can be displaced longitudinally and is sealed off in a cylindrical chamber 5 in the fixing element 3 . The piston element 4 and the cylindrical chamber 5 define a pressure chamber 7 , whose tightness is ensured by annular seals 6 . 1 and 6 . 2 . The pressure chamber 7 is filled with a pressure fluid and is connected via pressure fluid ducts to a non-illustrated transmission shifting mechanism that can be actuated hydraulically.
On the upper side of the fixing element 3 there extends a carrier element 8 produced from plastic. The carrier element 8 , in turn, bears on its upper side a flexible printed circuit board 9 . The flexible printed circuit board 9 implements an integral electrical wiring element, via which a large number of electronic or electromechanical subassemblies (for example transmission controller, actuators, sensors) that are distributed within the transmission are connected electrically to one another. In this case, the carrier element 8 is used for the support and defined routing of the flexible printed circuit board 9 in the interior of the transmission.
The carrier element 8 is optional, that is to say the flexible printed circuit board 9 can also bear directly on the upper side of the fixing element 3 .
A contact housing 10 made of plastic is fitted to the outer wall of the valve body 2 . The contact housing 10 has a top section 10 . 1 and a side wall 10 . 2 . The circumferential wall of the valve element 2 , the top section 10 . 1 and the side wall 10 . 2 of the contact housing 10 form a border around a contact space 11 , into which the flexible printed circuit board 9 projects at the bottom.
The contact space 11 is not sealed off in an oil-tight manner in the bottom area, so that it is possible for transmission fluid to penetrate into/emerge from the contact space 11 . However, the side wall 10 . 2 implements effective protection against the penetration of metal chips into the contact space 11 .
A contact spring element 12 is accommodated in the contact space 11 . The contact spring element 12 is anchored by an upper section (which cannot be seen in FIG. 1) in the top section 10 . 1 of the contact housing 10 . The upper section of the contact spring element 12 is connected, in a manner likewise not specifically illustrated, to an electrical lead through, which extends from the top section 10 . 1 through the wall of the valve body 2 and connects the contact spring element 12 electrically to the magnetic coil.
The upper fixing section of the contact spring element 12 is adjoined by an angled section 12 . 1 . The two legs of the angled section 12 . 1 are oriented at 90° to each other and bear with their outer surface on the inner wall of the contact housing 10 in the transition region from the top section 10 . 1 to the side wall 10 . 2 .
The angled section 12 . 1 of the contact spring element 12 is adjoined by a circular segment section 12 . 2 . The circular segment section 12 . 2 , in the prestressed state illustrated here, extends virtually over 180° and, by means of a bend, merges into a transition section 12 . 3 that runs in the axial direction of the valve 1 . The lower end of the contact spring element 12 is implemented by a pressing section 12 . 4 which extends in the shape of an arc or skid. The contact spring element therefore has an S-shaped section.
The action of the contact spring element 12 is as follows:
When the solenoid valve 1 is inserted into the fixing element 3 , the outer surface of the arcuate pressing section 12 . 4 of the contact spring element 12 comes into contact with the surface of the flexible printed circuit board 9 . At the same time, the circular segment section 12 . 2 is deformed or compressed by an amount that is predefined by the design, as a result of which a corresponding spring force is produced in accordance with Hook's law.
The spring force can be predefined exactly by means of material selection and dimensioning of the contact spring 12 , taking into account the precise installation position of the solenoid valve 1 , and is 12 to 15 N, preferably 14 N. It has been shown that such a pressing force, in combination with the arcuate pressing section 12 . 4 according to the invention, is optimal in order, firstly, still to guarantee a secure electrical contact, even when severe vibrations occur, and, secondly, to avoid damage occurring to the flexible printed circuit board in the contact region over time. At the same time, it is critical that the outer surface of the arcuate pressing section 12 . 4 has a rounded, edge-free course in the region wherein it bears on the opposing contact element.
The outer surface of the pressing section 12 . 4 can bear directly on an exposed surface of a conductor track (for example one made of copper). However, it is more beneficial if a metalization (contact pad) is applied to the conductor track as an opposing contact element. Excellent mechanical and electrical contact-making properties are achieved with a contact pad made of tin and a tinned outer surface (bearing surface) of the pressing section 12 . 4 .
The bearing surface of the pressing section 12 . 4 can be provided with slight embossing or structuring, which increases the positional stability of the pressing section 12 . 4 on the opposing contact element.
FIGS. 2A and 2B show a contact spring element 12 ′ which differs from the contact spring element 12 shown in FIG. 1 only in the upper region (angled section 12 . 1 ) as a result of the addition of an inclined section 12 . 5 ′ running at an angle of 45° with respect to the axial direction. The contact spring element 12 ′ has a thickness D of 0.4 mm and an overall length L of 25.2 mm in the unstressed state. The radius of the circular segment section 12 . 2 ′ is R=4 mm and merges into the transition section 12 . 3 ′ at an angle of 60°.
The radius R1 of the arcuate pressing section 12 . 4 ′ is 1.4 mm and preferably lies in a range between 1.2 and 1.7 mm. The arcuate course of the pressing section 12 . 4 ′ can likewise form an angle of 60°. From the start of the circular segment section 12 . 2 ′ as far as the vertex of the pressing section 12 . 4 ′, a dimension L1=14.5 mm can be provided.
FIG. 2B makes it clear that the contact spring element 12 ′ can have a lesser width in the region of the pressing section 12 . 4 ′ than in the remaining region. The width B of the pressing section 12 . 4 ′ (and also of the bearing surface 14 ′) is, for example, 4 mm.
FIG. 2C shows the lower region of the pressing section 12 . 4 ′ with the bearing surface 14 ′ in detail. The bearing surface 14 ′ is formed smooth and flat and, at its lateral edges, has projecting hooks or claws 13 . 1 ′, 13 . 2 ′, which are buried somewhat in the opposing bearing surface and prevent the bearing surface 14 ′ sliding on the opposing bearing surface.
The contact spring element 12 , 12 ′ can be formed from any suitable metal or any suitable metal alloy with good electrical conductivity and good permanently resilient properties. Suitable materials are the alloys CuSn 6 and CuNi 9 Sn 2 , by way of example. | The configuration makes electrical contact with an electric valve, in particular a shift or pressure regulating valve for automatic transmissions of motor vehicles. The configuration is equipped with a contact spring element arranged outside a valve housing of the electric valve. In the assembled state, the contact spring element acts on an exposed opposing contact element of a wiring element under spring pressure. For this purpose, the contact spring element has a pressing section with a rounded bearing surface and the mutual contact surfaces on the spring element and on the wiring element are tinned. | 5 |
This application is a continuation of U.S. application Ser. No. 10/224,256 entitled Aluminum Aerosol Can and Aluminum Bottle and Method of Manufacture filed Aug. 20, 2002, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to aerosol cans and, more particularly, to aerosol cans constructed of aluminum.
2. Description of the Background
Traditionally, beverage cans begin as disks of aluminum coil feedstock that are processed into the shape of a beverage can. The sides of these cans are approximately 0.13 mm thick. Generally, the body of a beverage can, excluding the top, is one piece.
In contrast, aerosol cans are traditionally made one of two ways. First, they can be made from three pieces of steel, a top piece, a bottom piece, and a cylindrical sidewall having a weld seem running the length of the sidewall. These three pieces are assembled to form the can. Aerosol cans may also be made from a process known as impact extrusion. In an impact extrusion process, a hydraulic ram punches an aluminum slug to begin forming the can. The sides of the can are thinned to approximately 0.40 mm through an ironing process that lengthens the walls of the can. The rough edges of the wall are trimmed and the can is passed through a series of necking dies to form the top of the can. Although aerosol cans made of steel are less expensive than aerosol cans made by an impact extrusion process, steel cans are aesthetically much less desirable than aerosol cans made with an impact extrusion process.
For a variety of reasons, aluminum aerosol cans are significantly more expensive to produce than aluminum beverage cans. First, more aluminum is used in an aerosol can than in a beverage can. Second, the production of aluminum cans by impact extrusion is limited by the maximum speed of the hydraulic ram of the press. Theoretically, the maximum speed of the ram is 200 strokes/minute. Practically, the speed is 180 slugs/minute. Beverage cans are made at a rate of 2,400 cans/minute.
One problem facing the aerosol can industry is producing an aluminum aerosol can that performs as well or better than traditional aerosol cans but is economically competitive with the cost of producing steel aerosol cans and aluminum beverage cans. Another problem is producing an aerosol can that has the printing and design quality demanded by designers of high-end products. Traditional beverage cans are limited in the clarity of printing and design that can be imprinted on the cans. Beverage cans are also limited in the number of colors that can be used in can designs. Thus, a need exits for an aluminum aerosol can that has the attributes of strength and quality, while being produced at a cost that is competitive with steel aerosol cans.
Producing aluminum cans of a series 3000 aluminum alloy coil feedstock solves some of these problems. Series 3000 aluminum alloy coil feedstock can be shaped into a can using a reverse draw and ironing process, which is significantly faster and more cost effective than impact extrusion, aluminum can production. Additionally, series 3000 aluminum alloy is less expensive, more cost effective, and allows for better quality printing and graphics than the use of pure aluminum.
Unfortunately, certain obstacles arise in necking a series 3000 aluminum alloy can. Series 3000 aluminum alloy is a harder material than pure aluminum. Therefore, cans made from series 3000 aluminum alloy are stiffer and have more memory. This is advantageous because the cans are more dent resistant, but it poses problems in necking the cans by traditional means because the cans stick in traditional necking dies and jam traditional necking machines. The solution to these obstacles is embodied in the method of the present invention.
SUMMARY OF THE PRESENT INVENTION
This invention relates to a method for making and necking an aluminum aerosol can from a disk of aluminum alloy coil feedstock where the method is designed to, among other things, prevent the can from sticking in the necking dies. Additionally, this invention relates to the aluminum aerosol can itself, which has a uniquely shaped profile and is made from aluminum alloy of the 3000 series.
The aluminum can of the present invention is comprised of a generally vertical wall portion having an upper end and a lower end, where the upper end has a predetermined profile. A bottom portion, extending from the lower end of the can, has a U-shaped profile around its periphery and a dome-shaped profile along the remainder of the bottom portion. Preferably, the generally vertical wall portion is approximately 0.20 mm thick, and the bottom portion is approximately 0.51 mm thick in the area of the U-shaped profile.
The present invention is also directed to a method of forming a neck profile in an aluminum can made of a series 3000 aluminum alloy, where the can is processed with at least 30 different necking dies. This invention solves the problems of necking a series 3000 aluminum alloy can by increasing the number of necking dies used and decreasing the degree of deformation that is imparted with each die. A traditional aerosol can, made from pure aluminum, which is 45 mm to 66 mm in diameter, requires the use of 17 or less necking dies. A can made by the present invention, of similar diameters, made from a series 3000 aluminum alloy requires the use of, for example, thirty or more necking dies. Generally, the number of dies that are needed to neck a can of the present invention depends on the profile of the can. The present invention processes the aluminum can sequentially through a sufficient number of necking dies so as to effect the maximum incremental radial deformation of the can in each necking die while ensuring that the can remains easily removable from each necking die.
There are several advantages of the can and method of the present invention. Overall, the process is faster, less expensive, and more efficient than the traditional method of impact extrusion, aerosol can production. The disclosed method of production uses a less expensive, recyclable aluminum alloy instead of pure aluminum. The disclosed can is more desirable than a steel can for a variety of reasons. Aluminum is resistant to moisture and does not corrode or rust. Furthermore, because of the shoulder configuration of a steel can, the cap configuration is always the same and cannot be varied to give customers an individualized look. This is not so with the present invention in which the can shoulder may be customized. Finally, aluminum cans are aesthetically more desirable. For example, the cans may be brushed and/or a threaded neck may be formed in the top of the can. Those advantages and benefits and others, will be apparent from the Description of the Preferred Embodiments within.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be easily understood and readily practiced, the present invention will now be described, for purposes of illustration and not limitation, in conjunction with the following figures, wherein:
FIG. 1 is a view of one example of an aluminum can formed by the method of the present invention, partially in cross-section;
FIG. 2 is a cross-sectional view of the bottom portion of the aluminum can of FIG. 1 ;
FIG. 3 is one example of a coil of aluminum alloy feedstock used for this invention;
FIG. 4 is one example of the coil of aluminum alloy feedstock of FIG. 3 showing metal disks punched from it;
FIG. 5 is a single metal disk of FIG. 4 made of a series 3000 aluminum alloy;
FIG. 6 illustrates the disk of FIG. 5 drawn into a cup;
FIGS. 7A–7C illustrate the progression of the cup of FIG. 6 undergoing a reverse draw process to become a second cup having a narrower diameter after completion of the reverse draw process;
FIG. 8 illustrates one example of a shaped bottom formed in the second cup of FIG. 7C ;
FIGS. 9A–9D illustrate the progression of the second cup of FIG. 7C or of FIG. 8 through an ironing and trimming process;
FIG. 10A shows the resulting shoulder profile of an aluminum can after the can of FIG. 9D has passed through thirty-four necking dies used according to one embodiment of the present invention;
FIG. 10B illustrates the resulting shoulder of the can of FIG. 10A after it passes through the last necking die used according to one embodiment of the present invention;
FIGS. 11A–11D are a sequence of views, partially in cross-section, of the aluminum can of FIG. 10B as it undergoes one example of a neck curling process;
FIG. 12A is an aluminum can of FIG. 11D having a tapered shoulder;
FIG. 12B is an aluminum can of FIG. 11D having a rounded shoulder;
FIG. 12C is an aluminum can of FIG. 11D having a flat shoulder;
FIG. 12D is an aluminum can of FIG. 11D having an oval shoulder;
FIG. 13 – FIG. 47 are a sequence of cross-sectional views illustrating thirty-five necking dies used according to one embodiment of the present invention;
FIG. 48 shows a cross-sectional view of the center guides for the first fourteen necking dies used according to one embodiment of the present invention;
FIG. 49 shows a cross-sectional view of the center guides for necking dies number fifteen through thirty-four used for one embodiment of the present invention;
FIG. 50 illustrates one example of a die holder with a compressed air connection according to the present invention;
FIG. 51 shows an aluminum can of the present invention having a brushed exterior, partially in cross-section;
FIG. 52 shows an aluminum can of the present invention having a threaded aluminum neck, partially in cross-section; and
FIG. 53 shows an aluminum can of the present invention having a threaded plastic outsert over the can neck, partially in cross-section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For ease of description and illustration, the invention will be described with respect to making and necking a drawn and ironed aluminum aerosol can, but it is understood that its application is not limited to such a can. The present invention may also be applied to a method of necking other types of aluminum, aluminum bottles, metal containers and shapes. It will also be appreciated that the phrase “aerosol can” is used throughout for convenience to mean not only cans, but also aerosol bottles, aerosol containers, non-aerosol bottles, and non-aerosol containers.
The present invention is an aerosol can and a method for making aluminum alloy cans that perform as well or better than traditional aluminum cans, that allow for high quality printing and design on the cans, that have customized shapes, and that are cost competitive with production of traditional aluminum beverage cans and other steel aerosol cans. The target markets for these cans are, among others, the personal care, energy drinks, and pharmaceutical markets.
A one piece, aluminum aerosol can 10 , as seen in FIG. 1 , has a generally vertical wall portion 12 . The generally vertical wall portion 12 is comprised of an upper end 14 and a lower end 16 . The upper end 14 has a predetermined profile 18 , and a neck 19 that has been curled. Alternatively, the neck can be threaded (see FIGS. 52 and 53 ). The aluminum can 10 also has a bottom portion 20 extending from the lower end 16 . As shown in FIG. 2 , the bottom portion 20 has a U-shaped profile 22 around the periphery of the bottom portion 20 and a wrinkle-free, dome-shaped profile 24 along the remainder of the bottom portion 20 . The U-shaped profile 22 is preferably 0.51 mm thick.
The aluminum can 10 of the present invention is made from aluminum alloy coil feedstock 26 as shown in FIG. 3 . As is known, aluminum alloy coil feedstock 26 is available in a variety of widths. It is desirable to design the production line of the present invention to use one of the commercially available widths to eliminate the need for costly slitting processes.
The first step in a preferred embodiment of the present invention is to layout and punch disks 28 from the coil feedstock 26 as is shown in FIG. 4 . It is desirable to layout the disks 28 so as to minimize the amount of unused feedstock 26 . FIG. 5 shows one of the metal disk 28 punched from a series 3000 aluminum coil feedstock 26 . The disk 28 is drawn into a cup 30 , as shown in FIG. 6 , using any of the commonly understood methods of making an aluminum cup, but preferably using a method similar to the method of U.S. Pat. Nos. 5,394,727 and 5,487,295, which are hereby incorporated by reference.
As shown in FIG. 7A , the cup 30 is then punched from the bottom to begin to draw the bottom of the can through the sidewalls (a reverse draw). As shown in FIG. 7B , as the stroke continues, the bottom of the cup 30 is drawn deeper so that the walls of the cup develop a lip. As shown in FIG. 7C , the completion of the stroke eliminates the lip altogether resulting in a second cup 34 that is typically narrower in diameter than the original cup 30 . The second cup 34 may be drawn one or more additional times, resulting in an even narrower diameter. The resulting cup 34 has the vertical wall portion 12 and the lower end 16 with the bottom portion 20 . The bottom portion 20 may be shaped as shown in FIGS. 8 and 2 . Although other configurations may be used, the domed configuration illustrated herein is particularly useful for containers that are pressurized.
As shown in FIGS. 9A through 9D , the vertical wall portion 12 is ironed multiple times until it is of a desired height and thickness, preferably 0.21 mm thick. The vertical wall portion 12 should be of sufficient thickness to withstand the internal pressure for the intended use. For example, some aerosol products require a can that withstands an internal pressure of 270 psi or DOT 2Q. The ironing process also compacts the wall making it stronger. The upper end 14 of the vertical wall portion 12 is trimmed to produce an aluminum can 10 , as shown in FIG. 9D .
According to one embodiment of the present invention, the can 10 is attached to a first mandrel and passed through a first series of necking dies. Subsequently, the can 10 is attached to a second mandrel and passed through a second series of necking dies. In the embodiment illustrated, the can 10 will pass through up to more than thirty necking dies. These necking dies shape the can 10 as shown in FIGS. 10A and 10B . Each die is designed to impart a desired shape to the upper end 14 of the generally vertical wall portion 12 of the can 10 , so that by the end of the necking process ( FIG. 10B ), the upper end 14 has the desired profile 18 and the neck 19 .
The can 10 , partially shown in FIG. 10B , is shown in full in FIG. 11A . As shown in FIGS. 11A through 11D , the neck 19 of the can 10 is curled through a series of curling steps. The resulting aerosol can 10 of the present invention (as shown in both FIG. 11D and FIG. 1 ) has the predetermined shoulder profile 18 , the curled neck 19 , and is adapted to receive an aerosol-dispensing device. As shown in FIGS. 12A through 12D , the predetermined shoulder profile 18 can be a variety of shapes including, that of a tapered shoulder, a rounded shoulder, a flat shoulder, and an oval shoulder, respectfully. The resulting aluminum can may be between 100 and 200 mm in height and 45 and 66 mm in diameter. The aluminum can may be customized in a variety of ways. One way would be to add texture the surface of the can, for example, by brushing the surface of the can as shown in FIG. 51 . Additionally, the predetermined shoulder profile can be adapted to receive an aerosol-dispensing device. The predetermined shoulder profile can also extend into or carry a neck, threaded or not (see FIGS. 52 and 53 ). An aluminum neck without threading can carry a threaded plastic outsert, as shown in FIG. 53 .
The present invention also encompasses a method of forming a shoulder profile in an aluminum can made of a series 3000, e.g. 3004, aluminum alloy. The first step of this method entails attaching the aluminum can to a first mandrel. The can is then passed sequentially through a first series of up to and including twenty-eight necking dies that are arranged on a necking table in a circular pattern. The can is then transferred to a second mandrel. While on the second mandrel, the can is sequentially passed through a second series of up to and including twenty-eight necking dies which are arranged in a circular pattern on a second necking table. This method includes trimming the neck after the can passes through a certain predetermined number of necking dies. That is, one of the necking dies is replaced with a trimming station. Trimming eliminates excess material and irregular edges at the neck of the can and helps to prevent the can from sticking in the remaining necking dies. A sufficient number of necking dies will be used so as to effect the maximum incremental radial deformation of the can in each necking die that is possible while ensuring that the can remains easily removable from each necking die. Effecting the maximum incremental radial deformation is desirable for efficient can production. A problem arises when the deformation is too great, thus causing the can to stick inside the necking die and jam the die necking machine. Generally, at least 2° of radial deformation can be achieved with each die after the first die, which may impart less than 2° of the deformation.
The shape and degree of taper imposed by each die onto the can is shown in FIGS. 13 through 47 . The method of the present invention may use a stationary center guide as shown in FIG. 48 for each of the first fourteen necking dies. FIG. 49 shows the center guides for the necking dies 15 through 34 . Compressed air can also be used to aid the removal of the can from the first several necking dies. For other shoulder profiles, movable guides and compressed air can be used on all necking positions. FIG. 50 shows a general die holder with a compressed air connection.
The necking dies used in the method and apparatus of the present invention differ from traditional necking dies in several ways. Each die imparts a smaller degree of deformation than the necking dies of the prior art. The angle at the back of the first necking die is 0° 30′0″ (zero degrees, thirty minutes, zero seconds). The angle at the backs of dies two through six is 3° instead of the traditional 30°. The necking dies of the present invention are also longer than those traditionally used, preferably they are 100 mm in length. These changes minimize problems associated with the memory of the can walls, which memory may cause the can to stick in traditional necking dies. Additionally, in the test runs, the top of the can was pinched and was sticking on the center guide of traditional dies. Therefore, the first fourteen necking dies have non-movable center guides. Finally, the present invention uses compressed air to help force the cans off and out of each necking die. The compressed air also helps to support the can walls.
While the present invention has been described in connection with preferred embodiments thereof, those of ordinary skill in the art will recognize that many modifications and variations may be made without departing from the spirit and scope of the present invention. The present invention is not to be limited by the foregoing description, but only by the following claims. | Aerosol cans, more particularly, aluminum aerosol cans made from disks of aluminum coil feedstock, are provided. A method for necking aerosol cans of a series 3000 aluminum alloy is also provided. The method prevents the cans from sticking in the necking dies and produces a can with a uniquely shaped profile. The aluminum aerosol cans that are produced have the attributes of strength and quality, while being produced at a cost that is competitive with steel aerosol cans. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to an enhanced and self sustaining system for the management of the internal combustion engine's crankcase, crankcase emissions and engine lubricating oil, more particularly a sequential method and apparatus for reducing crankcase operating pressures, removing contaminates from the crankcase, prolonging engine lubricating oil life and cleansing the crankcase emissions flow, including a bi-functional remote collector for residuals storage and maintenance of volumetric efficiency for the inventive apparatus. Additionally, the invention optimally relates to a method and apparatus to evenly distribute the cleansed emission flow to the engine's intake manifold air runners, and a method and apparatus to maintain an operable negative pressure to the PCV system at wide open engine throttle.
BACKGROUND OF THE INVENTION
[0002] Historically, engine lubricating oil efficiencies have been bolstered at the production level by the introduction of specific additives to the virgin oil. Engine oil is basically contaminated and degraded by the following: a) engine piston(s) blow-by (undesirable bi-products of engine combustion, a portion of which escapes past the pistons and piston rings into the crankcase) comprising fuel soot, partially burned and unburned fuel, steam and various gases and acids; b) foreign liquids, abrasive silicones (dirt), engine component wear particles and oil oxidation by-products; c) the emulsification of the foreign liquids with chemical elements common to the oil e.g., sulfur combines with liquids and elevated engine temperatures to produce corrosive sulfuric acid. The only form of management afforded to the oil in this hostile environment is the physical inclusion of an oil filter. Although the oil filter is effective in removing solids from the oil, its inability to remove dilutants such as moisture and acids leaves oil vulnerable to viscosity breakdown and eventual loss of lubricity. Further, filters that become plugged with sludge and other solids, force the filter by-pass valve to open, allowing unfiltered oil to circulate to downstream engine components. Thus a primary cycle of undue engine wear and over contamination of oil commences. Problems generated are diverse in nature, however of major concern in this instance is increased cylinder bore and piston ring wear. Consequently, the percentage of piston blow-by increases impacting a heavier than normal contaminant load upon the crankcase oil which accelerates degradation. The problem has now gone full cycle. Crankcase pressures increase accordingly and can force oil past engine gaskets and seals. The condition also facilitates the ejection of oil from the engine crankcase via the aspiration conduit fouling the air cleaner, culminating in elevated carbon monoxide emissions. Also oil is vented along with the contaminated crankcase emission vapours, migrating via the PCV system and engine intake manifold en route to the engine combustion chambers, adversely fouling the combustion process. Again, this results in undue component related wear and a higher percentage of piston blow-by entering the crankcase. Relevant PCV problems will be referred to later in this document. This phenomena continues to compound itself with every engine revolution. Increased fuel consumption; loss of engine power; elevated exhaust emissions and a host of other engine operating problems result. An additional compounding factor is the human element, and is a real world problem, in that many owner/operators do not regularly change their engine oil and filter as per OEM specified. They simply top-up the engine oil, sometimes to excess. Resultant problems are similar in nature to the aforementioned.
[0003] It has now been the law for approximately 40 years that crankcase emissions from internal combustion engines must be recirculated back to the engine's air-fuel induction system for recombustion in the piston chambers. The return flow of the emissions is normally through the oil return lines extending between the crankcase and the engine's valve or cam covers, and from the valve or cam covers through an external hose or tube to the engine's intake manifold where the emissions are blended with the air-fuel mixture from the carburetor/fuel injectors (in normally aspirated engines) for delivery to the combustion chambers. A positive crankcase ventilation (PCV) valve controls the flow of crankcase emissions into the fuel-air induction system, normally in response to engine running speeds.
[0004] The PCV (Positive Crankcase Ventilation) valve is usually located in one of three engine locations: 1) at the engine crankcase vent in the valve/cam covers; 2) in line with the return conduit; or 3) screwed directly into the engine intake manifold. The valve meters and blends the flow of contaminated crankcase emissions into the engines air/fuel delivery system (intake manifold) in response to existing negative pressures within the manifold at various engine load requirements. The path of the emissions from the crankcase via the PCV valve/system, intake manifold and combustion chamber (where they undergo a change of state) and partially re-enter the crankcase as piston blow-by, is the secondary engine cycle of wear and contamination. The PCV valve is also intended to arrest a dangerous back flow condition to the crankcase that could arise as a result of an engine intake manifold backfire. This could cause a crankcase explosion.
[0005] The source and nature of crankcase emissions is well known and need not be discussed in further detail. Suffice is to say that in addition to unburned and partially burned fuel and volatile gases that are desirably recycled for combustion, the emissions also include a number of entrained contaminants that, even if combusted, are harmful to the engine or the environment or both. To the extent that the contaminants are combusted, they are exhausted from the engine as harmful pollutants. On the way in and out of the engines combustion chamber(s) they impair the function of critical engine components including critical emission controls such as the oxygen sensor and catalytic converter(s). To the extent that the contaminants are not combusted, they simply remain in the engine, for example as efficiency destroying combustion chamber deposits, jamming piston rings open, hindering their function or they partially return to the crankcase where they contaminate the oil as previously mentioned. As a consequence, this culminates in a loss of lubricating efficiency, sludge build-ups and a host of other problems that degrade engine performance, increase fuel consumption, elevate exhaust emissions and shorten engine life. These problems increase cumulatively over time and are the result of the second cycle of wear and contamination originating within the engine crankcase. The first cycle exiting the crankcase via the oil filter by-pass valve and, the second exiting via the Crankcase vent and PCV valve/system.
[0006] Prior art inventions involving superseded carburetted engines have made a variety of attempts to recycle combustible volatile matter in crankcase emissions through insertion of various PCV system filtering devices, without also recycling the entrained contaminants. Varying degrees of success were achieved in this theatre of operations. However, due to their disposition between the PCV valve and the engine intake manifold, many of these inventions have been impractical and commercially unsuccessful. This was due primarily to imbalances that arose to the design calibrations of the intake manifold (air/fuel induction system) by their devices. This had the adverse affect of increasing the cubic capacity of the manifold, externally, which subsequently generated imbalances to the air/fuel ratios, of which the manifold is synergistic. As a consequence, either fuel efficiency or exhaust emissions or both were compromised. As previously stated, some devices attained limited success on older generation carburetted engines, and the technology of the day utilized in the static measurement of such fuel efficiency and exhaust emissions supported this. However, in today's high-tech world and with the availability of vastly advanced and sophisticated test models, procedures and measuring equipment e.g., Environmental Protection Agency and the Federal Test Procedure (EPA/FTP), which subjects the engine to a variety of driving and load conditions on a chassis dynamometer for testing, and is the only full and acceptable standard for measuring true engine performance in relation to the subject matter, indicate otherwise. Further, when attempts have been made to apply this class of older technology to ‘state of the art’ modern day computer controlled engines, they have been found to compromise OEM related fuel and exhaust emission efficiencies. The engine's oxygen sensor, located in the exhaust manifold, detects the additional air from the prior art devices and consequently additional fuel is injected into the intake manifold to counter the imbalance.
[0007] For example, Bush in U.S. Pat. No. 4,089,309, describes an open crankcase emission device that requires the use of an auxiliary air intake structure 43 that draws outside ambient air into the device for initial cooling of crankcase emissions. This introduces uncalibrated oxygen into the PCV system which, as previously indicated, is detected by the oxygen sensor utilized in today's computerized engine management systems and causes the system to inject fuel that is surplus to requirement. Bush, in a later U.S. Pat. No. 4,370,971, abandons the previous system configuration in favour of repositioning the system between the PCV valve 27 and the intake manifold entry port 36 . In doing so, Bush not only retains the auxiliary air intake structure 69 with attendant problems but also subjects the whole configuration to a negative pressure environment. This, claims Bush, relates to improvements in the control of crankcase emissions, without due concern to the detrimental affects on the intake manifold design and operation. Specifically, Bush's later configuration is now in direct communication with the interior of the engine intake manifold and unbalances the manifold calibrations by externally increasing its cubic capacity. This avails additional oxygen to and unbalances the stoichiometric air/fuel mixture within the manifold. Again, this condition is detected by the engine's oxygen sensor, and further confuses the computer which can only respond by injecting additional fuel to counter the imbalance. Even therefore if Bush removed and plugged the auxiliary air intake structure 69 to accommodate modern-day engines, his system's disposition would still fail it.
[0008] A similiar approach is taught by Costello in U.S. Pat. No. 5,190,018 to that of Bush in U.S. Pat. No. 4,370,971. Costello's device is similar in structure, operation and disposition to that of Bush, with all the attendant disadvantages, including creating an uncalibrated increase in the volume of the engine's intake manifold.
SUMMARY OF THE INVENTION
[0009] A self sustaining crankcase management system capable of removing contaminants from the crankcase, crankcase emissions and engine lubricating oil is important to maintaining and protecting OEM component and oil manufactures design efficiencies. These corrective steps help preserve and prolonged fuel efficiency, overall engine performance and exhaust emission standards. The contaminant removal steps reduce the presence of foreign liquids, reduce the formation of residual corrosives and negate the existence of constituents to sludge buildup. The process would further mitigate the existence of the primary and secondary cycles of wear and contamination and allow uncombusted volatiles and ketones to migrate beyond the crankcase management system to the engine combustion chamber(s) via the PCV system and intake manifold.
[0010] It is therefore an object of the invention to provide a supplementary crankcase vessel having an internal crankcase emissions separator that obviates and mitigates from the disadvantages of the prior art.
[0011] It is a further object of the present invention to provide a supplementary crankcase vessel that reduces and equalizes the operating pressure of the crankcase thereby maximizing the uninhibited removal of crankcase contaminants and emissions from the crankcase. It is a further object of the present invention to provide a supplementary crankcase vessel and separator which is invisible to the engine's computer management system and which does not disrupt the design calibrations of the engine's intake manifold or stoichiometric air/fuel ratios.
[0012] It is a further object of the present invention to optionally provide a remote bi-functional vessel to collect liquid and solid residuals draining from supplementary crankcase vessel and its separator to sustain their design efficiencies.
[0013] It is a further object of the present invention to provide the aforementioned apparatus that operates under the influences of positive rather than negative pressures.
[0014] It is a further object of the present invention to provide optional apparatus which will provide an operable negative pressure to the engine PCV system at wide open throttle condition. This previously has not been an OEM engine design feature.
[0015] It is a further object of the present invention to provide optional apparatus to the engine PCV system for even distribution of cleansed crankcase emissions to individual air runners of the intake manifold.
[0016] It is a further object of the present invention in a preferred embodiment that it be adaptable to internal combustion engines that consume gasoline, diesel, compressed natural gas (CNG), propane (LPG), ethanol, methanol and all other forms of fuels. Moreover, the broad principles of the invention can be applied to the separator of contaminants from bulk fluids such as, for example, the removal of water from compressed natural gas.
[0017] It is a further object of the present invention to provide the aforementioned apparatus that is economical to produce and install either as original equipment or as an after market addition, and which is easily and readily serviceable.
[0018] According to the present invention then, there is provided a method of treating crankcase emissions from an internal combustion engine, comprising the steps of directing emissions from said crankcase to an emissions separator; subjecting the emissions flowing through said separator to a cleansing operation for removal of contaminants; directing the flow of cleansed emissions through one way check valve means back to the engine for combustion; and collecting the separated contaminants for disposal.
[0019] According to the present invention, there is also provided an apparatus for treating crankcase emissions from an internal combustion engine, comprising a first housing having an inlet for the inflow of crankcase emissions, an outlet for the return flow of treated emissions to the engine for combustion therein and drain means for drainage of contaminants separated out from said crankcase emissions; a second housing disposed in said first housing, said second housing including an inlet in fluid communication with said inlet in said first housing, and an outlet in fluid communication with both said outlet and said drain means in said first housing; and treatment means disposed in said second housing for subjecting the crankcase emissions flowing therethrough to cleaning operations for separation of contaminants from said emissions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Preferred embodiments of the present invention will now be described in greater detail and will be better understood when read in conjunction with the following drawings in which:
[0021] [0021]FIG. 1 is a diagrammatic representation of an internal combustion engine including the present separator;
[0022] [0022]FIG. 2 is a side elevational cross sectional view of the separator
[0023] [0023]FIG. 3 is a top plan view of a velocity stack compression head forming part of the separator;
[0024] [0024]FIG. 4 is a plan view of an annular screen forming part of the separator;
[0025] [0025]FIG. 5 is a diagrammatic view of a negative pressure generator located in an intake runner;
[0026] [0026]FIG. 6 shows the intake runner at wide open throttle
[0027] FIGS. 7 to 9 are diagrammatic views of alternative negative pressure generators;
[0028] [0028]FIG. 10 is a side-elevational cross-sectional view of the upper portion of the materials drained from the separator of FIG. 2;
[0029] [0029]FIG. 11 is a side-elevational partially cross-sectional view of a gravity collector for draining the collector of FIG. 10;
[0030] [0030]FIG. 12 is a side-elevational cross-sectional view of a modified separator;
[0031] [0031]FIG. 13 is a side-elevational cross-sectional view of the upper portion of then separator of FIG. 12;
[0032] [0032]FIG. 14 is a side-elevational cross-sectional view of the mid-portion of the separator of FIG. 12;
[0033] [0033]FIG. 15 is a top plan view of the velocity stack compression head forming part of the separator of FIG. 12;
[0034] [0034]FIG. 16 is a side-elevational cross-sectional enlargement of part of the separator FIG. 12; and
[0035] [0035]FIG. 17 is an upper perspective view of the exterior of the separator of FIG. 12
DETAILED DESCRIPTION
[0036] With reference to FIG. 1, there is shown a conventional engine layout coupled to the present separator 200 used for separating crankcase emissions into liquid, solid and gaseous fractions and for collecting the non-gaseous fractions while recycling the gaseous fractions. The engine shown is a relatively low tech push rod, carbureted engine, still in common use particularly in fleet vehicles. The present invention however is equally suited for use with more modern fuel injected, overhead cam, computer managed engines.
[0037] Throughout the drawings, like numerals have been used to identify the elements.
[0038] As shown, engine 10 includes a crankcase 20 , an oil return line 100 that channels crankcase emissions to the interior of a valve cover 30 and a connector 35 on the valve cover for a conduit 110 that directs the emissions to separator 200 .
[0039] The emissions are forced by positive pressure in the crankcase into conduit 110 . This conduit preferably has an enlarged inner diameter (I.D.) for maximum non-restrictive fluid flow to the inlet of separator 200 . The use of conventional conduits having a smaller I.D. would preclude achieving a preferred high volume emissions flow and could constitute a restricted, less voluminous flow. The second enlarged I.D. conduit 120 is a return conduit for cleansed emissions. A third and smaller optional conduit 220 transfers filtered, precalibrated cooler non-ambient air, selectively sourced downstream from the throttle valve/valves, to an aerodynamically designed vortex generator and diffuser 222 . Conduit 220 may alternatively draw air upstream of the throttle valve/valves and downstream of the mass air-flow sensor when one is present.
[0040] In the following description, separator 200 is described as being mounted externally of the engine and in communication with the engine's crankcase through a connector in a valve cover. It is contemplated however that the separator could be internally installed, such as within the valve cover itself, and communication with the crankcase could be provided by a different connection point for example a dedicated check valve or coupling on the engine block. It is further contemplated that the separator could be constructed as an integral engine component or subsystem.
[0041] The separator 200 of the present invention is shown in grater detail in FIG. 2 and includes a main housing 230 and a cartridge 240 therein which preferably is consumable and replaceable. A closure cap 233 is secured to the open top of main housing 230 by means of threads 234 . O-rings 237 and 238 provide sealing between housing 230 and cap 233 and between shoulder 243 on cartridge 240 and the cap, respectively.
[0042] Entering the closure gap 233 is a direction adjustable, radiused right angle inlet port 210 with a concave venturi 212 for receiving crankcase emissions. In one embodiment constructed by the applicant, the inlet port 210 defines a diffusion chamber 216 intermediately downstream of its inlet. This diffusion chamber 216 can include a port 214 for the insertion and placement of a diffuser 222 . The diffuser includes an outlet 224 that allows filtered, cooler non-ambient calibrated air from conduit 220 to admix with the crankcase emissions as they flows past into cartridge 240 . An exit port 218 through cap 233 , similar in configuration to inlet port 210 , permits cleansed portions of the emissions flow to be directed back to the intake manifold of the engine via conduit 120 and one way PCV check valve 126 seen most clearly in FIG. 1.
[0043] Main housing 230 advantageously includes at its lowermost end concave floor 235 which communicates with an exit drain 236 leading to a collection vessel 400 . Inner wall 231 of main housing 230 includes a plurality of support brackets 238 for cartridge 240 . The brackets are spaced equidistantly about interior wall to support the cartridge above floor 235 . Main housing 230 may be optionally elongated to compensate for the absence of a drainage collector and/or drainage service unit as will be described below.
[0044] Cartridge 240 separates/fractionates the incoming crankcase emissions into liquid, solid and gaseous portions, the liquid and solid portions being decelerated, condensed and separated both in the cartridge and in a cassette 250 within cartridge 240 and then drained away. Cleansed fractionated emissions are meanwhile permitted to flow toward exit port 218 for exit from the housing via enlarged conduit 120 . As will be apparent, vacuum produced in the intake manifold when the engine is operating, coupled with positive pressure in the crankcase, causes the crankcase emissions to be forced into separator 200 . Venturi 212 formed in inlet port 210 accelerates the flow of emissions received from conduit 110 . Inlet venturi 212 also assists in maximizing the flow of crankcase emissions from the crankcase through conduit 110 , due to a slight drop in temperature of the emissions as they pass through the venturi.
[0045] As the emissions flow through inlet port 210 , they then pass into diffusion chamber 216 . Disposed in this chamber is the external, non-ambient air diffuser 222 with outlet 224 . Diffuser 222 is located centrally in chamber 216 to ensure that the calibrated non-ambient air from outlet 224 is introduced centrally into the emissions flow, rather than permitting this air to flow down the wall of the cartridge inlet conduit 242 . To enhance this function, diffuser outlet 224 is centrally located in the diffuser's lower surface where it comprises a minute orifice. This specific positioning in conjunction with turbulent vortices generated downstream of the diffuser enhances the oxidization and condensation of the emissions. Diffuser 222 is triangular in transverse cross-sectional shape, with its apex pointed up into the laminar flow of entering emissions. Laminar flow of emissions passing around the diffuser will break up on both sides of the diffuser, generating downstream turbulence and probably inter-molecular collisions. Therefore greater kinetic energy is produced via these generated turbulent vortices, to enhance cooling of the emissions flow. As a result, heavy hydrocarbon and foreign matter emissions are reduced to a liquid state, and pass through vortex generator 244 to an expansion chamber 245 in cartridge 240 .
[0046] Conduit 242 connects an upper venturi 243 ′ with vortex generator nozzle 244 . Emissions passing through conduit 242 are reaccelerated, straightened and marginally cooled. Vortex generator nozzle 244 produces large turbulent flow vortices within the emissions flow entering primary expansion chamber 245 , enhancing kinetic energy within the emissions flow.
[0047] Within separator 200 there are three expansion chambers: two within cartridge 240 , namely chambers 245 and 248 ; and one 258 within the removable cassette 250 that fits concentrically into cartridge 240 and which will be described in greater detail below. The number of chambers may however vary up or down and there is described below an embodiment having four such expansion zones.
[0048] Primary expansion chamber 245 is bounded on its sides and upper surface by the surrounding walls 246 of cartridge 240 and on its lower surface by a solid circular conic baffle 251 . Baffle 251 is the uppermost component of cassette 250 and is connected to the cassette by means of a threaded connection 253 to a drain tube 259 that passes axially through the cassette's centre and acts as a spine interconnecting the cassette's components. The baffle generates reverse vortex motion back into the incoming emission vortices generated by vortex generator nozzle 244 . This results in a first-stage separation of the emissions flow wherein undesirable heavy hydrocarbons and foreign matter are removed from the emissions flow by, it is believed, enhanced sidewall impingement and the condensing effect of inter-molecular collisions within the generated turbulent vortices. Baffle 251 also serves to protect the cassette's downstream components from direct and excessive contamination by the turbulent emissions flow entering chamber 245 .
[0049] Condensates tend to form in oil and moisture droplets of water, fuel, coolant,/anti-freeze, tar, varnishes and other crankcase contaminants that drain down cartridge wall 246 and over the lip 252 of baffle 251 to collect in the annular space 265 beneath the baffle and between the cartridge wall 246 and the opposed wall 266 of the cassette. Further downward drainage is prevented by O-ring's 268 that seals between the cartridge and the cassette. Fluid that collects in this area flows into concentric drain tube 259 via 2 or 3 radial drain lines 256 that open at one end through cassette wall 266 and at the other end into the drain tube. The placement of the radial drain lines can most easily be seen from FIG. 3 which is a plan view of the cassette's upper surface immediately below the baffle. The drain tube itself directs the condensates to the bottom of the cartridge and from there the residuals flow through drain 236 into a collector 400 (FIG. 1).
[0050] There follows a more detailed description of the elements comprising the consumable/disposable cassette 250 .
[0051] The basic elements of cassette 250 comprise, from top to bottom, baffle 251 , a venturied velocity stack compression head 254 , expansion chamber 258 , wire mesh screen 257 , gas deceleration and condensation element 261 , and exhaust skirt 267 .
[0052] Residual liquids condensed in expansion chamber 245 are, as aforesaid, drained away through lines 256 and 259 and therefore effectively by-pass the cassette, preventing it from becoming overly gummed up.
[0053] Compression head 254 is situated beneath baffle 251 and is separated from the baffle by a shoulder 253 on the baffle's lower surface. The expanded emissions from chamber 245 flow into this space and into a plurality of velocity stacks 255 formed through the compression head. The placement of these stacks is best seen from FIG. 3 where it will be seen that they are arranged to avoid interference with radial drains 256 . The velocity stacks themselves are substantially funnel-shaped to compress the remaining emissions flow. The emissions emerging from the stacks are then expanded somewhat into expansion chamber 258 before flowing through wire mesh matrix screen 257 located above deceleration and condensation element 261 . The screen provides a supplemental emissions impingement surface for additional condensation of residuals.
[0054] Deceleration and condensation element 261 advantageously comprises a primary packing of inert particles such as glass beads, each being 3-4 mils in diameter. Preferably as well, a secondary packing of smaller diameter glass beads, by comparison 2-3 mils in diameter, interfaces with the primary packing to further decelerate and condense undesirable heavy hydrocarbons and foreign matter from the flow. The beads can be perforated and other particulates, or fibres, can be used. This step is preparatory to the light hydrocarbons and volatiles being fractionated from the heavy hydrocarbons and foreign matter as the emissions emerge into succeeding expansion chamber 248 . By whatever process is involved, it has been found that the passage of the emissions through the glass beads results in significant additional separation of undesirable liquid and solid fractions that drain through wire mesh exhaust skirt 267 for eventual discharge into collector 400 . It is possible that the impingement of the emissions against the beads generates greater entrainment of the liquid fractions, separating these fractions from the vapour stage by deceleration and condensation.
[0055] Packing 261 can also act as a flame arrester in the event of an engine backfire through the intake manifold.
[0056] Cassette 250 terminates at exhaust skirt 267 which confines the glass beads within the packing.
[0057] The remaining emissions flow from the packing enters expansion chamber 248 where some additional condensation of heavier residuals can occur, particularly as the emissions impinge against cartridge wall 246 . These residuals also drain through the open lower end 249 of the cartridge for discharge into collector 400 .
[0058] In operation contaminates are transferred to gravity collector 400 through drain 236 of main housing 230 and the remaining gaseous emissions flow travels around cartridge terminus 249 and upward between inner wall 231 of main housing 230 and the outside wall of cartridge 240 . Travel of the emissions through this annulus 270 provides yet another opportunity for condensation of undesirable residuals that flow back down the annulus to the bottom of the separator for drainage.
[0059] In one preferred embodiment constructed by the applicant, the lower end of annulus 270 is provided with a screen 271 (FIG. 4) so that the annular space above the screen can be filled or partially filled with additional glass beads 260 . These beads can rise or fall in the annulus depending upon the level of suction induced by the engine's intake manifold acting through conduit 120 . This can maximize the exposure of their surface area to the emissions for a final cleansing impingement.
[0060] The cleansed emissions exit separator 200 via exit port 218 and conduit 120 to the engine intake manifold 124 after passing through PCV valve 126 .
[0061] Within the entire assembly represented by the main housing 230 , a vaporization effect of remaining volatiles is believed to take place. This thermal vaporization is due to the insulating characteristic of the main housing 230 , relative to encased inner cartridge 240 and cassette assembly 250 . Heat is derived from the convectional flow of hot engine crankcase emissions throughout the assembly. From this convectional flow, heat is absorbed via conduction of all exposed interior surfaces. This absorbed or conducted heat facilitates, through radiation, the vaporization of volatiles contained within the heavy hydrocarbons.
[0062] As is known, vacuum diminishes within an engine's intake manifold at high engine speeds, particularly at wide open throttle (WOT). At the same time, excess pressures will build up within the crankcase, due to the high speed pumping action of the pistons. Nonetheless, these pressures must somehow be vented and permitted to escape. Otherwise piston blowby pressures will back up through the crankcase aspiration conduit into the air cleaner, or air duct, thus contaminating the air filter and/or downstream components. In some cases, this condition creates a problem which causes excessively rich mixtures, ultimately leading to the production of undesirable tail pipe emissions. In addition, a further effect of non-aspiration of the crankcase by cooler ambient air is engine and engine lubrication heat stress. To date these problems have posed difficult solutions to engine design and operation. There will now be described a method and apparatus for negative pressure generation in the engine intake manifold irrespective of throttle opening.
[0063] [0063]FIG. 5 depicts a normal high vacuum condition in the intake manifold at partially open throttle. As the throttle progressively opens as shown in FIG. 6, vacuum diminishes, affecting the operational efficiency of the PCV system. To overcome this problem, a negative pressure generator 130 is introduced to the interior of the intake manifold. This generator, which is the outlet into the intake manifold for the cleansed emissions delivered through conduit 120 from separator 200 , produces a venturi effect at the high dynamic flow rates prevailing at open throttle settings, creating in effect a vacuum in its own wake. This draws in the cleansed emissions to maintain operation of the PCV system and ambient airflow throughout the engine crankcase at high engine speeds. This negative pressure generating function is largely inoperative and unneeded when vacuum exists in the intake manifold at lower throttle settings. The resultant function of maintained crankcase aspiration assists in cooling and preserving crankcase lubricants and engine components under extreme operating load conditions.
[0064] Alternative negative pressure generators 150 , 160 , and 170 are shown in FIGS. 7, 8 and 9 respectively, and their operation will be apparent to those skilled in the art without further detailed explanation.
[0065] As will be apparent, the separation and collection method and apparatus described above will function independently of the use of the negative pressure generators shown and described with reference to FIGS. 5 and 9.
[0066] [0066]FIG. 10 depicts the details of gravity collector 400 . It is connected to drain 236 of main housing 230 by means of conduit 270 for collection and storage of removed contaminants. The gravity collector 400 has an optional drainage service unit 500 (FIG. 11) which may also be installed.
[0067] The function of collector 400 is not only to receive residuals from separator 200 , but also to maintain pressure reduction and pressure equalization with the engine's crankcase. It comprises a main housing 402 and a housing closure 404 threaded thereto. O-ring 405 seals the housing and cap together. The collector may be disposed horizontally or vertically in the engine compartment, alongside the crankcase, sub-frame or wherever space permits at an elevation below drain 236 . Both inlet 406 and outlet 408 are offset from the center of the cap to facilitate access and ease of installation of conduits 270 and 420 respectively in the cramped quarters of the engine compartment and/or vehicle chassis. Inlet nipple 406 protrudes inwardly into the container chamber. It is of enlarged diameter, relative to outlet 408 . Scavenge line 410 is open-ended permitting access to residuals, should the collector 400 be set horizontally. Gravity drain plug 412 is set on the bottom, adjacent the scavenge line 410 . Fluid level sensor 413 is set within cap 404 , whereupon it may correctly gauge the fluid level whether the collector is set vertically or horizontally. Conduit 420 being interconnected to scavenger line 410 via outlet nipple 408 leads scavenged residuals from the collector 400 to interconnecting nipple 604 of coupler 600 .
[0068] The gravity collector 400 is provided with an ambient air vent conduit 422 originating on coupler 600 at the ambient air vent nipple 606 . The nipple has a vent nipple cap 606 ′. In the collector housing cap 404 , the vent conduit 422 terminates in the cap at vent nipple 414 .
[0069] Connecting the collector 400 to portable drainage service unit 500 is a check valve coupler 600 . This coupler is positioned on a header panel at the front of the engine compartment or wall bracket and is provided with nipples 602 - 604 . The former, nipple 602 , services conduit 420 from collector 400 and the latter, nipple 604 , connects conduit 520 to the succeeding drainage service unit 500 .
[0070] With reference to FIG. 11, the housing 502 of service unit 500 is provided with a hermetically sealed cap 504 which contains a check valve 508 and a vacuum source nipple 510 , said nipple having a dust cap 510 ′. Element 512 comprises a retractable dump spout which is self-sealing under the influence of negative pressure. Inlet nipple 506 of drainage service unit 500 is interconnected via conduit 520 to nipple 604 of coupler 600 . Outlet nipple 510 of drainage service unit 500 is interconnected via conduit 530 to a preselected vacuum source at the engine intake manifold to periodically empty collector 400 .
[0071] The basic method and apparatus herein may function independently of the drainage service unit 500 . Its inclusion is optional.
[0072] Such a drainage service unit might not be adapted to diesel engines as most lack an engine vacuum source but the collector 400 may be drained to the same effect.
[0073] Reference will now be made to FIGS. 12 to 17 showing the preferred embodiment of the present separator which is somewhat simplified in construction for more efficient manufacturing, particularly if the unit is to be made from plastics. This embodiment is, in its main features, the same as the embodiment described above with reference to FIGS. 1 to 4 with the principle exception being that cassette 250 is eliminated as a discrete element and is instead integrated into cartridge 240 for a more economical and simplified construction. The following description is therefore limited to the more significant differences between the two embodiments.
[0074] As will be seen particularly from FIG. 12, inlet port 210 and exit port 218 are straight, lacking the integrated elbows in the inlet and exit ports of the separator shown in FIG. 2. Rather, relatively inexpensive radiused elbows 195 can be used that can be either friction fit or clamped to the ridged outer surfaces of ports 210 and 218 . This also allows the elbows to be turned in the direction of conduits 110 and 120 to minimize unnecessary bends and crimps in these lines. The inlet port may still enclose a diffuser 222 as best seen in FIG. 13, the diffuser being supported in a cradle 227 located in the widened throat 228 of inlet 210 . The lower edge 229 of the cradle is camphered to nest into the correspondingly camphered upper venturi 243 ′. Diffuser 222 , if present, provides the same function as described above although in this embodiment, the diffuser is not adapted to discharge calibrated air from the intake manifold into the emissions flow. The triangular diffuser therefore merely generates turbulence. If such air is to be introduced into the emissions flow, the diffuser described above including outlet 224 can be substituted.
[0075] As described previously, the lower surface of expansion chamber 245 is bounded by a conic baffle 251 . In this embodiment, the baffle shown most clearly in FIG. 14, displays greater pitch along its sloped sides and is connected to the compression head 254 itself by a snap fit between sleeve 248 on the baffles' lower side and a circular stem 249 extending upwardly from the head's upper surface.
[0076] The purpose of the baffle is to generate reverse vortices back into expansion chamber 245 to promote condensation of liquid contaminants via collision. The condensates drain down inner walls 246 , past the baffle's lip 252 and into the annular space 265 beneath the baffle and between cartridge wall 246 and the opposed shoulder 266 of compression head 254 . In this embodiment however, O-ring's 268 are eliminated and instead, wall 266 is extended to include a lower surface 266 ′ so that annular space 265 is now a self-contained trough extending completely around the upper periphery of the compression head. Whereas in the previously described embodiment, fluid from this space drained into a drain tube 259 via radial drain lines 256 , drainage has been considerably simplified in this embodiment by forming two or three small holes 264 seen best in FIG. 15 in the trough's lower surface which allows the condensates to continue draining down the inner walls 246 of cartridge 240 towards drain 236 . In this way, radial drains 256 and drain tube 259 can be eliminated.
[0077] The top of wall 266 is bevelled as shown at 269 which, in co-operation with the upward flare of lip 252 on baffle 251 , provides a peripherally extending conically-shaped opening or venturi 279 , shown diagrammatically in FIG. 14 by broken lines, into an expansion area or chamber 275 between the baffle's lower surface 276 and an upper surface 277 of compression head 254 . There is believed to be an acceleration, and a concurrent cooling, of the emissions through opening 279 and then an expansion of the flow into chamber 275 in which, at least ideally, an equal and steady pressure is maintained over velocity stacks 255 . The emissions flow is then once again compressed and accelerated as it is forced through the velocity stacks 255 into expansion chamber 258 . This rapid series of compressions, expansions and accelerations is believed to promote separation of contaminants, particularly as liquid discharge from the velocity stacks into chamber 258 can sometimes be observed.
[0078] The function of the elements previously part of cassette 250 is substantially the same as described above with the exception that the entire internal volume of the space 258 between skirt 267 and velocity stack compression head 254 is occupied by the packing of inert articles such as glass beads. Compression head 254 is now an integrated part of the cartridge 240 as seen most clearly from FIG. 14, and skirt 267 snap fits into a circumferential notch or detente 278 formed into cartridge wall 246 as shown most clearly in FIG. 16. The beads can grade in size from 2 to 4 mls and can be inter-mixed or layered with the larger particles at the top. Advantageously, the beads can be perforated or made hollow to increase their surface area for purposes of more graduated deceleration of the heavy hydrocarbon and foreign liquids and solids in the emissions flow.
[0079] When the packing fouls to the point of ineffectiveness, the entire cartridge 240 can be removed and disposed of and a fresh cartridge is installed in its place. In this embodiment, there are four expansion chambers, numbers 245 , 275 , 258 and 248 proceeding from top to bottom.
[0080] [0080]FIG. 17 is perspective view of separator 200 's exterior including a bracket 205 useful to mount the separator at a convenient location in the vehicle's engine compartment.
[0081] Using the above described method and apparatus, one scavenges the undesirable by-products of combustion and foreign matter from the crankcase, before they are likely ingested into engine crankcase oils. This creates a cleaner dirt- and acid-free lubricant and environment. Emissions are purged from the crankcase into separator vessel 230 . The flow is thus directed through an enlarged conduit, accelerated and passed through the separator, wherein crankcase emission pressure is reduced by the addition of external cubic capacity afforded by vessel 230 and contaminants are separated by condensing and by induced vortex activity, by pressure and temperature differential separation, expansion, collision, induced fractionation, kinetic impingement and induced entrainment. The heavy hydrocarbons and foreign matter are drained from the separator into a separate gravity collector. The lighter hydrocarbons and volatiles derived from the crankcase emissions are rendered cleaner as a result of this overall process. These cleansed hydrocarbons and volatiles comprise a more sophisticated fuel which is now passed via a conduit advantageously to the downstream side of the throttle valve ahead of the intake manifold.
[0082] This is all accomplished in what is essentially a sealed system that draws in no outside uncalibrated air.
[0083] The above-described embodiments of the present invention are meant to be illustrative of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications, which would be readily apparent to one skilled in the art, are intended to be within the scope of the present invention. The only limitations to the scope of the present invention are set out in the following appended claims. | There is described an improved method for treating crankcase emissions from an internal combustion engine, comprising the steps of directing the emissions from the crankcase to an emissions separator, subjecting the emissions in the separator to a series of cleansing operations for removal of contaminants, directing the flow of cleansed emissions through a one way check valve back to the engine for combustion and collecting the separated contaminants for disposal. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for mounting and demounting an optical element, and more specifically, for inserting an optical element into an optical lens system, such as an image forming lens system of, in particular, a broadcasting television camera and removing the same from the optical lens system.
2. Description of Related Art
It is required so often for broadcasting television cameras such as electronic news gathering cameras (ENG cameras) to provide magnified images. An image forming lens system, namely a taking lens system, for such an ENG camera is provided with an optical element switch device for inserting an optical element such as a converter or extender lens into an optical path of the taking lens system for altering the focal length of the taking lens system and removing the optical element from the taking lens system. One of extender switching devices that is disclosed in, for example, Japanese Unexamined Patent Publication No. 9-171135 includes first and second extenders pivotally mounted on a common pivot shaft so as to be moves between a working position and rest positions independently through operation of a manual operation lever. The extender switching device is provided with urging means such as a tension spring for retaining an extender lens in a stationary state in a predetermined position and a damper mechanism for preventing generation of hitting sound and/or vibrations when the extender lens is moved from the rest position to the working position or vice versa.
However, the extender switching device disclosed in the publication needs a number of constituent parts for the retainer spring and the damper mechanism and increases the number of man-hour for fabrication in consequence.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a device for moving an optical element between a working position in an optical axis of a lens system and a rest position out of the optical axis of the lens system that is simple in structure and is smoothly operative.
The foregoing object is accomplished by an optical element switch device for bringing an optical element such as, for example, am extender lens, a ratio converter lens, or an optical filter for transmitting light according to wavelengths, into an optical path of an image forming lens system and removing it from the optical path that comprises a holder frame for fixedly holding the optical element which is movable between a rest position in which the optical element is put out of the optical path of the image forming lens system and a working position in which the optical element is put in the optical path of the image forming lens system, operating means for causing movement of the holder frame between the rest position and the working position, and urging means in the form of a leaf spring fixedly supported on a stationary part such as a housing of the device for applying urging force against the holder frame during movement of the holder frame between the rest position and the working position and inverting the urging force in direction with respect to the holder frame between the rest position and the working position.
According to the optical element switch device of the present invention, the urging means keeps itself applying urging force against the holder frame in a direction of movement and reverses directions of urging force with respect to the holder frame between the rest position and the working position. In consequence, the holder frame, and hence the optical element held by the holder frame, is firmly retained in an intended position, either the rest position or the working position, and prevented from generating hitting noises when reaching the rest position or the working position and causing cranky movement between the rest position and the working position. The directional inversion of urging force is distinctly recognizable, so that the optical element switch device is improved in operationality. Furthermore, the optical element switch device of the present invention eliminates installation of a tension spring and a damper mechanism and, in consequence, is simple in structure.
The urging means may comprise a leaf spring that is secured at one or both of opposite ends thereof to the stationary part, for example the housing, of the optical element switch device so as to be elastically bendable or deformable during movement of the holder frame between the rest position and the working position. In more detail, the leaf spring secured at one end thereof has a generally V-shaped form so that the leaf spring allows another end section to be bent by a projection or a rim of the holder frame. The leaf spring secured at both one ends thereof comprises bent and straight sections so that the leaf spring allows itself to be deformed by a rim of the holder frame.
The optical element switch device is especially suitably embodied as an extender switch device for inserting an extender lens into an optical lens system of, for example, a broadcasting television camera such as an electronic news gathering camera and removing the same from the optical lens system.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present invention will be clearly understood from the following detailed description when reading with reference to the accompanying drawings, wherein the same reference signs have been used to denote same or similar parts throughout the drawings, and in which:
FIG. 1 is an external plane view of a zoom lens for an electronic news gathering camera which is equipped with an extender switch device according to an embodiment of the present invention;
FIG. 2 is a rear view of the extender switch device;
FIG. 3 is a rear view of an interior structure of the extender switch device which is in a rest position;
FIG. 4 is a rear view of an interior structure of the extender switch device which is in a working position;
FIG. 5 is a rear view of an interior structure of an extender switch device according to another embodiment of the present invention which is in a rest position;
FIG. 6 is a rear view of an interior structure of the extender switch device which is in a working position;
FIG. 7 is a rear view of an interior structure of an extender switch device according to a further embodiment of the present invention which is in a rest position; and
FIG. 8 is a rear view of an interior structure of the extender switch device which is in a working position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings in detail, and in particular, to FIGS. 1 and 2 showing a zoom lens 10 that is capable of being detachably mounted to portable TV cameras such as electronic news gathering (ENG) cameras (not shown), the zoom lens 10 comprises a zoom lens part 12 and an extender part 20 having a switch lever 22 for manually switching an extender lens between working and rest positions. Zoom lenses generally comprise at least a focusing lens system and a zooming lens system arranged in order from the object side to the image side. Such a zoom lens is known in various types and takes any type well known in the art. Details of the zoom lens will not be set out in detail since their construction and operation can be easily arrived at by those skilled in the art.
As shown in FIG. 2 , the extender part 20 includes a housing 24 in which an extender lens 26 and a switch lever 22 are incorporated. The switch lever 22 is manually operated to switch the extender lens 26 between a rest position (see FIG. 3 ) in which an extender lens 26 is out of the zoom lens system and a working position (see FIG. 4 ) in which the extender lens 26 is put in the zoom lens system through a switching mechanism which will be described later.
FIGS. 3 and 4 show details of the switching mechanism for switching the extender lens 26 between the rest position and the working position, respectively. The extender lens 26 , which has a magnifying power of, for example X 2 and may consists of single or a plurality of lenses, is fixedly held in a holder frame 28 having a hub ring 28 A through which the holder frame 20 is pivotally mounted on a pivot shaft 30 fixed to the housing 24 . The holder frame 28 has circumferential locating faces 28 B and 28 C disposed at substantially diametrically opposite positions thereof. The locating face 28 B is brought into abutment with a stopper stud 32 fitted in a threaded hole 24 A formed in the housing 24 so as to retain the holder frame 28 in the rest position shown in FIG. 3 when the extender lens 26 is moved out of the zoom lens system. The locating face 28 C is brought into abutment with a stopper stud 34 fitted in a threaded hole 24 B formed in the housing 24 so as to position the holder frame 28 in the working position shown in FIG. 4 when the extender lens 26 is moved into the zoom lens system. These stopper studs 28 B and 28 C can be adjusted in threaded position for fine adjustment of the rest position and the working position, respectively. The switch lever 22 has a shaft 31 having an external gear 38 integrally formed therewith and pivotally mounted to the housing 24 . On the other hand, the hub ring 28 A of the holder frame 28 has an external gear 36 and a projection 44 integrally formed therewith. The switch lever 22 and the holder frame 28 are operationally coupled to each other through engagement between the external gears 36 and 38 .
The switching mechanism includes urging means comprising, for example in this embodiment, a generally V-shaped leaf spring 40 for preventing the holder frame 28 from generating hitting noises when the holder frame 28 hits the stopper studs 28 B and 34 and causing cranky movement between the rest position and the working position. The V-shaped leaf spring 40 is made from a steel strip having a predetermined width and comprises a pressure arm section 40 A, a base section 40 C and a bent section 40 B by which the pressure arm section 40 A and the base section 40 C are connected as an integral piece. The leaf spring 40 is fixed to the housing 24 by a fixing stud 42 fitted in a threaded hole 24 C formed in the housing 24 . The pressure arm section 40 A cooperates with the projection 44 of the hub ring 28 A of the holder frame 28 so as to urges the holder frame 28 . More specifically, when operating the switch lever 22 , the holder frame 28 is turned through engagement between the external gear 36 of the hub ring 28 A and the external gear 38 of the shaft 31 of the switch lever 22 . During movement of the holder frame 28 from the rest position to the working position and vice versa, the leaf spring 40 is elastically bent downward by the projection 44 as depicted by a broken line so as thereby to keep itself applying urging force against the projection 44 of the holder frame 28 . When the holder frame 28 is put in the rest position shown in FIG. 3 , the leaf spring 40 urges the projection in a counterclockwise direction so as thereby to retain the holder frame 28 in the rest position. Similarly, when the holder frame 28 is put in the working position shown in FIG. 4 , the leaf spring 40 urges the projection in a clockwise direction so as thereby to retain the holder frame 28 in the working position. In this manner, urging force against the holder frame 28 is inverted in direction according to the moved positions, namely the rest position and the working position, of the holder frame 28 .
In operation of the extender switching device thus structured, while the extender lens 26 is in the rest position as shown in FIG. 3 , the holder frame 28 is retained with the circumferential locating face 28 B abutted against the stopper stud 32 due to urging force applied against the projection 44 of the hub ring 28 A of the holder frame 28 in a counterclockwise direction by the leaf spring 40 . When operating the switch lever 22 in a counterclockwise direction, the holder frame 28 is moved in a counterclockwise direction through engagement between the external gear 36 of the hub ring 28 A and the external gear 38 of the shaft 31 of the switch lever 22 so as thereby to put the extender lens 26 into an optical path of the zoom lens system as shown in FIG. 4 . As a result, when the locating face 28 C is brought into abutment with the stopper stud 34 , the extender lens 26 is stationarily put in the optical axis of the zoom lens, and the holder frame 28 is retained in the working position by the leaf spring 40 shown in FIG. 4 . On the other hand, when operating the switch lever 22 in a clockwise direction when the extender lens 26 is in the optical path of the zoom lens system, the holder frame 28 is moved in a clockwise direction through engagement between the external gear 36 of the hub ring 28 A and the external gear 38 of the shaft 31 of the switch lever 22 so as thereby to remove the extender lens 26 out of the optical path of the zoom lens system as shown in FIG. 3 . As a result, when the locating face 28 B is brought into abutment with the stopper stud 32 , the extender lens 26 is completely removed out of the optical axis of the zoom lens, and the holder frame 28 is retained in the rest position by the leaf spring 40 shown in FIG. 4 .
The urging force applied against the projection 44 of the hub ring 28 A of the holder frame 28 is inverted before and after an intermediate point of the movement of the holder frame 28 from the rest position to the working position and the vice versa. While it is necessary to operate the switch lever 22 with excess force in order to cause the holder frame 28 to pass through the intermediate point of the movement against the leaf spring 40 , operation of the switch lever 22 becomes easy after the intermediate point of the movement because the leaf spring 40 applies urging force to the holder frame 28 in the same direction as movement of the holder frame 28 . In consequence, an inversion point of urging force is distinctly recognizable, and operationality of the switch lever 22 is improved. Furthermore, because the holder frame 28 is always urged by the leaf spring 40 during movement from the rest position to the working position and the vice versa, the holder frame 28 is prevented from dashing against the stopper stud 32 or 34 with the locating surface 28 B or 28 C, respectively, and hence, from generating hitting noises when the holder frame 28 reaches the rest position or the working position, besides prevented from causing cranky movement between the rest position and the working position.
FIGS. 5 and 6 show an extender switching device 20 according to another embodiment of the present invention in which alternative urging means is employed. As shown, the urging means for preventing the holder frame 28 mounting an extender lens 26 therein from generating hitting noises and causing cranky movement comprises an integral piece of leaf spring 50 . The leaf spring 50 is made from a steel strip having a predetermined width and has a generally U-shaped sections 50 A between opposite end legs 50 B. The generally U-shaped section 50 A comprises a plurality of straight segments joined together at certain angles as an integral piece. The leaf spring 50 at the end legs 50 B is fixed to the housing 24 by fixing studs 52 fitted in threaded holes 24 D formed in the housing 24 so as to allow the U-shaped sections 50 A to be elastically flatly deformable with external force. The holder frame 28 has a rim 28 D formed on a rear surface thereof against which the leaf spring 50 is forced.
The leaf spring 50 keeps itself pushing the rim 28 D of the holder frame 28 in a circumferential direction with the while the holder frame 28 is moved between a rest position shown in FIG. 5 and a working position shown in FIG. 6 . More specifically, the leaf spring 50 is deformed when the holder frame 28 moves between the rest position and the working position so that the urging force applied against the rim 28 D of the holder frame 28 is inverted before and after an in-between position between the rest position and the working position. As a result, the holder frame 28 is urged in a counterclockwise direction while the holder frame is in the rest position and, on the other hand, in a clockwise direction while the holder frame 28 is in the working position.
While the extender lens 26 is out of the zoom lens system, the holder frame 28 is urged by the U-shaped section 50 A of the leaf spring 50 so as to be retained in the rest position through abutment of the locating face 28 B against the stopper stud 32 . When operating the switch lever 22 so as to move the extender lens 26 into the zoom lens, the locating face 28 C of the holder frame 28 is brought into abutment against the stopper stud 34 , so as to retain the holder frame 28 in the working position. Because the holder frame 28 is always urged by the leaf spring 50 during movement from the rest position to the working position and the vice versa, the holder frame 28 is prevented from dashing against the stopper stud 32 or 34 with the locating surface 28 B or 28 C, respectively, and hence, from generating hitting noises when the holder frame 28 reaches the rest position or the working position, besides prevented from causing cranky movement between the rest position and the working position.
FIGS. 7 and 8 show an extender switching device 20 according to a further embodiment of the present invention in which alternative urging means is employed. As shown, the urging means for preventing the holder frame 28 mounting an extender lens 26 therein from generating hitting noises and causing cranky movement comprises a cantilever type of leaf spring 60 . The leaf spring 60 , that is made from a steel strip having a predetermined width, has a generally V-shaped distal sections 60 A and 60 B directed inversely to each other and is fixed at an end leg 60 C to the housing 24 by a fixing stud 62 fitted in a threaded hole 24 D formed in the housing 24 so as to allow the V-shaped sections 60 A and 60 B to be elastically bendable with external force. The holder frame 28 has a rim 28 D formed on a rear surface thereof against which the leaf spring 60 is forced.
The leaf spring 60 keeps itself pushing the rim 28 D of the holder frame 28 in a circumferential direction with the V-shaped sections 60 A or 60 B while the holder frame 28 is moved between a rest position shown in FIG. 5 and a working position shown in FIG. 6 . More specifically, the leaf spring 50 is deformed when the holder frame 28 moves between the rest position and the working position so that the urging force applied against the rim 28 D of the holder frame 28 is inverted before and after an in-between position between the rest position and the working position. As a result, the holder frame 28 is urged in a counterclockwise direction while the holder frame is in the rest position and, on the other hand, in a clockwise direction while the holder frame 28 is in the working position.
While the extender lens 26 is out of the zoom lens system, the holder frame 28 is urged in a counterclockwise direction by the V-shaped section 60 A so as to be retained in the rest position through abutment of the locating face 28 B against the stopper stud 32 . When operating the switch lever 22 so as to move the extender lens 26 into the zoom lens, the holder frame 28 elastically bends the leaf spring 60 and brings the rim 28 D into engagement with the V-shaped section 60 B. Then, when the locating face 28 C of the holder frame 28 is brought into abutment against the stopper stud 34 , the leaf spring 60 urges the holder frame 28 in a clockwise direction by the V-shaped section 60 B so as thereby to retain the holder frame 28 in the working position. In this manner, urging force against the holder frame 28 is inverted in direction at a point of movement of the holder frame 28 where engagement of the leaf spring 60 with holder frame 28 changes from the V-shaped section 60 A to the V-shaped section 60 B. Also in this embodiment, because the holder frame 28 is always urged by the leaf spring 60 during movement from the rest position to the working position and the vice versa, the holder frame 28 is prevented from dashing against the stopper stud 32 or 34 with the locating surface 28 B or 28 C, respectively, and hence, from generating hitting noises when the holder frame 28 reaches the rest position or the working position, besides prevented from causing cranky movement between the rest position and the working position.
Although the optical element switch device of the present invention has been described as to the extender switch device embodied in a zoom lens for an ENG camera by way of example, the optical element switch device may be incorporated in various types of image forming optical lens systems.
It is to be understood that although the present invention has been described with regard to a preferred embodiments thereof, various other embodiments and variants may occur to those skilled in the art, which are within the scope and spirit of the invention, and such other embodiments and variants are intended to be covered by the following claims. | An optical element mounting and demounting device for bringing an optical element ( 26 ) into an optical path of an optical lens system and removing it from the optical path includes a holder frame ( 28 ) for holding the optical element ( 26 ) that is supported for pivotal movement on a stationary shaft ( 30 ) so as to move the optical element ( 26 ) between a rest position and a working position, an urging member ( 40, 50, 60 ) for applying urging force against the holder frame during pivotal movement of the holder frame ( 28 ) between the rest position and the working position, the urging member being secured to a stationary member so as to invert the direction of urging force against the holder frame between the rest position and the working position, and a manually operable member elements for causing pivotal movement of the holder frame between the rest position and the working position. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 2003-24425 and 2003-24447, filed Apr. 17, 2003, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is related to a full-color flat panel display and, more particularly, to a flat panel display capable of embodying a white balance by changing a doping concentration or shape and size of an offset in a drain region and then varying a resistance value of the drain region in each unit pixel.
BACKGROUND OF THE INVENTION
[0003] Generally, as shown in FIG. 1, an organic light emitting diode (OLED) being a flat panel display includes a number of pixels 100 which are arranged in the form of a matrix, each pixel 100 comprising three unit pixels, that is, a unit pixel 110 R for embodying a red color (R), a unit pixel 120 G for embodying a green color (G) and a unit pixel 130 B for embodying a blue color (B).
[0004] The R unit pixel 110 R includes a red electroluminescence (“EL”) device 115 including a red (R) light emitting layer, a driving transistor 113 for supplying a current to the red EL device 115 , and a switching transistor 111 for switching the current supply from the driving transistor 113 to the red EL device 115 .
[0005] The G unit pixel 120 G includes a green EL device 125 including a green (G) light emitting layer, a driving transistor 123 for supplying a current to the green EL device 125 , and a switching transistor 121 for switching the current supply from the driving transistor 123 to the green EL device 125 .
[0006] The B unit pixel 130 B includes a blue EL device 135 including a blue (B) light emitting layer, a driving transistor 133 for supplying a current to the blue EL device 135 , and a switching transistor 131 for switching the current supply from the driving transistor 133 to the blue EL device 135 .
[0007] Conventionally, the driving transistors 113 , 123 and 133 of the R, G and B unit pixels 110 R, 120 G and 130 B of an OLED have the same size, that is, the ratio W/L of the width W to the length L of the channel layer, and the order of the EL devices in the order of their luminous efficiencies is B, R and G unit pixel, where the B unit pixel has the lowest luminous efficiencies. Since the sizes of the driving transistors 113 , 123 and 133 of the R, G, and B unit pixels 110 R, 120 G and 130 B are same while luminous efficiencies of each R, G and B EL layer 115 , 125 and 135 are different with one another, it was difficult to embody the white balance.
[0008] In order to embody the white balance, a relatively small quantity of current should be supplied to the EL device having high luminous efficiency, for example, green EL device, and a relatively large quantity of current should be supplied to the red and blue EL devices having low luminous efficiencies.
[0009] Here, since a current Id flowing to the EL device through the driving transistor begins to flow when the driving transistor is in the saturation state, the current is expressed as follows.
Id=Cox μW {( Vg−Vth )} 2 /2 L (1)
[0010] Therefore, one of the methods for controlling the current flowing to the EL device in order to embody the white balance is to make the sizes of the driving transistors of the R, G and B unit pixels, that is, the ratio W/L of the width W to the length L of the channel layer, different and then to control a quantity of the current flowing to the EL devices of the R, G and B unit pixels. A method for controlling the quantity of current flowing to the EL device in accordance with the size of the transistor is disclosed in the Japanese Laid-open Publication No. 2001-109399. In the Japanese patent, the sizes of the driving transistors of the R, G and B unit pixels are differently formed in accordance with the luminous efficiency of the EL device in each R, G and B unit pixel. That is, the quantity of the current flowing to the EL device of the R, G and B unit pixels is controlled by making the size of the driving transistor of the green unit pixel having a high luminous efficiency smaller than those of the driving transistors of the red or blue unit pixels having relatively low luminous efficiencies.
[0011] Another method to embody the white balance is to make the dimensions of the light emitting layers of R, G and B unit pixels different, which is disclosed in the Japanese Laid-open Patent Publication No. 2001-290441. In this Japanese patent, the same luminance is generated from the R, G and B unit pixels by making the light emitting areas different in accordance with light emitting efficiencies of the EL devices of the R, G and B unit pixels. That is, the same luminance is generated from the R, G and B unit pixels by making the light emitting areas of the R unit pixel or the B unit pixel having lower luminous efficiencies relatively larger than the light emitting areas of the G unit pixel having a relatively high luminous efficiency.
[0012] However, in the conventional method for embodying the white balance described above, since the light emitting area of the unit pixel having low luminous efficiency among the R, G and B unit pixels is enlarged, or the size of the transistor of the unit pixel having low luminous efficiency among the R, G and B unit pixels is increased, the area occupied in each pixel is increased, and therefore it is not easy to apply the method to a high definition flat panel display (FPD).
SUMMARY OF THE INVENTION
[0013] It is an aspect of the present invention to provide a flat panel display wherein a white balance can be embodied without increasing the area of a pixel.
[0014] A further aspect of the present invention provides a flat panel display wherein a white balance can be embodied by making resistance values of drain areas of driving transistors in each R, G and B unit pixel different.
[0015] It is yet another aspect of the present invention to provide a flat panel display wherein a white balance can be embodied by making doping concentrations of drain offset regions of driving transistors in each R, G and B unit pixel different.
[0016] Another aspect of the present invention provides a flat panel display wherein a white balance can be embodied by making geometric structures of drain regions of driving transistors in each R, G and B unit pixel different and changing resistance values of the drain regions.
[0017] An additional aspect of the present invention provides a flat panel display wherein a white balance can be embodied by making shapes and sizes of drain offset regions of driving transistors in each R, G and B unit pixel different.
[0018] According to an exemplary of embodiment of the present invention, there is provided a flat panel display, comprising a plurality of pixels, each of the pixels including R, G and B unit pixels to embody red (R), green (G) and blue (B) colors, respectively. Each of the unit pixels includes a transistor with source/drain regions, wherein the transistors of at least two unit pixels of the R, G and B unit pixels having drain regions of different geometric structures.
[0019] The unit pixels have different geometric structures which further include light-emitting devices, respectively, and channel layers of the transistors controlling currents supplied to the light emitting devices of the unit pixels are of the same size. A resistance value of a drain region of a transistor to drive a light emitting device having the highest luminous efficiency of the light emitting devices among the transistors in the unit pixels is higher than the resistance value of drain regions of transistors to drive light emitting devices having low luminous efficiency relatively.
[0020] The drain regions of the transistors of the R, G and B unit pixels are of a construction having the same length and different widths with one another, or a construction having the same width and different lengths with one another. The drain regions may have zigzag shapes.
[0021] The R, G and B unit pixels further include respective light emitting devices driven by the transistor. A drain region of a transistor to drive a light emitting device having the highest luminous efficiency of the light emitting devices among the transistors in the unit pixels has longer length or a narrower width compared with the lengths and widths of drain regions of transistors to drive light emitting devices having the relatively lower luminous efficiency.
[0022] The drain regions of the transistors of the R, G and B unit pixels include offset regions having different geometric structures from one another. The unit pixels further include respective light emitting devices driven by the transistors, and a drain offset region of a transistor to drive a light emitting device having the highest luminous efficiency among the transistors in the unit pixels has a longer length or a narrower width in comparison with the lengths and widths of drain offset regions of transistors to drive light emitting devices having relatively low luminous efficiency.
[0023] The drain offset regions of the transistors of the R, G and B unit pixels are of a construction having the same length and different widths from one another, or a construction having the same width and different lengths from one another. The drain offset regions may have zigzag shapes.
[0024] Another exemplary embodiment of the present invention provides a flat panel display, comprising a plurality of pixels, each of the pixels including R, G and B unit pixels to embody red (R), green (G) and blue (B) colors, respectively, and each of the unit pixels including a transistor with source/drain regions, wherein transistors of at least two unit pixels of the R, G and B unit pixels having drain regions of different resistance values.
[0025] The unit pixels having different resistance values further include light-emitting devices, respectively, and channel layers of the transistors controlling currents supplied to the light emitting devices of each unit pixel are of same size. A resistance value of a drain region of a transistor to drive a light emitting device having the highest luminous efficiency among the transistors in the unit pixels is larger than the resistance value of drain regions of transistors to drive light emitting devices having a relatively low luminous efficiency.
[0026] The drain regions of the R, G and B unit pixels include offset regions having different doping concentrations. The unit pixels further include light emitting devices driven by the transistors, respectively, and a drain offset region of a transistor to drive a light emitting device having the highest luminous efficiency among the transistors in the unit pixels has a doping concentration lower than those of drain offset regions of transistors to drive light emitting devices having a relatively low luminous efficiency.
[0027] The R, G and B unit pixels further include light emitting devices driven by the transistors, respectively, and the source/drain regions of the transistors include respective offset regions. Source offset regions of the transistors of the R, G and B unit pixels comprise non-doped regions, and drain offset regions of the transistors have different impurity doping concentrations in accordance with luminous efficiencies of the light emitting devices.
[0028] The R, G and B unit pixels further include light emitting devices driven by the transistors, respectively, and the source/drain regions of the transistors include respective offset regions. Source offset regions of the transistors of the R, G and B unit pixels comprise regions doped with the same impurity concentration, and drain offset regions of the transistors have different impurity doping concentrations in accordance with the luminous efficiencies of the light emitting devices.
[0029] The R, G and B unit pixels further include light emitting devices driven by the transistors, respectively, where the source/drain regions of the transistors include respective offset regions, and source/drain offset regions of the transistors of the R, G and B unit pixels have different impurity concentrations in accordance with luminous efficiencies of the light emitting devices.
[0030] The R, G and B unit pixels further include light emitting devices driven by the transistors, respectively, and at least two transistors of the transistors in the R, G and B unit pixels include offset regions which are doped with impurities having different doping concentrations. A drain offset region of a transistor to drive a light emitting device having the higher luminous efficiency in the at least two transistors has the doping concentration lower than that of a drain offset region of the other transistor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail embodiments thereof with reference to the attached drawings.
[0032] [0032]FIG. 1 is a view showing an arrangement of R, G and B unit pixels of a prior art flat panel display.
[0033] [0033]FIGS. 2A, 2B and 2 C are plane views of driving transistors of R, G and B unit pixels in a flat panel display in accordance with a first embodiment of the present invention.
[0034] [0034]FIGS. 3A, 3B and 3 C are plane views of driving transistors of R, G and B unit pixel in a flat panel display in accordance with a second embodiment of the present invention.
[0035] [0035]FIGS. 4A, 4B and 4 C are plane views of driving transistors of R, G and B unit pixels in a flat panel display in accordance with a third embodiment of the present invention.
[0036] [0036]FIGS. 5A, 5B and 5 C are plane views of driving transistors of R, G and B unit pixel in a flat panel display in accordance with a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0037] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the thickness of layers and regions are exaggerated for clarity. Like numbers refer to like elements throughout the specification.
[0038] [0038]FIGS. 2A, 2B and 2 C show plane structures of organic light emitting diodes in accordance with a first embodiment of the present invention, with each figure showing driving transistors of R, G and B unit pixels.
[0039] Referring to FIGS. 2A, 2B and 2 C, the driving transistors 113 , 123 and 133 of the R, G and B unit pixels in accordance with the first embodiment of the present invention each include a semiconductor layer 210 , a gate 230 and source/drain electrodes 251 and 255 . The semiconductor layer 210 includes a channel layer 224 formed on a part corresponding to the gate 230 and high concentration source/drain regions 221 and 225 formed at both sides of the channel layer 224 . Here, the source/drain regions 221 and 225 are electrically connected to the source/drain electrodes 251 and 255 through contacts 241 and 245 , respectively.
[0040] As for the driving transistors 113 , 123 and 133 of the R, G and B unit pixels, the semiconductor layers 210 of each further include offset regions 227 R, 227 G and 227 B formed between the channel layer 224 and the drain region 225 , respectively. Even though the offset regions 227 R, 227 G and 227 B have the same length of L2, the widths of the regions are different in accordance with the luminous efficiency. That is, the width WR2 of the driving transistor 113 of the R unit pixel is wider than the width WG2 of the driving transistor 123 of the G unit pixel having the highest luminous efficiency, and the width WR2 is narrower than the width WB2 of the driving transistor 133 of the B unit pixel having the lowest luminous efficiency.
[0041] [0041]FIGS. 3A, 3B and 3 C are views showing plane structures of an organic light emitting diode in accordance with a second embodiment of the present invention, with each figure showing driving transistors of the R, G and B unit pixels, respectively.
[0042] Referring to FIGS. 3A, 3B and 3 c , driving transistors 113 , 123 and 133 of the R, G and B unit pixels in accordance with the second embodiment of the present invention each include a semiconductor layer 310 , a gate 330 and source/drain electrode 351 and 355 . The semiconductor layer 310 includes a channel layer 324 formed on a part corresponding to the gate 330 and high concentration regions 321 and 325 formed at both sides of the channel layer 324 . The source/drain regions 321 and 325 are electrically connected to the source/drain electrodes 351 and 355 through contacts 341 and 345 , respectively.
[0043] As for driving transistors 113 , 123 and 133 of each R, G and B unit pixel, the semiconductor layer 310 of each further include offset regions 327 R, 327 G and 327 B formed between the channel layer 324 and the drain region 325 . Even though widths W3 of the offset regions 327 R, 327 G and 327 B are the same, lengths of them are different in accordance with the luminous efficiency.
[0044] That is, the length LR3 of the driving transistor 113 of the R unit pixel is shorter than the length LG3 of the driving transistor 123 of the G unit pixel having the highest luminous efficiency and the length LR3 is longer than the length LB3 of the driving transistor 133 of the B unit pixel having the lowest luminous efficiency.
[0045] As described above, the present invention can embody the white balance by making sizes of the drain offset regions of the driving transistors of the R, G and B unit pixels different and changing the resistances.
[0046] [0046]FIGS. 4A, 4B and 4 C are views showing plane structures of an organic light emitting diode in accordance with a third embodiment of the present invention, with each figure showing driving transistors of R, G and B unit pixels, respectively.
[0047] Referring to FIGS. 4A, 4B and 4 C, the driving transistors 113 , 123 and 133 of the R, G and B unit pixels in accordance with the third embodiment of the present invention each include a semiconductor layer 410 , a gate 430 and source/drain electrodes 451 and 455 . The semiconductor layer 410 includes a channel layer 424 formed on a part corresponding to the gate 430 , and high concentration source/drain regions 421 and 425 formed at both sides of the channel layer 424 . The source/drain regions 421 and 425 are electrically connected to the source/drain electrodes 451 and 455 through contacts 441 and 445 , respectively.
[0048] As for driving transistors 113 , 123 and 133 of each R, G and B unit pixel, the semiconductor layer 410 of each further include offset regions 427 R, 427 G and 427 B formed between the channel layer 424 and the drain region 425 . The offset regions 427 R, 427 G and 427 B are formed to have different geometric shapes in a predetermined space L4 between the drain region 425 and the channel region 424 . The offset regions 427 R, 427 G and 427 B are formed to have geometric structures of zigzag forms having different lengths in accordance with the luminous efficiency. That is, the offset regions 427 R, 427 G and 427 B of the driving transistors 113 , 123 , 133 have a zigzag shape so that the length of the driving transistor 113 of the R unit pixel is shorter than the length of the driving transistor 123 of the G unit pixel having the highest luminous efficiency and the length of the driving transistor 113 of the R unit pixel is longer than the length of the driving transistor 133 of the B unit pixel having the lowest luminous efficiency. While the offset regions are shown to have a zigzag shape, it is understood that other geometric shapes may also be used.
[0049] In the third embodiment of the present invention, the white balance can be embodied by making shapes of the drain offset regions of the driving transistors of the R, G and B unit pixels different and changing the resistances.
[0050] In the embodiment of the present invention, the offset regions are formed in the drain regions of all driving transistors of the R, G and B unit pixels. However, it may be possible that the drain offset region is not formed in the B unit pixel having the lowest luminous efficiency and the drain offset regions of geometric shapes having different resistance values are formed in the R and G unit pixels only.
[0051] In the embodiment of the present invention, the offset region of the drain has a shape of zigzag. However, all geometric shapes of the offset regions of the R, G and B unit pixels having differences in the resistance value in order to embody the white balance are applicable.
[0052] Even though the offset regions are formed in the drain regions in the embodiment of the present invention, the offset regions may be also formed in the source regions.
[0053] [0053]FIGS. 5A, 5B and 5 C are views showing plane structures of organic light emitting diodes in accordance with a fourth embodiment of the present invention, with each figure showing driving transistors of R, G and B unit pixels.
[0054] Referring to FIGS. 5A, 5B and 5 C, the driving transistors 113 , 123 and 133 of the R, G and B unit pixels in accordance with the fourth embodiment of the present invention each include a semiconductor layer 510 , a gate 530 and source/drain electrodes 551 and 555 . The semiconductor layers 510 each include a channel layer 524 formed on a part corresponding to the gate 530 , and high concentration source/drain regions 521 and 525 formed at both sides of the channel layer 524 . The source/drain regions 521 and 525 are electrically connected to the source/drain electrodes 551 and 555 through contacts 541 and 545 , respectively.
[0055] In the driving transistors 113 , 123 and 133 of the R, G and B unit pixel, the semiconductor layers 510 of each further include offset regions 523 R, 523 G and 523 B formed between the channel layer 524 and the source region 521 , and offset regions 527 R, 527 G and 527 B formed between the channel layer 524 and the drain region 525 .
[0056] In the driving transistor 113 of the R unit pixel, the source offset region 523 R of the offset regions 523 R and 527 R is an intrinsic region where no impurities are doped and the drain offset region 527 R is a region where impurities of relatively low concentration which have the same conductivity type with the source/drain regions 521 and 525 , are doped.
[0057] In the driving transistor 123 of the G unit pixel, the offset regions 523 G and 527 G are both intrinsic regions where no impurities are doped. Also, in the driving transistor 133 of the B unit pixel, the source offset region 523 B of the offset regions 523 B and 527 B is an intrinsic region where no impurities are doped, and the drain offset region 527 B is a region which has the same conductivity type with the source/drain regions 521 and 525 and is doped with impurities having higher concentration higher than that of the drain offset region 527 R of the R unit pixel.
[0058] In the fourth embodiment of the present invention, the white balance is embodied by forming driving transistors of R, G and B unit pixels having different light emitting efficiencies with the same size, making the lengths of the drain offset regions Lroff, Lgoff and Lboff the same, and making the drain offset regions have different resistance values according to the doping concentration.
[0059] That is, since the R and B unit pixels have light emitting efficiencies lower than that of the G unit pixel, the drain offset region 527 G of the G unit pixel having a relatively high luminous efficiency is not doped so that the drain offset region 527 G is formed to have a relatively high resistance value. The drain offset region 527 B of the B unit pixel having the lowest luminous efficiency is doped with a relatively high concentration so that it is formed to have a relatively low resistance value. The drain offset region 527 R of the R unit pixel having luminous efficiency between those of the G unit pixel and the B unit pixel is doped with a doping concentration lower than that of offset region 527 B of the B unit pixel so that the drain offset region 527 R is formed to have a resistance value between those of the G unit pixel and the B unit pixel.
[0060] In the fourth embodiment of the present invention, even though an offset region not doped with impurity is formed in the source, it may be possible that the source offset region of the R unit pixel is doped with a relatively low concentration and the source offset region of the B unit pixel is doped with as high a concentration as is in the drain offset region. Also, the offset region may be formed in the part of the drain.
[0061] Even though the drain offset region is not doped in the G unit pixel and the drain regions of the R and G unit pixels are doped with the low and high concentrations respectively, it may also be possible that the drain offset regions of the R, G and B unit pixels are differently doped with one another in order that the difference of the resistance values of drain regions to embody the white balance is generated.
[0062] In the first to fourth embodiments of the present invention, the white balance can be embodied by changing a doping concentration or shape and size of the drain region without changing the size of the channel layers of the driving transistors of the R, G and B unit pixels.
[0063] In accordance with the embodiments of the present invention, the white balance can be embodied, that is, an improved white balance may be achieved, by changing the doping concentrations of the drain offset regions of the R, G and B unit pixels and then changing the resistance value of the drain region without increasing the pixel area which is occupied by each unit pixel.
[0064] Also, the white balance can be embodied by making the drain offset regions of the R, G and B unit pixels have geometric structures having different shapes and sizes (W/L) and thus have different resistance values of the drain region without increasing the pixel area.
[0065] Although the embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | Disclosed is a flat panel display capable of enhancing a white balance by making a doping concentration or shape and size of drain offset regions of driving transistors different, in R, G and B unit pixels of each pixel. A flat panel display, comprises a plurality of pixels, where each of pixels including R, G and B unit pixels to embody red (R), green (G) and blue (B) colors, respectively. Each of the unit pixels includes a transistor with source/drain regions. Transistors of at least two unit pixels of the R, G and B unit pixels have drain regions of different geometric structures. In each unit pixel, a resistance value of the drain region of the transistor to drive a light-emitting device having the highest luminous efficiency among the transistors is higher than that of the drain region of a transistor to drive the light-emitting device having a relatively low luminous efficiency. | 7 |
OBJECT OF THE INVENTION
[0001] The present invention relates to a slip-proof cover for vehicle tyres in adverse weather conditions, preferably ice or snow.
[0002] The cover is characterised by a configuration that makes it easy to mount, providing a high reliability and positional stability and good mechanical properties regarding the abrasion implied by its use in its intended conditions.
[0003] The cover is also characterised by a structure and composition of the slit that optimise its slip-proof capacities and its resistance to abrasion.
BACKGROUND OF THE INVENTION
[0004] Driving a vehicle provided with inflatable tyres on slippery surfaces such as snow or ice is dangerous, due to the sharp reduction of the coefficient of friction.
[0005] If the coefficient of friction is reduced by the presence of ice, the latter's stiffness requires the use of solutions based on metal protrusions or the like.
[0006] Tyres are known with studs meant to insert in the ice or snow to improve the grip.
[0007] This type of tyres are used when there are snow or ice conditions at all times, such as for vehicles used in ski resorts.
[0008] In situations where an improved grip is occasionally required, such as when having to cross a snow-covered mountain pass, other auxiliary means are common that are easier to mount and remove, such as snow chains.
[0009] Auxiliary elements of this type use diverse attachment solutions that seek a simple installation.
[0010] Chains are bulky and take up significant space in the vehicle's luggage compartment. The stiffness of the chain allows it to stick in the snow; however, it also means that considerable stresses are applied on the tyre surface, damaging it.
[0011] This damage is greater when there are areas without snow to cushion the impact of the chain on the ground. These areas are sometimes so short that it is not worth removing and installing the chains again.
[0012] Also known is the use of covers as alternative to chains. In this sense must be cited European Patent with publication number EP1165329, which describes and protects a device that can be fitted on vehicle tyres to increase the friction between the tyre and the road.
[0013] The configuration of this cover consists of a belt that surrounds the tyre with an oversize of 4%, its outer part being fully closed and its inner part having a strip with an elastic peripheral asymmetric tensor.
[0014] The present invention consists of a design of a cover with a fabric specifically conceived to withstand shear stresses, improve the grip and improve positional stability.
DESCRIPTION OF THE INVENTION
[0015] The present invention consists of a slip-proof cover for vehicle tyres that consists of a main band made of high-strength textile material and symmetrically-arranged lateral elastic adjusters that facilitate mounting and removing it.
[0016] The high-strength central band consists of a swath of cord fabric made of several strands.
[0017] The presence of several strands allows to increase the strength and thickness of each cord to provide a surface with a better grip on the slippery surface.
[0018] The main textile band includes cords of different thickness, providing the band with protrusions and irregularities that improve its adherence to the ground.
[0019] The fabric incorporates a textile ligament, preferably made of taffeta, which completes the composition of the fabric.
[0020] The main band is a swath cut along an angle from 45° to 90° so that fibres that were originally longitudinal and transverse will be at a 45° angle. Note that angles under 45° result in equivalent configurations, as the longitudinal fibres become transverse fibres.
[0021] The specific case in which the angle is 45° with variations of up to 10° in the orientation of the fibres is of particular interest. This inclination has been compared to the natural orientation of 90° and has been shown to improve the two variables of greatest interest: friction on slippery surfaces such as snow or ice and resistance to wear.
[0022] The reason for this is that the unravelling is minimised, as the forces act identically on all fibres. It must be pointed out that if the longitudinal or transverse fibres suffer greater loads or abrasion than the others the entire fabric is deteriorated. The ideal solution is to balance the external demands on the fibre between the fibres having one orientation and the other, to provide an optimum overall performance.
[0023] Possible cutting means are laser, scissors or heat soldering. In cases in which cutting produces localised fusion, cut ends show a lower tendency to unravelling before they are sewn.
[0024] The cover of the invention can be treated to control the proliferation of mites and bacteria. For this purpose, the cord that forms part of the cover is treated with an anti-mite and antibacterial product. The cover can be stored unused for a long time without developing bad odours and without becoming a source of proliferation of micro-organisms.
DESCRIPTION OF THE DRAWINGS
[0025] The present descriptive memory is completed with a set of drawings that illustrate the preferred embodiment of the invention without limiting it in any way.
[0026] FIG. 1 is a schematic representation of the fabric constituted by longitudinal and transverse fibres, as well as of the orientation of the cut.
[0027] FIG. 2 is a perspective view of the cover without being folded and its position on the tyre. The tyre is not shown.
[0028] FIG. 3 shows a representation of an embodiment of the seams in the cover.
PREFERRED EMBODIMENT OF THE INVENTION
[0029] FIG. 1 shows a representation of the fabric ( 1 ) with its fibres arranged longitudinally and transversally.
[0030] On this fabric ( 1 ) a band ( 1 . 1 ) is cut along a 45° angle (α), which is considered most advantageous within the admissible range from 45° to 90°, such that with respect to this band the longitudinal and transverse fibres will now be diagonal.
[0031] The fabric is made of a material with a high tenacity spun from several strands (this example uses from 5 to 9 strands) to provide a sufficiently coarse texture to improve adherence and increase its resistance.
[0032] The fabric ( 1 ) has been manufactured with a surface density from 0.3 to 1 Kg/m2 using taffeta ligament.
[0033] On this fabric ( 1 ) a rectangular oblique cut (α) is made at 45° with a length equal to the perimeter of the cover plus the width of the seam strips and a width greater that that of the tyre.
[0034] Elastic adjusting straps ( 2 ) are incorporated on the sides of the cover that are fitted on either side of the tyre to stabilise the installation.
[0035] FIG. 2 shows dashed and dotted lines ( 1 . 2 , 1 . 3 ) representing the positional references for the tyre edges.
[0036] The fabric used for the cover is preferably polypropylene due to its high tenacity, its water-repelling properties and recyclability.
[0037] Polypropylene has a low density, less than that of water, so that the cover made with this material has a lower weight than covers with the same volume made with higher density materials.
[0038] In a second example of embodiment the material of the cover is para-aramid fibre, which is very strong, fireproof and corrosion proof.
[0039] In a preferred example of embodiment, the cover can be made of a closed annular piece with a seam ( 3 ) that joins the minor ends of the band ( 1 . 1 ).
[0040] This type of seams ( 3 ) are normally made by overlapping one end on the other, as shown in the top of FIG. 3 , and constitute the principal breaking point of the cover.
[0041] In the cover of the invention the seam ( 3 ) is made by folding the ends outward and sewing at the points of contact of said ends.
[0042] The bottom part of FIG. 3 shows the position of the ends of the band ( 1 . 1 ), folded outward at the time of constituting the seam so that this union line is reinforced.
[0043] The piece can be constituted as an open rectangular piece with closure means at its ends.
[0044] These closure means are preferably Velcro strips.
[0045] The essence of this invention is not affected by variations of the materials, shape, size and arrangement of the component elements, described in a non-limiting manner that should allow its reproduction by an expert in the field. | Slip-proof cover for vehicle tyres for use in adverse weather conditions, preferably snow or ice, with a configuration that allows a simple mounting. The cover is highly reliable and positionally stable, and has a good mechanical performance with respect to abrasion. The cover has a structure and composition of the cut swath that optimise its slip-proof characteristics and its resistance to abrasion. | 1 |
FIELD OF THE INVENTION
The present invention relates to a capacitive microphone, and more particularly, to a spacer for the capacitive microphone.
BACKGROUND OF THE INVENTION
In recent years, capacitive microphones, due to their low price and excellent performance, have been widely applied in electronic products such as cell phones and earphones. The critical element for a capacitive microphone is a capacitor component comprised of polar plates, a vibrating diaphragm and a spacer provided therebetween.
The spacer in a capacitive microphone mainly functions to isolate polar plates and the vibrating diaphragm to form a parallel plate capacitor. Generally, the spacer may be fabricated in advance, that is, the spacer is formed as a single separate ring sheet by punching and cutting and then mounted into the capacitive microphone. In some product structures, it is also possible to mount spacers that are not separated into a plurality of capacitive microphones arranged in an array and then separate them by punching and cutting. For example, the patent application No. CN200610099179.6 discloses a structure in which parts of multiple capacitive microphones are arranged in array and then cut separate after being assembled together, which teaches that the spacer is made from resin film or metal sheet.
However, if the spacer is made from resin film, the low cost and easy fabrication can be obtained, but static electricity may be easily produced during separation process, which causes impact on product performance. Furthermore, if the spacer is made from a metal sheet, the above electro-static problem may be solved, however, both the fabrication difficulty and costs are increased. Further, parasitic capacitance between polar plates and vibrating diaphragm is increased, and the sensibility limit of products is deteriorated. Therefore, it is needed for a capacitive microphone that is of low cost, simple structure and able to mitigate electrostatic influence.
SUMMARY OF THE INVENTION
The technical problem to be solved by the present invention is to provide a spacer for a capacitive microphone that has low cost and is not likely to induce electrostatic influence.
To solve the above technical problem, the technical solution of the present invention is a spacer for a capacitive microphone mounted between polar plates and vibrating diaphragm, the spacer comprises at least one insulating layer and at least one conductive layer bonded with the insulating layer.
The improvement of the present solution lies in that the insulating layer is an organic material layer, and the conductive layer is a quasi-metallization layer or a metal layer.
The improvement of the present solution lies in that the spacer comprises an organic material layer and a metal layer.
The improvement of the present solution lies in that the spacer comprises an organic material layer, on both sides of which is provided with a metal layer respectively.
The improvement of the present solution lies in that the metal layer has a thickness of 0.001 mm˜0.01 mm.
The improvement of the present solution lies in that the organic material layer has a thickness of 0.01 mm˜0.1 mm.
The improvement of the present solution lies in that the spacer has a ring-shaped structure and a plurality of connecting ribs are provided on the periphery of the spacer.
The improvement of the present solution lies in that the spacer has a ring-shaped structure and a periphery of the spacer is of square-shape.
The improvement of the present solution lies in that the insulating layer is an organic high molecular material layer, and the conductive layer is a conductive layer formed by conducting antistatic treatment on a surface of the organic high molecular material with proton bombardment technology in plasma environment.
The improvement of the present solution lies in that the organic material layer is an organic high molecular material layer, and the quasi-metallization layer or the metal layer is implemented by bombing the organic high molecular material layer with metal ions so as to metallize or quasi-metallize a surface of the organic high molecular material layer.
The improvement of the present solution lies in that the organic material layer is an organic high molecular material layer, and the metal layer is implemented by depositing a metal on the organic high molecular material layer with a wet chemical method such as electroplating or hot dipping.
The present invention further provides a capacitive microphone that uses the above various spacers, which can reduce product manufacturing costs and improve the quality of products effectively.
With the above solution, a spacer for a capacitive microphone is mounted between polar plates and vibrating diaphragm, and the spacer comprises at least one insulating layer and at least one conductive layer bonded with the insulating layer. The beneficial effects of the present invention is as follow: static electricity may be effectively prevented from occurring or being stored during manufacturing process of the spacer, and meanwhile, disadvantages such as difficult processing, high cost and tendency to increase parasitic capacitance while making spacer with metal sheet are overcome.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view showing a specific structure of a capacitive microphone provided with a spacer according to the present invention;
FIG. 2 is an enlarged schematic diagram of part A of the above mentioned capacitive microphone;
FIG. 3 is a planar view showing a specific structure of an individual spacer according to a first embodiment of the present invention;
FIG. 4 is a planar view showing a spacer array according to the first embodiment of the present invention;
FIG. 5 is a planar view showing a specific structure of an individual spacer according to a second embodiment of the present invention; and
FIG. 6 is a planar view showing a spacer array according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
The spacer for a capacitive microphone according to the present invention will be described in detail with reference to drawings in below.
FIG. 1 is a cross-sectional view showing a specific structure of a capacitive microphone provided with the spacer according to the present invention. As shown in FIG. 1 , the capacitive microphone with the spacer according to the present invention comprises a circuit board substrate 1 on the top, a circuit board base plate 3 on the bottom and a circuit board frame 2 between the circuit board substrate and the circuit board base plate, all or part of which may be fabricated from a circuit board and constitute a protection structure for the capacitive microphone. Here, a plurality of surface mountable electrodes 11 are provided on the top surface of the circuit board substrate 1 that faces outside of the microphone, and a signal amplification device 12 is provided on the bottom surface that faces inside of the microphone. In addition, a sound hole 31 for receiving outside sound signals is provided on the circuit board base plate 3 . Furthermore, inside the microphone, there are mounted a elastic metal connection device 4 , polar plates 5 , a spacer 6 , a vibrating diaphragm 7 and a vibrating ring 71 for securing the vibrating diaphragm 7 , in which the polar plates 5 , the vibrating diaphragm 7 and the spacer 6 provided therebetween constitute a capacitor component for a capacitive microphone.
The elastic metal connection device 4 has one end connected to the polar plates 5 and another end connected to the circuit board substrate 1 , thereby electrically connecting the polar plates 5 and the circuit board substrate 1 . The vibrating diaphragm 7 is connected to the circuit board substrate 1 via the vibrating ring 71 and a circuit (not shown) between the circuit board base plate 3 and the circuit board frame 2 , and necessary circuits are provided on both sides of and inside of the circuit board substrate 1 . Further, the signal amplification device 12 may function to amplify electrical signals. Normally, these are well known technology and will not be described in detail herein.
FIG. 2 is an enlarged schematic diagram of part A of the above mentioned capacitive microphone. As shown in FIG. 2 , the spacer 6 comprises an organic material layer 61 and a metal layer 62 provided over or under the organic material layer 61 . With this dual-layer spacer structure, during manufacturing process of the spacer, merits of both the metal sheet and the organic material themselves may be utilized at the same time, and the fabrication process might be rather simple, which only needs to coat a metal layer on an organic material layer. In addition, the metal layer 62 preferably has a thickness of 0.001˜0.01 mm, and the organic material layer 61 preferably has a thickness of 0.01˜0.1 mm. Materials such as copper foil, aluminum foil may be used for the metal layer, and materials such as PI may be used for the organic material layer.
FIG. 3 is a planar view showing a specific structure of an individual spacer according to the first embodiment of the present invention. As shown in FIG. 3 , the spacer 6 has a general ring-shaped structure with an opening section at the center and four equally spaced connecting ribs 63 which are integrally formed and extending outward. Here, four connecting ribs 63 are described as an example, however, the number of ribs 63 on a spacer is not limited to 4, but may be any number above 2. Generally, while manufacturing an individual capacitive microphone, the ringshaped spacer may be fabricated by punching and cutting, and then mounted into the capacitive microphone individually. However, while manufacturing array microphones suitable for mass automatic production, it is also possible to manufacture a spacer array with multiple spacers integrated in one piece by punching and then mount the spacer array into multiple capacitive microphones at the same time, after which individual spacers left in respective microphones are separated by cutting. FIG. 4 is a planar view showing the spacer array according to the first embodiment of the present invention, wherein 6 spacers form a 2×3 array and connecting ribs 63 of adjacent individual spacers are connected with each other via a connecting section 64 . The spacer array thus formed is mounted into multiple capacitive microphones at the same time, and individual spacers are made in separate status by cutting connecting sections 64 between adjacent spacers to thereby allowing them remain in individual capacitive microphones.
Second Embodiment
The specific structure of the spacer according to the second embodiment of the present invention will be explained below. Compared with the structure of the first embodiment in which the spacer is comprised of a metal layer 62 and an organic material layer 61 , the spacer of the second embodiment comprises two metal layers 62 located at outer levels and an organic material layer 61 sandwiched between these two metal layers. This structure may also realize effect similar to the first embodiment.
In addition, FIG. 5 shows another shape of the spacer 6 after modification, i.e. the spacer 6 is shaped as a square-shaped structure with an elliptic opening provided in the center. FIG. 6 shows the structure of a spacer array formed by connecting multiple spacers 6 shown in FIG. 5 together, wherein adjacent spacers 6 are connected via connecting sections 64 therebetween. Here, the connecting section 64 has an elongated strip shape extending along an edge of the spacer 6 , and this structure is also applicable to requirements of microphones by mass automatic production and may further enhance connections between individual spacers. It is understood that the structure of connecting rib 64 of the first embodiment may also be applied here.
In order to further reduce manufacturing cost, in a preferred implementation of the present invention, the organic material layer 61 is a high molecular organic material layer, and the metal layer 62 is implemented by depositing a metal on the organic material layer 61 with a wet chemical method such as electroplating or hot dipping.
In a preferred implementation of the present invention, it is also possible to use a quasi-metallization layer that equally has electrical conductivity instead of the metal layer, which may also effectively avoid static electricity production or storage during manufacturing process of the spacer.
Meanwhile, with respect to the quasi-metallization layer and metal layer of the present invention, it is also possible to bombard the high molecular organic material layer with metal ions so as to make the surface thereof metallized or quasi-metallized, thereby imparting it with electrical conductivity and electrostatic prevention function. With this process, the resulting quasi-metallization layer and the metal layer are securely bonded on the high molecular organic material layer and are not likely to suffer from wearing and peeling, which might realize better product reliability and product performance after being applied to the capacitive microphone product.
In the present invention, other forms of conductive layers may also be used for the conductive layers of the spacer. For instance, a high molecular organic material layer is used as an insulating layer, and the high molecular organic material layer is placed in plasma environment to be surface processed by proton bombardment technology so as to form a conductive layer on the originally insulating organic material layer, thereby imparting the spacer with antistatic function. Also, this process will not change other characteristics of the organic material layer and has the feature of being environmentally friendly.
As provided in the specification, the method of providing metallic conductive layer (quasi-metallic conductive layer) or other conductive layer on organic material layer is a preferred method of the present invention. Other similar methods in which an organic material layer is used as base material and a metal layer or quasi-metal layer or other conductive layer is provided on the organic material layer to impart the entire spacer with conductivity and antistatic function should be interpreted as equivalent method of the present invention.
The present invention further provides a capacitive microphone that uses the above mentioned various spacers, which can reduce product manufacturing costs and improve the quality of products effectively.
The above detail description of the spacer for a capacitive microphone and the capacitive microphone with such spacer claimed by the present invention is merely explanation of the principle and implementations of the present invention with reference to specific embodiments, and the explanation of the above embodiments is only to help understanding the gist of the present invention. Meanwhile, modifications to specific implementations and fields of application may occur to those skilled in the art according to the teaching of the present invention. In summary, the description should not be interpreted as limiting the present invention. | The present invention relates to a spacer for a capacitive microphone and a capacitive microphone with such spacer, in which the spacer is mounted between polar plates and vibrating diaphragm of the microphone and the spacer comprises at least one insulating layer and at least one conductive layer bonded with the insulating layer. With the above-mentioned structure, static electricity is effectively prevented from occurring or storing during manufacturing process of the spacer and meanwhile, disadvantages such as difficult processing, high cost and tendency to increase parasitic capacitance while making spacer with metal sheet are overcome. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to an LED lamp electrode structure, and more particularly to provide improved connection of LED lamp electrodes.
BACKGROUND OF THE INVENTION
[0002] Conventional LED lamps 1 a and 1 b, referring to FIG. 1 , have LED chips 11 a and 11 b with a heat conduction element 20 a at the bottom and electrodes 12 a and 12 b located at outer sides of the LED lamps 1 a and 1 b. When in use for illumination, the LED lamps 1 a and 1 b emit light and heat is conducted through the heat conduction element 20 a at the bottom to lower the temperature of the LED lamps 1 a and 1 b.
[0003] To facilitate wiring and replacing of the LED lamps 1 a and 1 b, they are made in a modular fashion and have the wiring formed on a printed circuit board (PCB) 3 a with the heat conduction element 20 a mounted thereon. Then the LED lamps 1 a and 1 b are soldered on the PCB 3 a to become a module. Such a module has drawbacks, notably:
[0004] 1. The LED lamps cannot be replaced individually on the LED lamp module, resource waste incurs.
[0005] 2. The PCB is formed in a fixed shape, direction and arrangement, and does not allow the LED lamps to be flexibly deployed thereon.
[0006] 3. The wiring is exposed to the PCB. It is not aesthetic appealing and has safety concern in terms of electric power utilization.
SUMMARY OF THE INVENTION
[0007] The primary object of the present invention is to solve the disadvantages of the conventional LED lamps that have electrodes located at two sides making deploying of the LED lamps inflexible and having exposed wiring to the PCB that result in use difficulty and safety concern.
[0008] To achieve the foregoing object, the present invention provide an improved LED lamp electrode structure with a single LED lamp as a module and electrodes moved from two sides of the LED lamp to the bottom thereof so that they can be directly connected to an electric wire or power supply without a PCB to allow the LED lamp module to emit light. The LED lamp also can be replaced individually.
[0009] The present invention is based on another invention of the inventor at U.S. application Ser. No. 11/907,279 incorporated with novel techniques, including repositioning LED chip electrodes, adding two electrode passages running through a jutting coupling portion at the bottom of an LED lamp, filling the electrode passages with a conductive medium such as silver paste or connecting electric wires to form electrodes to establish electric connection with the LED chip electrodes. By altering the positions of the LED lamp electrodes, installation and replacement of the LED lamp are simpler and easier.
[0010] By means of the construction set forth above, the present invention provides many benefits, notably:
[0011] 1. The electrodes are concealed at the bottom of the jutting coupling portion and wiring is hidden. It is safer and more aesthetic appealing.
[0012] 2. With the lamp electrodes concealed at the bottom of the jutting coupling portion, the PCB can be dispensed with. The LED lamp can be deployed and arranged more flexibly.
[0013] 3. The LED module can be shrunk to become a single LED lamp, and can be replaced individually and still maintain the convenience of modular structure.
[0014] 4. The LED lamp can be mounted onto a seat or heat conduction element at varying angles according to requirements to generate desired lighting styles and illumination.
[0015] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a conventional LED lamp electrode structure.
[0017] FIG. 2 is a top perspective view of the jutting coupling portion according to the invention.
[0018] FIG. 3 is a bottom perspective view of the jutting coupling portion according to the invention.
[0019] FIG. 4 is a sectional view of the jutting coupling portion according to the invention showing electrode passages.
[0020] FIG. 5 is a sectional view of the jutting coupling portion according to the invention screwed on a heat conduction seat and a PCB.
[0021] FIG. 6 is a schematic view of the invention mounted onto the heat conduction seat and the PCB.
[0022] FIG. 7 is a perspective view of the invention mounted onto the heat conduction seat and the PCB.
[0023] FIG. 8 is a sectional view of an embodiment of the invention showing a slanted electrode passage formed in the jutting coupling portion.
[0024] FIG. 9 is a perspective view of another embodiment of the invention with soldered electric wires.
[0025] FIG. 10 is a perspective view of yet another embodiment of the invention with a T-shaped track and a T-shaped trough.
[0026] FIG. 11 is a perspective view of yet another embodiment of the invention with the T-shaped track wedged in the T-shaped trough.
[0027] FIG. 12 is a perspective view of still another embodiment of the invention with a conductive clip formed on the jutting coupling portion.
[0028] FIG. 13 is a sectional view of still another embodiment of the invention with the conductive clip formed on the jutting coupling portion.
[0029] FIG. 14 is a perspective view of another embodiment of the invention mounted onto an arched heat sink.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Please refer to FIGS. 2 through 5 , the LED lamp electrode structure according to the invention mainly includes an LED lamp 4 that has an LED chip 41 inside with two chip electrodes 410 and a jutting coupling portion 40 at the bottom. The jutting coupling portion 40 has screw threads 401 on the periphery and two electrode passages 421 and 422 communicating with the chip electrodes 410 . One electrode passage 421 is tortuous and has an opening in the center of the bottom of the jutting coupling portion 40 , and the other electrode passage 422 has another opening close to the outer edge of the bottom of the jutting coupling portion 40 . The electrode passages 421 and 422 are filled with a conductive medium 423 such as silver paste so that the openings of the electrode passages 421 and 422 form two lamp electrodes 42 to electrically connect with the chip electrodes 410 .
[0031] Referring to FIGS. 5 , 6 and 7 , the jutting coupling portion 40 of the LED lamp 4 can be fastened to a tapped heat conduction seat 5 with an aperture 51 formed thereon. The heat conduction seat 5 has a PCB 6 located at the bottom. The PCB 6 has a plurality of power supply elements 61 each has a contact 611 in the center and a power supply ring 612 located around the contact 611 . When the LED lamp 4 is screwed on the heat conduction seat 5 and mounted onto the PCB 6 , the lamp electrode 42 in the center of the LED lamp 4 is connected to the contact 611 and the other lamp electrode 42 located at the outer edge is connected to the power supply ring 612 so that the LED lamp 4 is energized to emit light.
[0032] Referring to FIG. 8 , a slanted electrode passage 424 may also be formed in the LED lamp 4 with the opening in the center at the bottom of the jutting coupling portion 40 while the other electrode passage 422 has the opening close to the outer edge at the bottom. The two electrode passages 424 and 422 also are filled with the conductive medium 423 such as silver paste to form the lamp electrodes 42 at the openings to electrically connect with the two chip electrodes 410 as previously discussed.
[0033] Refer to FIG. 9 for another embodiment of the invention. Electric wires 7 are provided and inserted into the electrode passages 422 and 424 from the bottom of the jutting coupling portion 40 to the LED lamp 4 soldered to form electric connection.
[0034] Refer to FIGS. 10 and 11 for yet another embodiment of the invention. A T-shaped track 402 is provided at the bottom of the LED lamp 4 with the electrode passages 422 and 424 formed thereon to receive the electric wires 7 to electrically connect with the LED lamp 4 for lighting. The T-shaped track 402 is wedged in a T-shaped trough 531 formed on a heat conduction trough 53 . The heat conduction trough 53 has a notch 532 at the bottom to allow the electric wires 7 to run through the heat conduction trough 53 .
[0035] Refer to FIGS. 12 and 13 for still another embodiment of the invention. It has a jutting coupling portion 8 with a conductive clip 84 located thereabove and a fastening portion 81 located thereon to fasten an LED lamp 4 a. The LED lamp 4 a has lamp electrodes 42 a at two sides and electrode passages 82 beneath the lamp electrodes 42 a with openings formed at the bottom of the jutting coupling portion 8 close to the outer edge thereof. The jutting coupling portion 8 has screw threads 83 formed at a lower side on the periphery. A set of conductive clips 84 are elastic to clip the lamp electrodes 42 a at the two sides of the LED lamp 4 a. A set of electric wires 7 run through the electrode passages 82 to be soldered on lower sides of the conductive clips 84 to establish electric connection among the electric wires 7 , conductive clips 84 and lamp electrodes 42 a. Finally, the jutting coupling portion 81 is screwed into a socket 85 , and a lamp shade 86 can be coupled or screwed on the socket 85 .
[0036] Refer to FIG. 14 for another embodiment of the invention. LED lamps 4 are mounted onto an arched surface of an arched heat sink 52 which can conceal wiring. The LED lamps 4 can be positioned at varying angles in different directions by means of the arched heat sink 52 to meet special illumination requirements. | An LED lamp electrode structure includes a jutting coupling portion at a lower side of an LED lamp and two electrode passages corresponding to and communicating with LED chip electrodes. The electrode passages are filled with silver paste or hold electric wires to establish electric connection with the chip electrodes. Thus wiring can be concealed and aesthetic appealing improves, and safety and practicality are enhanced. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to the manufacture of composition board by extrusion and, more particularly, to an improved agitation mechanism for insuring the uniform dispersion of the composition material throughout the extrusion mold.
The manufacture of composition board by an extrusion process is well known in the art. Typical composition board is formed from a mixture of fine ligno-cellulose particles combined with a suitable resin binder. The mixture is metered from a large hopper into a feed chamber where a reciprocating piston forces the mixture into a heated mold. The mold is open at an outlet end opposite to the inlet end where the piston is situated so that successive compressive forces applied to the mixture by the reciprocating piston results in the continuous molding of composition board. Typical apparatus for manufacturing composition board in accordance with afore described process is disclosed, for example, in U.S. Pat. No. 3,229,009, the disclosure of which patent is hereby incorporated by reference herein.
A typical composition board which may be manufactured by a machine of the type described in the aforementioned patent is a continuous 40 inches wide sheet with 13/16 inch ribs every 2 inches across the width of the board on one side thereof. To maintain uniform density of the composition board in both the flat panel portions and the ribs, it is necessary to distribute evenly the constituent materials prior to it being forced into the mold by the piston. To accomplish this, a plurality of oscillating fingers are provided in the feed chamber above the reciprocating piston. These fingers are spaced along the width of the mold with a pair of fingers above the position of each of the ribs. These fingers are adapted to oscillate in opposite directions. It has been found that the oscillation of the fingers must be timed relative to the stroke of the reciporcating piston in order to maintain uniform board density. In particular, the fingers oscillate through a selected angle, suitably approximately 60° of rotation in opposite directions, "dead center" of the oscillation being in a vertical orientation with extremes of 30° angular displacement to either side. It has been found that at approximately the time the reciprocating piston is fully retracted and ready to move forward to force the mixture into the mold, the fingers should be at their extremities of oscillation at opposite ends from the vertical orientation. The fingers should move to the opposite point of maximum angular displacement before the piston enters the mold and should stay in that position for the remainder of the forward piston movement. The reverse direction of oscillation of the fingers occurs during the reverse travel of the piston. Thus, the agitation mechanism must be precisely coordinated with the movement of the reciprocating piston. Prior attempts to do this reliably have not been entirely successful. For example, in the aforedescribed patent the movement of the agitating fingers is controlled by a complex eccentric cam arrangement. However, such cams wear out relatively quickly. It has also been found that a mechanical linkage between the piston and the agitating fingers is unreliable in that it is extremely difficult to properly adjust the timing between the movement of the piston and the agitating fingers.
Another important aspect of the invention is the discovery that by varying the time at which oscillation of the fingers occurs relative to the movement of the piston the density of the legs can be controlled.
SUMMARY OF THE INVENTION
In accordance with the principles of this invention, an imporved agitation mechanism is provided in the feed chamber of an extrusion machine for the manufacture of composition board. Means are provided for sensing the position of the reciprocating piston. This means is, in accordance with one embodiment of the invention, a "target" mounted on a flywheel of the extrusion machine. When the target passes a first sensor, this indicates that the piston is in the fully retracted position. When the target passes a second sensor, this indicates that the piston is in the fully extended position. These sensors are utilized to generate signals which control the movement of the fingers. The fingers are moved by racks which engage pinion gears attached to the fingers. These racks are connected to hydraulic cylinders which are selectively pressurized responsive to signals from the sensors for pushing or pulling the racks to control the oscillation of the fingers. Since the piston may reciprocate at different rates and the hydraulic delay of the cylinders is constant, the position of the target on the flywheel is adjustable to insure that the oscillation of the fingers is properly coordinated with the movement of the piston.
DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings in which:
FIG. 1 is a sectional schematic view showing the improved apparatus of this invention and its relationship to the extrusion machine of the aforementioned patent;
FIG. 2 is a fragmentary plan view showing the placement of the improved apparatus of this invention in the feed chamber of the extrusion machine;
FIG. 3 is a fragmentary sectional view taken along the line 3--3 of FIG. 2;
FIG. 4 is a perspective view of the improved agitating fingers and their respective drive mechanisms;
FIG. 5 depicts the flywheel of the extrusion machine showing the relationship of the target and the sensors;
FIG. 6 is a combined electrical and hydraulic schematic diagram of an exemplary control system for moving the racks which drive the agitating fingers; and
FIG. 7 is a fragmentary perspective view of exemplary composition board.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Exemplary apparatus is depicted wherein like reference numerals indicate like parts throughout the several figures. The extrusion machine is of the type disclosed in the aforementioned U.S. Pat. No. 3,229,009, incorporated by reference herein, and only such detail as is necessary for an understanding of the operation of the present invention will be repeated herein.
Typical composition board 10 manufactured by the extrusion machine of the aforementioned patent is depicted in FIG. 7. Composition board 10 includes a generally flat panel 11 having an upper surface 12 and a lower surface 13. A plurality of spaced apart parallel bars, or ribs, 14 depend integrally from the lower surface 13 of the panel 11 and have a thickness substantially equal to the panel 11. The ribs 14 extend perpendicularly outwardly from the panel 11. Board 10 is formed by an extrusion process from lingo-cellulose particles combined with a suitable resin binder, the mixture being forced through a heated mold section and a curing cooker as described in the aforementioned patent.
To form the board 10, a mixture of ligno-cellulose particles and resin binder is metered from a hopper (not shown) into a feed chamber 15. The lower end of the feed chamber 15 is terminated in a lower mold 16. Lower mold 16 in cooperation with upper mold 17 forms a cavity of cross-sectional shape which is complementary to the shape of the board 10. Thus, the lower surface of upper mold 17 is planar and the upper surface of lower mold 16 is channeled. A piston 18 which has a cross-section shape identical to that of board 10 is reciprocated through the lower end of feed chamber 15 and pushes the constituent materials through the mold. The travel distance of piston 18 is approximately 21/2 inches and the length of the feed chamber is approximately `-5/8 inches. When piston 18 is in the fully retracted position, as shown in FIG. 1, its front face ia aligned with rear wall 19 of feed chamber 15. When piston 18 is in its fully extended position, it extends approximately 7/8 inch into the mold cavity. Piston 18 rides on slide block 20 which in turn rides on slide bearing 21. Slide block 20 includes a plurality of ears 22 each connected to a link 23. As shown in the aforementioned patent, link 23 is connected through a link mechanism eccentically to a rotating shaft. This link mechanism and the rotation of the shaft causes slide block 20 to move back and forth in the horizontal plane, reciprocating piston 18 as shown by the arrows. The shaft to which the link mechanism is connected is connected to a drive pulley at one end and a flywheel at the other end. The flywheel rotates completely for every full reciprocation of piston 18. The relevance of this relationship will become apparent from the discussion and description that follows. Returning now to FIG. 1, the mixture of constituent material which is forced by piston 18 through the mold cavity formed by lower mold 16 and upper mold 17 then passes through a cavity formed by upper cooker 24 and lower cooker 25, the cross-sectional shape of which is similar to that of the mold section. A plurality of heating elements 26 extend through the mold and cooker elements to maintain these elements at elevated temperatures for forming and curing the board. It should be noted at this point that FIG. 1 is not to scale, as in accordance with an operative machine the width of the mold is approximately 9 inches and the wodth of the cooker is approximately 4 feet.
Internal to feed chamber 15 are a plurality of agitation fingers denoted generally as 27. Fingers 27 are arranged in pairs, a pair of fingers being above each of the channels in lower mold 16. The pair of fingers 27 are journaled for rotation about shaft 28 by means of an oscillation mechanism which will be described infra. At this point it suffices to say that fingers 27 are caused to oscillate approximately 30 degrees in either direction from the vertical, with the oscillation of the fingers in each pair being opposite to one another. This oscillation is controlled by mechanism 29 and is coordinated with the reciprocation of piston 18.
FIG. 2 depicts a plan view of feed chamber 15 showing the placement of the agitating fingers 27 therein. Mechanism 29 is mounted on the rear wall 19 of chamber 15. A plurality of shafts 28 extend through mechanism 29 and wall 19 and mounted on shafts 28 within feed chamber 15 are the agitating fingers 27. Agitating fingers 27 are arranged in pairs, each pair being above a respective channel 30 of lower mold 16. Mounted at an extreme end of mechanism 29 are a pair of hydraulic cylinders 31 and 32. These cylinders 31 and 32 are of the double acting type, the internal pistons therein being adapted to move either toward the right or the left depending upon which end of the cyliner is supplied with pressurized hydraulic fluid. As shown in FIG. 2, each of the cylinders 31 and 32 has two hydraulic lines. The right line 33 of cylinder 31 is connected to the left line 34 of cylinder 32 and the left line 35 of cylinder 31 is connected to the right line 36 of cylinder 32. Each of the cylinders 31 and 32 has an internal piston therein connected to a respective rod which extends into mechanism 29. It is apparent from the connection of the cylinder pressure lines that when the rod and piston of cylinder 31 moves toward the left that the rod and piston of cylinder 32 will move toward the right, and vice versa. Connected to these rods are respective rack gears internal to mechanism 29. The fingers 27 are connected to respective pinion gears internal to mechanism 29, the pinion gears of the forward fingers engaging one rack and the pinion gears of the rearward fingers engaging the other rack. Since the racks move in opposite directions with respect to one another, it is apparent that the forward and rearward fingers will rotate oppositely. That is, all of the forward fingers will rotate in a clockwise direction when all of the rearward fingers rotate in a counterclockwise direction, and vice versa. The pressurizing of cylinders 31 and 32 is controlled in accordance with the position of the flywheel of the extrusion machine, in a manner to be described hereinafter.
Referring now to FIGS. 3 and 4, the drive mechanism for the agitating fingers will now be described. The forward one of the fingers 27 is mounted on disc member 37 and the rearward one of the fingers 27 is mounted on disc member 38. Disc member 37 is press-fitted onto shaft 28 and disc member 38 is press-fitted onto cylindrical member 39. Cylindrical member 39 is pressfitted onto bushing 40 and is adapted to rotate freely about shaft 28. Connected to cylinder 39 is pinion gear 41 and connected to shaft 28 is pinion gear 42. Two openings 43 and 44 extend laterally through block 45 which is mounted on wall 19 of feed chamber 15. Inside opening 43 is rack gear 46 and inside opening 44 is rack gear 47. These rack gears are adapted to move freely within the respective openings. Rack gear 46 is connected to the rod of pneumatic cylinder 31 and rack gear 47 is connected to the rod of hydraulic cylinder 32. Rack gear 46 engages pinion gear 42 and rack gear 47 engages pinion gear 41. Pinion gear 42 is wider than rack 46 to allow the position of the forward agitating fingers to be adjusted relative to wall 19. It has been found that this position affects the density of the composition board.
FIG. 5 depicts a flywheel 48, the position of which is utilized to control the timing of the oscillation of the fingers 27. Flywheel 48 corresponds to the flywheel designated 40 in the aforementioned U.S. Patent. Attached to the rim of flywheel 48 is a target 49 which comprises a metal plate having slots therein. These slots are adapted to accept bolts 50 and 51 which are threaded into the rim of flywheel 48. The slots allow target 49 to be moved relative to flywheel 48 to compensate for the inherent delay of the hydraulic system as the speed of the extrusion machine is varied. Fixedly mounted on the extrusion machine and diametrically opposed with respect to flywheel 48 are sensors 52 and 53 which are illustratively of the type known as Autotron Model A930 proximity timing controls manufactured by Autotron, Inc. of Danville, Illinois. These sensors have coils therein and inductively sense the presence of target 49 thereunder. One of the sensors corresponds to piston 18 being in the fully retracted position to cause the fingers 27 to oscillate in a first direction and the other sensor corresponds to piston 18 being in a fully extended position to cause fingers 27 to oscillate in the second direction. In the schematic diagram of FIG. 6, sensors 52 and 53 are illustratively depicted as switches for closing energization circuits for respective solenoids 54 and 55. Solenoids 54 and 55 are connected to opposite ends of a spool valve 56 which is illustratively of the type known as Model QM-005-0-10Bl manufactured by the AA Company of Manchester, Michigan. Spool valve 56 is connected in a hydraulic circuit which includes a reservoir of hydraulic fluid 57 and a pump 58. With the spool valve in the position shown in FIG. 6, pump 58 supplies hydraulic fluid under pressure to cylinders 31 and 32 so as to pull rack 46 towards cylinder 31 and to push rack 47 away from cylinder 32. When target 49 passes under sensor 53, solenoid 55 is energized, pulling the spool within spool valve 56 toward the right. In this position, the pressurization path for pump 58 is reversed with respect to cylinders 31 and 32 and rack 46 is pushed away from cylinder 31 while rack 47 is pulled towards cylinder 32. It is thus seen that with racks 46 and 47 engaging their respective pinion gears 41 and 42, the forward and rearward fingers oscillate in opposite directions. The hydraulic system of FIG. 6 has inherent delay such that the elapsed time from sensing target 49 by one of the sensors 52 or 53 to the time that the fingers oscillate is constant while the speed of the piston 18 may vary. Therefore, the target 49 must be adjusted so that the hydraulic system operation will either lag or lead the piston movement to compensate for the piston speed. It is readily apparent that the target 49 and sensors 52 and 53 may be replaced by a shaft encoder whereby the hydraulic system timing may be electronically changed as a function of piston speed rather than by mechanically adjusting the position of target 49.
To provide agitation to the composition board constituent material which drops into feed chamber 15 over a channel 59 directly adjacent the end wall 60 of feed chamber 15, there is provided a wheel 61 adapted to rotate within a corresponding opening in wall 60. Wheel 61 is spun by hydraulic motor 62, mounted on wall 60. Extending outward from wheel 61 into feed chamber 15 are a plurality, illustratively four, of pins 63 which agitate the constituent material to maintain the proper density of the manufactured board in the rib corresponding to channel 59.
It is desirable that the legs 14 and planar area 11 of the product be of uniform density. It has been discovered that density of the legs can be controlled by controlling the time at which oscillation of the fingers is initiated relative to initiation of movement of the piston. The legs can be made denser by initiating oscillation of the fingers earlier relative to movement of the piston. Conversely, a less dense leg is produced if initiation of oscillation is delayed. As indicated previously, the time at which oscillation should be initiated in order to maintain a constancy will vary as the rate at which the plunger is reciprocated varies. For higher rates of reciprocation of the plunger, oscillation of the fingers should be initiated earlier, and, conversely, oscillation of the fingers should be initiated later if the rate of reciprocation of the plunger is descreased.
Numerous other variations or modifications and adaptations of the present invention will be apparent to those skilled in the art. For example, other means, such as a shaft encoder can be used for providing signals indicative of the position of the plunger, and such as come within the spirit and scope of the appended claims are considered to be embraced by the present invention. | Method and apparatus for making composition board having a planar surface and legs by an extrusion process from its constituent materials wherein there is provided an improved agitation mechanism for insuring the uniform dispersion of constituent material in the legs of the mold. The improved mechanism includes a plurality of pairs of agitation fingers, each pair adapted to oscillate in opposite directions about the same axis. Separate rack and pinion arrangements control the oscillation of respective fingers of the pairs. A pair of hydraulic cylinders controls the movement of the racks, the pinions being coupled to the fingers. The hydraulic cylinders are arranged in a control circuit, the operation of which is timed by a flywheel on the extrusion apparatus. The improved mechanism includes means for adjusting the timing of the finger oscillation relative to movement of a piston driven by the flywheel for optimum operation. Density of the legs of the board is controlled by controlling the timing. | 1 |
[0001] This application claims priority to U.S. Provisional Application No. 60/626,912, filed on Nov. 12, 2004, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention generally relates to structural supports. In particular, this invention relates to structural supports for, for example, wind turbines, or the like.
[0004] 2. Description of Related Art
[0005] Conventional offshore platforms have deck legs that are vertical or are battered outward as they extend downwards. The conventional arrangement provides structurally efficient support for the deck but the associated dimensions of the platform at the water surface result in increased expense for the platform.
[0006] Wind turbines have traditionally been supported on mono-piles when placed offshore. However, recently, efforts have taken place to position wind turbines in deeper water (approximately six to seven or more miles offshore) in part to increase the aesthetics of the view from the shoreline. However, with the movement of wind turbines further offshore, the employment of mono-piles as the base on which wind turbines are placed has become less cost effective.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention is directed to a wind turbine in combination with a structure support that provides a sturdy and cost effective support even in deep waters. This combination includes a wind turbine comprising a base and a blade mechanism. The structure support further includes at least three elements configured in a substantially teepee shaped configuration, where the at least three elements encompassing a substantially vertical member. A first end of the at least three elements is capable of being affixed to a structure and a second end of the at least three elements adapted to be in contact with a surface. The at least three elements intersect between the first end and the second end. The combination also includes a mounting flange connecting the structure support to the wind turbine.
[0008] In accordance with a further embodiment of the present invention the at least three elements intersect above a waterline or at a waterline.
[0009] In accordance with another exemplary aspect of the present invention, a method of constructing a wind turbine on a structure support is disclosed. At least three legs are provided in a teepee configuration. A first end of the first three legs are placed on a mounting surface and a deck is affixed to a second end of the at least three legs. A wind turbine mounting flange is affixed to the structure and a base is affixed to the mounting frame and turbine element is affixed to the base. A blade mechanism affixed to the turbine element.
[0010] These and other features and advantages of this invention are described in or are apparent from the following detailed description of the embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The embodiments of the invention will be described in detail, with reference to the following figures, wherein:
[0012] FIG. 1 is a view in side elevation of an offshore platform according to the present invention;
[0013] FIG. 2 is a view in front elevation of the offshore platform according to the present invention;
[0014] FIG. 3 is a perspective view of the offshore platform with a wind turbine placed on a deck of the platform according to the present invention;
[0015] FIG. 4 is a side perspective view of the offshore platform with a wind turbine placed on the deck of the platform according to the present invention;
[0016] FIGS. 5-18 illustrate an exemplary method of assembling the offshore structure and wind turbine according to this invention;
[0017] FIGS. 19-21 illustrate another exemplary method of assembling the offshore structure and wind turbine according to this invention;
[0018] FIGS. 22 and 23 illustrate another exemplary offshore structure support foundation according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The exemplary embodiments of this invention will be described in relation to a support structure, such as an oil and gas platform or a platform for the placement of additional structures, supported by three piles and a central vertical member, such as drill pipe. However, to avoid unnecessarily obscuring the present invention, the following description omits well-known structures and devices that may be shown in block diagram form or otherwise summarized. For the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated that the present invention may be practiced in a variety of ways beyond these specific details. For example, the systems and methods of this invention can be generally expanded and applied to support any type of structure. Furthermore, while exemplary distances and scales are shown in the figures, it is to be appreciated the systems and methods of this invention can be varied to fit any particular implementation.
[0020] FIGS. 1 and 2 show an inward battered guide offshore platform indicated generally at 10 in which battered bracing piles 12 a , 12 c and 12 e are arranged so as to minimize platform dimensions at the water surface 14 while maximizing the spacing of the piles as they extend upward from the water surface so that loads from a deck 16 at the top of the piles are transferred directly to the piling. For example, if three or more piles are employed to create the structure, they could be spaced apart 120 degrees. Piles 12 b and 12 d are conductor piles used in oil and gas platforms.
[0021] The platform includes a pile guide structure 18 which fits over and is connected to a central vertical member 20 to receive the piles 12 a , 12 c and 12 e at the water surface. The piles extend angularly through guides 22 of the pile guide structure in such a manner that the distance between piles is minimized at the water surface, but the distances between angled piles is maximized both at the ends supporting the deck 16 as well as at the opposed end buried below the mudline 24 . The pile guide connects the piles to act in unison to restrain lateral movement of the entire offshore platform 10 including the central vertical member 20 .
[0022] The pile guide 18 also supports appurtenances such as ladders, boat landings, stairs, or the like, so that they can be installed in the field as a unit, thereby, for example, reducing installation expense for the platform. The legs 26 of the deck structure are connected to the tops of the piles. The increased pile spacing at the pile tops provides, for example, more structurally efficient support for the deck, reduced structural vibration periods for the platform and increased resistance to the rotation that results if the deck mass is eccentric to the central vertical member 20 than if the deck is supported by the central member. All field connections can be made above the water surface where structural integrity of the connections can be more easily verified than if the connections were made below the water surface.
[0023] Once the piles 12 a , 12 c and 12 e are in place, and the legs 26 and deck 16 are placed on the piles then, as shown in FIGS. 3 and 4 , a wind turbine 100 can be installed. FIGS. 3 and 4 show two different perspective views of the wind turbine 100 when installed on the deck 16 of platform 10 . The wind turbine 100 comprises: a base 125 including a lower section 110 and an upper section 120 ; a turbine element 130 ; and a blade mechanism 150 that comprises a rotor star 152 and individual blades 154 . While the wind turbine described herein comprises a base 125 and three individual blades 154 , other types of wind turbines can also be employed with the structure of FIG. 1 , for example, in the manner described above. For example, a wind turbine with a single base part or having a multitude of parts that make up the base can be employed. Moreover, the wind turbine can also include more or a lesser number of blades as well as different types of blade mechanisms.
[0024] FIGS. 5-19 illustrate an exemplary method for assembling a the platform 10 and wind turbine 100 in accordance with an exemplary embodiment of this invention with, for example, a barge boat, around a substantially vertical member 20 such as SSC 50 (Self Sustaining Caisson). In this exemplary embodiment, the SSC 50 has been installed by an oil and gas drilling rig, such as a rig drilling an exploration well. The vertical member 20 (SSC 50 ) can either be installed when the platform is assembled or alternately, the remaining parts of the platform can be assembled around a previously erected vertical member. This enables the platform to be advantageously built on existing already used oil drill caissons or mono-piles to support oil and gas wells.
[0025] In FIG. 5 , the position and orientation of the legs are determined and a lift boat 55 anchored and jacked-up relative to the installation point of the SSC 50 . Next, as illustrated in FIG. 6 , the guide structure 18 is unloaded from the barge 60 . Then, as illustrated in FIG. 7 , the piles 12 a , 12 c and 12 e , are unloaded, placed in the guide structure, and in FIG. 8 , installed via the guide structure into, for example, the ocean floor with the aid of a pile driving hammer (e.g., a hydraulic hammer). As can be seen from this illustration, the piles 12 a , 12 c and 12 e intersect at a point just above the water line. This allows, for example, the piles and all associated connections to be made above water. However, one would also understand that the intersection point could also reside at or below the waterline.
[0026] In FIG. 9 , the barge 60 is relocated and the deck 16 is unloaded. In FIG. 10 the deck 16 including legs 26 are installed on the piles. In accordance with an exemplary embodiment of the invention, the deck can be modified to employ and support a wind turbine 100 . Specifically to support the turbine a mounted flange can be built on the deck 16 . The flange can be attached to the deck via bolting, grouting or welding. Although as illustrated in FIG. 10 , the mounting flange 200 is shown being attached to the deck prior to placement on the legs 26 , the mounting flange 200 could be installed after the deck has been installed. FIGS. 11 and 12 provide a side view and top view of the deck 16 and mounting flange 200 when installed.
[0027] As illustrated in FIG. 13 , once the mounting flange 200 is placed and set onto the deck 16 , the tower lower section 110 is unloaded from the lift boat 55 and installed onto the mounting frame 200 . Next, as illustrated in FIG. 14 , the upper section 120 of the tower is unloaded and installed onto the tower lower section 110 . Once the upper section 120 of the base has been installed, as illustrated in FIGS. 15 and 16 , the turbine 130 is removed from the lift boat and attached to the upper section 120 of the tower.
[0028] As the tower lower section 110 , tower upper section 120 and turbine 130 are installed, the blade mechanism 150 is readied for installation. The installation of this part of the wind turbine 100 can be performed in a plurality of different ways, in accordance with the present invention, as discussed below.
[0029] In accordance with one exemplary embodiment of the present invention, as illustrated in FIGS. 17 and 18 , the complete, blade mechanism already fully assembled is unloaded from the lift boat 55 and attached to the turbine 130 .
[0030] Alternatively, as illustrated in FIGS. 19-21 , the blade mechanism does not need to be fully assembled prior to attachment to the turbine 130 . This is advantageous for several different reasons. The blade mechanism, if fully assembled would require extra stowage area for transport to the assembly area. If, for example, only two of the blades were assembled, then to the rotor star, then the required space needed to transport the blade mechanism is reduced. Furthermore, if the remaining blade is not attached to the rotor star until it is already attached to the turbine, additional monetary savings can be achieved since the crane employed to attach the blade can be smaller. In FIG. 19 , the blade mechanism having the two blades attached to the rotor star is raised (via a crane) and attached to the turbine (as illustrated in FIG. 20 ). Finally, in FIG. 21 , the remaining blade 158 is attached to the rotor star. Again, FIGS. 3 and 4 provide a side views of the assembled wind turbine on the offshore structure support 10 .
[0031] In accordance with another exemplary aspect of the present invention, a deck and associated mounting flange 300 is provided to receive a wind turbine, as illustrated in FIGS. 22 and 23 . Specifically, the mounting flange 300 includes a body 310 and an elliptical (or spherical) head 320 extending below deck 16 . The body 310 is circular and includes a deck end 312 and a head end 314 portion. A wind turbine 100 is able to be attached to the foundation body 310 at the deck end 312 of the foundation body, via bolting, for example. The foundation body 310 is also able to receive legs 26 that are connected to the batter bracing piles 12 a , 12 c and 12 e . Note that four piles are illustrated in FIG. 22 .
[0032] The elliptical (or spherical) head 320 is attached to the foundation body 310 at its deck leg connection end and enables the turbine foundation 300 a more fatigue resistant connection at the deck leg. For this same reason, as illustrated in FIG. 22 , the ends of the legs 26 also employ a curved surface. By making the intersection between the foundation body 310 and the elliptical (or spherical) head 320 as well as foundation body 310 and the elliptical shape of the legs 26 , a continuously curved intersection is provide and a sharp corner is avoided. As a result, hot spot stresses are reduced on the joints.
[0033] Additionally in accordance with the present embodiment discussed with regard to FIGS. 22 and 23 , the deck 16 includes structural support elements extending from the deck end of the turbine foundation to the edge of the deck 16 . While the deck 16 in the embodiment shown in FIG. 23 is illustrated as octagonal, one could understand that the deck could be made to be other shapes also, (e.g., hexagonal, rectangular, circular, or the like).
[0034] In accordance with another aspect of the present invention, the natural period of the offshore support structure can be adjusted to avoid the excessive vibration of the wind turbine while operating that would result if the natural period of the support structure was too close to matching the rotational period of the turbine. This tuning of the natural period can be accomplished by changing the size of the components of the support structure, by increasing or decreasing the batter of the piles, adjusting the spacing of the piles and/or by raising or lowering the elevations where the piles are laterally supported. The extent and combination of tuning measures required vary depending on the design and operational characteristics of the wind turbine and the water depth, meteorological and oceanographic conditions and soil characteristics at the location.
[0035] For example, a typical three blade wind turbine is controlled by adjusting blade pitch to make one rotation about every 4.5 seconds in most wind conditions. Therefore, for a typical wind turbine one of the three blades would than pass the wind turbine support tower every 1.5 seconds. To avoid the wind turbine rotational periods and limit potential for destructive resonance, frequency forbidden zones are established for the natural frequency of the entire support structure. For a typical wind turbine the forbidden natural frequency zones could be 0.18 Hz to 0.28 Hz and 0.50 Hz to 0.80 Hz. Likewise, the target natural frequency would be 0.30 Hz to 0.33 Hz and higher order natural frequencies should be above 0.80 Hz. If computed eignfrequencies are in a forbidden zone tuning will be necessary. Tuning can then be accomplished in the manner discussed above.
[0036] It is, therefore, apparent that there has been provided, in accordance with the present invention, a support and method for assembling a wind turbine for placement on an offshore support structure. While this invention has been described in conjunction with a number of illustrative embodiments, it is evident that many alternatives, modifications, and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, the disclosure is intended to embrace all such alternatives, modifications, equivalents and variations that are within in the spirit and scope of this invention. | A pile based braced caisson structural support device includes a number of legs in is used to support a wind turbine. The wind turbine includes a base, a turbine generator and a blade mechanism. The legs are configured in a teepee type configuration such that the footprint of the base is larger than the footprint of the opposing end. This structural support can be used as a base for an offshore platform in that the support reduces the lateral forces on the support caused by wave action. | 4 |
RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 10/052,492, filed Jan. 23, 2002, which is a continuation of Ser. No. 09/008,584 filed Jan. 16, 1998, which is a continuation in part of application Ser. No. 08/850,726 filed May 2, 1997, which is a continuation in part of application Ser. No. 08/684,004 filed Jul. 19, 1996 (the specifications of which are all herein incorporated by reference)
INTRODUCTION TO THE INVENTION
[0002] This invention relates to the installation of decorative coverings. It has been shown in the present inventor's first patent U.S. Pat. No. 4,822,658 that carpets having a looped backing can be conveniently installed on a floor by the use of complementary hooked tape. One of the primary ways disclosed in that patent is attaching the tape to the floor at the perimeter and seams (hereinafter “perimeter and seam” installation). The present inventor has also developed an anchor sheet which is described in U.S. patent application Ser. No. 08/684,004 filed Jul. 19, 1996, and continuation-in-part application Ser. No. 08/850,726 filed May 2, 1997. Rather than attaching the carpet directly to a hooked tape attached to the floor, an intermediate thin flexible relatively rigid anchor sheet is provided which gives rigidity and integrity and mass to the overlying pieces of carpet covering. The anchor sheet can be covered in hooks. The carpet has an underlying looped backing for attachment to the hooks. The carpet can be in pieces which overlap the anchor sheet pieces to provide rigidity and strength to the total unit.
[0003] The perimeter and seam method and the anchor sheet structure and method can both be used and will both work. However in some circumstances it may be advisable to use a combination of both methods in which a form of anchor sheet provides a stable framework into which either a cushion or a covering material or both can be inserted either attached to the floor by a hook and loop attachment method or as a “free float” within the framework. In these circumstances, the anchor sheet can be a support for a covering unit attached to the anchor sheet by hook and loop as shown in the earlier related cases. Carpet within the framework can then be installed with hook and loop or in a conventional manner, i.e., without hook and loop, by glue down or even by free floating.
[0004] In some circumstances the hook tape of a perimeter and seam installation can be the “framework” within which an anchor sheet installation can be made. In this case the anchor sheet may float within the framework created by hook tape attached to a floor. Additional methods of attaching a tape framework and a tape framework construction are disclosed as well as other methods of installing an anchor sheet as a framework, including the use of a form or jig.
BACKGROUND OF THE INVENTION
[0005] The need for flexibility in installing floor coverings is well known. Most floor coverings must be cut and fit on site and therefore must be flexible to provide for different physical limitations. In addition subflooring and supporting substrates differ widely in both quality and type, even in new construction. In old construction existing flooring may remain and present problems.
[0006] The background to the invention is substantially shown in the present inventor's prior issued patents U.S. Pat. No. 4,822,658 (Apr. 18, 1989, Pacione); U.S. Pat. No. 5,191,692 (Mar. 9, 1993, Pacione); U.S. Pat. No. 5,382,462 (Jan. 17, 1995, Pacione); and U.S. Pat. No. 5,479,755 (Jan. 2, 1996, Pacione). In addition attempts to make structural semi-permanent flooring and wall material incorporating a hook surface is also disclosed in the present inventor's earlier anchor board system U.S. Pat. No. 5,060,443 (Oct. 29, 1991, Pacione); U.S. Pat. No. 5,259,163 (Nov. 9, 1993, Pacione); and U.S. Pat. No. 5,144,786 (Sep. 8, 1992, Pacione).
SUMMARY OF THE INVENTION
[0007] A thin rigid but flexible anchor sheet has advantages to stabilize the overlying carpet to provide a relatively rigid subfloor for installation of an overlying carpet. When a resilient backing of cushioning material is attached to or supplied under such anchor sheet, the anchor sheet provides a novel subfloor which has significant advantages over existing underpads.
[0008] We have described the anchor sheet as both “flexible” and “rigid”. It is flexible in the sense that over a reasonable length it can bend and in most circumstances can even be rolled with a radius of curvature for example of perhaps 3 or 4 inches unlike for example plywood. It is rigid in the sense that if held at one end it can support itself for instance over a distance of 12-24 inches without drooping unlike a cloth or fabric tape.
[0009] It is not commonly appreciated that an underpad, while it provides resiliency, can lead to degradation in the overlying decorative textile surface. This is because the resiliency allows for the carpet to deform when walked upon or when furniture or other items are placed on the carpet. This deformation can, if it is not properly supported from below, result in crushing and eventual deterioration of the carpet structure.
[0010] The anchor sheet of this invention has a relatively rigid yet flexible thin sheet material, preferably a plastic or of a polymer material such as a polyester, polycarbonate, polypropylene or even a graphite or other advanced polymer material overlying a resilient cushion. This structure provides a surprising amount of resiliency and cushioning to the carpet. However because the overlying anchor sheet is relatively rigid, the carpet fibres are protected from crushing and therefore the life of the carpet is significantly extended while still appearing to have a sufficient degree of resiliency.
[0011] In order to provide the proper degree of resilience in the hooks and the proper degree of rigidity to the sheet, the hooks and sheets may need to be made from, for example, different plastic materials by lamination or coextrusion.
[0012] To the inventor's knowledge no person, until disclosed in this and the earlier related applications, has had the relatively unconventional idea of covering a resilient material with a thin flexible relatively rigid sheet material.
[0013] Thus the invention comprises in, one aspect, an anchor sheet subfloor comprising a laminate having an upper layer of a relatively thin and flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material.
[0014] While not as pronounced, the advantages of a relatively rigid but flexible anchor sheet to create a smooth subfloor and to tie overlying carpet pieces together into a stable mass can to some extent be achieved even without a resilient undercushioning. Thus the invention comprises in another aspect a relatively thin flexible rigid sheet material preferably of plastic or polymer which can be cut and fit on site to fit the contours of a room or other area to be covered to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be laid decorative covering pieces.
[0015] In another aspect the invention comprises a carpet and subfloor comprising a first layer of relatively resilient cushioning material overlaying the floor. A second layer of a thin flexible rigid polymer material overlaying the first layer and hooks covering at least a portion of the top surface of the second layer and a carpet having an undersurface covered in loops and detachably attached to the hooks covering the second layer to form a coherent stable carpet structure.
[0016] In another aspect, the subfloor and structure created by the first resilient layer and the second layer of anchor sheet, can be covered across its surface by perimeter and seam hooked tape so as to allow for installation of a carpet on the subfloor in accordance with the method described in U.S. Pat. No. 4,822,658. In this case the subfloor is actually not attached to the floor directly but is normally “floating” but this may be sufficient, in many installations, to stabilize the carpet.
[0017] As previously described, in some circumstances, the anchor sheet can act as a framework for either a carpet or an underpad or both. Thus, in another aspect, the invention covers an anchor sheet, carpet and an underpad combination for installing a carpet or underpad onto a floor comprising an anchor sheet installed along the perimeter of an area to be covered, describing and bounding that area, hook tape attached to the sheet along the perimeter of the upper face of the anchor sheet and a resilient underpad of a height matching the height of the anchor sheet sized to fit within the area bounded by the anchor sheet. A carpet having an underside covered in loops can then be overlaid. The anchor sheet perimeter and the resilient underpad may be either free floating or installed in a conventional manner within the anchor sheet framework.
[0018] A more complex anchor sheet framework can also be formed consisting of modular covering units made as disclosed in related application Ser. No. 08/850,726. Thus in another aspect the invention comprises a modular framework for carpet installation comprising a plurality of covering modules having decorative coverings attached to a thin flexible rigid anchor sheet so as to leave exposed overlapping areas of anchor sheet or covering for detachable attachment and interlocking relationship to an adjoining module as disclosed in related application Ser. No. 08/850,726. In this aspect of the invention, the modules are then detachably interlocked to define and enclose an area. Carpet or underpad or carpet and underpad depending upon the height of the framework created, is then cut and fit within the area defined by the covering modules.
[0019] As previously mentioned, an anchor sheet subfloor can also be installed within a perimeter bounded by hooked tape, in effect creating a hooked tape framework. In this aspect of the invention, a perimeter of hooked tape is attached to the floor. The tape may be of a form disclosed in, for instance, U.S. Pat. No. 5,382,462 or having a tape with a cushioned backing or a tape with a foundation sheet as disclosed in the present application.
[0020] In this aspect of the invention, a thin rigid flexible anchor sheet having an upper surface having a plurality of hooks in which the anchor sheet or anchor sheet and cushion is substantially the same height as the tape can then be cut and fit within the area bounded by the hooked tape to provide for a surface underlayment over which a carpet or other decorative covering having a looped backing can be installed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Embodiments of the invention will now be described, reference being had to the accompanying drawings, wherein:
[0022] [0022]FIG. 1 shows covering modules and a jig for installation.
[0023] [0023]FIG. 2 shows the covering modules and jig in the process of installation to a floor.
[0024] [0024]FIG. 3 shows the next step in installation of the covering module and jig.
[0025] [0025]FIG. 4 shows the finished covering module framework.
[0026] [0026]FIG. 5 shows the covering module framework at the commencement of the installation of an inserted cushion or carpet.
[0027] [0027]FIG. 6 shows the completed covering.
[0028] [0028]FIG. 7 shows the anchor sheet perimeter arrangement.
[0029] [0029]FIG. 7A shows another form of anchor sheet perimeter arrangement similar to that shown in FIG. 7.
[0030] [0030]FIG. 8 shows another form of anchor sheet perimeter arrangement in which the anchor sheet carries a decorative covering which contains a border pattern.
[0031] [0031]FIG. 8A shows a completed anchor sheet perimeter arrangement.
[0032] [0032]FIG. 9 shows a form of anchor sheet upon which is installed a perimeter and seam hook and loop tape arrangement.
[0033] [0033]FIG. 10 shows a form of tape suitable for use in a perimeter arrangement.
[0034] [0034]FIG. 11 shows a cross-section of a perimeter arrangement having a hooked tape bounding an area of anchor sheet and an overlying decorative covering.
[0035] [0035]FIG. 12 shows an arrangement of anchor sheet providing a border.
[0036] [0036]FIG. 13 shows another border arrangement with anchor sheet and cushion.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] In FIG. 1 is shown a variety of covering modules 2 and 4 . These are similar to the type of covering modules disclosed in related case Ser. No. 08/850,726. In the case of covering module 2 there is an anchor sheet 6 larger than the decorative covering piece 8 . In the case of covering module 4 there is a decorative covering piece 10 which overlaps the anchor sheet 12 .
[0038] Normally the anchor sheet areas would be substantially covered in hooks 14 as shown in only representative detail. The overlapping pieces 10 will have on their undersurface loops (not shown) for attachment to the exposed hooks. 14 of anchor sheet, for instance, 6.
[0039] A jig or pattern 16 is also shown in FIG. 1. Its use will become apparent.
[0040] The jig at 16 has corners for instance 18 and 19 which serve to locate the corresponding corners of decorative covering piece 8 at each of the four corners of the jig. Thus the covering modules are separated and appropriately spaced in the desired location. Covering module 4 can then be inserted along the sides of the jig abutting the jig as shown. Loops on the undersurface of covering piece 10 (not shown) will enable the covering piece to be installed in detachable attachment in a manner shown in related case Ser. No. 08/850,726 preferably by the use of a smooth slip cover as disclosed in related U.S. patent application Ser. No. 08/850,726. The slip cover can be a hard smooth piece temporarily inserted. It can then be removed when the pieces are in position and the covering modules will form a framework as shown in FIG. 3, in which pieces 4 and pieces 2 have combined to create a structure. Jig 16 is then removed as shown in FIG. 4 so that the anchor sheet framework now lies upon and circumscribes an area of floor 21 and also an area of hooked anchor sheet 20 which is at a different level than the surface of decorative covering 22 .
[0041] As shown in FIG. 5 a decorative covering unit 24 can be inserted into the framework 26 . The unit may be carpet having a looped backing (not shown) in which case the carpet would be detachably attached to hooks 28 in the area shown. Normally the complete area would be covered in hooks but only representative samples are shown.
[0042] If desired the floor area 21 could be made level with the hooked area 28 by the use of an anchor sheet of suitable thickness, also covered with hooks or smooth, or by the installation of a pad. The area of floor 21 could be left empty because of the low profile of the hooked area 20 .
[0043] [0043]FIG. 6 shows the unfinished subunit which is ready to be attached by hooks 30 to other adjoining anchor sheet units or covering modules.
[0044] In FIG. 7 is shown another form of anchor sheet perimeter installation in which an anchor sheet 32 is formed having a thin rigid flexible covering 34 preferably formed of a plastic or polymer material as described in related application Ser. No. 08/850,726 preferably of a polypropylene, polycarbonate or polyester material and laminated and bonded thereto is a resilient cushion 36 of polyurethane foam or other similar carpet underpad material. Similar anchor sheet units 32 A and 32 B are placed on the floor in abutting relation and the units may be joined together by a pressure sensitive adhesive hooked tape 38 overlying the seams of the anchor sheets or by plain single-sided pressure sensitive tape. Additional hooked tape 40 is added to the perimeter of the anchor sheet installation to provide for a regular perimeter and seam installation as shown in U.S. Pat. No. 4,822,658. It would be convenient if the tape covering joins 41 line up with carpet seams but if they do not, additional tape can be installed on the anchor sheet 32 to provide for at least seam coverage.
[0045] Of course if plain tape is used, then hooked tape will normally have to be installed at the carpet seams. Such tape is normally covered prior to installation. Full coverage could also be provided either by adding more hooked tape or by providing anchor sheet 32 with a flexible sheet pre-manufactured with a complete hook covering.
[0046] In FIG. 7A is shown an additional similar form of arrangement which combines a hooked tape 42 to be described later at the perimeter of the room, an underpad or anchor sheet with underpad 44 , an additional anchor sheet with underpad 46 , conventional underpads 48 and 50 and anchor sheets 52 and 54 with resilient cushioning and then tape 56 . Thus a complete resilient underlayment is created which is partly a framework made by tape 42 and anchor sheets 44 , 46 , 52 and 54 within which are contained conventional underpads 48 and 50 . A carpet can then be installed over top of this by perimeter and seam tape using tape 42 and 56 at the perimeter and tape 53 at the seams or by the use of an additional anchor sheet (not shown) to provide for decorative surface covering pieces. As shown in FIG. 8 an additional foundation sheet 58 of a similar material to the anchor sheet can have pre-attached permanently or detachably an anchor sheet 60 having a resilient undercushion 62 . The anchor sheet 60 could be one as shown in related application Ser. No. 08/850,726 having its upper surface substantially covered in hooks 64 . Decorative cover pieces, in this case carpet units 65 , can then be installed in any pattern over the anchor sheet. In the example given in FIG. 8 they are installed in a border pattern. When fully assembled as shown in FIG. 8A such a unit can create a framework within which carpet can be installed in a conventional way, or using hook and loop or perimeter and seam or in a small enough area free floated within the area bounded by the decorative border 66 as shown in FIG. 8A.
[0047] [0047]FIG. 9 shows an arrangement similar to FIG. 7 in which there is an anchor sheet and resilient cushion framework 68 on either side of conventional carpet pads 70 . The conventional carpet pads may be free floating or attached to the floor in a conventional manner. Normally if the anchor sheets 68 are on the perimeter of the room and abut, for instance, wall 71 on one side and wall 72 on the other side, the whole structure can be “free floating” in the sense that it is not attached to the floor. Hook tape 74 can be installed at the perimeter. Suspended tape 76 at the seams provides a form of perimeter and seam installation over top of a conventional cushion or a partial anchor sheet and conventional cushion. The carpet or other decorative surface covering has loops on its undersurface at 80 (not shown) for detachable attachment to hooks 81 on tape pieces 74 and 76 .
[0048] [0048]FIG. 10 shows a form of hook tape that can be used to create a perimeter for the installation of a conventional underpad 87 . This tape has a foundation layer 82 to which is attached the tape 84 having a resilient cushion layer 86 . The tape is hook tape and contains across its surface resilient hooks 88 . It normally would be supplied with a tape covering 90 . The foundation sheet 82 allows for a lip or area so that the hook tape may be stapled or nailed through the sheet 82 or through tape 84 to the floor or it can be installed using double-sided adhesive tape 92 or by hook and loop or by a conventional method.
[0049] Another form of tape 94 is also shown having foundation sheets 96 and 98 on both sides of the tape. The tape could be stapled to a floor and within the framework bounded by the tape could be inserted an appropriate underpad which could either be installed in a conventional manner or free floating between the tape and an overlying anchor sheet or an anchor sheet having hooked covering (not shown) could also be installed within the area bounded by the tape.
[0050] In FIG. 11 is shown a cross-section of hooked tape 100 having cushion 102 attached to the floor.
[0051] If the tape is as shown in FIG. 10 it could have foundation sheet 82 for installation. Anchor sheet 104 with (as shown) or without an attached resilient cushion can then be inserted within the area bounded by hooked tape 100 and a decorative covering 106 having an undersurface covered in loops 107 could be installed across the area created by the hooked tape and anchor sheet.
[0052] [0052]FIG. 12 shows an arrangement in which an anchor sheet 108 is provided with hooks at least over the exposed area 110 shown and also under carpet pieces 112 and border pieces 114 , 116 and 118 . Border pieces 114 , 116 and 118 may be detachably attached to anchor sheet 108 in a pattern and anchor sheet 108 with such pieces could be sold as a preassembled unit. Such piece could be attached to a floor by pressure sensitive adhesive, with hook and loop or by nailing through sheet 108 . Carpet 112 having a loop backing and a pile surface 120 could then be installed and attached to hooks on anchor sheet 110 .
[0053] [0053]FIG. 13 shows another arrangement, in which anchor sheet 122 , has a resilient cushion 124 and a carpet covering piece 126 detachably attached to the anchor sheet. A conventional cushion 128 can abut the anchor sheet and cushion and a carpet 130 having a loop backing 132 can be installed over the anchor sheet 122 and cushion 128 .
[0054] It will be recognized that within the description of this present case and the related earlier pending cases many variations and permutations and combinations are possible of anchor sheet and tape with or without cushion and with or without installation directly to the floor all of which come within the spirit of the described invention as defined in the attached claims. | An anchor sheet subfloor that includes a laminate having an upper layer of relatively thin flexible rigid sheet material and a bottom layer of a relatively resilient cushioning material. The upper sheet layer can be formed of a plastic or polymer material. In one arrangement, the sheet can be cut and fit within the boundaries of a room and the sheet has sufficient rigidity and mass to remain without distortion or buckling within the room by free floating on the existing floor without substantial attachment to the floor. It can be possible for a sheet to be cut and fit on site to fit the contours of a room to form by itself or in combination with other anchor sheets a free floating smooth subfloor on which can be overlaid decorative covering pieces. | 4 |
This application is a continuation-in-part of Ser. No. 07/881,732 filed May 11, 1992, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to window actuators for use in opening and closing single hung, double hung and horizontal sliding windows, with either a mechanical crank or power actuators which complies with: the requirements set forth in ANSI A117.1 as referenced by the Americans With Disabilities Act; and Chapter 12, 1204 of the 1991 Uniform Building Code ("Access and Exit Facilities and Emergency Escapes"). The invention can be used in both after market window conversions or can be incorporated into the design and manufacture of new window units.
DESCRIPTION OF THE PRIOR ART
Single hung, double hung and horizontal sliding windows are well known in the prior art. Actuating mechanisms for such windows, both mechanical and electrical, are also known.
A. A. Monson's Automatic Window Opener, U.S. Pat. No. 970,380, is designed exclusively for dual electric motor power activation that is dependant on an intact sash counterbalancing system. The opener includes a pair of electric motors D and D 1 , a pair of endless chains E, each including a counter weight 11 and a helical spring 12. It is stated that the weights 11 counteract the weight of the lower sash "so that it can be raised and lowered with a small amount of power." Springs 12 "tend to take the strain off of the motors when the sash C closes against the lower end of the window frame before the current is cut off from the motors." Pull on both sides of the window sash is not synchronized. There are no provisions for manual hand crank operation. Finally, this device is not for retrofit application and is intended only for permanent installation as part of the original window assembly, to be incorporated in new construction.
U.S. Pat. No. 1,952,821 to B. F. Quintilian discloses a complicated crank mechanism, including a rotating drum and a centrifugal governor for opening and closing the lower sash of a double hung window. The system includes a "hoisting cable 5" which is securely attached at its opposite ends to the frame of the lower sash. Cable 5 is actuated by cable 16 which is, in turn, controlled by the crank mechanism.
The window operating mechanism of J. A. Jepsen, U.S. Pat. No. 1,963,790, is designed for operating the upper and lower sashes of a double hung window in both directions, independently of one another. The mechanism for opening and closing the upper sash includes a crank, a chain 8, a first steel ribbon 10 and a second steel ribbon 11. One end of the chain is connected to the lower end of the upper sash. Ribbon 10 is connected to the other end of chain 8 and to one of the upper corners of the upper sash. Ribbon 11 is connected at one end to ribbon 10; its other end passes over pulleys 13 and 16, and is connected to the other upper corner of the upper sash. The mechanism for the lower sash is essentially the same. J. A. Jepsen's window operator is only for incorporation into the manufacture of new window units and is not for a retrofit application to be attached to existing windows in a structure.
R. E. Elvers' Window Sash Operating Mechanism, U.S. Pat. No. 2,260,013, is similar to the above devices in that it is only intended to be integrated in the manufacture of window assemblies for installation in new construction; not as a retrofit on existing windows. This device includes a complicated pulley arrangement and depends upon counterbalancing weights for its mechanical advantage in raising and lowering the window sashes.
D. E. Hendrikson's Electrically Operated Window, U.S. Pat. No. 2,979,328, is, once again, only intended for newly manufactured window assemblies and can not be used as a retrofit to be added on to existing construction. The mechanism includes a pair of chains 8, both operated by reversible motor 15, and a single drive shaft 13. There is, however, no provision for adjustment or sash balancing.
U.S. Pat. No. 3,261,113 to S. M. March discloses a dual motor operated apparatus for moving a pair of chalk boards (10 and 11) up and down. Board 10 is provided with two chains C1 and C2 and one of the motors. C1 is attached to the upper left hand corner of board 10; C2, to the upper right hand corner. Similarly, board 11 is provided with two separate chains, C3 and C4, and the other motor. Chain C3 is attached to the upper left hand corner of board 11; C4, to the upper right hand corner. In all cases the chains (i.e., C1, C2, C3 and C4) are attached to their respective board corners by "an attaching bracket 12" with a "threaded connector 13 and nut 14". See column 2, line 18. In all cases, the opposite ends of the chains re connected to the frame, not the boards. Thus, C1 is secured to "wall 25" by a "pin 26". See column 2, lines 31-35. Chain C2 is attached to the same location. Similarly, chains C3 and C4 are attached to wall 25 a, which is on the opposite side of frame 15. The pulleys 23 and 33 over which chains C1 and C2 pass are moved laterally by motor 42 and threaded shaft 36 to raise and lower board 10. Lowering is accomplished by gravitational forces. Neither board 10 nor 11 is pulled down by any chain or pulley system.
It is the basic object of the present invention to provide for a window actuator for single hung, double hung and horizontal sliding windows which: can be both easily retrofitted on existing windows as well as easily incorporated into the manufacture of new window units; can be actuated by either a mechanical crank or electrical power; and in which the power of actuation will be 5 pounds force (lbf) or less (with single handed operation, requiring no tight grasping, or pinching, or twisting of the wrist for operation, and with all controls within easy reach), so as to comply with the requirements of ANSI A117.1 as referenced by the Americans with Disabilities Act and, additionally, comply with national building codes and the requirements set forth in the Life Safety Code NFPA 101.
It is also an object of the present invention to provide a window opening and closing mechanism which is synchronized for simultaneous pull on both sides of the window sash, in both the opening and closing modes, for smooth tracking and to resist binding of the sash.
It is another object of the invention to incorporate unique drive and passive side sash attachments that automatically compensate for unequal sash balancing, and are not dependent on an intact sash balancing system.
It is another object to: manufacture the window operating mechanism of the present invention with, primarily, off the shelf parts, for simplicity of manufacturing and cost reduction; and use miniature synchronous timing belts, which are capable of 90 degree bend rotation to simplify power transmission to the movable sash on both the drive and passive sides.
It is yet another object of the invention to provide a unique belt tensioning mechanism to prevent belt slippage.
It is still another object of the present invention to provide an actuator which, both as a retrofit and when incorporated into new windows: allows the sash to be opened fully to permit emergency egress as required by the national building codes; allows simple manual "free wheeling" opening of the sash to which it is attached, quickly and without disconnecting the actuator from the sash; meets all applicable national building codes, American National Standards Institute, Inc. (ANSI) accessibility standards, Americans with Disabilities Act (ADA), and the National Fire Protection Association (NFPA) requirements; permits ease of operation by the disabled, elderly and children; and is capable of translating a typical 30 lb spring balanced closing force to less than 5 lbf. A "free wheeling" opening allows the operator to rapidly open the window to the maximum physical opening allowed by the window itself, without an appreciable amount of extra effort imparted by the window actuator modification. Thus, the device adds no restriction to the original range of movement of the sash and creates little additional drag on the standard and emergency operation of the window.
It is also an object of the present invention to provide a window actuator with a unique three position latching mechanism which: holds the sash in an infinite number of positions from fully opened to closed; can be operated one handed; can be operated very easily from the same side as the cranking mechanism to permit use by the disabled, elderly and children without movement from side to side of the window; and is not dependant on a fully intact window balancing mechanism for operation.
SUMMARY OF THE INVENTION
A mechanism for opening and closing the sash of a window which includes first and second sash brackets, a drive mechanism, first and second flexible timing belts, structure for connecting the timing belts to the sash brackets and mechanisms for interconnecting the two timing belts. Each timing belt has first and second ends. On the drive side the structure for interconnecting the first and second ends of the drive timing belt includes first and second belt attachment mechanisms coupled to each other by an adjustable linkage, the adjustable linkage passing through a projecting tab on the sash bracket. Each belt attachment mechanism includes a projecting tab and the adjustable linkage includes a compression spring captured between one of such projecting tabs and the projecting tab on the sash bracket. The linkage includes means for adjusting the distance between the projecting tabs on the belt attachment mechanisms. A similar belt interconnecting structure is provided on the idler side of the mechanism.
The opening and closing mechanism also includes springs attached to the timing belts to insure that they remain in tension during operation, and a latch mechanism. A method of tensioning the timing belts is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the preferred embodiment of the present invention, retrofitted to a previously installed window, with covers partially removed;
FIG. 2 is an enlarged view of the belt attachment and balancing mechanism on the power or drive side of the preferred embodiment;
FIG. 2A is an enlarged exploded view of one of the belt attachment units which are parts of the mechanisms illustrated in FIGS. 2 and 3;
FIG. 2B is an enlarged sectional view of one of the attachment units, taken along line A--A of FIG. 2;
FIG. 3 is an enlarged view of the belt attachment and adjustment mechanism used on the idler side of the preferred embodiment;
FIG. 4A is an enlarged view of the belt closing tensioning spring on the drive side, with the spring in its contracted position;
FIG. 4B is an enlarged view of the belt tensioning spring of FIG. 4A, with the spring in its extended or idle position;
FIG. 4C is a sectional view of belt and tension spring taken through FIG. 4A along line C--C;
FIG. 4D is a sectional view of belt and tension spring taken through FIG. 4B along line D--D;
FIG. 5 is an enlarged, partially broken away, perspective view of the latch and crank mechanisms of FIG. 1;
FIG. 6 is a sectional view of the latch and crank mechanisms of FIG. 5;
FIG. 7A is a schematic showing the wedge of the latching mechanism of FIGS. 5 and 6 in the position where the sash cannot be further opened;
FIG. 7B is a schematic showing the wedge of the latching mechanism of FIGS. 5 and 6 in the position where the sash cannot be closed;
FIG. 8 is a partial front view of the present invention with an alternate power transfer mechanism shown partially in perspective; and
FIG. 9 is a bottom view of the separation and tensioning mechanism used in the embodiment of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, retrofit window actuating mechanism 11 is shown installed on a conventional single hung or double hung window 13. Window 13 includes a lower sash 15, an upper sash 17, sill 19, jambs 21 and 23 and head 25.
Actuating mechanism 11 includes an attachment and balancing system 31, a latch mechanism 33, a power pulley assembly 35, a power transfer assembly 37, and an attachment and adjustment system 39. Attachment system 31, pulley assembly 35, and power transfer assembly 37 are all interconnected by a standard 1/5 pitch timing belt 41. In the preferred embodiment this belt is 3/8" wide. As explained in greater detail below, belt 41 is open ended, with its opposite ends connected to attachment and balancing system 31. Similarly, transfer assembly 37 and adjustment system 39 are interconnected by idler timing belt 43, the opposite open ends of which are connected to adjustment system 39.
With reference to FIG. 2, attachment and balancing system 31 includes sash attachment bracket 45 having, in horizontal cross-section, a generally Z-shaped configuration and a projecting tab or bracket 47 having a circular opening therein. Bracket 45 is attached to sash 15 via, for instance, screws (not shown which are seated in through holes such as illustrated at 51. System 31 also includes: attachment unit 65; a balancing shaft 53, having a slotted head (not shown) on its upper end and threaded at least on the lower portion thereof (as illustrated by 53'; a compression spring 57 captured between the lower, horizontal leg of L-shaped bracket 64 (of belt attachment unit 65, FIG. 2A) and tab 47 of bracket 45; and belt attachment unit 65'. Attachment units 65, 65' are interconnected by shaft 53, as illustrated, with the slotted head seated against the horizontal leg of bracket 64 and with bracket 64' being retained by adjustment nut 59 (shown in broken lines). Spring 57 is pre-loaded in compression by double jam nuts 49 counter tightened against each other. Each belt attachment unit 65 and 65' include slots 67, for receiving teeth of timing belt 41, and a compression plate 69 and screws 66 to securely capture belt 41 without pinching or crimping. Double jamb nuts 49 prevent movement of balancing shaft 53 in, as viewed in FIG. 2, an upward direction relative to bracket 47. However, as explained below, shaft 53 is free to move downward relative to bracket 47 against the bias of spring 57. Tongue 68 of belt attachment unit 65 mates into elongated slot 70 of bracket 45 reducing any potential for shaft 53 to rotate or twist relative to bracket 45.
Latch mechanism 33, FIGS. 5 and 6, includes a housing 73 in the form of a rectangular open ended tube, a latching lever 75, an engaging wedge 77, a biasing spring 79 and a centering ball latch 81. Lever 75 is connected to wedge 77 via shaft 83 and sleeve 85, which is counterbored to receive both lever 75 and shaft 83. The relative positions between lever 75, shaft 83 and sleeve 85 are adjustable and, also, lockable via set screws 87 and 88. Shaft 83 is supported by bored holes 89 in housing 73 and fixed to wedge 77 via roll pin 91 received in bore in wedge 77. Ball latch 81 is received in bore 95 in wedge 77, as is spring 97, which biases ball 81 into detent opening 99 in housing 73, to hold wedge 77 in its neutral position. Biasing spring 79 includes a projecting tab 101 (which is captured in bore 103 of housing 73) a coiled portion 105 and a second tab 107 (which is received in a bore 109 in wedge 77). Wedge 77 also includes an oil hole 93.
When wedge 77 is in the neutral position, as illustrated in FIGS. 5 and 6, spring 79 is compression loaded and would like to extend, thereby pushing wedge 77 into either the position illustrated in FIG. 7A or FIG. 7B. Wedge 77 is maintained in the neutral position so long as ball 81 is received in detent 99. However, when lever 75 is rotated either clockwise or counterclockwise, ball 81 is forced out of detent 99, thereby allowing spring 79 to bias wedge 77 into engagement with belt 41.
Again, with reference to FIGS. 5 and 6, power pulley assembly 35 is also positioned in housing 73, beneath and adjacent to latch mechanism 33. Assembly 35 includes: a pulley shaft 111, journaled by bearings 113 positioned in the front and back sides of housing 73; a conventional timing belt drive pulley 115 keyed or otherwise secured to shaft 111; an adjustable length crank shaft 117; an adjustable length crank arm 119; and a crank handle 121 which rotates relative to housing 122. Crank shaft 117 is counterbored to adjustably receive shaft 111, after which set screw 123 is tightened. Crank shaft 117 also has a through bore, which slidably receives arm 119, and a second set screw 125 that is used to hold arm 119 in the desired position. Finally, housing 73 includes mounting holes 126. As those skilled in the art will appreciate, other crank mechanisms, as well as fixed and portable electrical power (such as a standard cordless screwdriver) can be used to rotate shaft 111 and pulley 115.
Power transfer assembly 37, FIG. 1, includes a pair of L-shaped brackets 131, secured (by screws or other suitable fasteners, not shown) to opposite sides of window head 25. Brackets 131 are provided with oppositely facing bores which support the opposite ends of power transfer shaft 133. Fastened to the opposite ends of shaft 133 are a pair of power transfer pulleys 135 and 137. Pulleys 135 and 137 are, like drive pulley 115, standard timing belt pulleys.
As is also evident from FIGS. 1 and 2, belt 41 is secured at its lower end 141 to attachment unit 65', passes through housing 73, around drive pulley 115, then over power transfer pulley 135 and then connected at its opposite end 143 to the upper end of attachment and balancing system 31, via attachment unit 65. Adjacent end 141 of belt 41 is opening tension spring 145, including spring attachment clips 147. As is evident from FIG. 1 and FIGS. 4A and 4B, located on belt 41, between drive pulley 115 and power transfer pulley 135, is closing tensioning spring 149, including a pair of spring attached clips 151. The function of springs 145 and 149, and clips 151, is explained below.
With reference to FIG. 3, attachment and adjustment system 39 includes an attachment bracket 45', which in horizontal cross-section has a generally Z-shaped configuration, and an L-shaped tab or bracket 47'. Bracket 45' is also secured to sash 15, via additional screws (not shown) and through holes 51', on the side portion of sash 15 directly opposite to bracket 45. System 39 also includes: an L-shaped bracket 64'; a threaded shaft 54 which passes through the openings (not shown) in brackets 64', 47', and 64 with the slotted head 54' of shaft 54 seated against the lower horizontal leg of bracket 64'; a first pair of adjustment nuts 50, threaded on shaft 54 on opposite sides of bracket 47'; and a second adjustment nut 59' (shown in broken lines) which captures the upper horizontal leg of L-shaped bracket 64.
Belt 43 is secured at its lower end 177 to a third attachment unit 65, as illustrated in FIG. 3. As illustrated in FIG. 1, belt 43 then passes around idler timing belt pulley (not shown), positioned within housing 181 which is secured (by fasteners, not shown) to jamb 23, passes over power transfer pulley 137 and then back down to attachment and adjustment system 39. End 183 is connected to a fourth attachment unit 65', as also illustrated in FIG. 3. As with belt 41, belt 43 includes a closing spring tensioner 185, secured via attachment clips 187, and an opening tensioning spring 189, secured via the same type of clips used for spring 149 (see FIGS. 4A and 4B).
Installation and adjustment of system 11 is quick and easy. First systems 31 and 39 are attached to the opposite sides of lower sash 15 as illustrated in FIG. 1. Assemblies 33, 35, 37 and housing 181 with its idler pulley are attached to jams 21 and 23. Belts 41 and 43 are then attached to, respectively, systems 31 and 39. Next the majority of slack is manually removed from belt 41 and the plates 69 of attachment units 65 and 65' (see FIG. 2) tightened to securely attach the belts thereto. Tension springs 145, 149, 185 and 189 are then attached, at the locations indicated in FIGS. 1, 2 and 3, via clips (e.g. 147, 151, and 187). The tension on spring 149 at initial installation is as illustrated in FIG. 4B. The distance between clips 151 and the spring rate of spring 149 is chosen to provide the correct belt tensioning. Further, as illustrated in FIGS. 4A and 4B, each of clips 151 has opposing 35° bends from perpendicular, between which belt 41 passes, which assists belt 41 to fold inwards towards spring 149 (when taking up belt tension during normal operation), as illustrated in FIG. 4A. This causes the belt slack to double loop which takes up less space horizontally. The installation of spring 145 is the same. Finally, nut 59 is adjusted, relative to shaft 53, to pull belt 41 taut and to stretch both spring 149 (to the position illustrated in FIG. 4B) and spring 145. Belt 41 is correctly tightened when all slack is removed from between belt attachment clips 147, 147 and 151, 151.
A similar procedure is followed for correctly tensioning belt 43. First, the majority of the slack is manually removed and plates 69 of attachment units 65 and 65' tightened. Secondly, tension springs 185, 189 are attached in the locations indicated in FIGS. 1 and 3. Adjustment nut 59' is then adjusted relative to threaded shaft 54 to pull belt 43 taut. Finally, adjustment nuts 50 are also adjusted relative to threaded shaft 54, either up or down, to insure that sash 15 is both parallel and square with the rest of window 13. Adjustment nuts 50 are then counter tightened against each other to lock them in position. Further adjustment or repositioning should not be required.
Once installed, attachment and balancing system 31, timing belt 41, timing belt 43, and attachment and adjustment system 39 may, for cosmetic purposes be covered with an L-shaped channel, such as illustrated at 161 in FIG. 1. Similarly, power transfer assembly 37 is covered by a U-shaped channel 163 in FIG. 1.
In operation, with the drive system located on the right hand side of window 13, crank shaft 111 is rotated in a clockwise direction to open sash 15; counterclockwise to close. If the drive system is located on the left hand side of window 13, which can be achieved by simply reversing the position of the drive and idler sides, the motion of crank shaft 111 will be just the opposite. Belt 41 passes over power pulley 135, rotating shaft 133 and power pulley 137 in unison. This, in turn, moves belt 43 substantially in unison with belt 41 so that the opening and closing forces are applied substantially equally on both sides of sash 15. During this movement of belts 41 and 43, the tensioning springs 145, 149, 185 and 189 function to take up belt slack on the slack side of the belts. Thus, for instance, during opening spring 149 remains in the position illustrated in FIG. 4B, while spring 145 takes up the slack between pulley 115 and attachment and balancing system 31. When window 13 is being closed spring 149 has the configuration illustrated in FIG. 4A, while spring 145 has the same configuration as illustrated for spring 149 in FIG. 4B. Springs 185 and 189 function in just the opposite manner.
In the event the drive side of sash 15 seats against sill 19 before the idler side when sash 13 is being closed, the balancing portion of attachment and balancing system 31 operates as follows: with continued rotation of crank shaft 111, lower end 141 of belt 41 will continue to move downward pulling balancing shaft 53, and the upper end 143 of belt 41 with it, compressing spring 57. Attachment bracket 45 remains stationary. However, because belt 41 continues to move, power continues to be transferred to belt 43, via pulleys 135 and 137 and shaft 133. This motion of belt 43 pulls the idler side of sash 15 into seating position with sill 19. The balancing spring 57 is sized to the system so that the force required for complete compression is greater than that required for proper seating, but less than the minimum force required to do damage to the system 11 or the window 13. In the preferred embodiment, balancing shaft 53 has a maximum travel of, approximately 3/4 inches. The maximum force required at the crank handle to accomplish this maximum 3/4" travel is less than 5 lbf, with crank handle 121 positioned approximately 6 inches from crank shaft 111.
If the idler side of sash 15 closes ahead of the driver side, the designed "give" (i.e., the stretch in belts 41 and 43 and the spring twist of shaft 133) in the components of system 11, between attachment and adjustment system 39 and power pulley 115 permit an additional, approximately 3/4", closing travel on the driver side.
With the inclusion of latching mechanism 33, sash 15 may be latched from either opening or closing in any position. This provides a feature missing from almost all windows, the ability to crack window 13 for ventilation and securely hold sash 15 in the desired position. This also provides a hold open mechanism for windows in which the counter balance systems have failed or are missing. With reference to FIGS. 5, 6, 7A and 7B, latching is achieved when lever 75 is pushed either up or down from its center (neutral) position, with enough force (less than 5 lbf) to push ball 81 out of detent 99 and simultaneously rotate wedge 77. Preloaded torsional spring 79 then pushes wedge 77 into engagement with belt 41. In the case of the position illustrated in FIG. 7A, sash 15 can be closed, either via crank mechanism 39 or by manually pushing down on sash 15, but not opened. In the case of the position illustrated in FIG. 7B, sash 15 cannot be closed, but can be opened, again either via crank mechanism 39 or manually. Once wedge 77 is set, force used in attempt to move the window against its latched position only further wedges or locks the belt 41 against the side walls of housing 73. This design complies with Chapter 12, §1204 of the Uniform Building Code.
With reference to FIGS. 8 and 9, system 201 with alternate power transfer mechanism 203 is illustrated. In system 201, drive belt 41 passes over pulley 205 (instead of 135 as in the previous embodiment). Pulley 205 is secured to a stub shaft 207, along with pulley 209, which shaft is rotatably secured in the internal channel of jamb 211. Similarly, idler belt 43 passes over pulley 213 which is secured to shaft 215, along with pulley 217 for simultaneous rotation therewith. Shaft 215 is similarly rotatably secured in the internal channel of jamb 219.
Pulley 209 is connected to pulley 217 via continuous belt 221. Power transfer mechanism 203 includes a belt tensioning mechanism 223 which includes central roller 225 and tensioning roller pairs 227, 229 and 231, 233. Roller pairs 227 and 229 are biased toward each other by springs (not shown), as are rollers 231, 233, which provide the force necessary for static tensioning of belt 221. Rollers 227, 229, 231 and 233, along with large roller 225 also twist belt 221, as illustrated, so that opposing sides thereof do not rub.
In operation, correct belt tensioning must be present at both sides of pulleys 209 and 217 to prevent belt slippage and, therefore, the system going out of sync. With the present design, when power is transferred via section 235 of belt 221, slack (due to belt stretch) develops in section 237. This causes large roller 225 to be pushed into belt section 237 to take up this slack. Roller 225 is mounted in a track 241 which allows it to move freely in directions perpendicular to, but not parallel with, belt 221. Similarly, rollers 227, 229, 231 and 233 are mounted in parallel tracks 243 and 245.
Whereas the drawings and accompanying description have shown and described the preferred embodiment of the present invention, it should be apparent to those skilled in the art that various changes may be made in the form of the invention without affecting the scope thereof. | A mechanism for opening and closing the sash of a window which includes first and second sash brackets, a drive mechanism, first and second flexible timing belts, structure for connecting the timing belts to the sash brackets and mechanisms for connecting the two timing belts. The structure for connecting the timing belts is adjustable in length to facilitate the tensioning of the belts. Tensioning springs are also included. | 4 |
Priority is claimed to Swiss Patent Application No. CH 00571/05, filed on Mar. 30, 2005.
The present invention relates to a method to control a static frequency converter, with which method an alternating voltage generated in a generator and having a first frequency is first rectified in a switched rectifier and the direct voltage thus present in an intermediate circuit is converted in a switched inverter into an alternating voltage having a grid frequency, whereby the generator is a generator having at least one excitation coil.
BACKGROUND
Large power plants that serve to generate electricity normally encompass a synchronous generator that is directly connected to the electric grid. The generator is driven by a turbine, which can be a gas turbine, a steam turbine or a water turbine.
As a result of the fact that the generator is connected directly to the grid, the speed of the generator is given and constant. A problematic aspect of this fact is that the optimal speed of the turbine is normally not the same as that of the generator, so that consequently a mechanical gearbox is often arranged between the turbine and the generator. This is particularly true of gas turbines, whose optimal operating speed is considerably higher that the grid frequency. In the case of water turbines having a low speed, at least a partial adaptation can be achieved by using a generator having the appropriate number of poles.
Such a gearbox is sensitive and expensive to produce whenever large quantities of power have to be transformed, in addition to which it requires an extraordinary amount of maintenance. Moreover, gearboxes cannot be employed in the highest power ranges, as a result of which the configuration of the turbine and its mode of operation have to be selected outside of the optimum range. Furthermore, the optimal speed of the turbine depends on the load present and the optimal efficiency at different loads can only be ensured if the turbine can be operated at different speeds. Unfortunately, this is not possible in the case of a rigid arrangement.
In order to circumvent this problem, German application DE 103 30 473 A1, for instance, describes the possibility of using a flexible electronic solution to replace the rigid connection involving a gearbox. The turbine is coupled directly to the synchronous generator but the latter is connected to the grid via a frequency converter (see FIG. 1 in DE 103 30 473 A1). A completely regulated voltage intermediate circuit converter (voltage source converter) having a controlled rectifier (converter on the machine side), a capacitive intermediate circuit and a controlled inverter (converter on the grid side) is used in order to efficiently uncouple harmonics between the generator and the grid.
In order to avoid excessive switching losses, the converter is operated in the square-wave mode, in which the switching frequency corresponds to the fundamental frequency. In this case, only the frequency between the input voltage and the output voltage can be varied, but not the amplitude (hence the name frequency converter). The amplitude of the voltage can be adapted by means of the excitation of the generator, as is commonly done in the classic arrangement with a direct connection between the generator and the grid.
The generated active power and reactive power can be controlled by means of the excitation of the generator and so can the phase shift between the generator and the voltages of the rectifier as well as between the inverter and the grid voltages. Even though DE 103 30 473 A1 describes these fundamental principles of the mode of operation of such a converter, this document does not indicate any specific strategy or structure for controlling the converter since various solutions are possible.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to put forward a stable and simple possibility to control a static frequency converter. This is to be done in conjunction with a frequency converter in which an alternating voltage generated in a generator and having a first frequency is first rectified in a switched rectifier and the direct voltage thus present in an intermediate circuit is converted in a switched inverter into an alternating voltage having a grid frequency. In this context, the generator has at least one excitation coil that can be actuated in a regulated manner. This means that, in order to control the power fed into the grid, means are provided for regulating at least the strength of the excitation field generated by the at least one excitation coil and optionally also the phase relation between the frequency converter voltage and the generator voltage or grid voltage. The present invention provides a method for controlling a static frequency converter wherein the control of a frequency converter in the rectifier is carried out in such a way that the frequency of the alternating voltage of the rectifier on the generator side is regulated to an essentially constant value of the first frequency, and the control in the inverter is carried out on the basis of a measured value of the direct voltage in the intermediate circuit.
According to the present invention, the frequency converter is kept at a fixed frequency on the side of the generator so to speak, and the frequency is regulated exclusively on the side of the grid. Symmetry-related considerations explained in greater detail below show that such a control is surprisingly easy to achieve in that the direct voltage in the intermediate circuit is used as the regulating parameter, preferably the voltages present in the intermediate circuit over the capacitances.
Naturally, the frequency of the turbine and/or of the generator can be set, for instance, for partial load so that it can continue to run within the optimal operating range. In this situation, a lot of time is available to set a different frequency. Accordingly, with such a change in the frequency of the turbine and/or of the generator, the control of the rectifier can be adapted quasi-steadily (that is to say, dynamically, but with such slow changes to the state as to remain close to the stationary state).
In a first embodiment of the method according to the invention, the control in the inverter is carried out in such a way that the frequency of the inverter on the grid side is regulated according to the following function
ω i =ω n +Δω
wherein the function Δω, the frequency differential between the frequency of the inverter ω i and of the grid ω n , is expressed by
Δω K P (u C −u* C )|, (20)
wherein K P stands for a specified, proportional control gain, and u* C stands for a reference value of the capacitance voltage that is selected as a function of the desired reactive power, optionally dynamically. The reference value u* C can be set according to formula (41) shown below in conjunction with formula (3), whereby in formula, (3), û 1 is replaced with U i according to formula (41).
Thus, in the state of equilibrium, the value of Δω is typically zero, since the frequency of the inverter and of the grid in this state should be the same. In this context, the function Δω, preferably also taking into consideration the damping, can be employed with a predefined differential control gain K D for purposes of the control in the inverter, and this is done concretely according to the formula:
Δ
ω
′
=
Δ
K
P
(
u
C
-
u
C
*
)
+
K
D
ⅆ
ⅆ
t
(
u
C
-
u
C
*
)
=
Δ
ω
+
K
D
K
P
ⅆ
Δ
ω
ⅆ
t
(
21
)
Another embodiment of the method according to the invention is characterized in that the strength of the excitation field generated by the at least one excitation coil and its phase relation is set by means of an excitation voltage that is controlled as a function of the generator voltage, the generator frequency, the active power and the reactive power of the generator. This is preferably done according to an equation that is depicted in FIG. 8 and that can be derived from formulas (25) to (38).
According to another embodiment, the frequency converter is a three-stage converter whereby, for regulation purposes, preferably the direct voltage in the three-level intermediate circuit is ascertained as the mean value of the voltages present over the two capacitances between the two levels + and 0 as well as between the two levels 0 and −.
In another embodiment, the controlled rectifier and/or the controlled inverter are operated in fundamental-frequency clocking, whereby the controlled rectifier is preferably a three-level rectifier and the controlled inverter is preferably a three-level inverter, both of which are operated in fundamental-frequency clocking.
Typically, the static frequency converter is configured in such a way as to comprise thyristors such as, for instance, GTOs, IGBTs, MOSFETs or ICGTs.
Another embodiment is characterized in that a central control unit is provided which uses the measurement of the voltage and/or the current upstream and/or downstream from the static frequency converter to make an adaptation of the amplitude of the alternating voltage fed into the grid by appropriately actuating the means for controlling the strength of the excitation field generated by the excitation coil.
As already mentioned, the present invention also encompasses a device to carry out the method as was described above. The device is particularly characterized in that a generator is equipped with at least one regulatable excitation coil, a static frequency converter comprising at least one controlled rectifier in fundamental-frequency clocking and at least one controlled inverter in fundamental-frequency clocking, as well as at least one control unit to regulate these elements. In addition, means for measuring the values of the direct voltage are arranged in the intermediate circuit, whereby these measured values are employed for control purposes in the inverter. The actuation of the regulatable excitation coil involves means with which the amplitude of the alternating current used for the excitation is adapted to the requirements of the grid.
Other preferred embodiments of the invention are described in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail below with reference to embodiments in conjunction with the drawings. The following is shown:
FIG. 1 a schematic diagram of a power plant employing a gear arrangement;
FIG. 2 a schematic diagram of a power plant employing a static frequency converter;
FIG. 3 ( a ) a circuit diagram and ( b ) a vector diagram of two voltage sources with the voltages U and E which are connected via an inductance;
FIG. 4 the output voltage waveform and the fundamental component of a three-stage converter operated in the square-wave mode;
FIG. 5 a schematic circuit diagram of the power plant;
FIG. 6 a schematic diagram of the regulation according to the invention;
FIG. 7 a modulator as schematically shown in FIG. 6 , in detail;
FIG. 8 a schematic diagram of the implementation of the controlled excitation voltage;
FIG. 9 results of the stimulation; mechanical part of the generator;
FIG. 10 results of the stimulation; electric part of the generator;
FIG. 11 results of the stimulation: grid; and
FIG. 12 results of the stimulation: waveforms of the voltage and current on the side of the generator and on the side of the grid.
DETAILED DESCRIPTION
As already explained, in conventional power plants of the type shown, for example, in FIG. 1 , a turbine 1 is connected directly to a generator 3 via a gearbox 2 arranged on a shared shaft. The generator is subsequently connected to the grid 4 either directly or via a transformer. The drawbacks of such a solution have already been explained above.
In contrast to this, the solution being proposed here uses an arrangement as shown in FIG. 2 . In this case, the turbine 1 is directly and rigidly connected to the generator 3 via the shaft. The alternating voltage (typically three-phase) generated by the generator 3 is subsequently converted in a frequency converter 5 and adapted to the frequency of the grid 4 . The frequency converter 5 consists of a rectifier 6 that generates a direct current from the alternating current supplied by the generator. This is done by means of power electronics, that is to say, on the basis of switched thyristors such as, for instance, GTOs, IGBTs, MOSFETs or ICGTs.
In the next step, the direct voltage present in the downstream intermediate circuit 8 (here, a capacitance C is arranged between each of the two levels of the intermediate circuit) is once again converted into alternating voltage in an inverter 7 , namely, at a frequency that is adapted to the grid.
The properties and the behavior of electric machines are comprehensively explained in the literature, for example, in C.-M. Ong, Dynamic Simulation of Electric Machinery. 1 st Ed., Upper Saddle River, N.J., United States: Prentice Hall, 1998, or in J. Chatelain, Machines électriques in Traités d'Électricité, 1 st Ed., Lausanne, Switzerland: Presses Polytechniques et Universitaires Romandes, 1983, Vol. X. Below, the underlying behavior will only be taken into consideration in a simplified form, ignoring losses since this is sufficient to elucidate the principles of the proposed strategy of regulating a frequency converter. Consequently, machines are assumed here in which a complete conversion of mechanical energy into electric energy takes place and the power electronic system carries out a loss-free conversion of direct-current energy into alternating-current energy (and vice versa).
Electric machines and the grid are primarily inductive. The interaction between the machine, the voltage intermediate circuit converter (or frequency converter) and the grid can be appropriately modeled [sic] by two voltage sources having the voltages E and U, which are connected to each other via an inductance L. This situation is shown schematically in FIG. 3 a ). The vector diagram depicted in FIG. 3 b ) shows the relationships between the two voltages E and U as well as between the current I that flows through the inductance L, this being for sinusoidal signals having an angular frequency Ω. For a circuit having a single phase, the following expressions are obtained for the active power P and for the reactive power Q as they occur at the voltage source:
P
=
UI
cos
φ
=
UE
sin
δ
ω
L
(
1
)
Q
=
UI
sin
φ
=
U
(
E
cos
δ
-
U
)
ω
L
(
2
)
The vector diagram also shows how the vector of the voltage E has to be changed in order to alter the active power P and/or the reactive power Q. For small values of the displacement angle δ, the active power P is essentially determined by the angle δ, while the reactive power Q is mainly determined by the amplitude of E.
FIG. 4 shows the waveform of the output voltage generated by a three-stage converter operated in the square-wave mode. The amplitude equals the voltage u C over the capacitance in the intermediate circuit. The amplitude û 1 of the fundamental wave u 1 is proportional to the voltage over the capacitance, with a modulation index m that is a function of the commutation angle α:
u
^
1
=
mu
C
,
(
3
)
m
=
4
π
sin
α
.
(
4
)
A commutation level u α can be defined which is equal to the fundamental wave at the moments of the commutation:
u α =û 1 cos α. (5)
For the commutation angle α, an optimal value should be selected with respect to the generated harmonics. Minimal harmonics are obtained around a value of
α
≈
5
12
π
=
75
∘
.
(
6
)
This minimum is quite flat, and consequently, variations within the range of ±5° still yield good power.
Under stationary conditions of operation, the active power P is determined completely by the mechanical torque T m , which is supplied by the turbine. The behavior is determined by the dynamic movement equation
J ⅆ ω m ⅆ t = T m - T e , ( 7 )
wherein J stands for the moment of inertia, ω m for the mechanical angular frequency of the generator and T e for the electromagnetic torque. The relationships between power and torque are as follows
P m =ω m T m , (8) P e =ω m T e . (9)
wherein P m stands for the mechanical power and P e for the electromagnetic power.
In a cylindrical synchronous machine, the electromagnetic torque in equilibrium can be expressed as
T e ≈ 3 ω m UE X d sin δ = T k sin δ , ( 10 )
wherein X d is the synchronous reactance of the d-axis, T k is the (excitation-dependent) dynamic breakdown torque and δ is the load angle that corresponds to the above-mentioned displacement angle between the rotor and the grid. The reactive power Q is determined by the excitation although it is also dependent on the active power P.
The dynamic behavior of the machine can be described as “voltage behind the transient reactance” with a damping term. In the case of small values of the variation of the speed, the damping torque is approximately proportional to the speed and the resulting electromagnetic torque can be approximated as
T e ≈ 3 ω m UE ′ X d ′ sin δ + D Δ ω = T k ′ sin δ + D Δ ω ( 11 )
wherein X′ d is the transient reactance of the d-axis, E′ is the corresponding voltage of the excitation, T′ k is the dynamic breakdown torque and D is the damping coefficient.
By employing the difference of the frequency of the rotor and the grid, taking into account the number p of pole pairs according to
Δ ω=pω m −ω n |, (12)
the load angle or displacement angle δ can be expressed as
δ
=
∫
Δ
ω
ⅆ
t
(
13
)
The dynamic movement equation (7) can now be written as
J
p
ⅆ
2
δ
ⅆ
t
2
+
D
ⅆ
δ
ⅆ
t
+
T
k
′
sin
δ
=
T
m
(
14
)
This result is known as the “swing equation”.
If this result is then applied to an arrangement according to FIG. 2 , the following additional considerations are necessary: in the arrangement according to FIG. 2 , a frequency converter 5 is connected between the generator 3 and the grid 4 . Owing to the voltage intermediate circuit characteristic of the proposed converter 5 , its coupling to the generator 3 configured as a synchronous generator as well as its coupling to the grid 4 can both be depicted as shown in FIG. 3 .
In the first case, the rectifier 6 functions somewhat like a grid for the generator. If the rectifier is regulated at a constant frequency ω r , this results in the same machine dynamics and machine mode of operation as explained above. The frequency of the rectifier, however, can be adapted in a quasi-steady manner in order to allow an optimal mode of operation of the turbine and generator. On the side of the alternating current, that is to say, towards the generator, the rectifier 6 generates a voltage whose value U r is proportional to the voltage u C over the capacitance C in the intermediate circuit 8 . Towards the direct current side, the rectifier supplies a current i r which corresponds to the converted power P r
P r = u C i r = P e ( 15 )
which corresponds to the electromagnetic power P e that is supplied by the generator.
In the second case, the voltage source E corresponds to the voltage of the inverter 7 on its alternating current side. Its frequency ω i on the alternating current side can be completely regulated and the magnitude of the voltage U i is proportional to the voltage u C over the capacitance in the intermediate circuit 8 . The voltage source U corresponds to the grid whose voltage U n as well as its frequency ω n are normally predefined. The inductance L is formed by the transformer 16 as well as by the inductances in the grid and, if applicable, additional inductances of filters.
On the direct current side, the inverter draws a current i i which corresponds to the converted power P r
P i = u C i i = 3 U n U i sin δ ω n L ( 16 )
that is supplied to the grid 4 . In the expression for this current i i ,
i i = 3 u C U n U i ω n L sin δ = I k sin δ ( 17 )
I k stands for a maximum or breakdown current.
The difference between the currents (or the power) of the rectifier and inverter flows through the capacitance C in the intermediate circuit 8 and charges it according to
C
ⅆ
u
C
ⅆ
t
=
i
r
-
i
i
(
18
)
This behavior according to formula (18) together with formulas (15), (16) and (17), has the same form as the behavior that describes the movement of the generator according to formulas (7), (8), (9) and (10). Correspondingly, a duality exists between the voltage over the capacitance C and the frequency of the generator 3 , between the current in the intermediate circuit 8 and the torque, as well as between the capacitance C and the moment of inertia.
In order to make such a system seem like a conventional system, a new regulation strategy can be employed which imparts the frequency converter with similar properties to those of a synchronous generator. Following the cited duality, this can be achieved in that the frequency differential Δω, which is defined as
Δω = ω i - ω n , ( 19 )
is set as being proportional to the error or to the deviation of the voltage over the capacitance C; this is done according to
Δω K P (u C −u* C ) (20)
In this context, u* C is a reference value for the voltage over the capacitance C.
In the final analysis, the reference value u* C can be derived from the reactive power desired by the operator of the power plant and it can also be set dynamically. In order to determine u* C , it is possible to employ, for instance, the formula below, which is based on formula (3) in combination with formula (4)
u* C =U i /m=πU i /(4 sin α) (20a)
In this context, a value that has been optimized with respect to the harmonics can be used as the commutation angle α (see formula 6). For purposes of determining the alternating voltage U i of the inverter 7 , formula (41), which is discussed below, can be employed, so that the reference value u* C is then formulated as a function of α, U n , ω n , L, Q n , and P n . Here, the values of the alternating voltage U n of the grid as well as the angular frequency ω n of the grid are predefined by the grid and cannot be freely selected. The reactive power Q n and the active power P n of the grid can be set by the power plant operator, whereby especially P n is influenced by the grid and the transformer inductance (as L) as well as by the torque of the turbine. Therefore, a target value for u* C that is needed in principle, is first predefined.
K P is a proportional control gain and is likewise predefined.
In order to additionally dampen the system, a corresponding term can be added with a differential control gain K D :
Δω
′
=
Δ
K
P
(
u
C
-
u
C
*
)
+
K
D
ⅆ
ⅆ
t
(
u
C
-
u
C
*
)
=
Δω
+
K
D
K
P
ⅆ
Δω
ⅆ
t
(
21
)
The value of K D is likewise predefined and the values for K P and K D are selected in such a way that the system responds quickly, no strong oscillations occur after transitions and there are as few harmonics as possible.
The expression for the displacement angle δ′ can then be written as
δ
′
=
∫
Δω
′
ⅆ
t
=
∫
Δω
ⅆ
t
+
K
D
K
P
Δω
=
δ
+
K
D
K
P
ⅆ
δ
ⅆ
t
(
22
)
For small values of the damping K D , the current in the intermediate circuit according to formula (17) can be approximated by means of
i
i
=
I
k
sin
δ
′
≈
I
k
(
sin
δ
+
cos
δ
K
D
K
P
ⅆ
δ
ⅆ
t
)
(
23
)
Using these equations, the following expression for the behavior according to formula (18) in the intermediate circuit is obtained
C K P ⅆ 2 δ ⅆ t 2 + I k cos δ K D K P ⅆ δ ⅆ t + I k sin δ = i r , ( 24 )
which is a result similar to the swing equations of the generator according to formula (14).
In order to perform the regulation, formula (20), optionally taking into consideration the damping of formula (21), is resolved as
ω i =ω n +Δω
and the inverter 7 is actuated in such a manner that it displays a frequency ω i towards the grid. As explained above, the rectifier 6 is set to the fixed frequency ω r .
The regulation will now be explained with reference to FIGS. 5 to 8 .
FIG. 5 depicts the electric switching circuit that will serve as the basis for the considerations outlined below. The figure shows a generator 3 whose excitation voltage is set via an excitation 9 . This excitation 9 supplies an excitation voltage U f as well as an excitation current i f in a regulated manner. The input value that has to be set for the excitation voltage U f will be explained below.
The mechanical torque T m of the turbine acts on the generator, giving rise to the circuit frequency ω m (wm in FIG. 5 ) of the generator 3 , to the angle position thm in the rotor (phase), to the electromagnetic torque Te and to the magnetic flux Ydq.
The generator 3 transfers the generated electric energy in the form of three phases. A measurement device 10 here supplies the values of the generator voltage U g as well as the generator current ig. The three phases are then fed to the rectifier 6 . The rectifier 6 is controlled by a control signal sg. This rectifier converts the alternating current into direct current, whereby the direct current in this three-stage converter is kept at three levels in the intermediate circuit 8 , namely, at the (+) level according to reference numeral 12 , at the (0) level according to reference numeral 13 and at the (−) level according to reference numeral 14 (also see FIG. 4 ). A capacitance C 1 and a capacitance C 2 are arranged between levels 12 and 13 as well as between levels 13 and 14 , respectively. The voltages present over these capacitances are picked up at measurement points 15 and made available for the regulation.
The three levels of the direct current are subsequently converted into alternating current in the inverter 7 that is regulated via a control signal sn. The three phases of this alternating current are monitored by a measurement device 11 , that is to say, the alternating voltage U n of the grid as well as the current supplied to the grid are monitored. This is followed by the grid 4 downstream from a transformer 16 .
The regulation of such a device is shown schematically in FIG. 6 . The measured value of the direct voltage u C in the intermediate circuit 8 is the only parameter that is regulated and, as can be clearly seen above, this is the mean value of the two voltages picked up at the measurement points 15 (u C =½(u C1 +u C2 )). The reference value of the capacitance voltage u* C as well as the value of phg* (generator phase, is used to set the reactive power) and the value of tt* (corresponds to the mechanical torque T m * of the turbine, setting of the active power) are statically (or dynamically) defined.
As already explained above, the rectifier 6 is set at a fixed frequency. Accordingly, it can be seen in FIG. 6 how the control signals sg for the rectifier 6 are generated on the basis of the predefined value of the generator frequency ω g (corresponding to wg in FIG. 6 ) after an appropriate setting of the phase shift ph 3 (−0, −120, −240) for the three phases present and after evaluation of a sine function in a modulator 18 (see below for the details). Therefore, no reference is made to the regulation parameter u C in order to control the rectifier 6 .
The excitation voltage U f is likewise set without referring to the value of u C . As shown in the lower part of FIG. 6 , only phg* and tt*, u* C as well as ω g and U g are employed as input values in order to set the excitation voltage U f , whereby these values are evaluated on the basis of formulas (25) to (36), which will be discussed below and depicted in FIG. 8 .
In other words, the excitation voltage U f is set as a function of the desired reactive power Q, of the active power P, of the generator voltage U g and of the generator frequency ω g . Details of the formula for the excitation voltage U f can be found below, especially in FIG. 8 .
The essential part of the regulation now takes place with reference to the control of the inverter 7 . In this case, the measured value of the direct voltage u C in the intermediate circuit 8 is evaluated with the integrated formulas (19) to (21) resolved on the basis of the circuit frequency ω i of the inverter 7 .
This means that, first of all, the difference u C −u* C is formed and this difference is subsequently multiplied by the proportional control gain K p as well as by the differential control gain K D , and afterwards the product is integrated with K P and the K D expression is inserted through the integration in order to obtain the phase angle for the control of the inverter 7 . For this purpose, the phase relation for the three phases is set once again at the end by means of the phase displacement ph 3 and the corresponding value is transferred to a modulator 17 following an evaluation with a sine function. From this, the modulator 17 generates a control signal sn for the inverter 7 .
The general pulse width of the square-wave blocks is specified by a value ua (commutation level) whereby an attempt is made to avoid harmonic waves, if possible (also see formulas 3 to 6). Therefore, the value of ua corresponds to the desired commutation angle.
The signals sn or the signals sg are generated in the modulator 17 and in the modulator 18 , respectively, according to the following scheme (see FIG. 7 ):
u*>ua→s=1 −ua≦u*≦ua→s=0 u*<−ua→s=−1
The regulation was ascertained on the basis of typical reference values for a turbogenerator and for a transformer with realistic values for capacitances in the intermediate circuit, a process in which the parameters indicated in Tables 1 and 2 were used:
TABLE 1
System parameters of the simulation
Description
Variable
Value
Unit
Machine
Apparent power
S
73.8
MVA
Power
P
59.0
MW
Voltage
U
11.5
kV
Current
I
3.705
kA
Power factor
cos φ
0.80
Frequency
f
85
Hz
Pole pair number
p
1
Basic impedance
Z
1.792
Ω
Stator resistance
R s
0.0035
p.u.
Stator leakage reactance
X ls
0.160
p.u.
d-axis synchronous reactance
X d
2.47
p.u.
q-axis synchronous reactance
X q
2.28
p.u.
d-axis transient reactance
X′ d
0.239
p.u.
q-axis transient reactance
X′ q
0.390
p.u.
d-axis subtransient reactance
X″ d
0.181
p.u.
q-axis subtransient reactance
X″ q
0.190
p.u.
Transient open-circuit time
T′ do
6.65
s
constant of the d-axis
Transient open-circuit time
T′ qo
0.78
s
constant of the q-axis
Subtransient open-circuit time
T″ do
0.018
s
constant of the d-axes
Subtransient open-circuit time
T″ qo
0.027
s
constant of the q-axes
Time constant of the moment of inertia
T J
0.80
s
Grid
Voltage
U
11.5
kV
Frequency
f
50
Hz
Transformer
Winding ratio
n
1
Resistance
R
0.005
p.u.
Inductance
L
0.20
p.u.
Magnetization inductance
L m
100
p.u.
Converter
Intermediate circuit capacitance (a)
C
25
p.u.
Control
Commutation angle
α
74
°
Proportional gain factor
K P
0.2
p.u.
Differential gain factor
K D
0.2
p.u.
(a) The total energy stored corresponds to 35 J/kVA.
TABLE 2
Nominal values of the simulation in the per unit system (b)
Description
Variable
Value
Machine
Phase voltage amplitude
u g
1.0
Phase current amplitude
i g
1.0
Angular frequency
ω g
1.7
Apparent power
S g
1.5
Power factor
cos φ
0.80
Mechanical torque
T m
0.71
Grid
Phase voltage amplitude
u n
1.0
Phase current amplitude
i n
1.0
Circuit frequency
ω n
1.0
Apparent power
S n
1.5
Power factor
cos φ
0.80
Inverter
Voltage over capacitance in the intermediate
u C
0.82
circuit
(b) In the per unit system, the quantities are each related to the base quantity, and this is done according to the formula: basic value in p.u. = (quantity in SI units)/(nominal value of the voltage or power).
The excitation of the generator via the voltage U f is calculated employing a standard machine model (in this context, see, for instance, C.-M. Ong, Dynamic Simulation of Electric Machinery. 1 st Ed., Upper Saddle River, N.J., United States: Prentice Hall, 1998, and J. Chatelain, “Machines électriques” in Traités d'Électricité, 1 st Ed., Lausanne, Switzerland: Presses Polytechniques et Universitaires Romandes, 1983, Vol. X.).
The various operation points are taken into consideration by means of the reference values for the voltage, frequency and reactive power or active power, and employing formula (3).
FIG. 8 shows a schematic diagram of the evaluation of the excitation voltage U f . The values of the generator voltage U g , the generator frequency ω g , the desired reactive power Q g and the desired active power P g serve as the input values, as is indicated on the left-hand side of FIG. 8 as the input. Moreover, L md is specified as a fixed value, whereby L md in FIG. 8 is designated by -K-.
The induced voltage E f is proportional to the field current I f which, in turn, is proportional to the field voltage (excitation voltage) U f (amplitudes of alternating current quantities are employed):
U f =R f I f , (25)
E f =X md I f . (26)
The formula for the stator side, employing complex vectors, is:
jE f =( U d +jU q )+ j ( X d I d +jX q I q ). (27)
This can be written as:
E f =( U+X d I sin φ) cos δ+( X d I cos φ) sin δ, (28)
wherein φ is the phase angle between U and I and δ is the displacement angle or load angle between E f and U . It can be demonstrated that
( U + X q I sin φ ) + j ( X q I cos φ ) = E d ′ + jE q ′ = E ′ ⅇ jδ ,
and thus that ( 29 ) cos δ = E d ′ E ′ , ( 30 ) sin δ = E q ′ E ′ , ( 31 )
which can then be used in formula (28). Since the active power P and the reactive power Q can be expressed in a three-phase system as
P = 3 2 UI cos φ , ( 32 ) Q = 3 2 UI sin φ , ( 33 )
the following can be constructed using the amplitude of the output voltage U and of the current intensity I
I cos φ = 2 P 3 U , ( 34 ) I sin φ = 2 Q 3 U , ( 35 )
which can then be employed in formulas (28) and (29). All of the reactances are expressed as
X=ωL, (36)
since the generator frequency can vary. The equations given above are valid for stationary modes of operation. In order to improve the behavior in the case of faster dynamics, an amount
U f ′ = L md ⅆ ( I f - I d ) ⅆ t ( 37 )
is added to the output, using
I d =I sin φcos δ+ I cos φsin δ (38)
as the current component of the direct axis.
On the basis of formulas (25) to (38), it is then possible to construct the general formula for the excitation voltage U f which, as schematically depicted in FIG. 8 , is expressed as a function of the generator voltage, the generator frequency, the active power and the reactive power of the generator as well as of the constant L md .
The control has three reference points, each of these points influencing one power quantity in the system, namely, (I) the torque of the turbine T* t for the active power P, (II) the power factor angle φ g for the reactive power Q g of the generator, as well as (III) the voltage u* C over the capacitance in the intermediate circuit for the reactive power Q n of the grid 4 .
In the stationary mode of operation, the mechanical power transferred by the torque of the turbine to the generator shaft is completely transferred to the grid, which determines the active power P throughout the entire system (I).
The power factor angle of the generator acts upon the excitation system (II).
The voltage over the capacitance in the intermediate circuit acts like a generator excitation for the inverter that is coupled to the grid (III). Its reference value u* C can be ascertained from the amplitude of the grid voltage as well as from the desired active power and reactive power. In this context, the calculations are considerably simpler than in the case of excitation by the generator since there is no difference between the reactances along the axes d and q. The equation for the grid side employing complex vectors is expressed as follows:
U i = U n +jω n L I I n . (39)
This can be written as
U i √{square root over (( U n +ω n LI n sin φ n ) 2 +(ω n LI n cos φ n ) 2 )}{square root over (( U n +ω n LI n sin φ n ) 2 +(ω n LI n cos φ n ) 2 )}, (40)
wherein φ n is the angle between U n and I n . Therefore, by using equations (34) and (35) for the grid side, one obtains the following:
U
i
=
(
U
n
+
ω
n
L
2
Q
n
3
U
n
)
2
+
(
ω
n
L
2
P
n
3
U
n
)
2
.
(
41
)
This expression for U i can then be employed in equation (20a), which yields an expression for u* C .
Several transitions are simulated, whereby one second of time was given for each transition. The individual characteristic quantities are compiled in graphic form in FIGS. 9 to 12 .
Here, the system is operated without load in the area between 0 and 1. In this case, the mechanical torque T m as well as the electromagnetic torque T e and the load angle δ m equal zero (see FIG. 9 ).
A first transition is then simulated in the area between 1 and 2. In this transition, the torque of the turbine is shifted to the nominal value. In other words, in FIG. 6 , the value of tt* is shifted to the nominal value. Subsequently, the torque T m of the turbine no longer changes and remains constant (see FIG. 9 , uppermost part).
In response to this transition, the excitation current i f (see the top of FIG. 10 ) and, by the same token, the generator current i g (see the middle of FIG. 10 ) increase. The reactive power Q s as well as the active power P g of the generator rise (see the bottom of FIG. 10 ). In response to this, one can also see an increase in the current i n supplied to the grid (see the middle of FIG. 11 ) and in the active power P n fed to the grid. The reactive power Q n fed to the grid remains essentially at zero during this first transition. The voltage u C in the intermediate circuit likewise remains constant, as can be seen at the top of FIG. 11 .
The second transition takes place in the area between 3 and 4. During this transition, the voltage u C in the intermediate circuit 8 , which acts on the grid side like the excitation of the generator, is likewise raised in order to obtain the nominal value of the reactive power in the grid. In other words, the reference value of the capacitance voltage of u* C shown in FIG. 6 is raised somewhat above the nominal value. The value of the reactive power Q n supplied to the grid does indeed respond, as can be seen at the bottom of FIG. 11 . On the side of the generator, the voltage U g likewise increases slightly, which gives rise to an adjustment of the excitation voltage u f in order to retain the reactive power, although this is done at a different operating point with a different power factor.
During the third transition, which is the area between 6 and 7, the power factor of the generator is set to 1, which means that the excitation (see field current i f , top of FIG. 10 ) is adjusted. In other words, in FIG. 6 , the value of phg* is reduced somewhat below the nominal value. The reactive power Q g on the side of the generator can be essentially eliminated through this step (see the bottom of FIG. 10 ).
For the sake of completeness, FIG. 12 shows the appertaining waveforms of the voltage (U g and U n ) as well as of the current (i g and i n ) on the generator and grid sides, respectively. | A method for the control of a static frequency converter, in which an alternating voltage provided by a generator with a first frequency is first rectified in a switched rectifier, and in which the DC-voltage thus present in an intermediate circuit is inverted to an alternating voltage with a grid frequency by means of a switched inverter. The generator is provided with an excitation coil and with means for controlling the power made available to the grid by means of controlling the strength of the excitation field provided by the excitation coil and, if need be, also of the phase relationship between the voltage of the frequency converter and the generator voltage and the grid voltage, respectively. The generator side alternating voltage of the rectifier is controlled to a frequency which is substantially constant in accordance with the first frequency and the inverter is controlled on the basis of the measured value of the DC-voltage in the intermediate circuit. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the invention
[0002] This invention relates to a method of enabling traffic to be driven and tracked to an e-commerce site, the traffic relating to interactions between the e-commerce site and a mobile wireless device. Traffic is driven to an e-commerce site when an end-user does not visit that site directly but instead visits another site (or any kind of information carrying channel or media, including online, mobile or offline) first and as a consequence of that visit goes on to interact with the e-commerce site. Tracking occurs when the interactions between an end-user and the e-commerce site can be logged or measured in some manner; tracking also includes monitoring, which usually refers to real-time logging or measurement.
[0003] The term ‘e-commerce site’ will be used to refer to a WWW site that offers goods or services for end-users.
[0004] The term ‘mobile wireless device’ covers any device which can send data and/or voice over a long range wireless communication system, such as GSM, GPRS or 3G. It covers such devices in any form factor, including conventional mobile telephones, PDAs, smart phones and communicators.
[0005] 2. Description of the Prior Art
[0006] Navigating on the World Wide Web (using a web browser on a PC) relies on an HTML hyperlink in a web page; when this hyperlink is selected it re-directs the browser to fetch a different WWW (i.e. web) site, defined by a new URL that is based on the hyperlink. The new URL itself does not merely include the host of the destination web site (e.g. the domain name of the server that hosts the destination web site), but can include a great deal of further information, including information defining the source web site as well (sometimes referred to as the anchor). Hence, if one types ‘books’ as a search query into Google, you will get a list of hits returned, and the URL may look like:
[0007] http://www.goggle.co.uk/search?num=20&hs=JHZ&hl=en&safe=off&client=firefox-a&rls=org,mozilla%3Aen-US%3Aofficial s&q=books&btnG=Search&meta=
[0008] You can tell from this a fair bit of information about the query and the browser used. If one selects the link to one of the paid-for advertisements (perhaps Amazon), one automatically gets redirected to the related web site. The URL might then be:
[0009] http://www.amazon.co.uk/exec/obidos/search-handle-url/index%3Dbooks-uk%26field-keywords%3Dbooks%26results-process%3Ddefault%26dispatch%3Dsearch/ref%3Dpd%5Fsl%5Faw%5Ftops-2%5Fbooks-uk%5F6561722%5F2/202-6319787-6482263
[0010] This includes information (known as a URL tracking code) that tells Amazon that the URL request came from a Google paid for advertisement. In this scenario, Amazon might actually pay Google a small amount of money because one clicked through from its advertisement that appeared in the Google results for the ‘Books’ search to the Amazon site. This is an example of an ‘affiliates program’.
[0011] In the World Wide Web, remuneration is often based on this kind of a model, in which ‘affiliates’ drive visitor traffic to e-merchants with e-commerce web sites and are paid on a commission basis using a computer implemented ‘affiliates management system’; affiliates can also access multiple e-merchants through aggregators that act as an exchange or marketplace where e-merchants and affiliates meet. Any member in the ‘affiliation chain’ may track the traffic his site is generating for different e-commerce sites using a web-based tracking system.
[0012] To Re-Cap on the Terminology:
[0013] Affiliate—An entity with the ability to drive new consumers/visitors and new business to an existing e-merchant; it includes webmasters, portals, online marketers, community moderators, search engines etc. Affiliates are sometimes called ‘distribution partners’. The term ‘affiliate’ or ‘distribution partner’ covers any media or partner that encourages end-users to seek out an existing e-merchant by advertising or promoting on different media such as: internet content sites, TV, radio, billboards, opt in DB's, WAP portals, on deck applications etc
[0014] E-Merchant—An online transactional e-commerce site wishing to attract new clients and business to its site.
[0015] Affiliate Management System—The computer implemented system that an e-merchant deploys to enable entities to become affiliates and to enable those affiliates that drive traffic to its e-commerce site to be identified by allocating to them a unique tracking identifier, such as a URL tracking code.
[0016] Affiliate Program—The incentive scheme implemented by the Affiliate Management Program. All affiliate programs are results driven, either by visits, sales, revenue share or new registrants.
[0017] Affiliate Aggregator and Exchange—Aggregators bring together multiple merchants, Exchanges facilitate a merchant/publisher meeting place.
[0018] Affiliate Tracking System—A tool allowing the affiliates and the e-merchants to monitor (sometimes in real time) campaign results. Generally, it is the e-Merchant that tracks in detail—they allocate the URL tracking codes and track activity against it. Affiliates may also track (e.g. they can track that the user clicked on a link, but not much more e.g. whether they went on to buy). Affiliates can also require tracking on the ‘landing page’—usually a hidden pixel that effectively calls-back to the affiliate to know that the user ‘landed’. Tracking may involve real-time tracking, or tracking with results fed back within a few minutes or hours.
[0019] Hence, the technical infrastructure set up to allow a referring web site to be identified by the destination e-commerce web site and hence paid for each visit, registrant or sale (respectively, pay-per-click; pay-per lead; pay-per sale) is called an affiliate management system. Affiliate management systems include a web based interface that readily allows any potential referring site to automatically participate in the affiliate program through a simple registration form that results in the allocation of an affiliate URL tracking code to that affiliate. In turn, the affiliate can then embed its affiliate URL tracking code in any URL/link that he uses in order to promote the destination e-commerce site (directly, or indirectly). This code allows the tracking system to monitor the activity generated by this affiliate.
[0020] This commission based paradigm to driving traffic to e-commerce web sites has become very important in the economy of the World Wide Web. Where the referring site is one of the major web search engines, then, as noted earlier, a listing of a given e-commerce site might only be present because it has been paid for; whenever an end-user clicks from the listing to the e-commerce site, the search engine gets paid. This drives the income of companies such as Google, Inc. In this context, Google would be an affiliate of the site that it drives traffic to.
[0021] This affiliates model has yet to be adopted in the mobile wireless space because implementing it seemed technically impossible; one barrier is the difficulty in verifiably establishing the identity of the entity that drove specific traffic to a specific e-commerce site, over wireless communications network using wireless specific languages and protocols—i.e. the difficulty in including tracking codes for mobile telephony based interactions with conventional WWW e-commerce sites.
[0022] More generally, interacting with e-commerce sites using a mobile telephone (sometimes called m-commerce) has in the past been very limited. Manual browsing, web spiders, web scraping and direct data feeds are known approaches. Of these, direct data feeds are well established, but have the disadvantages of being expensive, requiring time consuming and often complex IT integration and exposing existing systems to security vulnerabilities. Direct feeds also preclude any kind of affiliates program and usually may not enable a two way commercial transaction. Few mobile network operators built e-commerce sites using this direct feed approach; they were adopting a so-called ‘walled garden’ approach, in which users of one network would engage in mobile commerce solely with entities within the control borders of that network.
[0023] WAP based e-commerce sites should in theory be an effective way of enabling mobile telephones to interact with on-line sites, but there are very few WAP sites of any interest to consumers, not least because it can be costly for a merchant to replicate a web site to give a WAP presence. WAP navigation also precludes any kind of affiliate program because the URLs in WAP are length limited and hence it is impossible in practice to reliably include within the URL of a destination WAP site any indication of the source WAP site that the end-user is navigating from. It is thus also impossible to use several redirects for the same link. Moreover, WAP links may be used to navigate only within WAP pages (and not WWW sites), which are rare and hard to find.
[0024] The technical challenge is therefore to be able to allow mobile wireless devices to interact with conventional WWW based e-commerce sites that can be browsed by a PC web browser, and, in addition, to implement some kind of tracking functionality that makes it possible to work out why traffic is driven to a given e-commerce site and what kind of interactions does that traffic represent; this would enable an affiliates management system to be built for m-commerce (i.e. mobile telephones interacting with e-commerce sites). But to date, even the possibility of deploying an affiliates program and related management system for the m-commerce space has not been appreciated.
[0025] The present applicant introduced a new technology, called Web Agents, in PCT/GB02/03702 (equivalently EP 1419459, the contents of which are incorporated by reference) that enables a more effective process of software interacting with e-commerce sites. Web Agents technology is a framework that allows easy, rapid and robust implementation of extremely lightweight software components that automate browsing on the web. The main idea behind the framework is to look at the web as a huge cluster of databases. It uses a transfer protocol support to link itself to and perform actions on such a “database”. It also queries the “database” using a query language, in order to extract information from it. In a Web Agents implementation, the mobile telephone does not interact directly with an e-commerce site, but instead with a remote server. It is the server that deploys the Web Agents framework and directly interacts with the e-commerce web site, sending results back to the mobile telephone to display. PCT/GB02/03702 does not however disclose any kind of tracking functionality that makes it possible to work out why traffic is arriving at a given e-commerce site and hence does not disclose any kind of affiliates management system suitable for mobile wireless devices.
SUMMARY OF THE PRESENT INVENTION
[0026] In a first aspect, the invention is a method of enabling traffic to be driven to an e-commerce site, and that traffic tracked, the traffic relating to interactions between the e-commerce site and a mobile wireless device; the method comprising the steps of:
(a) an entity registering as an affiliate of the e-commerce site and publishing information that promotes that e-commerce site; (b) an end-user seeing that information and as a consequence sending, or causing to be sent, a request to a remote server that can interact with the e-commerce site under control inputs from an application running on the device, the request including data that uniquely defines the affiliate.
[0029] In practice, there will be many thousands, perhaps tens of thousands of affiliates seeking to push traffic to the more successful e-commerce sites. When you factor in there being thousands of highly successful sites, and millions of sites that still justify some level of traffic directing effort, then the practical problem of establishing which particular affiliate out of this huge universe is responsible for initiating a given item of traffic (e.g. a particular visit from a mobile wireless device to a given site; or an individual registering at a given site or buying one item from a site) and the downstream problem, of monitoring all subsequent interactions is quite huge.
[0030] Hence, the invention addresses the technical problem of establishing the identity of a referral entity and tracking the interactions between an end-user with a mobile wireless device and an e-commerce site that are a consequence of that referral. It permits the reliable, automated identification of the entity (possibly the first entity, but not necessarily) in the causal chain of entities that leads the mobile wireless device to reach a particular destination e-commerce site and interact with that site. The term ‘identity’ should be broadly construed to cover some information uniquely linked to the entity and that enables the entity to be directly or indirectly established. It may simply be a unique number, which does not of itself reveal the name of the identity (see below). The request is a request/query that indicates that the end-user wishes to interact with an e-commerce site in some manner.
[0031] Prior to this invention, mobile wireless devices have interacted with e-commerce sites (i.e. WWW sites) using specialised Web Agents technology, but without there being any mechanism to enable traffic to be driven to a specific e-commerce site from an affiliate and for that traffic to be tracked.
[0032] Furthermore, the entity can interact directly with an affiliates management system associated with the e-commerce site to become an affiliate. This in turn allows the e-commerce site to remunerate the entity directly using its well established web affiliates program. This can be done with no alteration to the existing web affiliates program or the affiliate management system of an e-merchant; indeed the merchant may well be completely unaware that it is happening and need incur no costs in changing its technical infrastructure or integrating its e-commerce site with any third party technology.
[0033] Furthermore, by implementing a Web Agents type intelligent system that allows a server to interact directly and fully with an e-commerce site, passing back data for the mobile wireless device to display, it is possible for an existing, e-commerce site (i.e. a WWW site designed for non-wireless web browsing) itself to require no adaptation at all for effective interaction with mobile wireless devices.
[0034] The present invention can be implemented using any way of publishing the information; in practice, however there are three main ways:
Offline channel (e.g. a magazine, newspaper, billboard, TV, Radio or other print or digital media—i.e. anything that is not online (i.e. internet connected) or mobile (wireless WAN connected)—see below; Online channel (a channel that requires an internet connected PC with a web browser looking at web content, e.g. a banner advert on a web site, links, forms, content, keyword advertising on a web site etc.); Mobile channel (a channel that requires a wireless WAN connected mobile computing device looking at non-web, mobile specific content, e.g. WAP portals, mobile operators' on deck applications, J2ME applications, off deck portals, WAP Push, opt-in DB's MMS etc.)
[0038] We will briefly deal with each in turn. First, offline; the information that is published offline can be a unique identifier comprising at least a destination number, the unique identifier being associated with both the given e-commerce site and the entity. Then:
(a) the end-user uses the mobile wireless device to send a message to the destination number to initiate an interaction with the e-commerce site; (b) a remote server then interacts directly with the e-commerce site but enables the end-user to interact only indirectly with that site using the downloaded application; (c) the identity of the entity is established using the unique identifier.
[0042] The unique identifier can be a unique code or text (the ‘key word’), as well as the destination number (the ‘short code’). The unique text can be conceptually related to the goods or services offered by the e-commerce site. Hence, an affiliate could log onto a conventional computer implemented affiliates management system for an online retailer that sells National Lottery tickets and register as a new affiliate. That system gives the entity a unique affiliate number 123 and a unique identifier that the affiliate can use in promoting the National Lottery to mobile telephone users; this identifier is the key words ‘Get Lucky’ and a SMS short code number 686874. The phrase ‘Get Lucky’ (or some other slogan etc.) could instead be devised by the affiliate entity itself and provided to the affiliates program. In this scenario, the ‘identity’ is the number 123, the ‘unique identifier’ is ‘Get Lucky’ and the ‘destination number’ is short code 686874. The affiliate could publish a newspaper advert for the National Lottery, reading “Text ‘Get Lucky’, to 686874 to play the National Lottery on your mobile”. The ‘Get Lucky’ key word uniquely identifies this particular affiliate to the remote server (the server itself is contactable via the network operator who routes the message to the remote server); the server knows that any end-user texting in this phrase is doing so because of seeing the newspaper advert placed by this particular affiliate (different affiliates would usually have different key words, and would therefore be distinguishable). Any end-user (identified by the mobile wireless device's telephone number) can be linked to this affiliate; the remote server and also the affiliate can hence track future interactions by that end-user with the National Lottery web site. Consequently, that affiliate can be paid on a normal affiliates basis. To actually interact, the mobile wireless device needs the client application that gives the control inputs to the remote server. This could be downloaded to the device as a consequence of the ‘Get Lucky’ text, or could already be installed. The application could also be pre-installed on a mobile device at the time of sale.
[0043] Where the information is published on-line by an affiliate on a WWW site, then the information can include an icon, button or other user selectable feature that, when selected, causes the application to be downloaded to the mobile wireless device. Selecting the user selectable feature also fetches an implementation page that explains how the user should install the application on the mobile wireless device. In this example, the data that uniquely defines the affiliate is a URL tracking code. The National Lottery affiliate could for example be given URL tracking code XX-123-ZZ for a particular online campaign for a particular new lottery product. This tracking code is used in the request sent by the online affiliate's site to the remote server; the end-user's mobile telephone number is also entered into the affiliate's web site and sent to the remote server. The remote server links the mobile telephone number to that particular affiliate, allowing all future interactions to be tracked, reported to the affiliate and used as the basis for commission payments.
[0044] Where the information is published in using a mobile channel (e.g. a WAP site, so that the end-user views that site using a WAP browser on the mobile wireless device), then the WAP site includes a hyperlink that, when selected, causes the application to be downloaded to the mobile wireless device. The data that uniquely defines the affiliate is a URL tracking code. This is used in the same way as for the on-line example.
[0045] To re-cap, the request from the end-user can, in one implementation, be sent to a remote server that stores the number of the mobile wireless device of the end-user in association with a tracking code that links that end-user to a specific affiliate. This remote server sends an application (a J2ME application typically) to the mobile wireless device, which the device loads to enable the end-user to interact indirectly with the e-commerce site. Alternatively, the application can be pre-installed on the device, or have been installed earlier. The remote server can identify not only the affiliate responsible for causing an end-user to send the request that identifies the affiliate, but also a specific campaign/promotion that the affiliate has initiated, and can track all interactions for each end-user, relating them to a particular affiliate.
[0046] The remote server can also interact directly with an affiliates management system associated with the e-commerce site; the affiliates management system causes a payment to be made to the entity that operates the remote server when pre-defined kinds of interactions occur between the end-user and the e-commerce site. The affiliates management system can also cause a payment to be made to the affiliate when pre-defined kinds of interactions occur between the end-user and the e-commerce site. This eliminates the need for a costly and complex billing infrastructure, with attendant IT integration issues.
[0047] An e-commerce merchant can therefore publish a web traffic affiliate program online using an affiliate management system and any potential affiliate can register online with that program, not only for conventional web traffic promotion but also in relation to interactions from mobile wireless devices mediated by the remote server. Hence, the entry barriers to a WWW based e-commerce merchant entering into mobile commerce are substantially removed. Furthermore, powerful tracking features are enabled; for instance, the request sent by the end-user to the remote server can uniquely identify a campaign or product being promoted by the affiliate. The traffic that is driven to the e-commerce site includes traffic relating to one or more of: the end-user visiting the e-commerce site; the end-user registering with the e-commerce site; the end-user purchasing goods or services from the e-commerce site. The affiliates management system allows the e-merchant and any affiliates to monitor or track the success and detailed activity of any specific marketing campaign. With an implementation of the present invention, it is possible to track anything the user does after he first requests the download of the application to his mobile wireless device. But more importantly, the affiliation tracking system knows which campaign this user has come from: e.g.—that an advertising campaign in Canary Wharf, London for a particular betting product on a particular e-commerce site has generated 100 initial requests, which in turn resulted in 20 application downloads, which in turn resulted in 15 full registrations, with which the end-users on the average bet 535 50 a week. Or, for example after two days of a banner advertisement on Yahoo.com, the affiliate that sponsored this banner can see that it results in registration of women betting only few pounds—driving him to change to a more “male oriented” banner.
[0048] Another feature is that the application that is loaded onto the mobile wireless device provides a user interface that enables the end-user to interact indirectly with the e-commerce site. The user interface is created by a presentation layer that allows customisation of the user interface for any different e-commerce site. The remote server remotely interrogates one or more e-commerce sites in response to information requests from the application loaded onto the mobile wireless device; it can not only parse data on the site but also interact with transactional flows or routines of that site. The remote server can deploy Web Agents; it then includes a query engine which operates on XML format data obtained from content data extracted from the e-commerce site, the query engine parsing the XML format data into SAX events which are then queried by the query engine. Web Agents allow the end-user to interact indirectly with the e-commerce site, including undertaking one or more of the following: account creation, login/out, searching, browsing, account maintenance, purchasing. This interaction from the remote server requires no adaptation of an existing e-commerce site; entry barriers previously preventing a WWW based e-commerce site from entering into mobile commerce can hence now be removed.
[0049] Other aspects of the invention are as follows:
A printed publication that promotes an e-commerce site and is controlled by an entity that is an affiliate of that e-commerce site, the publication including a unique identifier that, when sent, or caused to be sent, by an end-user to a remote server using a mobile wireless device, uniquely defines the affiliate. A web site that promotes an e-commerce site and is controlled by an entity that is an affiliate of that e-commerce site, in which the web site includes an icon, button or other user selectable feature that, when selected, causes a request to be sent to a remote server, the request uniquely defining the affiliate. A WAP site that promotes an e-commerce site and is controlled by an entity that is an affiliate of that e-commerce site, in which the web site includes an icon, button or other user selectable feature that, when selected, causes a request to be sent to a remote server, the request uniquely defining the affiliate. A mobile wireless device when programmed with an application downloaded because of an interaction with the printed publication, web site or WAP site defined above. A method of remunerating an affiliate via an affiliate program, in which the affiliate produces the printed, online or WAP publication defined above. An affiliate remunerated using the method of remuneration defined above.
[0056] Overall, the present invention is a significant enabler for mobile commerce between mobile wireless devices and WWW e-commerce sites because:
It makes is easy to become an affiliate able to drive traffic from a mobile wireless device to a WWW e-commerce site; this is based on the re-use of existing affiliate management systems (previously not thought relevant to the m-commerce environment); The mechanism for creating traffic for a WWW e-commerce site is easy; it just involves an affiliate publishing certain information; It is easy to track interactions between a mobile wireless device and a WWW e-commerce site and link them to appropriate affiliates; this is again based on the re-use of existing affiliate management systems (previously not thought relevant to the m-commerce environment); It is easy to pay affiliates, as well as the infrastructure operator that runs the Web Agents server, since both can be paid using the existing affiliate management systems (previously not thought relevant to the m-commerce environment).
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] The present invention will be described with reference to the accompanying drawings in which
[0062] FIG. 1 is a schematic of the overall process and flow of the present invention;
[0063] FIG. 2 is a schematic showing the relationship between merchants, affiliates, users and the operator of the remote server infrastructure (Cellectivity);
[0064] FIG. 3-10 are screen shots from an Affiliates Management System offered by Cellectivity.
DETAILED DESCRIPTION
[0065] The present invention provides a system and method to enable a mobile wireless device to interact with e-commerce sites. It enables e-commerce sites to be promoted (e.g. online, WAP, printed media such as billboards, adverts in papers etc) using a novel mechanism that allows the identity of an entity that successfully drives traffic to an e-commerce site to be reliably identified. This is a necessary pre-condition to entities becoming affiliates. But an added feature of the invention is that it can implement the entire web-based affiliation process in the mobile space; it hence enables affiliates to be remunerated on a commission basis (e.g. pay-per-click, pay-per-lead, pay-per-sale, revenue share etc.).
[0066] An implementation comprises 4 main features:
1. Remote integration—In the non-mobile space (e.g. HTML based web sites) it is easy for a potential affiliate to integrate into a merchant's e-commerce site as that entity just adds a link that points to that e-commerce site in the entity's own site; a user can, using a web browser, then easily navigate from one the entity's site to that merchant's site by clicking on the link. But in the mobile space, this cannot be done straight forwardly: it requires either direct access to the e-merchants' back-end system, or requires the merchant to build a mobile dedicated UI. The Web Agents technology (see below) does allow remote integration to a merchant's site from a mobile wireless device and, because of a presentation layer (see below) it also allows use of the existing web based UI of that site. 2. Remote transaction: again, this is very easy on the Web as the user is on the merchant site (or sometime a white-label of the merchant site). The Web Agents technology enables remote transactions between a mobile telephone and an e-commerce site via a remote server that deploys the Web Agents technology; it is this server and not the mobile telephone that interacts directly with the e-commerce site. 3. Tracking system On the web, tracking is achieved by using a URL tracking code that is added to a link, so that the original web site that is linked to the merchant's e-commerce site (i.e. clicking on the link initiated the transfer to the merchant's e-commerce site) can be uniquely identified. This enables the e-commerce site to identify the source of hits on its site. This in turn enables revenue share/commission payments to be made back to the original referring site. In the mobile space, we either use URL tracking to download an application from our servers (not the merchant's e-commerce site) or we use a novel solution: a unique text string or other kind of unique identifier which is sent (typically via SMS) to a defined destination number (n.b. both the string and/or the destination number can serve as the unique identifier). This identifier uniquely identifies the affiliate.
[0070] 4. Downloading an application to the mobile telephone is one variant of the integration process—an end-user sees a publication (e.g. online advertisement, paper advertisement etc.) promoting particular goods or services or a particular merchant(s). The publication might, using he earlier example, be a billboard or TV advert with the words:
“Text ‘Get lucky’ to 68684’ to pay the National Lottery”
[0072] The publication includes a unique identifier, which could be a specific destination number to which a message should be sent (68684 alone in the example above); the unique identifier could also include the message to be sent as well (the phrase ‘Get Lucky’ as well as the destination number 68684).
[0073] The end-user sends a SMS (or similar) text message including the unique key word identifier code (e.g. ‘Get Lucky’) from his mobile telephone to the short code destination number (or else a blank message to the destination number if that number alone serves as the unique identifier) and an application is automatically sent to and loads on his mobile telephone. In the above example, it is an application that allows the end-user to play the National Lottery—e g. choose a set of numbers, pay for them and be notified automatically if they are winning numbers. Many other applications are possible, e.g. a betting application could allow an end-user to choose a sport (football, horse racing etc.), obtain odds from different bookmakers, place a bet and collect winnings.
[0074] The unique identifier gives the remote server (and/or some other resource) the information it needs to establish the identity of the entity responsible for the publication (e.g. the affiliate, such as which particular magazine or web site etc.). The remote server (and/or some other resource) can hence maintain a database log of all affiliates and what kind and level of traffic each generates and for which destination e-commerce sites and which campaign/which product or service. The local application downloaded to the mobile telephone takes care of the rest of the entire process by sending instructions to the remote server; the instructions in turn run the Web Agents technology that resides on the remote server. Responses back to the remote server, from the e-commerce site or sites being interacted with, are in turn processed by the remote server and then fed back by the server to the mobile telephone for appropriate display. Because the local application includes a flexible presentation layer that determines the user interface presented on the mobile telephone, it is also possible for this user interface (e.g. the arrangement and layout of icons, fields, buttons, text and graphics, plus the way of interacting with any of the above) to mimic the user interface that would be presented to the end-user if he were to interact directly with the e-commerce site using a PC with browser over a conventional wire based WAN, as opposed to a mobile telephone using predominantly a wireless WAN.
[0075] More on a Web Agents Implementation
[0076] The Web Agents technology enables a mobile telephone or other mobile wireless device to interact with web resources in a sophisticated manner, enabling an end-user to undertake many different kinds of e-commerce transactions. The Web Agents technology can automatically search across different web sites, query and interact (read and write) with those sites and, as required, return information to the end-user or perform tasks on her behalf. Reference should be made to PCT/GB2002/003702, the contents of which are incorporated by reference. This discloses a web interaction system comprises a query engine which operates on XML format data obtained from content data extracted from a web site, the query engine parsing the XML format data into SAX events which are then queried by the query engine.
[0077] One of the drawbacks of this system however is that it does not provide for the automatic identification of how an end-user came to visit a particular e-commerce site—e.g. how was the end-user prompted to visit a particular e-commerce site. It is in effect silent on any kind of mechanism for tracking how traffic for a given site was in fact generated. Further, it requires a complex billing system to pay the operator or other entity responsible for running the remote server that interacts with the e-commerce site. The present invention addresses the former (as noted above) by defining a new mechanism that does allow entities that promote successfully an e-commerce site to be identified reliably and for all subsequent interaction to be tracked; it addresses the latter by proposing a remuneration infrastructure—i.e. that the existing affiliates management system normally used for web sites that drive traffic through hyperlinks can also be adopted as the payment mechanism for the operator of the remote server, as well as the mechanism for setting up affiliates and paying them.
[0078] Conventional affiliates management systems are used to reward web sites that direct traffic to a web merchant's conventional web site. Once directed to that web site, the PC based end-user then interacts with the web site in the normal way. With Web Agents technology, the end-user does not interact directly with a merchant's web site in the way a PC based end-user would—instead, the Web Agents technology searches across multiple sites and extracts out the critical data needed for an interaction from a mobile telephone, making the interaction far simpler. The end-user can complete the entire transaction without needing to visit the actual merchant web site; critically, the entity that makes the search and interaction possible (e.g. a mobile operator offering the Web Agents service) can itself be paid not by directly billing the end-user (which would require a complex billing infrastructure) but instead by using the affiliates program of that merchant. A web merchant's affiliates payment program system has not previously been used as the payment infrastructure for a service that locates goods/services requested from a mobile telephone and enables an end-user to complete an entire transaction from the mobile telephone without the end-user having to directly visit and interact with the merchant's web site. Instead, they have only been used to pay entities that refer traffic to that web site using HTML hyperlinks over a non-wireless link and then go on to interact with the web site.
[0079] But with the present invention, the service that locates goods/services (and operates the remote server running Web Agents) can hence readily be remunerated by a web merchant when an end-user using the service interacts with the web merchant (e.g. registers with that merchant, initiates an e-commerce action such as buying goods or placing a bet etc.) The mechanism used can be simple: the service itself registers as an affiliate on the affiliate program offered by the web merchant. The service is allocated automatically a unique label or tag by the affiliate's management system; whenever the service interacts with that merchant's e-commerce site on behalf of an end-user, all interactions use this tag. Hence, the merchant and service have a detailed record of all visits, new customers, new sales etc. generated by the service. This record can be the basis for payment on the standard affiliates basis (pay-per-lead, pay-per-click; pay-per-sale).
[0080] In addition, the service can also pass back some of this remuneration (or otherwise pay) to the entity that directed an end-user to use the service in the first place. This ability to remunerate the entity that typically promotes the service is very important since without it the ability to effectively promote the service is severely limited. Alternatively, the entity can itself directly register as an affiliate with one or more merchants' affiliates programs.
[0081] One mechanism used to enable the service to identify the promoting entity and track the consequential or subsequent interactions between an end-user and an e-commerce site. This is shown schematically in FIG. 1 : the promoting entity 1 first registers 2 on-line using a web based management system 3 of a merchant with an e-commerce site 4 . In the offline channel model, the affiliate selects or is given a word or number by the service; this word or number is unique to a given entity and features in all promotional material 5 for the service from that entity, with the instruction that a potential end-user 6 should text 7 the word or number to the service/remote server 8 to initiate the entire web interaction process using their mobile telephone 20 . For example, imagine that there are 2 different entities that are promoting the same e-commerce betting services via the mobile telephone. In the adverts in a campaign from one entity, the end-user 6 is told to text the word ‘win’ to a given number. In the adverts for the other, the end-user is told to text the word ‘lucky’ to the same number. The entities 1 could be different search engines, newspapers/magazines, or different organizations etc. Each text is received by the service 8 that locates goods/services and operates the remote Web Agents server; it can hence differentiate between end-users that have come to it from each different entity. The service 8 logs the mobile telephone number of the telephone 20 , and stores this together with the data in request 7 that uniquely identifies each affiliate 1 (and in this case, a particular campaign for a particular e-commerce site from a particular affiliate). Any subsequent interactions from this mobile telephone number for this betting e-commerce site can hence be associated with a specific affiliate 1 and particular campaign. Receipt of the text request 7 from a given mobile telephone triggers the service 8 to send a WAP push link 9 to the device; if the end-user 6 accepts the link, then an acceptance message 10 is returned to the service 8 . This causes service 8 to send out a J2ME application to the mobile telephone 20 ; this loads on the mobile telephone 20 , as shown at 21 , and provides the user interface that enables the end-user to efficiently interact with web resources 4 via Web Agents technology deployed by the remote server 8 . The loaded J2ME application 21 communicates in background with the remote server 8 . The presentation layer of the JME application 21 is configured to mimic the UI of the e-commerce site 4 being indirectly interacted with.
[0082] In one implementation, a mobile telephone user 6 sends a request 11 for goods and services using the local J2ME application 21 that it downloaded to his mobile telephone 20 after seeing a particular advertisement 5 etc. The request 11 uses a protocol which is device and bearer agnostic (i.e. is not specific to any one kind of device or bearer) and is sent over the wireless network (e.g. GSM, GPRS or 3G) operated by a mobile telephone operator (e.g. Vodafone). The request is directed to the operator, who then routes it through to the remote server 8 (typically operated by an independent company specializing in designing the software running on such servers, such as Cellectivity Limited), which initiates a search through appropriate suppliers 4 by using the above described Web Agents web interaction system.
[0083] The Web Agents web interaction system 8 automates the entire web browsing process which a user would normally have to undertake manually. The user in effect delegates tasks to the web interaction system 8 , eliminating the need for continued real time connection to the Internet. The search may also depend on business logic set by the operator—e.g. it may be limited to suppliers who have entered into commercial arrangements with the mobile telephone operator controlling the web interaction system.
[0084] The web interaction system 8 interacts 22 with the e-commerce site web resources 4 (not simply WAP, iMode or other wireless protocol specific sites), querying them, submitting forms to them (e.g. password entry forms) and returning results to the translation engine. The translation engine converts the results content (usually HTML, but the system is not limited to that content language) into properly nested XML by generating SAX events; the query engine then applies appropriate queries to the SAX events in order to extract the required information and generally interact with the web site in a way that simulates how a user would manually browse through and interrogate the site in order to assess whether it offers goods/services of interest and to actually order those goods/services.
[0085] The objective is for the consumer experience to be a highly simplified one, using predefined user preferences in order to make sure that the goods/services offered to the consumer are highly likely to appeal.
[0086] The kind of traffic received at an e-commerce site can be monitored by the site itself, but can also be monitored by the remote server. This can give an independent audit trail of events. Typical traffic data stored includes the nature of the interaction (e.g. new customer registering, new purchase, just a browse) plus other information such as the length of time spent on the site, amount of money spent, identity of the remote server that inter-mediated the transaction, the identity of the entity that published the promotion/advert/information that initiated the downloading of the application to a mobile telephone that in turn enabled the web interaction via the remote server to take place etc. This data in turn is fed to the affiliates payment system of the merchant, triggering an automated payment to the promoting entity; the amount depends on the kind of affiliate relationship entered into. Affiliates (which can include the remote server as well) can at any time track the volume of traffic they are generating and for whom and can hence fine tune/adapt any marketing campaigns to improve results. Because data capture is entirely automatic, it can happen very rapidly, enabling an affiliate to adapt a promotional campaign very rapidly—perhaps within hours or days. This kind of rapid feedback would be extremely costly to implement conventionally, requiring costly and time consuming IT integration. Annex II is a system requirements document for an Affiliate Management and Reporting System that can be deployed with the present invention.
[0087] Annex 1
[0088] Web Agents in More Detail
[0089] The Web: A Virtual Database
[0090] E-merchants maintain highly available web interfaces for their inventory. In essence, each interface Web-site) is a semantic representation of the merchant's dumb data which also captures the merchant's business and transactional flows. Using unique software components, Web Agents are able to capture and interact with these abstraction layers. This allows the remote server that deploys Web Agents to operate the internet as its own virtual data-base in real time. This is done to the extent where most of the functions that commercial data management tools provide over a traditional data-base (e.g. Oracle) are supported in this virtual data-base. In turn it allows the automation of complex tasks for the benefit of the end-user. A payment transaction can be completed without the need for feedback from the user and without the continued connection to the client. In principle, the end-user delegates demanding tasks to the application and waits for its fulfilment, resulting in a simple and efficient user experience. This requires no technical integration with the individual web sites.
[0091] Application/Logic Layer
[0092] This mostly includes business services which are re-useable across multiple applications, a few specific business rules, and the logic of individual applications. In addition, the logic employs personalization and decision making tools to filter information according to the end-user profile. This design allows the rapid development of entirely new applications.
[0093] The behaviour of each application is determined by two factors: the preferences and profile of the end-user, and the business rules set by the mobile operator. The company uses its own internal SDK to develop new applications rapidly.
[0094] Presentation
[0095] The key feature of the presentation layer is the separation of the consumer experience (user flow) from the application logic. This feature allows one to customise the consumer experience to the specifications of each mobile operator. The presentation layer is also responsible for detecting the optimal content presentation for the protocol and device combination, and for acting as a controller for push and pull services to the client. This presentation layer allows us to efficiently deploy applications across past and future protocols and to provide extensive customisation opportunities.
[0096] The advantage of the Web Agents technology can be summarized as follows:
Identifies and interacts with the semantics and flow of web interfaces Retrieves information which cannot just be scraped (e.g. showing the user only available flights at a certain moment, requiring a complex multi-step interaction with the web-site that cannot be mimicked by parsing alone) Starts and completes commercial transactions without requiring any dedicated effort (or even awareness) on the vendor's behalf Is robust to syntactical changes on the web (e.g. different wording, location of text, etc.) Automatically identifies changes in logic (user flow or semantic) on the web Uses the standard IP address of the vendor (usually designed for high-availability, and continuously monitored) to communicate Exploits the entire functionality of the vendor's site, including purchasing, log in/out, account creation and maintenance, search, browsing Able to access any functionality added or any problems corrected by the vendor. Flexible and takes advantage of any changes on the vendor's side such as promotions etc. which may appear on the site but not through a feed of bare data. Launches within weeks rather than years
[0107] Annex I
[0108] This Annex will outline the functional requirements for an affiliate managements system operated by Cellectivity Limited.
[0109] The system is required to gather essential information from various sources and combine it in ways useful for all user groups to consume. This Annex will cover reports required by all user groups and derive what is the information needed to assemble those reports.
[0110] System User Definitions
[0111] This section will define the system user types in terms of their interaction with the system and how they are identified through out.
[0112] Application Users
[0113] Application users are individuals interacting with the system using mobile phones. This is done either via WAP portals, by sending SMS messages, or via mobile applications.
[0114] Users are identified by their mobile telephone number. When a user is referred by another portal their telephone number may not always be passed along, in which case they would be asked to provide it and it will need to be verified by an SMS or password if they already exist on the system.
[0115] Application users are likely to be referred by affiliates in which case they would be assigned to the referring affiliate and their actions will be reflected in the appropriate affiliate reports.
[0116] Merchants (Partners)
[0117] Merchants are providers of services, which are made available to mobile users via mobile applications, through the Cellectivity network (i.e. the network that places the Web Agents server at its core). They may provide their own applications or the applications could be developed by Cellectivity and interact with the merchant's system.
[0118] Merchant's revenue is shared with Cellectivity according to different deal structures, which are described further in this document.
[0119] Merchants are identified by unique merchant ids assigned to them by Cellectivity.
[0120] Affiliates
[0121] Affiliates are application distributors who refer users to Cellectivity's network. They generate revenue based on the users' actions and the affiliate agreements.
[0122] Affiliates are identified by Cellectivity assigned Affiliate ids. In some cases they need to be separately identified on merchants' networks, by merchant affiliate ids, which are linked to the Cellectivity ids.
[0123] Apart from standard affiliates there will also be merchant affiliates. These will be used, when the merchant is marketing the applications themselves. These affiliate accounts will not be paid out, but there revenues will be deducted from the amount the merchants are invoiced.
[0124] Internal Users
[0125] Internal users administer the internal systems and extract relevant information.
[0126] It is required that there are various access levels available.
[0127] User Interaction
[0128] Users are referred by affiliates via SMS and/or the affiliates' mobile portals. For SMS referrals the affiliates are assigned unique per application keywords for their users to send to short numbers resulting in a WAP push of the URL containing the requested application. The FIG. 2 diagram below represents the typical user interaction: an application user referred by an affiliate downloads a merchant's application from Cellectivity.
[0129] If a user is referred via SMS, this means that they have sent the affiliate short code to the number requesting a particular application. Since the short codes are unique per affiliate the system will be aware who the referring affiliate is. The telephone number of the user will be extracted from the database. It will be logged in the database and a unique identifier will be assigned to the number, which will identify the user to belong to the referring affiliate for that application.
[0130] If the downloaded application is Cellectivity's then all actions by the user are logged as the application interacts with the servers. If the application belongs to a third party, they are required to provide daily updates of user actions to be included in the affiliate reports.
[0131] Deal Structures
[0132] This section will outline the various merchant and affiliate deal structures.
[0133] The deal structures refer to the actions performed by the system users, which trigger payments to be made between merchants, Cellectivity and affiliates.
[0134] Merchant Deal Structures
[0135] There are different merchant deal structures, specific to the verticals the merchants operate in. The deal structures outline the payments to be received by Cellectivity based on the users' actions.
[0136] Betting
[0137] Bounty
[0138] A bounty is a payment for a bet placed by a user. It is required for the system to allow flexibility in terms of which transactions generate a bounty for different merchants. I.e. a merchant may pay the bounty amounts for the first and the fourth bets made by a user, while another merchant may pay bounties on bets five and nine.
[0139] Share of Ongoing Revenue
[0140] The share of the ongoing revenue could be one of the following:
Percentage of the total stake regardless of the bet outcome. This could be paid either immediately or after the event has occurred. percentage of revenue, which is calculated per affiliate on a monthly basis as house wins—house losses—tax. These will always be paid after the event.
[0143] The system will need to support different commission figures for users who had signed up for accounts directly with the merchants prior to using the affiliate applications.
[0144] Shopping
[0145] Per Transaction
[0146] Shopping merchants pay commission per transaction, the commission could be either a percentage of the transaction cost or a set amount.
[0147] It is required for the system to support volume based commission structures. I.e. for the first 100 sales the commission is x, for any sales after the commission would be y.
[0148] Per Lead
[0149] Merchants may pay per clicks to their website.
[0150] Dating
[0151] New Users
[0152] For new users signing up via the mobile application the merchants will pay a percentage of the subscription fees.
[0153] Existing Users
[0154] If the users already have a subscription to the dating service and wish to use the mobile applications merchants will pay a percentage of the monthly subscription for that month.
[0155] Casino/Poker
[0156] Merchants will pay commissions on monthly revenues per affiliate.
[0157] Revenue=house wins—house losses—taxes
[0158] Q: Are the subtracted taxes different between different merchants?
[0159] The commissions paid will be different based on weather the application is promoted by the merchant.
[0160] Affiliate Deal Structures
[0161] The system will support different affiliate structures, which can be combined for one affiliate distributing multiple applications.
[0162] Pay Per Click
[0163] The Affiliate is paid per click for any users, who click through from their site to a merchant.
[0164] Pay Per Download
[0165] The Affiliate is paid when a user they have referred downloads a merchants' application.
[0166] Pay Per Registration
[0167] The affiliate will receive payment once their user registers with Cellectivity or a merchant
[0168] Pay Per First Transaction
[0169] The affiliate will receive payment once the user executes the first transaction with a merchant.
[0170] Revenue Share
[0171] The affiliate will receive a share of the revenue on an ongoing basis.
[0172] In this case the affiliate will receive revenue only for new users they have referred and not for users with existing accounts.
[0173] Reporting Requirements
[0174] Affiliate Reporting
[0175] The affiliate reporting interface will be an external web based reporting interface accessible via http. Affiliates will be required to supply their username and password to access the interface.
[0176] The navigation between the various sections will be tab based across the top of the screen, any sub menus relevant to each section will be displayed as links below the tabs. Each page will include the company name, affiliate id and company logo (if available), the navigation will be similar to the FIG. 3 diagram.
[0177] Affiliates will only be able to see tabs, which are relevant to their deal structures.
[0178] Once the affiliates have logged in successfully, they will be presented a summary screen giving them an overview of their account.
[0179] The screen will look similar to the FIG. 4 diagram.
[0180] Affiliates will be able to edit their affiliate profiles (contact details, URLs etc) as well as their username and password.
[0181] Their account summary will display:
Total active accounts Total unique users Clicks (last 7 days) Downloads (last 7 days) New accounts last 7 days) Deposits (last 7 days) Share of bets stake Share of bets revenue
[0190] Within the foyer page there will be a graph indicating the overall revenue in the last 7 days and a window, which can be used by Cellectivity to post any communication to the affiliates, such as scheduled down time, or new feature introductions.
[0191] Within each reporting section the dates for which the reports will be customisable. There will be a shortcut date selection box, which will contain:
This month—default value Last month Last 7 days Last week (Mon-Sun) Last business week (Mon-Fri)
[0197] Or alternatively the user will be able to select between any dates they wish using a date picker drop down boxes. The reports within the date ranges will be broken down per day.
[0198] There will be the ability to view each report as a printer friendly version or export to CSV or Excel.
[0199] Clicks Reporting
[0200] If the affiliate is enabled to be paid per click they will be able to view the clicks report and see how much revenue they have generated over the selected date range.
[0201] The report will look similar to the FIG. 5 diagram.
[0202] On each line there will be a ‘view details’ link which will display the different click prices for the day, which sum up to the total figure.
[0203] Downloads Reporting
[0204] If the affiliate is enabled to be paid per download they will be able to view the downloads report and see how much revenue they have generated over the selected date range.
[0205] The report will look similar to the FIG. 6 diagram below.
[0206] FIG. 4 . 1 . 1 . 1 : Downloads Reporting
[0207] On each line there will be a ‘view details’ link which will display the different download prices for the day, which sum up to the total figure.
[0208] Registrations Reporting
[0209] If the affiliate is enabled to be paid per registration they will be able to view the registrations report and see how much revenue they have generated over the selected date range. The report will look similar to the FIG. 7 diagram.
[0210] On each line there will be a ‘view details’ link which will display the different download prices for the day, which sum up to the total figure.
[0211] Revenue Share
[0212] If the affiliate is enabled to be paid on an on going revenue share they will be able to view the revenue share report and see how much revenue they have generated over the selected date range.
[0213] Since this report will be compiled based on figures provided by merchants, it may be incomplete and unconfirmed for some days, if those days exist in the selected date range there will be an appropriate notice displayed. Additionally each line within the report will be marked as confirmed or not.
[0214] The report will look similar to the FIG. 8 diagram.
[0215] The above report will only include figures for bets on events, which have completed and the outcome is known. Events, which have not yet completed and the outcome is unknown will be marked as pending bets and will be included in a separate report. The revenue for them will be recognised in the month they complete.
[0216] The pending bets report will look similar to the FIG. 9 diagram.
[0217] Since the report will only display the current pending bets it will not include a date filter.
[0218] Stake Share
[0219] If the affiliate is enabled to be paid on an on going revenue share of the stake they will be able to view the revenue share report and see how much revenue they have generated over the selected date range.
[0220] For this report to be complete it will need to be amended with figures, which are provided by merchants, it may be incomplete and unconfirmed for some days, if those days exist in the selected date range there will be an appropriate notice displayed.
[0221] Additionally each line within the report will be marked as confirmed or not.
[0222] The report will look similar to the FIG. 10 diagram.
[0223] Total Revenue Report
[0224] The total revenue report will combine all figures together and once all figures for the month are updated and confirmed it will be used by the affiliates for invoicing.
[0225] The payment history link will enable the affiliate to view any previous invoices and their status. The available date ranges for this report will only be monthly as the affiliate payments are only issued on a monthly basis. | An entity registers as an affiliate of an e-commerce site and then publishes information that promotes that WWW e-commerce site; an end-user with a mobile wireless device, sees that information and as a consequence sends a request to a remote server that can interact with the e-commerce site under control inputs from an application running on the device. The request includes data that uniquely defines the affiliate. This approach makes is easy to become an affiliate able to drive traffic from a mobile wireless device to a WWW e-commerce site; this is based on the re-use of existing affiliate management systems (previously not thought relevant to the m-commerce environment). Further, the mechanism for creating traffic for a WWW e-commerce site is easy; it just involves an affiliate publishing certain information. Still further, it is easy to track interactions between a mobile wireless device and a WWW e-commerce site and link them to appropriate affiliates; this is again based on the re-use of existing affiliate management systems (previously not thought relevant to the m-commerce environment). Finally, it is easy to pay affiliates, as well as the infrastructure operator that runs the remote server, since both can be paid using the existing affiliate management systems (again, previously not thought relevant to the m-commerce environment). | 6 |
FIELD OF THE INVENTION
The present invention relates to a method for operating an internal combustion engine having at least one combustion chamber, one induction pipe, and one throttle valve.
BACKGROUND INFORMATION
In modern internal combustion engines having direct fuel injection and/or having an electronic gas pedal, the quantity of gas to be introduced into the combustion chamber is determined, inter alia, according to the quantity of fuel to be injected into the combustion chamber. This is necessary, inter alia, in order to generate a mixture in the combustion chamber in which combustion-generated emissions and fuel consumption are minimized. In this context, the quantity of gas, or the “gas charge,” is defined as a function of the actual position of the throttle valve, because the assumption is made that at a defined throttle position only a certain quantity of gas can reach the combustion chamber.
However, the problem in defining the gas charge of the combustion chamber in this manner is that the throttle valves themselves are manufactured within certain tolerances, so that when different throttle valves are set at the same angle, the result can be differing gas charges in corresponding combustion chambers. The gas charge actually present in the combustion chamber can therefore differ from the gas charge defined by the throttle valve position in ways that are not immediately predictable, which makes the creation of an optimal mixture dependent on the accidental presence of a “standard throttle valve.”
SUMMARY OF THE INVENTION
The present invention therefore has the objective of refining a method of the type cited above so that the mixture can always be adjusted with great precision.
This objective is achieved as a result of the fact that the minimum gas pressure is measured that is present in the induction pipe assigned to the combustion chamber at the end of the intake stroke, and that from this a value is determined which better approximates the actual gas charge of the combustion chamber.
The method according to the present invention is based on the following consideration: In an internal combustion engine having one intake valve, the piston at the beginning of the intake stroke is located in the upper dead center and then travels to the lower dead center. In this context, the quantity of gas behind the throttle valve continually expands in volume. This has the consequence that the pressure falls. In the lower dead center, the maximum volume and therefore the minimum pressure is achieved. Shortly thereafter, the intake valve closes. At this point in time, roughly the same pressure exists in the combustion chamber as in the induction pipe. By taking account of the characteristic data of the internal combustion engine, the gas charge in the combustion chamber can be calculated from this minimum pressure. Since this gas charge is calculated from the gas pressure that actually exists in the induction pipe, the leakage through the throttle valve and behind the throttle valve due to manufacturing tolerances is taken into account in the gas charge. This value is therefore more precise and can be used to produce mixtures more precisely. The pressure in the induction pipe is preferably measured by a sensor provided in the induction pipe.
In one very advantageous refinement, a gas charge of the combustion chamber is defined from the actual position of the throttle valve, the defined value is compared with the measured value, and then, if the comparison shows that the difference between the measured and the defined gas charge lies outside of a permissible range, the position of the throttle valve is corrected. Therefore, in this refinement, the gas charge measured from the minimum gas pressure and the gas charge defined by the actual position of the throttle valve are combined with each other. In this context, by determining a permissible range, a range of tolerance created, which makes it unnecessary to resort to control interventions too frequently.
In this context, the correction takes place preferably so that the difference between the measured and the defined gas charge is equal to zero. This means that the gas charge is optimized.
The above-mentioned method is particularly well suited for internal combustion engines that have a plurality of combustion chambers and also is particularly well suited for internal combustion engines in which each combustion chamber or a group of combustion chambers (e.g., a cylinder bank) has assigned to it its own induction pipe and its own throttle valve. For this reason, it is proposed in one refinement that the above-mentioned method be carried out independently for a plurality of combustion chambers having their own induction pipe and especially their own throttle valve. In this way, for each individual combustion chamber or for each group of combustion chambers, a value can be calculated which more closely approximates the actual gas charge of this individual combustion chamber, and the position of the throttle valve. assigned to this combustion chamber can be corrected. In this manner, the emissions and fuel consumption characteristics of the individual cylinders of the internal combustion engine are optimized.
Correcting the position of the throttle valve can take place in varying ways. One possibility is to correct an offset, usually taken into account in calculating the gas charge, and a slope. This offset is a value which makes it possible to take into account the air leakage streams through gaps between the throttle valve and the wall of the induction pipe and through other leakage points between the throttle valve and the combustion chamber. The slope takes into account the multiplicative errors in the throttle valve system. In response to a difference between the value for the gas charge defined by the actual position of the throttle valve and a value calculated on the basis of the minimal gas pressure, it can be assumed that the offset and the slope do not optimally reflect the actual reality. This can be partially compensated for by correcting the offset as proposed in accordance with the present invention. The same applies to the slope. In this context, the correction can take place in a multiplicative manner, meaning a change in the slope, or in an additive manner, meaning a change in the “offset.” A correction of the offset and/or the slope is recommended especially in response to generally low pressure levels in the induction pipe, i.e., in an operating state in which the throttle valve is closed relatively far, because in an operating state of this type the aforementioned leakage streams play a relatively large role.
Intervening in the control of the throttle valve position has the advantage over regulating the throttle valve position directly on the basis of the pressure-based gas charge that the optimal gas charge can be achieved more rapidly and without transient effects. Calculating the gas charge on the basis of the throttle valve position makes it possible to react immediately to a change in the driver's requests. On the other hand, the minimum pressure in one cylinder can only be measured anew after an entire rotation of the camshaft.
At an overall high induction pipe pressure, as is also mentioned in one refinement of the present invention, the regulation of the throttle valve position is influenced. In addition, it is also possible to influence the calculation of a setpoint value of the throttle valve. Both measures make it possible to react quickly to differences between the defined and the measured values.
The precision of the above-mentioned method is even more improved in one refinement which, in calculating the gas charge, takes into account the partial pressure of the internal residual gas.
The present invention also relates to a computer program, which is suited to carrying out the above-mentioned method, if it is executed on a computer. In one preferred refinement of this computer program, it is stored in a storage device, in particular in a flash memory.
Finally, the present invention relates to a control and regulating unit for an internal combustion engine, especially of a motor vehicle, having at least one combustion chamber, one induction pipe, and one throttle valve, the unit defining a gas charge of the combustion chamber from the actual position of the throttle valve. To improve the emissions and fuel consumption behavior of the internal combustion engine, the control and regulating unit is connected to a pressure sensor arranged in the induction pipe, and it determines a value that more closely approximates the actual gas charge from the minimal gas pressure existing in the induction pipe assigned to the combustion chamber at the end of the intake stroke.
Especially preferred is the refinement of the control and regulating unit, in which, if the comparison shows that the calculated gas charge of the combustion chamber does not roughly correspond to the defined gas charge, then a correction signal for the position of the throttle valve is generated.
Finally, a control and regulating unit of this type is particularly advantageous if it is suited for internal combustion engines having a plurality of combustion chambers and a plurality of pressure sensors and throttle valves each assigned to one combustion chamber. This is the case in the refinement in which the control unit is connected to a multiplicity of pressure sensors, each assigned to one combustion chamber, and, in particular, generates a plurality of independent correction signals for the corresponding throttle valves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic representation of components of an internal combustion engine having two combustion chambers.
FIG. 2 depicts a simplified representation of a method for operating the internal combustion engine from FIG. 1 .
FIG. 3 depicts a detailed flowchart of the method represented in FIG. 2 .
FIG. 4 depicts a diagram of the pressure curves in the induction pipe of the internal combustion engine represented in FIG. 1 .
DETAILED DESCRIPTION
In FIG. 1, an internal combustion engine is designated overall by reference numeral 10 . It has two combustion chambers 12 and 14 , each of which is supplied with air via its own induction pipe 16 and 18 , respectively. The internal combustion engine can be, e.g., an SI engine having an electronic gas pedal (“e-gas”). The corresponding pistons, etc., are not depicted. In the area of the intake of induction pipe 16 and 18 feeding into combustion chambers 12 and 14 , respectively, intake valves 20 and 22 are schematically depicted in FIG. 1 . The exhaust gases can escape via exhaust pipes 24 and 26 , which are connected via exhaust valves 28 and 30 to combustion chambers 12 and 14 , respectively.
Arranged in induction pipes 16 and 18 are throttle valves 32 and 34 , whose positions are set by servomotors 36 and 38 , respectively. The actual position of throttle valves 32 and 34 is transmitted in each case by position sensors 40 and 42 to a control and regulating unit 44 , which in turn drives servomotors 36 and 38 , respectively. Between throttle valves 32 and 34 and intake valve 20 and 22 , respectively, there are in each case pressure sensors 46 and 48 , which measure the pressure in induction pipes 16 and 18 between throttle valves 32 and 34 and intake valves 20 and 22 , respectively, during the operation of the internal combustion engine 10 . Pressure sensors 46 and 48 also convey corresponding signals to control and regulating unit 44 . The latter is also connected to a remote-position indicator 50 of a gas pedal 52 .
The quantity of air flowing through induction pipes 16 and 18 into combustion chambers 12 and 14 (arrows 54 and 56 ), respectively, is fundamentally influenced by the piston of throttle valves 32 and 34 . The control and regulation of the latter is now described with reference to FIGS. 2-4.
First, an air charge setpoint value rlsol is calculated by control and regulating unit 44 as a function of a signal which control and regulating unit 44 receives from remote-position indicator 50 of gas pedal 52 . This air charge setpoint value rlsol is identical for both combustion chambers 12 and 14 and represents the gas charge that is optimal for the fuel quantity to be injected. Calculating this value takes place in a block 58 .
As a function of air charge setpoint value rlsol, for each throttle valve 32 and 34 in a charge control process 60 and 62 , a setpoint wdksl and wdks 2 is established for the position of throttle valves 32 and 34 , respectively. These setpoint values wdksl and wdks 2 are in turn supplied to a position controller 68 and 70 , which drives servomotors 36 and 38 of throttle valves 32 and 34 , respectively. Actual position wdk 1 (block 72 ) of throttle valve 32 and actual position wdk 2 (block 74 ) of throttle valve 34 are measured by remote-position indicator 40 and 42 , respectively, and are conveyed to position controllers 68 and 70 , respectively. Position controller 68 , servomotor 36 , and remote-position indicator 40 as well as position controller 70 , servomotor 38 , and remote-position indicator 42 therefore constitute a closed control loop.
Actual positions wdk 1 and wdk 2 of throttle valves 32 and 34 ,. respectively, are also supplied to a throttle-valve-based charge measurement system 76 and 78 , which from supplied values wdk 1 and wdk 2 in blocks 80 and 82 define a “theoretical” actual position rldk 1 for combustion chamber 12 and rldk 2 for combustion chamber 14 . This gas charge is theoretical because it does not take into account the individual tolerances of throttle valves 32 and 34 and can therefore distinguish these gas charges from the actual gas charges.
From pressure sensors 46 and 48 arranged in induction pipes 16 and 18 , respectively, pressures P 1 and P 2 are continuously determined which exist in induction pipes 16 and 18 , respectively, corresponding to the curves in FIG. 4 . Using a minimum value characterizer that is not depicted in the drawing, for each curve P 1 and P 2 , minimum value P 1 min and P 2 min is determined in blocks 84 and 86 , respectively.
Both of these pressures P 1 min and P 2 min are the pressures at the end of the intake stroke and this is so for the following reason: when intake valves 20 and 22 open during the charge changing phase, the (undepicted) piston is situated at the upper dead center and then travels to the lower dead center. In this context, the gas quantity behind throttle valve 32 and 34 expands to an ever greater volume, and the pressure therefore falls. At the lower dead center, the maximum volume; and therefore minimum pressures P 1 min and P 2 min are reached.
Shortly thereafter, intake valves 20 and 22 close. Pressures P 1 min and P 2 min, measured in induction pipes 16 and 18 , closely approximate the pressure in combustion chambers 12 and 14 , respectively, from which the charge can be calculated.
In a computing loop that is also not depicted in the drawing, from minimum pressure values P 1 min and P 2 min, gas charge rldss 1 (block 88 ) and rldss 2 (block 90 ) are calculated, which more closely correspond to the actual gas charge.
Gas charge rldk 1 (block 80 ) in combustion chamber 12 , defined by the position of throttle valve 32 , is now compared in a comparator 92 to gas charge value rldss 1 (block 88 ), calculated from minimum pressure P 1 min in induction pipe 16 . In response to a difference between two gas charges rldk 1 and rldk 2 , a query is raised in comparator 92 in block 94 as to whether pressure level P 1 in induction pipe 16 is relatively low overall. This is the case, e.g., when throttle valve 32 is closed relatively far. If the answer in block 94 is yes, then learned additive quantity msndko 1 , representing a measure for the air leakage streams through throttle valve 32 and behind this throttle valve 32 , is changed. Quantity msndko 1 is used for correcting the charge measurement in block 76 and for correcting the charge control in block 60 .
If the answer in block 94 is no, then a multiplicative correction of the charge measurement in block 76 and of the charge control in block 60 is carried out by a factor fkmsdk 1 . (block 98 ).
Analogously, for other combustion chamber 14 , a comparator 100 , a decision block 102 , and correction quantities msndko 2 (block 104 ) and fkmsdk 2 (block 106 ) are provided. In this manner, despite identical setpoint value rlso 1 (block 58 ) for both combustion chambers 12 and 14 , different setpoint angles wdks 1 and wdks 2 result in blocks 64 and 66 , which compensate for the tolerance differences between two throttle valves 32 and 34 , respectively.
Monitoring the normal operation of the method can be carried out in a simple manner: The pressure signal made available by pressure sensors 46 and 48 is superposed on a minimum, which is smaller than p 1 min and p 2 min in blocks 84 and 86 and which does not coincide temporally with the closing of intake valves 20 and 22 , respectively. The charge measurements in blocks 76 and 78 in blocks 80 and 82 now supply a value rldk 1 and rldk 2 that is too small. The system (controller 68 and 70 ) must now react to a leak behind a throttle valve 32 and 34 , simulated in this manner, by closing upstream throttle valve 32 and 34 . | A method for operating an internal combustion engine. The latter has at least one combustion, one induction pipe, and one throttle valve. From the actual position of the throttle valve, a gas charge of the combustion chamber is defined. To improve the emissions and fuel consumption characteristics of the internal combustion engine, the minimum gas pressure is measured that exists in the induction pipe assigned to the combustion chamber at the end of the intake stroke. From this gas pressure, a value is determined which more closely approximates the actual gas charge of the combustion chamber. | 8 |
This is a continuation of application Ser. No. 281,999, filed July 10, 1981 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates in general to the manufacture of insulated concrete planks for use in walls and floors of building structures.
Reinforced precast, prestressed concrete planks or panels have been used for a number of years as wall and floor structures in buldings. Because of the increasing emphasis on producing well-insulated buildings, it became apparent some time ago that such planks were extremely poor in their insulation qualities. One approach to overcoming this defect of such panels was to cast panels in a "sandwich" configuration with a sheet of insulating material such as polyurethane or polystyrene between adjacent layers of concrete. Such a sandwich construction provided a noticeable improvement in the insulating qualities of the panel.
One of the problems which has been noted in sandwich concrete panels is the tendency of the top concrete layer to form stress cracks in the surface. It has been noted that such stress cracks most commonly form above the butt joint between adjacent pieces of insulating material. Such stress cracks have a highly undesirable cosmetic effect since the outer face layer of concrete is often exposed to view without any additional surface treatment being applied thereto.
SUMMARY OF THE INVENTION
The insulated concrete panel, according to the present invention utilizes insulating sheets having interfitting edges to form an interlocked insulating layer comprised of a plurality of interlocked insulating sheets.
The interlocked structure of the insulating panels is symmetrical in configuration so that a particular panel can be used for either interlocking function by merely rotating the panel 180°.
Insulating panels, according to the present invention, do not have a heat conducting gap between adjacent abutting sheets of insulating material. Avoidance of the discontinuities in insulating characteristics inherent in prior art sandwich panels results in a virtual elimination of the stress cracking of the surface layer of concrete and provides superior insulating characteristics of the insulated panels as a whole.
The improved process of manufacturing insulated concrete panels is not complicated by the use of the interlocking insulation sheets. The sheets can be applied to the cast bottom layer of concrete one at a time during the casting process. The particular structure of the interlock permits a subsequent sheet to be interlocked with an already positioned sheet without the necessity of moving the already positioned sheet. Additionally, the structure of the interlocks permits either of the interlocked sides of a sheet to be aligned with an already positioned sheet merely by rotating the subsequent sheet 180° about an axis perpendicular to its surface. In other words, the two lock structures are interchangeable merely by rotating the sheet.
OBJECTS OF THE INVENTION
It is, accordingly, an object of the invention to provide an insulated concrete panel having an insulating layer comprised of a plurality of interlocked insulating sheets without gaps therebetween.
It is a further object of the present invention to provide an insulating sheet for an insulated panel which can be readily interlocked with adjacent sheets to facilitate the manufacture of an insulated concrete panel. It is a still further object of the present invention to provide a method for manufacture of insulated sandwich panels having an insulating layer with substantially uniform insulating characteristics.
These and other objects and advantages of the present invention will become apparent to those skilled in the art from the detailed description of a preferred embodiment of the invention which follows and taken in conjunction with the accompanying drawings in which like parts are designated by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view of an insulating sheet according to the present invention showing the interfitting locking edges thereof;
FIG. 2 is a perspective view of a hollow core concrete panel; and
FIG. 3 is a fragmentary side view of the concrete panel shown in FIG. 2 illustrating the interlocking of insulating sheets in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an insulating sheet 10 according to the present invention. For an insulated panel of 8-foot wide width, as shown, for example, in FIG. 2, the sheet 10 has a length substantially equal to the width of the concrete panel, about 8 feet in a preferred embodiment. The width of the insulating sheet 10 can be any convenient width in the neighborhood of three to five feet. The insulating sheet 10 has interlocking means 12 and 14 along two opposite edges along its length. The interlocking means 12 and 14 are used to interlock adjacent insulating sheets 10 to form an interlocked insulating layer between the lower concrete layer 16 and upper concrete layer 18, as shown in FIG. 2. Conventional staple means 19 are used to form a bond joining the bottom, top and insulation layers into a single structure as is known in the prior art.
FIG. 1 illustrates the preferred embodiment of the interlocking means 12 and 14. Seen in side view, each individual interlocking structure resembles one-half of a dovetail mortise and tenon locking structure divided on a plane bisecting the dovetail interlock and perpendicular thereto. The interlocking edges 12 and 14 have 180° symmetry relative to each other. The sheets are rotated by 180° relative to each other to permit the mating of one edge of an insulating sheet 10 with a particular prepositioned sheet, no matter which edge is exposed, merely by turning the interlocking sheet over. The sheet can also be more readily manufactured if the same locking structure is formed on both edges. Thus, the angle of the fan-shaped tenon portion is identical on both interlocking edges 12 and 14, as are the depths of the various corresponding cuts L, H and D, as indicated in FIG. 1.
The use of the interlocking structure, as shown in FIGS. 1 through 3, accomplishes definite improvements over prior art insulated panels. Where the insulated panel is formed by abutting sheets of insulating material in edge-to-edge relationship, there is a conductive path remaining between adjacent sheets which permits non-uniform heat flow between the lower concrete layer 16 and the upper layer 18. This is particularly troublesome when accelerated curing methods are used to cure the concrete panel. When such accelerated curing is utilized, the lower concrete layer 16 is heated by means of a heated pallet 20 upon which the panel is cast or by other similar means.
The uneven transmission of heat during curing often resulted in the formation of stress cracks in prior art insulated panels in the upper concrete surface 18 aligned with the junction between adjacent insulating sheets, Such joints between insulating sheets also resulted in additional insulation loss through the panel.
Although other edge mating approaches could be envisioned to avoid the non-uniform insulating characteristics caused by butting two sheets of insulating material together along their unmodified edges, those other structures have been considered and found not to provide all of the advantages provided by the structure in accordance with the present invention. For example, if the edges of the insulating material are merely mitered, there is no interlocking between adjacent sheets, and the advantages of an interlocked insulating layer are lost.
If the edge of an insulating sheet were modified into half of a conventional mortise and tenon joint with all right angles and having a pair of interfitting edges, some improvement might be noted, but the resulting structure would not be interlocking. It would also not have as long a thermal path as the lock according to my invention because the partial dovetail structure, according to my invention, has a heat transmission path along the joint betwen the two sheets which, because it doubles back on itself, is longer than the path on a comparable partial mortise and tenon lock.
FIG. 2 shows a typical bond between two insulating sheets 10 in a typical sandwich panel. It can be seen that the path between the adjacent sheets in longer than the path that would be formed between abutting sheets with straight sides. | An insulated concrete panel utilizing interlocking sheets of insulation material sandwiched between two layers of concrete. The insulation material sheets are interlocked utilizing a symmetrical partial dovetail locking structure permitting subsequent sheets of insulating material to be interlocked with previously emplaced sheets without disturbance. | 4 |
BACKGROUND OF THE INVENTION
This invention is directed toward a child resistant bottle closure assemblage which can be used to seal containers for such items as detergents, insecticides, pharmaceuticals, and the like.
Typical child resistant bottle closures usually require the user to perform some preliminary manipulations before the bottle can be opened. For example, there are bottle closures that require the user to align a mark on the closure with a mark on the bottle in order to remove the closure (normally, a snap off cap). Other closures require the user to squeeze or pinch the closure while simultaneously rotating it to remove it. Still other closures require the user to exert downward pressure on the closure and simultaneously rotate the closure in order to remove it from the bottle.
Although such closures are effective, they require the exertion of some strength by the user. Many users, because of illness, manual deformation, manual flexibility limitations, and the like either have difficulty in removing the closures or are unable to remove them at all. In addition, although such closures are touted as "child resistant", "tamper proof", and the like, observant and innovative children have been known to readily remove such closures.
SUMMARY OF THE INVENTION
It has now been found that shortcomings of typical child resistant bottle closures are overcome by the bottle closure assemblage of this invention which requires minimum manipulation and exertion by the user and, although simple to use, presents a formidable challenge to children who attempt to remove the closure from a bottle.
The child resistant bottle closure assemblage of the invention generally comprises an outer cap member, an inner cap member and an interlocking member.
The inner cap member is cylindrical and is provided with means to be secured to a bottle, such as by conventional mating threads or conventional snap-on/snap-off mating beads and grooves, and serves to seal the contents of the bottle from air and moisture. The inner cap member is formed with a plurality of spaced, external grooves about its outer circumferential surface, these grooves being formed so that they are parallel to each other and parallel to the longitudinal axis of the inner cap.
The interlocking member is also cylindrical and has a closed upper end and an open lower end. Spaced upwardly from its lower end, are a plurality of spaced pins projecting inwardly from its inner circumferential surface and a plurality of spaced pins projecting outwardly from its outer circumferential surface. The inwardly projecting pins are spaced so that they engage and mate with the external grooves in the outer circumferential surface of the inner cap member thus securing the interlocking member to the inner cap member while enabling the interlocking member to freely slide vertically up and down in the external grooves of the inner cap member. The closed, upper end of the interlocking member limits its downward movement along the external grooves of the inner cap member.
The outer cap member is cylindrical and open at each end, the lower end having means to rotatably secure the outer cap member to the lower end of the inner cap member with the interlocking member contained between the outer cap and the inner cap members.
A plurality of spaced grooves are formed about the inner circumferential wall of the outer cap member. These grooves are formed so that they are parallel to each other, but angularly off-set from the longitudinal axis of the outer cap member.
When the assembled bottle closure members are secured to a bottle in its normal, up-right position, the outer cap member can be rotated without engaging the interlocking member and the bottle will remain closed.
When the bottle is inverted, this permits the interlocking member to fall by gravity toward the upper end of the outer cap member. With the interlocking member in this position, the outer cap member can then be slowly rotated until the outwardly projecting pins of the interlocking member engage the angular, inner grooves of the outer cap member permitting the interlocking member to slide downwardly through the outer cap member along its angular grooves until the interlocking member extends outwardly beyond the upper, planar surface of the outer cap member. When this occurs, all the members are interlocked so that the bottle can be reinverted to its normal up-right position and the outer cap member or the protruding portion of the interlocking member or both of these members can be grasped and the entire bottle closure assemblage removed to open the bottle; e.g., by unscrewing or snapping off the interlocked bottle closure assemblage.
In a further embodiment, the bottle closure assemblage of the invention includes a tamper evident means. One such means can be in the form of a tab member positioned across the open, upper end of the outer cap member and formed as an integral part of the outer cap member. This tab member is produced so that it can be readily removed from the outer cap member by breaking it off without undue effort. Before being removed, the tab member prevents the interlocking member from extending through the open, upper end of the outer cap member and also prevents the members of the bottle closure assemblage from being fully engaged and interlocked so that the bottle can not be opened. In addition, a message can be provided on the outer, upper surface of the interlocking member alerting the user that unless the user has removed the tab member, a missing tab member might indicate that the integrity of the contents of the bottle may have been compromised.
DETAILED DESCRIPTION OF THE INVENTION
The bottle closure assemblage of the invention will become more apparent from the ensuing description when considered together with the accompanying drawing wherein like reference numerals denote like parts and wherein:
FIG. 1 is a perspective view showing the members of the bottle closure assemblage in exploded relation to each other and to a bottle to which they can be secured when assembled;
FIG. 2 is a sectional view taken substantially on the line 2--2 of FIG. 1;
FIG. 3 is a perspective view illustrating the bottle closure assemblage as it would appear secured to a bottle its normal, up-right position;
FIG. 4 is a perspective view illustrating the bottle closure assemblage shown in FIG. 3 after the bottle has been inverted with the interlocking member extending beyond the upper, planar surface of the outer cap member enabling the assemblage to be removed from the bottle;
FIG. 5 is a sectional view taken substantially on the line 5--5 of FIG. 3 but showing the members in assembled relationship to each other;
FIG. 6 is a sectional view taken substantially on the line 6--6 of FIG. 4; and,
FIG. 7 is a perspective view illustrating a tamper evident means that can be provided with the bottle closure assemblage of the invention.
As shown in FIGS. 1 and 2, the bottle closure assemblage of the invention comprises a cylindrical inner cap 10, a cylindrical interlocking member 20 and a cylindrical outer cap 30.
At its lower end, inner cap 10 is provided with conventional means, such as threads 11, so that it can be secured to a bottle 12 by means of mating threads 13. Alternatively, inner cap 10 can be secured to a bottle 12 by any conventional means such as snap-on, snap-off means (not shown) which enable the bottle closure assemblage to be snapped onto and off of a bottle.
At the upper end of threads 11 of inner cap 10 is a sealing member 14 (FIG. 2) which serves to seal bottle 12 and protect its contents from contamination by air and moisture when inner cap 10 is secured to a bottle.
Inner cap member 10 has a plurality of spaced grooves 15 formed in the land portion 16 of its outer circumferential surface, reference numeral 17 denoting the base of land 16 and reference numeral 18 denoting the upper end of inner cap 10. Spaced grooves 15 are preferably provided in the lower portion of inner cap 10, and are formed to be parallel to each other and parallel to the longitudinal axis of inner cap 10. For purposes of economy, inner cap 10 is tubular except for sealing member 14.
Cylindrical interlocking member 20 has a closed upper end 21 and an open lower end 22. A plurality of spaced, inwardly projecting pins 23 (FIG. 2) are provided about the inner circumferential wall of interlocking member 20 adjacent its open, lower end 22. Similarly, a plurality of spaced, outwardly projecting pins 24 are provided about the outer circumferential wall of interlocking member 20 adjacent is open, lower end 22. Inwardly projecting pins 23 and outwardly projecting pins 24 are preferably located in the lower half of interlocking member 20.
Inner cap 10 and interlocking member 20 are sized so that interlocking member 20 can be fitted over inner cap 10 with inner pins 23 of interlocking member 20 engaged in the grooves 15 of inner cap 10. In this arrangement, interlocking member 20 is not only securely locked to inner cap 10, but is also free to slide vertically upwardly and downwardly in and along grooves 15. The extent of the downward, sliding movement of interlocking member 20 along grooves 15 is arrested and limited by the closed end 21 contacting the upper end 18 of inner cap 10.
Cylindrical outer cap 30 is tubular and has an inwardly extending circumferential recess 31 (FIG. 2) formed at its open, lower end 32. Positioned upwardly from open, lower end 32 are a plurality of spaced grooves 33 formed in the land 34 on the inner circumferential wall of outer cap 30, reference numeral 35 identifying the base of land 34. Grooves 33 are preferably contained in the upper half of outer cap 30 and have an open lower end 36, a closed upper end 37 and are formed to be parallel to each other, but angularly off-set from the longitudinal axis of outer cap 30 so that grooves 33 are similar to rifling in the bore of a rifle.
As shown in FIG. 5, outer cap 30 is sized so that it can be positioned over both the interlocking member 20 and the inner cap 10 with the recess 31 of outer cap 30 engaging the lower circumferential end 19 of inner cap 10 so that outer cap 30 is rotatably secured to inner cap 10.
Thus, the diameter of base 35 of outer cap 30 is sized to be slightly larger than the diameter of land 34 and slightly larger than the circumferential plane defined by the extremities of outwardly projecting pins 24 of the interlocking member 20.
In this arrangement, outer cap 30 can be freely rotated without engaging the interlocking member 20 so that the assembled bottle closure cannot be removed from a bottle and, when secured to a bottle 12 appears as shown in FIG. 3. However, when bottle 12 is inverted to an up-side down position as seen in FIG. 4, interlocking member 20 slidably falls from the force of gravity toward the open, upper end 38 of outer cap 30. Unless outwardly projecting pins 24 of interlocking member 20 happen by chance to be aligned with the open ends 36 of grooves 33, further descent of interlocking member 20 will be arrested when its outwardly projecting pins 24 contact land 34. While in this position, outer cap 30 is rotated until outwardly projecting pins 24 are aligned with and engage the open lower ends 36 of grooves 33. When this occurs, interlocking member 20 is free to slidably fall along grooves 33 toward and through the open end 38 of outer cap 30 until outwardly projecting pins 24 engage the closed upper ends 37 of grooves 33 permitting a portion of the interlocking member 20 to extend beyond the open, upper end 38 of outer cap 30 as illustrated in FIGS. 4 and 6. At this time, outer cap 30 is secured to inner cap 10 through interlocking engagment of outwardly projecting pins 24 in grooves 33 and interlocking engagement of inwardly projecting pins 23 in grooves 15. The bottle 12 can then be re-inverted to its normal up-right position and the interlocked bottle closure assemblage removed by unscrewing (or snapping off) outer cap 30.
To re-secure the bottle closure assemblage to a bottle, the same procedure is followed (i.e., the outer cap 30 is turned up-side down and rotated until the interlocking member 20 extends beyond the open, upper end 38 of outer cap 30) and the interlocked bottle closure assemblage is screwed onto (or snapped onto) the bottle.
The bottle closure assemblage of the invention can also be provided with tamper evident means. As illustrated in FIG. 7, one such means can be in the form of a break-off tab 40 which is secured across the open, upper end 38 of outer cap 30 by means of legs 41, 42. Tab 40 can be fabricated as an integral part of outer cap 30 and be such that it can be removed from outer cap 30 by readily breaking it away at legs 41 and 42 as shown by the dashed extension lines in FIG. 7.
Prior to its removal, break-off tab 40 prevents interlocking member 20 from being extended beyond the open, upper end 38 of outer cap 30 so that the bottle closure assemblage cannot be removed from a bottle. By providing a message on the outer exposed surface of closed upper end 21 of interlocking member 20, a user can be alerted to the fact that unless the user has removed tab 40, the integrity of the bottle contents may have been compromised.
In the foregoing description of the bottle closure assemblage of the invention, reference has been made to a plurality of grooves 15 on inner cap 10, a plurality of inwardly projecting pins 23 and outwardly projecting pins 24 on interlocking member 20, and a plurality of angularly off-set grooves 33 in outer cap 30. It should be understood, however, that the bottle closure assemblage of the invention is operable with a single groove 15 on inner cap 10, a single inwardly projecting pin 23 and a single outwardly projecting pin 24 on interlocking member 20 and a single, angularly off-set groove 33 in outer cap 30. Preferably, at least two, more preferably at least four, such grooves and pins should be provided and each should be equi-spaced. Thus, while the bottle closure assemblage of the invention has been described with particularity and in detail, it should be understood that modifications can be made therein without departing from the scope of the invention defined in the claims. | There is disclosed a child resistant bottle closure assemblage comprising an outer cap member, an inner cap member and an interlocking member disposed between the inner and outer cap members. When secured to a bottle in its normal, upright position, the outer cap member can be rotated without engaging the interlocking member so that the assemblage can not be removed from the bottle. When the bottle is inverted so that the interlocking member engages the outer cap member, rotation of the outer cap member results in removal of the entire assemblage from the bottle. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to the field of signal detecting and measuring systems, particularly those employing arrays of sensors and signal processing apparatus to post-process the signals received from such sensors. More specifically, the invention relates to a method of an apparatus for accurately determining the relative and/or absolute position of individual transducers in such signal-detection systems through the analysis of signals received from sources whose precise bearing is not known.
BACKGROUND OF THE INVENTION
Passive surveillance systems are widely used to detect underwater objects. These systems employ a plurality of individual signal sensors, sometimes as many as 1,000, placed at different locations surrounding the area to be monitored by the system. Because each sensor is situated at a different location, a single signal emanating from a single source will produce slightly different responses at each sensor. For example, sensors which are closer to the source will receive the signal earlier. Generally, the object of a passive surveillance system is to compare and contrast the signals received by individual sensors--looking particularly at the delays between the sensor-received signals--to determine the location of the signal source.
In an ideal environment, determination of the signal source location is a relatively straightforward process, and follows directly from well understood principles of analytic geometry and linear systems theory. Real systems, however, must contend with a variety of factors that substantially complicate the source location process. These factors include background noise (both environmental and system-generated), multi-path interference caused by reflection of the signal off the surface or bottom of the ocean, or simultaneous reception of multiple signals, to name a few.
To improve noise immunity and the ability to perform sophisticated signal-processing of the transducer-received signals, modern passive surveillance systems typically operate by (i) digitally sampling the signals at each transducer, (ii) converting each signal to the frequency domain and (iii) performing some type of statistical correlation analysis utilizing these frequency domain transducer signals. The type of correlation analysis performed varies depending upon the objective to be achieved. For example, U.S. Pat. No. 4,980,870, entitled ARRAY COMPENSATING BEAMFORMER, incorporated herein by reference, describes a passive surveillance system wherein the signals from individual transducers are mathematically combined in a manner that maximizes the reception of signals from a certain direction, and/or minimizes the reception of signals from other directions, so as to act like a highly-directional microphone pointed in the "steering direction." U.S. Pat. No. 5,099,456, entitled PASSIVE LOCATING SYSTEM, incorporated herein by reference, uses a similar frequency-domain digital sampling apparatus, but instead analyzes the individual frequency-domain signals with an aim to ascertain the location of the common source from which these signals emanate.
In all passive surveillance systems, it is assumed that the location, or at least the relative location, of each sensor is known. This sensor location information is required to interpret the sensor-received signals in a meaningful way. Once the system knows the relative location of its sensors and the velocity of signal propagation in the particular medium, the system can anticipate the time it should take for a given signal to propagate (along a particular steering direction) from one sensor to another. By comparing the times at which the signal is actually received at various sensors to the predicted times-of-arrival, the system can determine the direction from which the signal emanates.
Inaccurate information regarding the sensor locations introduces serious errors into the process. Without accurate sensor position information, the system cannot predict the expected delays between sensors along given propagation paths and, as a result, will be unable to accurately compute the signal source location. If the array is instead used in a beam-forming application, the inaccuracy in sensor locations will be reflected as reduced directional specificity in the "beam" and/or reduced detectability of the signals monitored using the beam.
Unfortunately, measuring and maintaining exact sensor locations is not as simple as might appear, at least in the underwater environment. First, the long wavelengths involved often mandate sensor arrays of a mile or more. Clearly, therefore, a fixed, rigid array structure (wherein the relative sensor locations cannot shift) is impractical, or at least highly uneconomical.
Thus, there is a need for a method and apparatus for ascertaining the relative positions of sensors in a passive sonar system, preferably without need for high signal bandwidth in the sensors.
SUMMARY OF THE INVENTION
In light of the above, one object of the invention is an improved method and apparatus for determining the relative positions of a plurality of sensors in a passive monitoring system.
Another object of the invention is a method and apparatus for determining the locations of such sensors without need for expensive hardware.
Still another object of the invention is a method and apparatus for calibrating a passive monitoring system using calibrator signals whose bandwidth is not substantially greater than that of the signals to be monitored.
In accordance with one aspect of the invention, a passive monitoring system is calibrated by computing--preferably through correlation processing--the delays between sensors for each of two non-parallel calibration signals. These delays are used to formulate equations for the sensor positions ("sensor position equations"), where the "unknown" variables are the propagation angles of the calibration signals. Iterative solution, based upon assumptions about the deformation characteristics of the array, is used to find feasible values for the calibration signal angles. Once these angles are determined, the sensor position equations provide orthogonal coordinates, relative to a reference sensor, for each sensor in the array, thereby facilitating beam-forming and other phased array applications.
In accordance with other aspects of the invention, the calibrator signals may comprise sinusoidal signals or wideband signals, such as FM chirps or other broadband noise signals. Sinusoidal signals offer the advantage of not requiring high-bandwidth sensors for calibration purposes, and not requiring a synchronization between transmission of the calibration signal(s) and the sensors and other receiving apparatus which monitor the calibration signals. High-bandwidth calibration signals, on the other hand, offer the advantage of superior multi-path immunity.
BRIEF DESCRIPTION OF THE DRAWINGS AND APPENDICES
The present invention is described in the detailed description below, which description is intended to be read in conjunction with the following set of drawings and appendices, in which:
FIG. 1 depicts the overall physical organization of a passive sonar apparatus in accordance with the invention;
FIG. 2 depicts the process of acquiring input data from the sensors in an apparatus in accordance with the invention;
FIG. 3 depicts the geometric configuration from which the sensor position equations are derived;
FIG. 4 depicts the iteration process used to solve the sensor position equations;
APP. 1 contains the source code used in a present embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1, which depicts the overall structure of a passive sonar apparatus in accordance with the present invention. As depicted, a passive sonar apparatus comprises an array 10 of sensors 1-n, and means 13 for communicating signals 12 received by said sensors to a computer 15, which processes said signals to, among other things, ascertain sensor locations and form beams.
The type of signals 12 which emanate from the sensors and the means 13 for communicating said signals to computer 15 can take many different forms. For example, sensors 10 may be analog transducers, preferably underwater piezoelectric microphones, in which case analog signals 12 are coupled by means 13, which may perform sampling and/or A/D conversion, to computer 15. Alternatively, sampling and/or A/D conversion may be performed at or proximate to the sensors themselves, in which case signals 12 will be of a sampled and/or digital form. It is also possible for means 13 to process--e.g., sample and compute FFT's--signals 12 before communicating said signals to computer 15, thus relieving the processing burden on computer 15. Those skilled in the art will recognize that numerous signal processing boards and chips are available to perform these functions.
Signals 12 may be communicated from sensors 1 to means 13 via any sort of energy pathway, and may be communicated by any means of transmission, including electrical, optical, acoustical, electro-magnetic, magnetic, electro-mechanical, mechanical, or a combination thereof. In a presently preferred embodiment, signals 12 are digitized at the Nyquist frequency, and communicated to the shore using fiber optic cables.
Reference is now made to FIG. 2, which depicts the input of calibration signals in accordance with the invention. As depicted, signals received by sensors 1-n are provided--by whatever means and in whatever form--to an FFT unit 22, which outputs a plurality of time-sampled FFT coefficient vectors z 1 -z n , where vector z k contains the FFT coefficients derived from sensor k. (It is, of course, not required that input data be stored or organized as "vectors"; vector algebra formulations are used merely to facilitate concise description of the sequence of operations performed in accordance with the invention.) FFT unit 22 preferably performs a vernier filtering operation, so as to focus on the frequency of the calibrator signal of interest.
Delay Computation
A preliminary step in the source location process is to convert the narrow-band FFT measurements into relative range delays from sensor 1, which is used as a reference, to other sensors in the array. This delay computation is preferably performed twice, once for each calibrator signal.
Recall that z n represents a vector, whose elements are a series of FFT coefficients corresponding to the signal received at sensor n at successive time intervals. A complex coherence vector v can be computed as follows: ##EQU1## where z n ' represents the complex conjugate transpose of z n . (In theory, the summation operation is not actually necessary, but is preferred since its averaging effect tends to enhance the accuracy of the complex coherence calculation.) The phase delays, in radians, between sensor 1 and sensor n are computed as follows:
g=angle(v)rads
where g i is the relative phase delay between sensors 1 and sensor i. Because the distance between sensor 1 and i may exceed a wavelength, it is preferable to "unwrap" the phase delays. Unwrapping is performed using an assumption that the phase difference between sensors does not exceed 180 degrees, or, if one or more of the sensors is defective, using a deformed line array assumption, as described below. The MATLAB™ software package provides a routine for performing the preferred unwrapping. The unwrapped phase delays are:
q=unwrap(g)rads
The phase delays q are converted to range delays as follows:
r=q(rads)×λ(meters/cycle)/2π(rads/cycle)
where λ is the wavelength of the calibrator sinusoid. As used below, the range delays from the first calibrator sinusoid are contained in the vector r 1 , while those from the second appear in the vector r 2 .
Orthogonal Mapping
Using range-delay vectors r 1 (i.e. the range delays, relative to sensor 1, from the first calibrator signal) and r 2 (i.e. the range delays for the second calibrator signal), one can formulate "sensor position equations" to determine the sensor positions, relative to sensor 1, in orthogonal x-y coordinates.
A vector d contains these sensor positions, where
d=x+jy
and d i represents the x-y coordinates of sensor i relative to sensor 1. Referring to FIG. 3, and assuming a planar wavefront from each of the calibrators, the following 2n equations for x and y can be specified:
r.sub.1 =-[sin(Θ.sub.1)]x -[cos(Θ.sub.1)]y
r.sub.2 =-[sin(Θ.sub.2)]x -[cos(Θ.sub.2)]y
where Θ 1 is the angle from the y-axis to the direction of propagation of the first calibrator and Θ 2 is the angle to the second calibrator. Solving these equations for x and y, one obtains the following sensor position equations:
x=[(-r.sub.1 /cos(Θ.sub.1)tan(Θ.sub.2)) -r.sub.2 /sin(Θ.sub.2)]/[1-tan(Θ.sub.1)/tan(Θ.sub.2)]
y=-r.sub.1 /cos(Θ.sub.1)-xtan(Θ.sub.1)
If Θ 1 and Θ 2 are precisely known, the sensor position equations can be easily solved by well-known techniques to provide the relative x-y coordinates of the sensors. In actual underwater environments, however, Θ 1 and Θ 2 typically vary 0 to 15 degrees from the expected values, thus causing traditional solution techniques to diverge. Iteration provides a practical means for solving these equations.
Iterative Solution of Position Equations
Without accurate values for Θ 1 and Θ 2 , the x and y equations do not accurately predict the relative x-y locations of the sensors. Thus, iteration is used to find values for Θ 1 and Θ 2 which, when applied in the x and y equations, yield accurate sensor location results. The difficulty, even with iteration, is knowing whether a proposed set of Θ 1 /Θ 2 values yields accurate x-y sensor locations when the "actual" sensor locations are unknown. In accordance with the invention, use of a deformed line-array constraint allows the sensor position equations to be solved iteratively, at least for most cases of practical interest.
The deformed line-array constraint can be explained with reference to FIG. 1. It assumes that sensors 1-n are distributed along a line, which may be straight or (as depicted) deformed, with bends at the sensor locations. As illustrated, there is a segment S k ,k+1 between sensors k and (k+1). The deformed line-array constraint assumes that these individual segments are straight. With this assumption, it is apparent that the distance between adjacent sensors remains constant; these distances are simply the length of the segments connecting the sensors, since the individual segments are assumed to be straight. Since the individual segment lengths remain constant, so does the total length of all segments. It is this total length, which is known a priori, that is used to guide the iterative process using the deformed line-array assumption.
The deformed line-array constraint can be mathematically expressed as follows. Assuming some estimated Θ 1 and Θ 2 , one can use the previously described x and y equations to derive a vector of estimated sensor positions d=x+jy, where d depends upon the Θ 1 and Θ 2 estimates, and the measured range delays r 1 and r 2 . Using these estimated sensor positions d, total line length (assuming a deformed line array) can be computed as follows: ##EQU2## where d i is the estimated position of sensor i. The difference between this estimated line length D, and the actual line length D, is used to guide the iteration process. Although this deformed line array assumption does not perfectly model the physical geometry of the system, it yields acceptable results, even in the face of one or more severe deformations.
Reference is now made to FIG. 4, which shows a flowchart of the iteration process. Iteration begins with initial calibrator angle Θ 1 /Θ 2 , estimates 32, and iterates to converge on a mathematically consistent value for Θ 1 . Field tests reveal that the initial estimates typically vary about 0-15 degrees from the actual values. A position estimation step 33 computes "estimated" sensor positions using the calibrator angle estimates and the measured range delays 30. Step 34 computes the total estimated length D of the array, using the deformed line-array assumption and the sensor position estimates computed in step 33. Step 35 compares the estimated length D to the actual line length D. Based on this comparison, step 36 makes a determination whether the sensor position estimates are accurate, in which case the iteration ends at step 37, or whether additional iteration is desirable, in which case step 38 modifies the estimate of calibrator angle Θ 1 and the iteration process returns to position estimation step 33.
Estimate modification step 38 operates by comparing the "errors" (i.e., the difference between the estimated and actual lengths, D--D) for the current iteration to that from the previous iteration to determine an appropriate modification for the Θ 1 estimate. Those skilled in the art will recognize that this Θ 1 update can be computed using a number of well-know techniques, such as adding or subtracting fixed angular increments according to the sign of the error, or updating according to the slope (or gradient) of the error function. Preferably, angular estimate updating is performed using knowledge about the nominal shape of the error function (or its transfer function), which permits convergence in approximately nine iterations.
Once the error is within acceptable bounds, final orthogonal positions of the sensors are computed, and the array is calibrated for operation.
Use of FM Chirps or Wideband Noise
If bandwidth and other constraints permit, one can employ FM chirp or other wideband noise type calibrator signals instead of sinusoids. With such signals, the delay computation step is performed by cross-correlating the sensor-1 waveform with respective waveforms at each other sensor to determine the relative time delays; no FFT processing or phase unwrapping is required. Since velocity is known, these time delays are easily converted into range delays, from which the invention further operates as described above.
Source Code
To ensure complete satisfaction of the disclosure obligations under 35 U.S.C. §112, attached APP. 1 contains a listing of the source code utilized in connection with a present embodiment of the invention. This source code is written in the MATLAB™ language, which permits compact expression of the required mathematical computations. (Of course, those skilled in the art will recognize that the invention could alternatively be implemented using a wide variety of available programming languages or, if desired, entirely in hardware.)
APP. 1 contains the following five sub-modules:
(1) pa2×1 a.m: CPL Measurements Start (pages 1-1 to 1-9). This is essentially a data input module for collecting and storing samples of the sinusoidal calibrator signals.
(2) pa×1b.m: CPL Measurements End (pages 2-1 to 2-8): This module, among other things, calculates the phase delays, and converts these into range delays for use in the mapping process.
(3) pa×2.m: CPL X-Y Map Iteration (pages 3-1 to 3-8): This module performs the iterative sensor position estimation.
(4) pa2×3.m: CPL Polar Mapping (pages 4-1 to 4-5): This module converts the computed relative x-y sensor positions to polar coordinates oriented to true North.
(5) pa×fm.m: FM Range Delay Measurement (pages 5-1 to 5-4): This is an alternative to modules (1)-(2); it computes range delays using FM chirp or other broadband noise type calibrator signals. ##SPC1## | An apparatus and method for accurately determining the relative locations of sensors in a passive sonar or like monitoring system utilizes two non-parallel (but not necessarily orthogonal) calibrator signals to calculate the relative positions of sensors in a sensor array. Iteration, using a deformed line array constraint, permits reliable solution of the sensor position equations, even when the relative angle between the calibrator signals is initially unknown. | 6 |
FIELD OF INVENTION
Combustible air-and-fuel mixture is directed in a two stroke cycle internal combustion engine via communication ports from the engine carburetor through the crankcase and into the cylinders. A type of fuel pump which is popularly used with single cylinder two stroke cycle engines such as model airplane engines comprises a pulsated expansible tubular diaphragm fitted with appropriate check valves for placement in the fuel line between the fuel tank and carburetor of the engine. Within the fuel pump housing an annular space surrounds the diaphragm and is communicated to the engine crankcase to subject the diaphragm to pressure fluctuations which emanate from the engine crankcase and produce pulsed expansion and contraction of the diaphragm and incremental volumetric change in the diaphragm chamber. The pumping action of the chamber provides positive pressure delivery of fuel to the carburetor.
BACKGROUND OF INVENTION
Regulating the fuel-to-air ratio of a carbureted mixture through a range of throttle settings is difficult, especially for engines equipped with non-metering, non-aspirating carburetors in which fuel is continuously sprayed under pressure into an air stream. Placing a pressure regulator in the fuel line suffers the disadvantage that the flow throttling passage constriction embodied in a pressure regulator impedes flow of fuel at full throttle settings and limits the maximum power which can be obtained from an engine.
SUMMARY OF THE INVENTION
A pulsed diaphragm fuel pump is equipped with a mechanically adjustable damper extending through the fuel pump housing for contacting the diaphragm and lessening the amplitude of vibrations induced in the diaphragm by fluctuations in crankcase pressure and reducing the incremental volumetric change produced in the diaphragm chamber. The volumetric change dynamically produced by pressure pulsations is self-compensating for the volumetric change statically produced in the chamber by change in fuel head pressure, whether resulting from change in fuel level in the fuel tank or from elevational change of the fuel tank.
DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-sectional elevation of an embodiment of a fuel pump of this invention;
FIG. 2 is an elevation of a check valve member of the embodiment of FIG. 1.
In crankcase scavenged two stroke cycle internal combustion engines, carbureted fuel-and-air mixture is conveyed into the crankcase through a port which is opened during upward travel of the piston in the cylinder and closed during downward travel of the piston. The port may be disposed either in the cylinder wall for being covered and uncovered by the reciprocating piston or may be disposed in the engine crankshaft when the crankshaft is drilled for passage of the carbureted mixture. After the crankshaft inlet port is closed during downward travel of the piston in the cylinder, further downward movement of the piston compressed the mixture in the sealed crankcase and forces it through a further port in the cylinder wall which is uncovered by continued downward movement of the piston, into the partial vacuum created in the cylinder by downward piston travel. Sub-atmospheric pressure can then exist in the crankcase, and in greatest degree during engine idle when the carburetor passage is constricted by partial closing of the throttle valve. The effect of the cyclic compression and evacuation of the crankcase environment is to create very pronounced pressure pulsations which can be used, through means of a crankcase tap, to drive the diaphragm of a fuel pump.
Referring to FIG. 1, fuel pump 10 comprises rigid shell configured body 11 of elongated center portion and reduced diameter end portion 13. Closure member 12 is fitted into open bore 30 at the opposite end extremity of body 11, secured therein by swaging of the end extremity of body 11 to provide a lip peripherally secured against the outboard face of member 12. End portion of body 11 and closure member 12 are both configured to receive and frictionally retain attached tubing by provision of tapered nipple portions 18 and 19, respectively, tubing attachment being made to the carburetor and fuel tank, respectively, of the engine on which fuel pump 10 is an accessory.
Resiliently expansible tubular diaphragm 21 is disposed with body 11, separated annularly along the preponderant portion of its length from body 11 by annulus 25. A preferred material for mold casted diaphragm is silicone rubber of about 50 durometer softness reading. A membrane suitable for use in a fuel pump of a two stroke cycle engine of fractional cubic inch displacement, e.g. one-quarter cubic inch displacement as commonly used for model airplanes, might be from 0.3 inch to 0.5 inch in length and about 0.225 inch internal diameter with a wall thickness of about 0.015 inch. The membrane might be proportionately increased in size for use with larger size engines such as used in lawn mowers, chain saws, snowmobiles, outboard motors, motorcycles, etc.
Retaining ring 15 is disposed internally of membrane 21, press fitted into place to fix the membrane in the bore of reduced diameter formed by shoulder 26 in body 11. End closure check valve portion 24 is integrally molded into the discharge end of membrane 21 and comprises hinged flap portion 27 which closes against retaining ring 15 and opens by swinging to the left as viewed in FIG. 1. Check valve 31 disposed at the inflow end of membrane 21 recessed in closure member 12 is shown in FIG. 2, and in salient features is similar to check valve portion 24. Flap portion 42 is hinged integrally to peripheral portion 31 with the two portions being separated except at the hinge by annulus 33. Flap portion 42 seats against the inboard face of closure member 12 and opens to the left as viewed in FIG. 1 similarly to valve portion 24, enabling fluid to flow leftward through fuel pump 10 as shown and preventing back-flow of fluid in the opposite direction.
Membrane 21 is diametrically enlarged adjacent the inlet end of pump body 11 by the provisions of shoulders 28 and 29 which provide a snug fit and seal for the diaphragm within the bore and counterbore of body 11. Retaining ring 14 compressively abuts the annular end faces of membrane 21 and valve member 31 seating and tightly sealing the two members within fuel pump 10.
Tubing nipple portion 37 is provided on fitting 35 which protrudes transversely and upward as shown from the mid-portion of body 11 to provide communicating connection between the interior of the engine crankcase and annulus 25. Threaded base portion 36 of fitting 35 sealably engages threaded opening 38 in body 11 and knurled ring portion 40 provides means for manual turning of fitting 35 into greater or lesser engagement with membrane 21. Contact between smooth, rounded, non-abrading end extremity 39 of fitting 35 and membrane 21 dampens and reduces the amplitude of vibrations induced in the membrane by pressure fluctuations communicated from the engine crankcase to annulus 25. The response of membrane 21 to surges in external pressure is diminished in proportion to the degree with which fitting 35 interferes with the amplitude of diametrical expanding and contracting movement of membrane 21, and correspondingly the incremental volumetric change effected in the confine of member 21 by the pulsation is decreased proportionately, resulting in regulation of the volumetric pumping capacity of fuel pump 10 for each pressure pulse. Volumetric regulation so achieved is self-compensating for changes in fuel head pressure which result from raising or lowering the fuel level in the fuel tank or elevationally changing the fuel tank with respect to the fuel pump. Changes in static fuel head pressure expand or contact the diameter of membrane 21 and cause a corresponding increase or decrease in the deflection of membrane 21 resulting from contact with non-yielding fitting 35. Thus, the effects of static pressure change from variation in fuel head pressure compete with dynamic pressure fluctuations communicated from the engine crankcase to provide, in a properly designed system, exact balancing of effect and self-compensation and constancy of response in volumetric pumping of fuel by fuel pump 10 to engine speed independent of fuel head pressure. Such constancy of response is of primary importance, for example, in model airplane engines which utilize carburetors which are sensitive to flooding when fuel flow to the carburetor increases without causative increase in engine speed, but rather solely because of increase in fuel head pressure, and which provide the engine with too little lubricant, which is mixed with the fuel, for proper lubrication if the carbureted mixture is too lean because of reduction in fuel head pressure. The provision of volumetric flow control in the described manner provides the additional advantage over pressure regulated control by providing unimpeded connections between the fuel pump and carburetor free of flow throttling constrictions which characterize pressure regulators.
Application of a mechanical damper to a flat or otherwise configured diaphragm may be made, but is not preferred because lesser degree of control is obtained. In operation, an engine run at idle speed will experience relatively more extreme sub-atmospheric crankcase pressure tahn when the same engine is operated at full throttle, at upward from twelve thousand revolutions per minute for model airplane engines, and the mean expansion of the fuel pump diaphragm will be correspondingly greater at idle speed than at full throttle setting, but greater diaphragm expansion will produce a greater deflection of the diaphragm by fitting 35 and proportionately reduce the incremental volumetric change experienced cyclically by the membrane to compensate for the greater absolute volume due to membrane expansion. The two effects can be engineered to be self-compensating to provide constancy of response to engine speed alone in similar manner as described relative to changes in fuel head pressure. | An adjustable mechanical damper for the diaphragm of a fuel pump of a type in which the diaphragm is pulsated by fluctuations in engine crankcase pressure is provided to regulate the amplitude of diaphragm pulsations and the incremental volumetric change produced in the diaphragm-enclosed chamber by the pulsations. Provision of the damper renders the fuel pump self-compensating for changes in fuel head pressure and insures constancy in the output response of the fuel pump to crankcase pressure. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of fluid dispensing systems. In particular, the present invention relates to an automated and robotic system for providing repeatable, high throughput dispensing of a plurality of fluids.
BACKGROUND OF THE INVENTION
[0002] Fluid dispensing systems are useful in a variety of areas, including the area of preparing fluid mixture samples to be screened for identification of a fluid mixture capable of crystallizing a protein that is, in turn, studied with x-rays to determine its function and the function of the gene encoding it.
[0003] With the identification of the more than 31,000 genes of the human genome, the determination of each gene's role in the functioning of the human body has become of paramount importance. Genes generally function to produce at least one protein, and thus the functions of numerous proteins produced by genes also are studied. Ascertaining protein structure can be an important step in understanding the function of that protein.
[0004] One technique for ascertaining a protein's structure is to obtain high-quality x-rays of the protein's crystalline structure. To do so, a preliminary step is crystallizing the protein. One technique for protein crystallization involves crystallizing the protein in a fluid mixture formulated to provide a stable crystal structure for that particular protein. Growing protein crystals using such a technique, however, can be difficult and very time consuming. Each new protein crystallization typically requires a unique concentration and mixture of fluids for crystal growth. It can be necessary to screen a protein sample against hundreds or even thousands of available fluid mixtures in order to determine a proper fluid mixture that will crystallize a single protein. For example, finding the proper fluid mixture may require varying the composition of the mixture using a multidimensional array of variables, such as different salt and buffer fluids, different concentrations and pH values for each fluid, and different atmospheric conditions.
[0005] Screens for suitable protein crystallization conditions are currently conducted manually using skilled technicians. Performing each screen can be a labor intensive process in part because the different fluids into which the proteins are deposited must themselves be deposited in very small amounts into very small fluid reservoirs. The physical act of dispensing such small amounts into such small fluid reservoirs is itself a time consuming and inaccurate process. In addition, the amount of protein available for each individual screen is often limited, and screening fluids used in each screen are typically measured in microliters. This requires a high level of precision and accuracy that can be difficult even for skilled technicians. Reliability and repeatability of each screen is integral to the precision and accuracy of each screen. Accordingly, there exists a need to automate the screening process, and to increase the level of precision, accuracy and repeatability of the process.
[0006] Conventional crystallization techniques may require that each protein to be crystallized is screened against numerous different fluid mixtures (typically hundreds, or many thousand) in order to find a proper composition that provides stable crystallization conditions for the particular protein in question. In a manual screening process, a technician is primarily responsible for measuring, mixing, and dispensing each unique fluid mixture. Such a manual process is time consuming and expensive, and therefore the variations of fluid mixtures are often limited because of time constraints in the screening process. Unfortunately, by reducing the granularity of the screen, a less than optimum fluid mixture will likely be selected. Further, such a manual screening process is highly susceptible to human mathematical and measurement errors in fluid preparation. In such a manner, the screen may produce erroneous, unreliable, or unrepeatable results.
[0007] Yet another problem associated with screening crystallization conditions is that many of the known buffer fluids, and other fluids used in the screens tend to be highly volatile. These volatile fluids can evaporate or change in character over time. Therefore, it can be difficult to manually prepare a screen having a large number of individual tests because of the time required to deposit the fluids into each well. As the different fluids are deposited in each well, the volatile fluids can evaporate or otherwise change composition, rendering the particular screen inaccurate.
[0008] Therefore, there exists a need for a fluid dispensing system that can quickly and repeatedly perform the multiple fluid depositing steps required for large numbers of screens or other types of precise, highly repeated, fluid handling processes.
SUMMARY OF THE INVENTION
[0009] The present invention alleviates to a great extent the disadvantages of the known protein crystallization and screening techniques by providing an automated system and method of performing multiple fluid depositing steps for high throughput processing protein screening and crystallization.
[0010] Briefly, in a preferred embodiment, fluid wells are positioned below a plurality of fluid dispensing devices. For example, syringes may be configured to dispense fluid into the individual fluid wells. The fluid dispensing devices are configured to be positionable relative the fluid wells. This enables different fluid dispensers to be sequentially positionable over a particular fluid well. A controller preferably controls the relative movement between the fluid wells and the fluid dispensing devices. It is preferred that the controller include software that allows operator flexibility in determining the relative movement between the fluid wells and the fluid dispensing devices.
[0011] In operation, the controller selectively operates a multi-well vessel transport in one direction and moves the fluid dispensing devices in a second direction. When directed by the controller, a selected fluid dispensing device deposits a determined quantity of a fluid into a selected individual well of the appropriate multi-well vessel.
[0012] It is preferred that a plurality of multi-well vessels and fluid dispensing devices be arranged to work in close association with each other so that an increase in throughput is achieved. Accompanying the increase in throughput is an increase in reliability and repeatability, and a decrease in the time associated with fluid deposition. The increased throughput substantially eliminates the conventional problem of having the character of the deposited fluids change as a result of volatility.
[0013] In one aspect the present invention features an apparatus for automatically preparing mixtures of fluids in a plurality (e.g., 96, 384, or 1536) of wells of a multi-well holder. The apparatus includes a plurality of fluid dispensing devices capable of being sequentially positioned above the wells. Each fluid dispensing device is capable of dispensing a fluid into a well when the well is positioned below the fluid dispensing device. The apparatus also includes a controller that controls dispensation of the fluid from the fluid dispensing devices and the relative movement between the fluid dispensing devices and the wells.
[0014] In preferred embodiments, the plurality of tubes are configured so that 1, 2, 3, 4, 5, 6, 7 or 8 multi-well holders can be beneath the plurality of tubes at the same time. Preferably, the plurality of tubes are configured so that the dispensing mechanisms can deliver the material to 1, 2, 3, 4, 5, 6, 7 or 8 multi-well holders at the same time. The plurality of tubes may be configured so that all of the dispensing mechanisms can deliver the material at the same time. In one preferred embodiment, the moving element has a length of at least n multi-well plates, wherein n is the number of multi-well plates, wherein each multi-well plate has m wells, wherein m is the number of wells, wherein the apparatus processes a multi-well plate every m dispensings even though the muti-well plate is in the apparatus for n times m dispensings. For example, the moving element has a length of at least five multi-well plates, wherein each multi-well plate has 96 wells, wherein the apparatus processes a multi-well plate every 96 dispensings, even though the multi-well plate is in the apparatus for 480 dispensings. The dispensor controller preferably directs the delivery of the material from each fluid container to each multi-well plate, for example the dispenser controller may direct the delivery of the material from each of at least eight fluid containers to each of at least five multi-well plates.
[0015] In another aspect, the invention features a system for efficiently loading mother liquors in a plurality of multi-well sample plates for a course screen, the plurality of sample plates arranged with corresponding columns aligned, the system including: (a) a plate arranging area configured to receive the plurality of sample plates; (b) a plurality of fluid containers, each fluid container holding a predetermined mother liquor mixture; (c) a plurality of syringes arranged in an array, the array, each syringe being in fluid communication with an associated one of the fluid containers; (d) a drive mechanism constructed to sequentially position the syringes in the array directly over each column of wells in the sample plate; (e) a dispensing mechanism associated with each syringe; and (f) a fluid controller communicating to the dispensing mechanism; wherein the fluid controller directs the dispensing mechanisms to deliver a quantity of each associated mother liquor into each sample well in a column before the drive mechanism moves the syringe array to a next column.
[0016] In preferred embodiments the plurality of syringes are configured so that 1, 2, 3, 4, 5, 6, 7 or 8 sample plates can be beneath the plurality of syringes at the same time. The plurality of syringes preferably are configured so that the dispensing mechanisms can deliver the material to 1, 2, 3, 4, 5, 6, 7 or 8 sample plates at the same time. The plurality of syringes may be configured so that all of the dispensing mechanisms can deliver the material at the same time. In one preferred embodiment, the system includes a moving element that has a length of at least n sample plates, wherein n is the number of sample plates, wherein each sample plate has m wells, wherein m is the number of wells, wherein the system processes a sample plate every m dispensings even though the sample plate is in the system for n times m dispensings. For example, the moving element has a length of at least five sample plates, wherein each sample plate has 96 wells, wherein the system processes a sample plate every 96 dispensings, even though the sample plate is in the system for 480 dispensings. The fluid controller preferably directs the delivery of the material from each fluid container to each sample plate, for example, the dispensor controller directs the delivery of the material from each of at least eight fluid containers to each of at least five multi-well plates.
[0017] In another aspect, the present invention provides a method for automatically preparing a mixture in a well of a multi-well holder. The method involves the steps of: (a) moving the multi-well holder so that the well is positioned below a fluid dispensing device; (b) dispensing fluid from the fluid dispensing device into the well; and (c) repeatedly moving the multi-well holder so that the well is positioned below a next fluid dispensing device and dispensing fluid from the next fluid dispensing device into the well until a predetermined mixture is prepared.
[0018] In preferred embodiments, the plurality of syringes are configured so that 1, 2, 3, 4, 5, 6, 7 or 8 multi-well holders can be beneath the plurality of syringes at the same time. The plurality of syringes preferably are configured so that the syringes can deliver the material to 1, 2, 3, 4, 5, 6, 7 or 8 multi-well holders at the same time. The plurality of syringes may be configured so that all of the syringes can deliver the material at the same time. In one preferred embodiment, the sample plates are on a moving element that has a length of at least n sample plates, wherein n is the number of multi-well plates, wherein each multi-well plate has m wells, wherein m is the number of wells, wherein the method processes a multi-well plate every m dispensings even though the method involves n times m dispensings. For example, the sample plates are on a moving element that has a length of at least five multi-well plates, wherein each multi-well plate has 96 wells, wherein the method processes a multi-well plate every 96 dispensings, even though the method involves 480 dispensings. Preferably, a controller directs the delivery of the material from one or more fluid containers to each sample plate. For example, the controller directs the delivery of the material from each of at least eight fluid containers to each of at least five multi-well plates.
[0019] Finally, in another aspect, the present invention provides a syringe array for dispensing liquid into a plurality of multi-well sample plates. The syringe array includes a plurality of N syringes coupled into a linear array. N is a whole number multiple of the number of sample wells in one line of each sample well. Each sample plate includes sample wells organized in a geometric pattern. The line may be a row or a column. By way of example, the number of sample wells in a line may be 12 and N may be 96.
[0020] In preferred embodiments of any of the aspects of the invention described herein, the footprint of the tubes in the column direction (i.e., the column length footprint) of the multi-well holder is at least 5.030, 10.060, 15.090, 20.120, 25.150, 30.180, 35.210, 40.240, or 45.270 inches long.
[0021] It readily will be appreciated that an advantage of the present system is to increase the speed, accuracy and reliability of protein crystallization and processing operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features and advantages of the present invention will be appreciated from review of the following detailed description of the invention, along with the accompanying figures in which like reference numerals refer to like parts throughout.
[0023] [0023]FIG. 1 is an elevation of a fluid dispensing system in accordance with the present invention;
[0024] [0024]FIG. 2 is a perspective view of a plurality of multi-well vessels positioned underneath a tube array in accordance with the present invention;
[0025] [0025]FIG. 3 is an elevation of a tube array and fluid source in accordance with the present invention;
[0026] [0026]FIG. 4 is a plan view of a plurality of tubes positioned adjacent a multi-well vessel in accordance with the present invention;
[0027] [0027]FIG. 5 is a flow-chart illustrating a method for dispensing a plurality of fluids in accordance with the present invention; and
[0028] [0028]FIG. 6 is a plan view of a multi-well vessel positioned underneath a section of a tube array in accordance with the present invention.
[0029] Some or all of the Figures may be schematic representations for purposes of illustration and do not necessarily depict the actual relative sizes or locations of the elements shown.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In the following paragraphs, the present invention will be described in detail by way of example with reference to the drawings. Throughout this description, the preferred embodiments and examples do not limit the scope of the present invention.
[0031] I. A Multi-Fluid Dispensing System
[0032] Referring now to FIG. 1, an apparatus for preparing a fluid mixture is shown. More particularly, the apparatus for preparing a fluid mixture is illustrated as a multi-fluid dispensing system 20 . The multi-fluid dispensing system 20 provides an automated and robotic process for handling, dispensing and storing fluid samples. The fluid samples may be, for example, genetic material, chemicals, or living cells. In one embodiment, the fluids may be “mother liquors” for the growth of protein crystals. Other types of fluids can be employed in the present invention. Although the illustrated examples are used to prepare fluid mixtures for screening protein crystallization mixtures, the apparatus and method for preparing fluid mixtures may be used for other purposes and in other fields.
[0033] The multi-fluid dispensing system 20 comprises a plurality of fluid dispensing tubes 25 mounted in a tube array 23 . The tube array is attached to a tube transport 30 . In one embodiment, 96 tubes 25 are mounted to the tube array 23 in a single row. Different numbers of tubes 25 mounted in a different arrangement on the tube array 23 can be employed. For example, shown in FIG. 4, a plurality of tubes 25 are mounted in a staggered configuration on tube array 23 .
[0034] Referring to FIGS. 2 and 3, tube transport 30 mounts the tube array so that the plurality of tubes are aligned with a conveyor 50 . In a preferred embodiment the conveyor 50 provides for movement of multi-well vessels in the positive X-direction 95 . The tube transport 30 is configured to move the tube array 23 in both the positive and negative Y-direction 100 , which is substantially perpendicular to direction of movement provided by the conveyor 50 . Although the conveyor 50 and the tube transport 30 are configured to provide relative movement between the tubes 25 and the vessels 45 , other arrangements may be used for providing such relative movement. For example, either a conveyor or a tube transport may be individually constructed to provide both X- and Y-axis movement.
[0035] In a preferred embodiment, tube transport 30 communicates with controller 65 and is moved by electric motors, although other types of transport devices can be employed to move tube transport 30 , such as pneumatic, hydraulic or other suitable devices.
[0036] A fluid source 35 comprises a plurality of fluid pumps 37 for pumping fluid to the tubes 25 . The fluid pumps 37 are controlled by a plurality of pump control boxes 39 , which are preferably operated by a controller 65 . The controller 65 may be, for example, a general purpose computing device such as a commonly available PC which has been programmed to perform the steps required by the present invention. The controller 65 is operated through an operator interface 70 such as a touch-activated CRT. Other devices can be used to interface with the controller 65 , such as a keyboard, or voice-activated system. Also, controller 65 may be a dedicated controller circuit or processor configured as an embedded controller, and may be locally present or accessed through a network, such as a local or wide area network.
[0037] In one embodiment, the fluid pumps 37 are solenoid valve dispensers that are connected to the tubes 25 , which are positive displacement syringe pumps. The syringe pumps are configured to dispense very small amounts of fluid. For example, one embodiment of the present invention employs tubes 25 that dispense nanoliters or microliters of fluid, preferably about 1-10 nanoliters or microliters. In a preferred embodiment, the fluid source 35 comprises 96 solenoid valve dispensers each communicating with the 96 tubes 25 .
[0038] When configured for protein crystallization growth, fluid pumps 37 are each coupled to a fluid source, with each fluid source being a “mother liquor” designed to facilitate growth of protein crystals. These mother liquors can be salts, buffers, detergents, organic chemicals, and other suitable fluids. Virtually any fluid can be dispensed by the fluid pumps 37 into tubes 25 .
[0039] Referring to FIGS. 1 and 2, the tube array 23 is arranged to dispense fluid through the tubes 25 into individual wells 40 located in a multi-well plate or vessel 45 . The multi-well plates 45 are dispensed from plate dispensers 55 onto a conveyor 50 . The multi-well plates 45 are carried down the conveyor 50 , and fluid is dispensed into the wells 40 . The plates 45 are collected at the other end of the conveyor by plate receivers 60 . Alternatively, the plates 45 can be delivered to a diving board 62 for delivery to another device or technician for further processing.
[0040] Illustrated in FIG. 1, plate dispensers 55 can store a plurality of vessels or plates 45 for dispensing onto conveyor 50 . The plate dispensers 55 communicate with controller 65 to lower vessels 45 by a rack-and-pinion unit (not shown). In a similar arrangement, the plate receivers 60 can hold a plurality of plates or vessels 45 . The vessels 45 are loaded into plate receivers 60 by an arrangement of posts which are rack-and-pinion driven (not shown). Other devices can be used to store and dispense vessels 45 . For example, other robotic or manual arrangements may be employed.
[0041] In one embodiment, the present invention can be configured to dispense a multiplicity of different mother liquor fluid combinations into a plurality of wells located in vessels 45 . In one embodiment, vessel 45 contains a total of 96 wells 40 arranged in eight columns and nine rows, as illustrated in FIGS. 2, 4 and 6 . The twelve rows are parallel to the y-direction 100 and the columns of vessel 45 are parallel to the x-direction 95 . More or fewer wells 40 may be contained in vessel 45 .
[0042] One particular method of dispensing fluids for growing protein crystals employs four vessels 45 , each vessel containing 96 wells 40 for a total of 384 wells. 96 different fluids are dispensed from the 96 tubes 25 mounted on the tube array 23 . The combination of tubes 25 and their corresponding fluids dispense different combinations and concentrations of fluids so that each of the 384 wells contains a unique mixture of fluids. The specific unique mixture in each well is known by the controller and may be used for later process decisions or displayed on the operator interface 70 . In this manner, a screen to determine the best combination and concentration of fluids for growing an optimum protein crystal can be quickly determined.
[0043] In a preferred embodiment, after dispensing the fluids into the 384 wells, protein crystals are grown and selected based on the quality of the crystal according to user-defined criteria. For example, the 16 “best” quality crystals are isolated and the specific combination and concentration of fluids used to grow those crystals are recalled by controller 65 and displayed using operator interface 70 . Preferably, a “fine-screen” test is performed to optimize the concentration and combination of fluids for each of the 16 fluid combinations that resulted in the 16 best crystals.
[0044] During the fine-screen process of this preferred embodiment, 24 variations of each of the 16 fluid combinations are dispensed from the fluid dispensing tubes 25 into new vessel 45 wells 40 . For example, if one of the 16 fluid combinations that resulted in a high-quality protein crystal comprised 5 percent of fluid A and 95 percent of fluid B, the corresponding fine screen would be composed of variations of the fluid combination of 5 percent of fluid A and 95 percent of fluid B. As an example, one of the 24 fine screen variations could be composed of 5.1 percent of fluid A and 94.8 percent of fluid B. Other variations could be 5.2 percent of fluid A and 94.9 percent of fluid B or 4.9 percent of fluid A and 95.1 percent of fluid B. In this manner, an optimized fluid combination and concentration can be determined for growing an optimum protein crystal.
[0045] II. Method for Dispensing Fluids
[0046] Referring to FIGS. 2, 4 and 5 , one method and procedure for dispensing fluids or mother liquors into vessel 45 wells 40 are described. One embodiment of the present invention can dispense a multiplicity of mother liquor combinations and concentrations for later testing. This is useful because a range of fluid combinations and concentrations must be tested to determine which conditions will achieve a suitable protein crystal, since the specific criteria required to achieve a suitable protein crystal has not yet been determined for each protein in the human genome.
[0047] Referring to FIG. 5, in step 200 , a combination of fluids to be dispensed into a vessel 45 well 40 is determined. In step 205 , each of the fluids in the combination is assigned to a respective tube. In step 210 , the vessel 45 well 40 is moved to one of the tubes. The fluid is then dispensed in a specific amount into the vessel 45 well 40 in step 215 . Next, step 220 determines of whether the vessel has received all of the fluids of the specific fluid combination. If all of the required fluids have been dispensed into the vessel 45 well 40 , the process ends. However, if additional fluids must be dispensed into the vessel 45 well 40 , then the vessel 45 well 40 is moved to another tube 25 , in step 210 . Then step 215 and step 220 are performed as discussed, and this process is repeated until all of the necessary fluids have been dispensed into the specific vessel 45 well 40 .
[0048] Referring to FIGS. 2 and 5, another procedure for dispensing mother liquors into specific vessel 45 well 40 will be described. Vessels 45 are placed on conveyor 50 . Each vessel 45 comprises 12 rows 42 and 8 columns 44 . Each well 40 and each vessel 45 has a column 42 height of about 9 millimeters and a row width of about 9 millimeters. Other vessels 45 can be employed having different numbers of wells 40 and different well 40 dimensions.
[0049] After the vessel 45 is placed on the conveyor 50 the conveyor moves the vessel 45 in 9 millimeter increments in the X-direction 95 . Tube array 23 containing 96 tubes 25 is moved by tube transport 30 in the Y-direction 100 . Illustrated in FIG. 6, controller 65 aligns the first tube 25 A of the tube array 23 over a first well 40 in a first row 42 A, first column 44 A. As discussed above and illustrated in FIG. 5, the controller determines whether or not a fluid must be dispensed into that specific vessel 45 well 40 . If the controller orders fluid to be dispensed into that specific well 40 , the fluid is dispensed through the first tube 25 A.
[0050] The tube array 23 is then moved by tube transport 30 over one column (i.e., 9 millimeters). This positions the first tube 25 A over a second well 40 in the first row 42 A, second column 44 B. Again, controller 65 determines whether or not fluid is to be dispensed into the second well 40 . Once the fluid has been dispensed, if necessary, the tube transport 30 moves the tube array 23 a distance of 9 millimeters to the next column 44 C and positions the first tube 25 A over a third well 40 . This process is repeated until the first tube 25 A has been positioned over each well 40 in the first row 42 A of the plate 45 . Conveyor 50 then moves the plate 45 in the X-direction 95 9 millimeters, positioning the first tube 25 A over the first well in the second row 42 B.
[0051] Illustrated in FIG. 6, first tube 25 A coupled to tube array 23 and second tube 25 B also coupled to tube array 23 are positioned over the first well 40 of the first two rows 42 A and 42 B. The procedure described in step 210 of FIG. 5 is now repeated for the first well 40 in row 42 B as well as the first well of row 42 A. Because two tubes 25 A and 25 B are positioned over two wells 40 , two different fluids can be dispensed simultaneously, if necessary, depending upon the combination of fluids to be dispensed into each well 40 . Once the controller has determined if a fluid is to be dispensed into each well and that dispensing has occurred, the tube transport 30 moves the tube array 23 in the Y-direction 100 to position the first tube 25 A and second tube 25 B over the next column 44 B in the plate 45 . The dispensing of fluids then commences if necessary for that well 40 . In this manner, appropriate fluids can be dispensed in the appropriate combination and concentration into each well 40 of each vessel 45 .
[0052] Referring to FIGS. 2 and 4, as the vessels 45 progress down the conveyor 50 and are exposed to more tubes 25 and the tube array 23 , the controller can dispense up to 96 fluids substantially simultaneously if necessary. In this manner, an extremely high throughput of fluid combinations can be achieved in the wells 40 of each vessel 45 . The rate of fluids that can be dispensed by the present invention is unachievable by human technicians and allows any for an extremely high number of combinations of fluids to be dispensed. In addition, each combination and concentration of fluids in each well 40 can be recalled from the operator interface 70 , and can be repeated with repeatable accuracy due to the automated process performed by the present invention.
[0053] The arrangement of tubes need not be in a linear arrangement as illustrated in FIG. 2. For example, shown in FIG. 4, the tubes 25 can be arranged in a staggered configuration or any other suitable configuration.
[0054] Referring to FIG. 4, the tubes 25 can be periodically rinsed and dried so that the concentrations of fluids dispensed through the tubes remain consistent. Tube transport 30 positions the tube array 23 over the tube bath 80 that contains a suitable tube rinse, such as ethanol or ionized water or any other suitable rinsing fluid. The tubes are immersed in the rinse and then the tube array 23 is moved by the tube transport 30 to the tube dryer 85 that is connected to a vacuum source 90 . The tube dryer 85 includes tube holes 87 into which the tubes 25 are inserted by the tube transport 30 . The vacuum source 90 is turned on by the controller 65 , drying the tubes 25 .
[0055] One skilled in the art will appreciate that the present invention can be practiced by other than the preferred embodiments which are presented in this description for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow. For example, features of the methods and devices described in International Patent Publication WO 00/78445, published Dec. 28, 2000, incorporated herein by reference in its entirety including any drawings or figures, can be used in conjunction with the methods and devices of the present invention. It is noted that equivalents for the particular embodiments discussed in this description may practice the invention as well. | A system and method for preparing and dispensing fluid mixtures is provided. Fluid wells are positioned below a plurality of fluid dispensing devices, such as syringes configured to dispense fluid into the individual fluid wells. The fluid dispensing devices are configured to be positionable relative the fluid wells to enable different fluid dispensers to be sequentially positionable over a particular fluid well. A controller controls the relative movement between fluid wells and the fluid dispensing devices. In a preferred embodiment, the controller selectively moves multi-well vessels in one direction and moves the fluid dispensing devices in a second direction so that when directed by the controller, a selected fluid dispensing device is enabled to deposit a determined quantity of a fluid into a selected individual well of the multi-well vessels. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention refers to a crossbar for heald-carrying frames comprising an improved attachment of the heald-carrying plate to said crossbar.
2. Description of the Related Art
As is well known to skilled people in the field, the heald-carrying frame is a device used in weaving looms to achieve the shifting of groups of warp yarns, thanks to the alternate movement thereof in a vertical plane perpendicular to the weaving plane. In the weaving loom a certain number of heald-carrying frames is arranged, the greater the degree of complexity of the pattern to be woven on the fabric, the higher the number of such frames, and the individual frames are controlled by a weaving machine in order to achieve a preset pattern on the fabric.
Each heald-carrying frame comprises a rectangular rim consisting of two side elements making up the guides for the alternate sliding of the frame, and of two horizontal elements, called crossbars, on whose opposite inner sides a plurality of thin steel rods is fastened, provided with an intermediate eye for one or more warp yarns to pass through. Such rods are called indeed healds.
The two side elements and the two crossbars must further be mutually fastened at a right angle, in the angular positions of the frame, so as to provide a rigid and stable structure, capable of withstanding the high stress levels which the frame undergoes during its rapid, and sometimes very rapid, alternate movement within the loom.
Over the last few years continuous efforts have been made to improve the performance of the above-said devices, in particular towards reducing the mass and increasing the useful life thereof. Such objects are of course in conflict, since a lighter structure is more prone to fatigue breaking, which typically represent the most frequent cause of breaking of the devices undergoing continuous and rapid inversions of inner stresses, as indeed in the case of heald-carrying frames. In order to reduce the incidence of this problem, a number of attempts have been made to form the crossbars using, instead of the conventional aluminium-based light alloy metal sheets or light alloy metal sheets made of other low specific-weight metals, composite materials made of different types of fibres, synthetic resins and foam materials, all materials which are less affected by the problem of fatigue breaking over metallic materials. However, the much higher costs of this type of heald-carrying frames has not allowed a sufficiently wide diffusion thereof yet and the frames in metallic materials consequently still represent a considerable portion of the market.
Such frames, however, have—as shown—an excessively short useful life, especially in connection with the inherent fragility induced in a heald-carrying frame by the system fastening the heald-carrying plates to their respective crossbars. As a matter of fact, the majority of the frames on the market currently provides a mutual fastening by means of rivets of the above-said components. This system—which is certainly very inexpensive, safe and allows quick assembly, and which is consequently currently preferred—however, has remarkable and noticeable disadvantages, particularly in terms of its dramatic reduction of the fatigue-withstanding properties of the crossbars.
As a matter of fact, as is known, the operations of crossbar drilling, and of the subsequent upsetting of the rivet on the respective holes for the fastening of the heald-carrying plate, induce very strong localised stresses in the metallic profile making up the crossbar. These, understandably, drastically reduce the fatigue breaking limit of the crossbar, and as a result cause a very short useful life of the heald-carrying frames.
This problem then becomes the more serious the faster the looms whereon the heald-carrying frames are mounted; as a matter of fact, the higher speed implies greater dynamic stresses and a higher number of cycles of alternate stresses per time unit, both conditions reducing the fatigue limit. In the more recent air-jet looms, wherein weaving speeds are extremely high, the problem of breaking frequency or of scheduled replacement of the heald-carrying frames has hence become such as to negatively affect the entire weaving operation.
BRIEF SUMMARY OF THE INVENTION
It is hence the object of the present invention to provide a crossbar for heald-carrying frames overcoming the drawbacks highlighted above and hence having—still keeping the market-demanded crossbar structure made of light metallic materials—a much longer useful life than that of the crossbars currently on the market.
According to the invention, such object is achieved by means of a crossbar with an improved fastening of the heald-carrying plates having the features reported in the accompanying main claim. Further features of the crossbar of the invention are reported in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The invention will now be described in greater detail, with reference to an embodiment of the same, among the many ones possible, shown in a diagrammatic way in the accompanying drawings, wherein:
FIG. 1 is an elevation side exploded view with parts separated of the end extension of a crossbar for heald-carrying frames and of a heald-carrying plate according to a first embodiment of the invention;
FIG. 2 is a similar view to FIG. 1 , wherein the two parts are mutually assembled and make up the end extension of a crossbar ready for use;
FIGS. 3 and 4 are similar views to FIGS. 1 and 2 which show a second embodiment of the invention; and
FIGS. 5 and 6 are similar views to FIGS. 1 and 2 which show a third embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a heald-carrying plate 1 and an end extension 2 of a crossbar for heald-carrying frames intended for the formation of a heald-carrying frame. As a matter of fact, as is well-known to skilled people in the field, a crossbar for heald-carrying frames comprises a box-like portion—intended to impart structural rigidity to the crossbar and arranged on the external part of the frame—and an extension projecting therefrom, towards the inside of the frame, whereto the heald-carrying plate is fastened. Such extension is precisely the one shown in the drawings and which, for greater clarity, will be simply called “crossbar” in the following.
Plate 1 consists of a rectangular-section bar having rounded-off edges, of a material having high mechanical and wear-withstanding properties, such as for example a steel alloy or other metallic alloys, so as to be able to directly withstand the repeated forces and impacts discharged thereon by the healds. Plate 1 is shaped so as to have, on the side facing crossbar 2 , a longitudinal groove 3 whose side walls have a certain degree of undercut, for example a dove-tail-section groove of the type shown in the drawings.
Crossbar 2 supports said plate 1 and consists, as seen above, of a solid profile of light metallic material, in particular aluminium or magnesium or some sort of special alloy made of these or other metals having a low specific weight. In correspondence of the area of engagement with plate 1 , crossbar 2 comprises a longitudinal rib 4 apt to tightly fit groove 3 of plate 1 .
At the bottom of rib 4 , crossbar 2 has suitable flutes 5 , apt to allow a perfect abutment between the inner face 1 a of plate 1 and the corresponding resting surface 2 a of crossbar 2 , when these two elements are brought into contact by introducing rib 4 in groove 3 .
At the top of rib 4 a recess 6 is instead provided, apt to ease the plastic strain of rib 4 during the operations of introduction and upsetting of said rib into groove 3 .
In order to accomplish the coupling between plate 1 and crossbar 2 , said elements are firstly joined introducing rib 4 into groove 3 and they are then exposed to pressure in a mounting press. During this operation rib 4 , which for this purpose has a height slightly greater than the depth of groove 3 , undergoes a plastic strain which allows it to adapt perfectly to the inner form of groove 3 , hence remaining tightly and steadily anchored to the same due to the undercut with which such groove is shaped.
The crossbar obtained by the above-described fastening, in addition to allowing a perfectly stable and slack-free coupling over time between crossbar 2 and plate 1 , has the remarkable advantage of requiring no prior drilling operation of the crossbar 2 made of light metallic material which is hence not weakened in any way. Moreover, the coupling is accomplished along the entire crossbar, in a continuous and simultaneous manner; localised deformations and the consequent concentrated stresses, typical of known-type crossbars wherein the plate/crossbar coupling was accomplished by using rivets, are hence fully removed. Finally, the above-described plate/crossbar coupling can be mounted extremely quickly, thereby contributing to a reduction of the manufacturing costs of the heald-carrying frame.
In order to facilitate the plastic deformation of rib 4 , it is possible to provide, within groove 3 , longitudinal elements of a suitable shape and arrangement which are sufficiently rigid to be non-deformable with respect to the light alloy material making up the crossbar, said elements being apt to cooperate with recess 6 during the step of mounting plate 1 and crossbar 2 on the press.
In a second embodiment of the invention, shown in FIGS. 3 and 4 , such longitudinal element consists of a bead 7 formed in an axial position within groove 3 . During mounting, bead 7 wedges itself into recess 6 , easing the bilateral plastic strain of rib 4 and partially occupying, once mounted, the clearance of recess 6 .
In a third embodiment of the invention, shown in FIGS. 5 and 6 , such longitudinal element consists instead of a steel wire 8 which is laid upon and provisionally fastened, for example by gluing, along the entire mouth of recess 6 , the diameter of wire 8 being greater than the opening of said mouth. During mounting, following the introduction of rib 4 into groove 3 , wire 8 rests against the bottom of the groove itself and hence facilitates, in a fully similar way to what has already been said for bead 7 , the bilateral plastic strain of rib 4 . At the end of the assembly operation, rib 4 has undergone the desired, permanent plastic strain occupying the undercut area of groove 3 , whereas thread 8 has occupied almost entirely the clearance of recess 6 .
From what has been set forth above it is clear how the crossbar of the present invention has fully achieved the desired object, considering that the useful life of the crossbar has noticeably increased, on the one hand because any form of localised structural weakening of the crossbar—due to drilling of the same and subsequent upsetting on the holes of the rivets used for connecting the heald-carrying plate—is avoided and, on the other hand, because a plate/crossbar coupling with a continuous fastening is accomplished, thereby achieving perfect distribution on the crossbar of the stresses induced on the plate by the action of the healds.
The above-reported description has been given with specific reference to the embodiments shown in the drawings and must hence be considered only as illustrative of the invention. A number of other embodiments of the particular plate/crossmember attachment characterising the invention are possible, in particular changing the shape and arrangement of groove 3 and correspondingly of rib 4 , by means of devices within easy reach of a person skilled in the field, which must consequently all be considered comprised in the scope of protection of the invention, as defined in the accompanying claims. | Crossbar for heald-carrying frames of weaving looms comprising a main element of the crossbar made, at least in part, of a light metallic material, such as aluminium, magnesium or alloys thereof; and a heald-carrying element made of a high-resistance material, such as steel. The heald-carrying element is steadily fastened to the main element of the crossbar by means of a lock joint, through plastic strain between a longitudinal rib projecting from the main element of the crossbar and a corresponding groove formed in the heald-carrying element. | 3 |
This is a continuation of application Ser. No. 747,508, filed Dec. 6, 1976, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to apparatus for stacking flexible sheets which consist of paper or the like, and more particularly to improvements in apparatus for converting a stream of partially overlapping sheets into a pile wherein the sheets are accurately stacked on top of each other.
Sheets which are obtained by severing a continuous web of paper or the like at regular intervals are normally assembled into stacks for further processing in printing plants or in other types of establishments. In many instances, the sheets which are separated from the leader of a continuous web by a suitable knife are assembled into a stream of partly overlapping sheets to reduce the speed of forward movement of sheets and to thus facilitate accurate stacking of sheets on top of each other. The formation of a stream of partly overlapping sheets is particularly desirable when the frequency at which the web is severed is very high so that it is necessary to greatly reduce the speed of sheets before they reach a magazine, a platform or an analogous support in or on which the sheets are piled on top of each other. Accurate stacking of sheets is desirable for a number of reasons, e.g., to reduce waste which is a necessary adjunct of secondary treatment (trimming) of stacks wherein the sheets are not in accurate register with each other.
As mentioned above, accurate stacking of sheets can be achieved by reducing the speed of sheets which approach the stacking station. The aforementioned formation of a stream of partially overlapping sheets is an effective procedure to reduce the speed of sheets between the severing and stacking stations. The speed of sheets cannot be reduced at will because, otherwise, the sheets are likely to come to a full stop ahead of the optimum position of accurate overlap with the preceding sheets. The selection of such speed depends, among other factors, on the weight of sheets and the finish of their surfaces.
German Offenlegungschrift No. 1,461,212 discloses a stacking apparatus wherein the lower reaches or stretches of two conveyor belts travel below the bottom wall of a suction chamber at a level above the stacking station. The bottom wall of the suction chamber has an elongated slot which is flanked by the lower reaches of the belts. Thus, when a sheet is fed to the undersides of the lower reaches of the belts, such sheet is attracted by the suction chamber and is moved forwardly by the two lower reaches. The pressure in the interior of the suction chamber is only slightly less than atmospheric pressure, especially when the sheets are readily flexible, because excessive suction would cause the sheet to flex or bulge and to enter the slot between the belts. Moreover, such flexing or bulging of the sheet into the interior of the suction chamber would interfere with orderly transport of the sheet and would prevent the apparatus from stacking successive sheets with a requisite degree of reproducibility. When a sheet reaches its foremost position, it is mechanically stripped off the lower reaches of the belts by a forked separating device which directs the separated sheet onto the topmost sheet of the stack therebelow.
The just described apparatus is not suited for stacking of readily flexible lightweight sheets because the slot in the bottom wall of the suction chamber invariably causes at least some deformation of readily flexible sheets and also because the mechanical separating device often or invariably deforms the leading edges of the sheets during stripping off the lower reaches of the belts. If the pressure in the suction chamber is only slightly less than atmospheric pressure, so that the slotted bottom wall of the suction chamber is unlikely to deface or deform the sheets, the apparatus is incapable of insuring proper transport of each and every sheet all the way into the range of the mechanical separating device.
SUMMARY OF THE INVENTION
An object of the invention is to provide a novel and improved apparatus which can convert a stream of sheets into a stack without any damage to and/or defacing of central and/or marginal portions of sheets, which can be used for stacking of relatively stiff or readily flexible and relatively heavy or lightweight sheets, and which can be used as a simpler, more reliable and more versatile substitute for conventional stacking apparatus.
Another object of the invention is to provide an apparatus wherein successive sheets of a stream, particularly a stream of partly overlapping sheets, can be converted into stacks with a heretofore unmatched degree of reproducibility, even if the sheets are fed to the stacking station at an elevated speed and even if the sheets are readily deformable due to the nature of their material and/or low specific weight.
A further object of the invention is to provide the apparatus with novel and improved means for regulating the force with which successive sheets are held during transport to the stacking station and for regulating the locus of application of such force.
An additional object of the invention is to provide the apparatus with novel and improved means for advancing the sheets of a continuous stream of partially overlapping sheets to the stacking station.
The invention is embodied in an apparatus for converting a stream of partially overlapping sheets, particularly paper sheets, into a stack of fully overlapping sheets. The apparatus comprises a support for the stack of sheets (such support may constitute a platform or a magazine), at least one endless perforated conveyor (e.g., an endless foraminous belt) having an elongated lower reach or stretch which is disposed above the support, means for driving the conveyor so as to advance the lower reach in a direction from one toward the other end of the lower reach, a suction chamber or analogous means for establishing a pressure differential between the upper side and the underside of the lower reach with the lower-pressure region located above the lower reach, means for feeding a stream of partially overlapping sheets to the one end of the lower reach whereby the lower reach attracts successive foremost sheets of the stream to its underside and advances the thus attracted sheets toward a position of register with the support, and a sealing plate or analogous means for varying the length (and preferably the location) of that portion of the lower reach of the conveyor which attracts the sheets to the underside of the lower reach. This renders it possible to pinpoint the locus where the sheets become separated from the lower reach as well as the timing of separation. Each of the thus separated sheets can advance toward an optimum position relative to the support due to its inertia, due to frictional engagement with the next-following sheet and/or under the action of the feeding means.
The sealing plate is preferably disposed between the foraminous bottom wall of the suction chamber and the lower reach of the conveyor and is preferably provided with a handle or analogous means for moving it lengthwise of the lower reach.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved apparatus itself, however, both as to its construction and its mode of operation, together with additional features and advantages thereof, will be best understood upon perusal of the following detailed description of certain specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary longitudinal vertical sectional view of an apparatus which embodies the invention; and
FIG. 2 is an enlarged fragmentary end elevational view of the apparatus as seen from the right-hand side of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown an apparatus which serves to convert a continuous stream 2 of partially overlapping flexible paper sheets 1 into a stack 5 wherein the neighboring sheets are in accurate register with each other. The apparatus comprises a support 3 which defines the stacking station and constitutes a magazine having a front side wall 8 which is vibrated by a shaker of conventional design, a rear side wall 6 which is remote from the stream 2, at least one lateral side wall (see the side walls 6a, 8a shown in FIG. 2) which is vibrated by a shaker (not shown) similar or analogous to the aforementioned shaker, and a stationary or mobile bottom wall (not shown) on which the lowermost sheet 1 of the stack 5 rests. The reference character 7 denotes an oscillating jogger.
The apparatus further comprises two endless conveyors here shown as perforated belts 11 (see FIG. 2) each having a slightly inclined lower reach 11A which is longer than the distance between the side walls 6, 8 and is disposed above the support 3. The perforations of the belts 11 are shown at 11a. FIG. 2 shows that the perforations 11a may but need not be identical, i.e., they may include circular, oval and/or otherwise configurated holes.
The means for feeding the stream 2 to the left-hand ends of the lower reaches 11A of the belts 11 comprises at least one endless belt or chain conveyor 4 driven by suitable prime mover means, not shown, to advance the stream-supporting upper reach 4A in a direction to the right, as viewed in FIG. 1. The means for driving the conveyor 4 includes a shaft 4b which is rotated in the direction indicated by arrow. The belts 11 are driven at the speed of the conveyor 4 by a shaft 9b which drives one of the pulleys 9, 10 for the respective belts. It will be noted that the lower reaches 11A of the belts 11 are driven to advance in the same direction as the upper reach 4A of the conveyor 4. The latter can receive sheets 1 from a severing station at which the leader of a continuous paper web is severed at regular intervals by a knife, not shown.
The lower reaches 11A of the belts 11 pass through suitable cutouts or openings 6a in the upper portion of the side wall 6.
The means for establishing a pressure differential between the upper sides and the undersides of the lower reaches 11A comprises a suction chamber or suction box 12 which has a foraminous bottom wall 12A disposed immediately above or very close to the upper sides of the lower reaches 11A. The perforations of the bottom wall 12A are shown at 12a. The perforations 12a form two rows each of which is aligned with the row of perforation 11a in the respective belt 11. The bottom wall 12A can have more than two rows of perforations 12a, and the combined number of rows of perforations 11a may but need not equal the number of rows of perforations 12a. The suction chamber 12 has an outlet 18 which is connected with a suitable suction generating device (e.g., a fan, not shown) by a conduit 14 which may constitute a flexible hose.
In accordance with a feature of the invention, the apparatus further comprises a non-permeable device 15 serving to vary the length and locus of that portion of each lower reach 11A which attracts the adjacent sheet 1 during transport along the open top of the support 3 and toward the rear side wall 6. The device 15 is a thin plate-like slide which is mounted between the bottom wall 12A and the upper sides of the lower reaches 11A and has a handle 16 or analogous means for moving it lengthwise of the belts 11 (see the arrow 17 in FIG. 1). The slide 15 is shiftable to select the length of those portions of lower reaches 11A which attract successive sheets 1 during transport in the direction indicated by arrow 18.
It will be noted that the slide 15 overlies the lower reaches 11A in the region of the rear side wall 6, i.e., at that side of the support 3 which is remote from the feeding conveyor 4. Since the trailing portions of foremost sheets 1 of the stream 2 are overlapped by the next-following sheets of the stream, the slide 15 cooperates with each next-following sheet to determine the length of that interval during which the leader of the foremost sheet 1 of the stream is attracted to the undersides of the lower reaches 11A. When the leader of the foremost sheet 1 begins to move under the slide 15, it is not attracted to the lower reaches 11A and can descend toward the uppermost sheet of the stack 5 in the support 3. The final stage of movement of such sheet toward the rear side wall 6 takes place due to inertia, due to friction with the next-following sheet and/or due to engagement with the upper side of the upper reach 4A of the feeding conveyor 4.
If the sheets 1 fail to reach the rear side wall 6 and/or if the leading edges of the sheets are deformed or defaced on impact against the inner side of the side wall 6, the attendant simply changes the position of the slide 15 to thereby change the length of those portions of the lower reaches 11A which attract the foremost sheets of the stream 2. The progress of successive sheets 1 toward the side wall 6 can be observed from one or more sides of the support 3 and/or from above so that the attendant can immediately terminate the adjustment of slide 15 when the operation of the apparatus is satisfactory. The slide 15 actually determines the number of perforations 12a which are free to draw air through the adjacent portions of the lower reaches 11A. It is clear that the slide 15, or an analogous device for varying the effective length of lower reaches 11A, can be installed in the interior of the suction chamber 12 or below the lower reaches of the belts 11. The illustrated mounting is preferred because it does not present problems in connection with sealing of the chamber 12 and also because the slide 15 does not interfere with forward progress of sheets 1 along the undersides of the lower reaches 11A. Moreover, the slide 15 is readily accessible for inspection, cleaning and/or replacement. For example, the entire slide, together with the handle 16, can be inserted into or withdrawn from the space between the bottom wall 12A and lower reaches 11A by moving the handle at right angles to the plane of FIG. 1.
The number of belts 11 can be refunded to one or increased to three or more. It has been found that, in most instances, two perforated belts suffice to insure satisfactory transport of sheets into full register with the uppermost sheet of the stack 5.
An important advantage of the improved apparatus is that the effective length of the lower reaches 11A of belts 11 can be varied at will in a very simple way and also that the sheets 1 are neither damaged nor defaced during transport from the feeding conveyor 4 onto the stack 5. This is due to the fact that the sheets do not contact the suction chamber 12 at any time and also that (at least in the illustrated embodiment) the sheets cannot come into contact with the normally stationary slide 15. Therefore, suction in the chamber 12 can be quite pronounced without any damage to or deformation (especially flexing or bulging) of sheets because the dimensions of perforations 12a are of no consequence since the sheets adhere to the undersides of the lower reaches 11A and the intervals of full or nearly full alignment (if any) of perforations 11a with the perforations 12a thereabove are so short that the sheets cannot be drawn into the perforations 12a during travel toward the rear side wall 6. In fact, and if the perforations 11A are rather small, the bottom wall 12A of the suction chamber 12 (in the regions above the lower reaches 11A) can be formed with perforations in the form of elongated slots.
In many instances, the apparatus of the present invention can be used for simultaneous transport of two or more fully or nearly fully overlapping sheets toward the stacking station. For example, if the sheets are relatively thin and porous, suction in the chamber 12 will suffice to enable the lower reaches 11A to transport two or more fully or nearly fully overlapping sheets from the feeding conveyor 4 toward the rear side wall 6 of the support 3.
Another important advantage of the improved apparatus is that it prevents buckling of sheets 1 during transport from the conveyor 4 toward the side wall 6. This will be readily appreciated by bearing in mind that the speed of the lower reaches 11A preferably equals or closely approximates the speed of the upper reach 4A and that (when the sheets are not overly porous and partially overlap each other) the lower reaches 11A attract only the leader of each foremost sheet, i.e., that portion of such foremost sheet which extends beyond the next-following sheet of the stream 2. Therefore, the sheets remain flat and their leaders begin to move downwardly toward abutment with the side wall 6 only when they reach the region below the slide 15. The side wall 6 invariably intercepts the foremost sheets of the stream 2 because it extends to a level above the lower reaches 11A.
If the discharge end of the conveyor 4 is so remote from the side wall 6 that the conveyor 4 cannot push the foremost sheets of the stream 2 all the way into contact with the side wall 6, the apparatus may comprise a roller (not shown) which is adjacent to the outer side of the front side wall 8 and serves to advance successive foremost sheets of the stream 2 upon termination of transport of such sheets by the lower reaches 11A of the belts 11.
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 and specific aspects of my contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims. | The upper reach of a first belt conveyor delivers a stream of partly overlapping sheets to one end of a perforated second belt conveyor whose lower reach is located above the open top of a magazine and below the perforated bottom wall of a suction chamber. The lower reach attracts the non-overlapped leaders of successive foremost sheets of the stream and transports them toward a position of register with the open top of the magazine. Timely separation of sheets which are attracted to the underside of the lower reach is insured by a non-foraminous slide which is installed between the suction chamber and the lower reach and is movable lengthwise of the lower reach to seal a selected number of perforations in the lower reach in the region of that side wall of the magazine which is remote from the first conveyor. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a plasma display panel, and more particularly, to a method of driving a plasma display panel for improving contrast by minimizing the quantity of luminescence during a non-luminescent display period, that is, a reset period.
2. Description of the Prior Art
A plasma display panel (hereinafter, PDP) displays images including characters or graphics by making UV lights of 147 nm, which is produced in a non-active mixed gas discharge of He+Xe or Ne+Xe, hit phosphor and radiate. In this PDP, super thin and light structure is easily achieved, and greatly enhanced image can be provided by recent technology development. Particularly, in three electrodes AC normal radiation type PDP, because wall electric charges are accumulated at a surface in discharge and electrodes are protected from sputtering due to discharge, there is an advantage of low voltage driving and longevity.
FIG. 1 is a perspective view showing a conventional AC normal radiation PDP.
As shown in FIG. 1 , a discharge cell of three electrodes AC normal radiation type PDP includes a scanning electrode 12 Y and a sustain electrode 12 Z formed on an upper substrate, and an address electrode 20 X formed on an under substrate.
An upper dielectric layer and a protection layer are formed on the upper substrate which has the scanning electrode 12 Y and the sustain electrode 12 Z formed in order thereon. Wall electric charges produced in plasma discharge are accumulated in the upper dielectric layer 14 . The protection layer 16 not only protects damage of the upper dielectric layer 14 from sputtering in plasma discharge but also improves production efficiency of secondary electron. Conventionally, an MgO is used as the protection layer 16 . An under dielectric layer 22 and a barrier rib 24 are formed on the under substrate 18 having the address electrode 20 X formed thereon, and a phosphor 26 is applied to surfaces of the under dielectric layer 22 and the barrier rib 24 . The address electrode 20 X is formed in a direction crossing the direction of the scanning electrode 12 Y and the sustain electrode 12 Z.
The barrier rib 24 is formed in order with the address electrode 20 X, and protects UV lights and visible lights produced in discharge from leakage to adjacent cells. The phosphor 26 is excited by UV lights produced in plasma discharge, and then produces any one visible light of red, green, and blue. Non-active gas is injected into a discharge space between the upper and under electrodes 10 , 18 and the barrier rib 24 for gas discharge.
Such discharge cells are arranged in a matrix form, as shown in FIG. 2 . As shown in FIG. 2 , a discharge cell 1 is formed over an area where a scanning electrodes Y 1 and a sustain electrodes Z 1 cross an address electrodes X 1 . A plurality of scanning electrodes Y 1 , . . . , Ym are drove in sequence, and a plurality of sustain electrodes Z 1 , . . . , Zm are drove in common. And a plurality of address electrodes X 1 , . . . , Xn are drove in division of even lines and odd lines.
In the above-described three electrodes AC normal discharge type PDP, it is the basic principle of each cell that first, address discharge is caused in a space between a the scanning electrode 12 Y and the address electrode 12 X in order to produce wall electric charge therein, second, sustain discharge is caused between the scanning electrode 12 Y and the sustain electrode 12 Z in order to make discharge gas a plasma, thereby producing an UV lights, and then the UV lights is made to excite phosphor in order to produce visible lights.
Such three electrodes AC normal discharge type PDP is drove in division of a plurality of sub-fields. And, in respective the plurality of sub-field periods, luminescence are produced several times, the number of which is proportional to weighted value of video data, thereby realizing contrast display. For example, in the case of displaying an image in 256 contrasts using 8 bits video data, one frame display time in respective discharge cells (for instance, a sixtieth second=about 16.7 msec) is divided into eight sub-fields SF 1 , . . . , SF 8 , as shown in FIG. 3 .
Respective sub-fields SF 1 , . . . , SF 8 is divided again into a reset period, an address period, and a sustain period, and then weighted values are allowed to the sustain period at the rate of 1:2:4:8:, . . . , 128. In this case, the reset period is a period for initializing a discharge cell, the address period is a period for causing an alternative address discharge in accordance with the logic value of video data, and the sustain period is a period for sustaining the discharge in the discharge cell where the address discharge is caused. The reset period and the address period are equivalently allowed in respective sub-field periods, but respective sustain periods are allowed at the rate of 1:2:4:8:16:32:64:128.
Therefore, 256 contrasts, each of which is different from 0 to 255, can be realized in one frame by properly selecting ON/OFF sub-fields. For Example, in the case of 1 contrast, only period of first sub-field, that is, period of SF 1 is used. And, in the case of 100 contrast, only periods of third, sixth, and seventh sub-fields SF 3 , SF 6 , SF 7 are used, and in the case of 256 contrast, periods of all sub-fields are used.
FIG. 4 is a diagram showing driving waveform of a conventional PDP in the case of using lamp waveform reset pulse in reset periods of all sub-fields in one frame.
As shown in FIG. 4 , a reset pulse RP is applied to a scanning electrode Y in a reset period RPD of all sub-fields SF 1 , . . . , SF 8 . The reset pulse RP has a lamp waveform where a voltage increases in Set-up and a voltage decreases in Set-down. Because of reset discharge caused in Set-up, wall electric charges are formed at the upper dielectric layer 14 . Then, decreasing voltage in Set-down erase unnecessary charge particles partially, so that wall electric charge decrease to the state for next address discharge without fault discharge.
To decrease the wall electric charge, a positive DC voltage Vs is applied to the sustain electrode Z in Set-down of the reset pulse RP. Because the reset pulse RP is applied in gradual decrease against this positive DC voltage Vs, the scanning electrode Y becomes relatively negative in comparison with the sustain electrode Z, that is, the polarity thereof reverses, thereby decreasing wall electric charges which are produced in Set-up.
In an address period APD, scan pulse SP is applied to the scanning electrode Y and data pulse CDP is applied to the address electrode X at the same time, thereby causing an address discharge. This address discharge produces a wall electric charge, and then the wall electric charge is sustained while the other discharge cells are addressed.
By applying triggering pulse TP to the scanning electrode Y in the initial point of sustain period SPD, sustain discharge is caused in discharge cells where wall electric charges are fully formed in the address period APD. Then, sustain pulses SUSPz and SUSPy are applied to the sustain electrode Z and the scanning electrode Y alternately, thereby sustaining the sustain discharge in sustain period SPD.
In an erasing period EPD following such sustain period SPD, by applying an erasing pulse to the sustain electrode Z, the sustained discharge is stopped. The erasing pulse EP is a lamp waveform having small size of luminescence, or has narrow pulse width such as about 1 us. As a result of short erase discharge due to such erase pulse EP, electric charges are erased, thereby stopping the discharge.
However, because the reset discharge caused in reset periods of all sub-fields in one frame has no connection with cell selection, there is a disadvantage of contrast reduction
To compensate such disadvantage resulting from the formation where all sub-fields include reset period, Japanese Laid-Open Patent Publication No. 2000-242224 discloses a technology that one field period has sub-fields SF 1 , . . . , SF 8 each of which has reset period, address period, and sustain period, and a part of reset operation in reset periods of SF 2 , . . . , SF 8 excluding SF 1 is simultaneously made with the sustain operation of sustain period of previous sub-field, thereby decreasing reset time and discharge.
But, because reset period is not completely erased in this related art, there is a disadvantage that contrast is not improved greatly.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to substantially obviate one or more of the problems caused by limitations and disadvantages of the related art.
It is another object of the present invention to provide method of driving PDP where quantity of luminescence non-luminescent period is minimized by applying a reset pulse to each cells in one frame, and in addition, ON/OFF states of cell are converted into each other by changing wall electric charge distribution in cell using discharge between a scanning electrode Y and an address electrode X or between a sustain electrode Z and the address electrode X in an address period.
In a method of driving PDP according to the present invention, the method of driving PDP comprising a plurality of discharge cells including a plurality of scanning electrodes, a plurality of sustain electrodes, and a plurality of address electrodes comprises a step of forming a frame having a plurality of sub-fields; a step of causing a reset discharge in only first sub-fields of respective the plurality of discharge cells; a step of deciding ON/OFF state of discharge cells in current sub-field in accordance with ON/OFF state of discharge cells in previous sub-field; and a step of converting the discharge cell into any one of ON/OFF wall electric charges in accordance with ON/OFF state of the decided discharge cell.
Further, in the frame including the plurality of sub-fields, the first sub-field is divided into a reset period, an address period, and a sustain period, the other sub-fields are respectively divided into address period and sustain period, and the step of converting the discharge cell into any one wall electric charge of ON/OFF is achieved by controlling voltage applied to the plurality of scanning electrodes, a plurality of sustain electrodes, and a plurality of address electrodes in accordance with ON/OFF state of a previous discharge cell in address period of a current sub-field.
In addition, the step of converting the ON state discharge cell in the previous sub-field into OFF state wall electric charge in address period of the current sub-field comprises a step of applying a scan pulse to the scanning electrode in the address period; a step of applying a sustain pulse having higher DC voltage than positive DC voltage applied in Set-down of a reset pulse to the sustain electrode, and a step of applying data pulse of negative polarity to the address electrode.
And, the step of sustaining the ON state discharge cell in the previous sub-field to ON state wall electric charge in address period of the current sub-field comprises a step of applying a scan pulse to the scanning electrode in the address period; a step of applying a sustain pulse having higher DC voltage than positive DC voltage applied in Set-down of a reset pulse to the sustain electrode, and a step of applying data pulse having 0 voltage to the address electrode.
Furthermore, the step of converting the OFF state discharge cell in the previous sub-field into ON state wall electric charge in address period of the current sub-field comprises a step of applying a scan pulse to the scanning electrode in the address period; a step of applying a sustain pulse having DC voltage equivalent to positive DC voltage applied in Set-down of a reset pulse to the sustain electrode, and a step of applying data pulse of positive polarity to the address electrode.
Also, the step of sustaining the OFF state discharge cell in the previous sub-field to OFF state wall electric charge in address period of the current sub-field comprises a step of applying a scan pulse to the scanning electrode in the address period; a step of applying a sustain pulse having DC voltage equivalent to positive DC voltage applied in Set-down of a reset pulse to the sustain electrode, and a step of applying data pulse having 0 voltage to the address electrode.
Further, in a method of driving PDP according to the present invention, the method of driving PDP where one frame screen is realized by making a selective combination X numbers of sub-fields SF 1 , SF 2 , SF 3 , . . . , SFX, sustain period of each of which is allowed at the rate of 2 0 :2 1 :2 2 2 3 : . . . :2 X-1 so as to display multi contrast image on PDP, in the unit of cell for a certain period, wherein only one reset discharge in only first sub-field SF 1 of respective the plurality of discharge cells is caused and the discharge cell in current sub-field is converted into any one wall electric charge of ON/OFF in accordance with ON/OFF state of the discharge cell in previous sub-field.
Additional advantage, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will he described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIG. 1 is a perspective view showing a conventional AC normal radiation PDP;
FIG. 2 is a diagram showing electrode arrangements of PDP shown in FIG. 1 ;
FIG. 3 is a diagram showing a frame formation according to conventional sub-field driving method.
FIG. 4 is a diagram showing a driving waveform for driving the PDP shown in FIG. 1 in a frame;
FIG. 5 is a diagram showing a driving waveform according to the method of driving PDP in accordance with the preferred embodiment of the present invention;
FIGS. 6 a and 6 b are diagrams showing wall electric charge distribution of OFF and ON states cells in all sub-fields in a frame;
FIGS. 7 a and 7 b are diagrams illustrating a conversion mechanism from ON state cell in sustain period of previous sub-field into OFF state cell in address period without reset period;
FIGS. 8 a and 8 b are diagrams illustrating a conversion mechanism from OFF state cell in sustain period of previous sub-field into ON state cell in address period without reset period; and
FIGS. 9 a and 9 b are diagram illustrating a method of sustaining distribution of wall electric charge produced in sustain period of previous sub-field without a change.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, the preferred embodiment of the present invention will be described in detail with reference to FIGS. 5 through 9 b.
FIG. 5 is a diagram showing a driving waveform according to the method of driving PDP in accordance with the preferred embodiment of the present invention.
As shown in FIG. 5 , a method of driving PDP in accordance with the present invention includes applying a reset pulse to only a first sub-field in a frame.
First, a reset pulse RP is applied to a scanning electrode Y in a reset period RPD of a first sub-field SF 1 . The reset pulse RP has a lamp waveform where voltage increase in Set-up and voltage decrease in Set-down. Because of reset discharge caused in Set-up, wall electric charges are formed at an upper dielectric layer 14 . Then, decreasing voltage in Set-down erase unnecessary charge particles partially, so that discharge without fault discharge. To decrease the wall electric charge, a positive DC voltage Vs is applied to the sustain electrode Z in Set-down of the reset pulse RP.
Because the reset pulse RP is applied in gradual decrease against this positive DC voltage Vs, the scanning electrode Y becomes relatively negative in comparison with the sustain electrode Z, that is, the polarity thereof reverses, thereby decreasing wall electric charges which are produced in Set-up.
Therefore, the reset discharge is caused for the whole reset period (Set-up & Set-down), the polarity reversion is caused in the reset period. And, negative wall electric charges are formed at the scanning electrode Y, positive wall electric charges are formed at the sustain electrode Z, and positive wall electric charges are formed at the address electrode X in the Set-up period where the voltage of the scanning electrode Y increases. And, a portion of negative wall electric charges formed on the scanning electrode Y are erased, positive wall electric charges formed on the sustain electrode Z are converted into negative wall electric charges, and a portion of positive wall electric charges formed on the address electrode X are erased in the Set-down period where the voltage of the scanning electrode Y decreases. Thus, after the reset period, positive wall electric charges are formed at the address electrode X, and negative wall electric charges are formed at the scanning electrode Y and the sustain electrode Z.
In an address period APD, scan pulse SP is applied to the scanning electrode Y and data pulse DP is applied to the address electrode X at the same time, thereby causing an address discharge. This address discharge produces a wall electric charge, and then the wall electric charge is sustained while the other discharge cells are addressed. At this time, data pulse DP applied to the address electrode X is characterized by selecting any one of positive and negative data pulses and applying it.
In this point, the data pulse DP selection is changed with response to the ON/OFF states of cell. Thus, when positive wall electric charges are formed at the address electrode X and negative wall electric charges are formed at the scanning electrode Y and the sustain electrode Z through the Set-down of reset period of the first sub-field, state of the cell becomes OFF state.
By applying triggering pulse TP to the scanning electrode Y in the initial point of sustain period SPD, sustain discharge is caused in discharge cells where wall electric charges are fully formed in the address period APD. Then, sustain pulses SUSPz and SUSPy are, applied to the sustain electrode Z and the scanning electrode Y alternately, thereby sustaining the sustain discharge in sustain period SPD.
In a second sub-field SF 2 , there is no reset period, and begin with address period APD. In the address period APD, scan pulse SP is applied to the scanning electrode Y and data pulse DP is applied to the address electrode X at the same time, thereby causing an address discharge. This address discharge produces a wall electric charge, and then the wall electric charge is sustained while the other discharge cells are addressed.
At this time, data pulse DP applied to the address electrode X is characterized by selecting any one of positive and negative data pulses and applying it, and the data pulse DP selection is changed with response to the ON/OFF states of cell.
Further, unnecessary charge particles are partially erased by decreasing voltage in Set-down of the first sub-field SF 1 . Thus, so as to decrease the wall electric charges to the state for next address discharge without fault discharge, a positive DC voltage Vs is applied to the sustain electrode Z in Set-down of the reset pulse RP but a positive DC voltage Vs is applied to the sustain electrode Z in the second sub-field SF 2 with the beginning of the address period APD.
In applying a scan pulse SP to the scanning electrode Y and applying data pulse DP to the address electrode X at the same time, an address discharge is caused by applying higher DC voltage Vsh more than positive DC voltage Vs to the sustain electrode.
That is, when higher DC voltage Vsh more that positive DC voltage Vs is applied to the sustain electrode, an address discharge is caused by applying negative data pulse DP to the address electrode X.
Thereby, ON state cell in sustain period of previous sub-field is changed into OFF state cell without reset period. And, this will now be described in detail with reference to FIGS. 7 a and 7 b.
By applying triggering pulse TP to the scanning electrode Y in the initial point of sustain period SPD, sustain discharge is caused in discharge cells where wall electric charges are fully formed in the address period APD. Then, sustain pulses SUSPz and SUSPy are applied to the sustain electrode Z and the scanning electrode Y alternately, thereby sustaining the sustain discharge in sustain period SPD.
In a third through an eight sub-fields SF 3 –SF 8 , discharge is caused in the same method of driving in the second sub-field.
FIGS. 6 a and 6 b are diagrams showing wall electric charge distribution of OFF and ON states cells in all sub-fields in a frame.
As shown in FIGS. 6 a and 6 b, FIG. 6 a is a diagram showing wall electric charge distribution of OFF state cell reset pulse. Namely, positive wall electric charges are formed at the address electrode X, and negative wall electric charges are formed at the upper dielectric layer over surfaces of the scanning electrode Y and the sustain electrode Z.
In this point, because negative wall electric charges are formed at the upper dielectric layer over surfaces of scanning electrode and sustain electrode, though a sustain voltage is applied, there is no sustain discharge.
Here, the sustain voltage is a voltage which is applied alternately to the scanning electrode Y and the sustain electrode Z in the sustain period.
FIG. 6 b is a diagram showing wall electric charge distribution of ON state cell where positive wall electric charges are formed at the address electrode X and the sustain electrode Z and negative wall electric charges are formed at the scanning electrode Y.
That is, in the ON state cell, the scanning electrode Y has an opposite polarity to the sustain electrode Z for the sustain period.
In wall electric charge distribution of ON state cell, because polarities of wall electric charges accumulated at the dielectric layer over surfaces of the scanning electrode Y and the sustain electrode Z are different from each other, sustain discharge continue to be caused due to the sustain voltage. During the sustain period SPD where sustain discharge continue to be caused, wall electric charge are accumulated alternately in the scanning electrode Y and the sustain electrode Z, if the last pulse of sustain pulse comes to the scanning electrode Y, there is wall electric charge distribution equivalent to the state in FIG. 6 b.
FIGS. 7 a through 9 b are diagrams showing wall electric charge distribution in ON/OFF state conversion of cell without reset period in address period by using wall electric charge distribution produced in sustain period of previous sub-field through driving waveforms shown in FIG. 5 .
FIGS. 7 a and 7 b are diagrams illustrating a conversion mechanism from ON state cell in sustain period of previous sub-field into OFF state cell in address period without reset period.
As shown in FIGS. 7 a and 7 b, FIG. 7 a is a diagram showing that negative scan pulse is applied to the scanning electrode Y and positive enhanced DC voltage Vsh is applied to the sustain electrode Z in ON state cell shown in FIG. 6 b.
At this time, negative data pulse DP is applied to the address electrode X to convert ON state cell into OFF state, thereby causing a discharge between the sustain electrode Z and the address electrode X.
In this case, voltage between the scanning electrode Y and the sustain electrode Z is not over the voltage for address electrode X and the sustain electrode Z exceeds the voltage for beginning to cause discharge so as to cause discharge between the address electrode X and the sustain electrode Z.
Due to such induced discharge, as shown in FIG. 7 b, wall electric charge distribution is equivalent to the state of cell which are sustained OFF state shown in FIG. 6 a. And then, there is no discharge in sustain period SPD.
FIGS. 8 a and 8 b are diagrams illustrating a conversion mechanism from OFF state cell in sustain period of previous sub-field into ON state cell in address period without reset period.
As shown in FIGS. 8 a and 8 b, FIG. 8 a is a diagram showing that negative scan pulse is applied to the scanning electrode Y and positive DC voltage Vs is applied to the sustain electrode Z in OFF state cell shown in FIG. 6 b. At this time, positive data pulse DP is applied to the address electrode X to convert OFF state cell into ON state.
Thereby, discharge is caused between the scanning electrode Y and the address electrode X, so that positive wall electric charge different from the polarity of the sustain electrode Z are accumulated in the address electrode X.
In this case, wall electric charges, polarities of which are different from each other, are formed at the upper dielectric layer over the scanning electrode Y and the sustain electrode Z, respectively, so that discharge is caused in sustain period. And then, cell comes to the state of FIG. 8 b.
FIGS. 9 a and 9 b are diagram illustrating a method of sustaining distribution of wall electric charge produced in sustain period of previous sub-field without a change.
As shown in FIG. 9 a, it is shown that wall electric charge state in the case that ON state cell formed in reset period of previous sub-field remains cell having ON state wall electric charge distribution without a change, and voltage applied to each electrodes.
Namely, it is shown that negative scan pulse is applied to the scanning electrode Y and positive enhanced DC voltage Vsh is applied to the sustain electrode Z. The moment cell is selected, as described above, if voltage is not applied to the address electrode X, discharge is not caused between the address electrode X and the sustain electrode Z, so that the state of wall electric charge is sustained. Thus, ON state cell in previous sub-field remains ON state wall electric charge just as it is.
However, voltages of the scanning electrode Y and the sustain electrode Z have to be controlled in order to prevent discharge in non-selected cell.
As shown in FIG. 9 b, it is shown that wall electric charge state in the case that OFF state cell formed in reset period of previous sub-field remains cell having OFF state voltage applied to each electrodes.
Namely, it is shown that negative scan pulse is applied to the scanning electrode Y and positive DC voltage Vs is applied to the sustain electrode Z. The moment cell is selected, as described above, if voltage is not applied to the address electrode X, discharge is not caused between the address electrode X and the scanning electrode Y.
But, it is condition of voltage level that voltage between the scanning electrode Y and the sustain electrode Z remains a level where no discharge is caused between the scanning electrode Y and the sustain electrode Z, and voltages of the scanning electrode Y and the sustain electrode Z remains a level where no discharge is caused in non-selected cell.
As described above, it is provided the method of driving PDP according to the present invention that wall electric charge distribution in cell is changed by causing a discharge with minimizing quantity of luminescence in non-luminescent display period by causing only one reset discharge in each cell in a frame and changing the polarity of data pulse applied in address period of sub-field with reference to the state of previous sub-field at the same time, thereby reset period after the second sub-field is unnecessary so that contrast ratio is improved.
The foregoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other methods of driving PDP. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. | A plasma display panel (PDP), and a method of driving plasma display panel, achieve improved contrast by minimizing quantity of luminescence in a non-luminescent display period, that is, a reset period. A method of driving a PDP having a plurality of discharge cells with a plurality of scanning electrodes, a plurality of sustain electrodes, and a plurality of address electrodes involves forming a frame having a plurality of sub-fields; causing a reset discharge in only first sub-fields of the respective plurality of discharge cells; deciding ON/OFF state of discharge cells in current sub-field in accordance with ON/OFF state of discharge cells in previous sub-field; and converting the discharge cell into any one of ON/OFF wall electric charges in accordance with the ON/OFF state of the decided discharge cell. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to compositions of a type used as floor sweeping compounds. Floor sweeping compounds are of course age-old. The idea is that use of the composition will aid in effectively sweeping and also cleaning the floor. Dust control is a common problem for floor sweeping. In the past, the most effective dust control agent has been oil. Hydrocarbon oil, in an appropriate percentage, is simply added to the carrier composition, thus enhancing the pick up of dust.
As it has developed in the art over the years, conventional sweeping compounds include a mixture of a carrier, is a hydrocarbon oil product, and perhaps, other cleaning and disinfecting aids. The oil is usually bottoms residue obtainable from refineries.
Carriers such as sawdust, rice hulls, oat hulls, corncobs and sand have been used for years as a medium to which the oil product adheres. The sand, when used, functions as both a carrier and abrading cleaner, and a weighting compound to assure that the sweeping composition will "hug" the floor. Variable proportions of sand are used, depending upon the age and the composition of the floor being cleaned. For example, with newly finished floors, sand in the composition is usually eliminated. However, as the floor gets older and abraded, sand is used to make sure that the composition effectively hugs the floor and causes slight abrasion to enhance cleaning.
In known sweeping compounds, the oil product fraction functions as a non evaporating moistening agent to control dust. Unfortunately oil in the sweeping compounds not only enhances dust removal, but also has the ability to damage certain flooring materials or at least the finish of some flooring materials. Further, oil is expensive. Oil also offers the additional disadvantage in that oil saturated sweeping compound becomes an environmental pollutant, disposal of which may often be difficult. As a result, there is a continuing need for development of effective sweeping compositions which avoid the inherent problems of an oil additive, or at least reduce the oil content, but at the same time, will still provide the effective dust control normally associated with oil use.
In the past, attempts to provide additives to floor sweeping compositions which will allow effective dust control and not tarnish, damage, or otherwise harm a natural floor surface have been explored. In this regard, many additives have been used from time to time in lieu of oil. Thus, deliquescence compounds have been added from time to time. Those include both organic compounds such as solid salts that are hygroscopics, such as calcium and magnesium chlorides, see for example Punch, U.S. Pat. No. 944,276; Singer, U.S. Pat. No. 827,887; and Burland, Great Britain Patent No. 17,246.
Each of these references describe carrier compositions that contain sawdust as the major carrier with the addition of hygroscopic materials. Singer describes the addition of dried, granulated, comminuted, or pulverized hygroscopic absorbent. Punch describes fine sawdust, water, calcium chloride, sodium chloride, or common salt, preferably pulverized rosin and an oily substance such as a paraffin oil. Burland describes sawdust mixed with either dry, granulated, or a saturated concentrated solution of hygroscopic salts, and in the case where it is a solution, using a sufficient quantity of the salt to make the mixture damp, but not wet.
In sum, hygroscopic salts have been used in the past, for the most part in dry, granulated form, and in some occasions, at a sufficient moisture level to make the mixture damp but not wet. Nevertheless, none of these prior compositions have been as effective as oil for a variety of reasons.
In the first instance, effective sweeping compositions which are to be sold commercially, must be packaged and capable of stability over a wide range of temperatures, ranging form well below zero up to as much as 100° F. Especially, being stable at low temperature is a problem. Put another way, the more water, the more likely the composition will freeze. The more concentrated the solution the greater the probability the solution will fall out at low temperatures. Freezing and thawing is, of course, unacceptable as it often causes some phase separation for the composition. The ideal composition is one which maintains a stable homogenous relationship under a wide range of conditions, and one which will effectively control dust, and also effectively enhance floor cleaning, all without harming the floor. Moreover, since the amount of sand in a composition will vary, as floor sweeping compositions are customized for either new or old floors, the customized for either new or old floors, the composition must be usable in the presence of a wide range of sand levels, depending upon whether there is no sand as for a new floor composition, or a high level of sand as for an old worn floor.
A primary object of the present invention is to provide an effective floor sweeping composition which does not use oil or incorporate oil at reduced levels as a dust control agent.
Another primary objective of the present invention is to provide a floor sweeping composition of enhanced sweeping capability and of highly effective dust control, which remains stable over a wide range of temperature conditions, from below freezing to as much as 100° F.
Another objective of the present invention is to provide a floor sweeping composition which can be conveniently packaged, shipped and stored, and which will remain stable during this entire time.
Another objective of the present invention is to provide a floor sweeping composition for effective dust control which provides maximum flexibility in that the dust control agent is effective where the floor composition ranges from no sand up to as much as 80% to 90% sand.
A yet further objective of the present invention is to provide a floor sweeping composition which has at least comparable dust control capability in comparison with oil, and which therefore, can be disposed of without environmental restrictions.
An even further objective of the present invention is to provide a floor sweeping composition can effectively control dust as well as oil does when it is used as a dust control agent.
Another objective of the present invention is to provide a floor sweeping composition that is less expensive to produce than those which use oil as a dust control agent.
A still further object of the present invention is to provide a floor sweeping composition that is safe to use with various flooring materials without damage to the floor or its finish.
Other objects, advantages and novel features of the present invention will become apparent from the following description of the invention.
SUMMARY OF THE INVENTION
A floor sweeping composition including a floor sweeping carrier and a liquid hygroscopic alkali or alkaline earth salt solution, preferably selected from the group of magnesium chloride and calcium chloride. The liquid enhances the effectiveness of the sweeping composition and its ability to collect and remove fine dust materials.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing comparison data for the samples of Example 1, samples 1 through 5.
FIG. 2 is a graph showing comparison data and percent reduction in dust for runs of Example 1 showing comparisons of samples 1, 4, 6 and 7.
DETAILED DESCRIPTION OF THE INVENTION
As earlier indicated, the floor sweeping composition of the present invention uses a conventional solid carrier. That carrier can be any of those known in the art and generally is sawdust, rice hulls, oat hulls, and variable levels of sand. Both the sawdust and the sand can be sifted initially to provide aggregate particle size control. Particle size would approximate the following U.S. standard screen sieve mesh:
______________________________________Sand Max % Sawdust Max %______________________________________Retained on #20 1% Retained on #8 1%sieve, weight sieve, weightbased on total based on totalsand content sawdust content Passing through #40 40% sieve, weight based on total sawdust content______________________________________
Sand level is variable. For new floors, usually no sand will be used, and for older floors, up to as much as 80% or 90% sand will be used.
It is to be emphasized that the hygroscopic alkali or alkaline earth salt used in this invention is a liquid hygroscopic salt solution. Simply adding of dry, pulverized hygroscopic salt such as magnesium chloride or calcium chloride will not work. This has been found to lack effectiveness for a variety of reasons. The most important of which is that dry granulated calcium chloride or magnesium chloride negatively impacts upon the floor sweeping effectiveness of the composition. Moreover, while it is true that the dry pulverized form is hygroscopic, it is not as effective as even plain water in dust collection when mixed with the solid carrier composition. In addition, the addition of a saturated concentrated solution of hygroscopic salts will not work. This has been found to lack effectiveness for storage and shipping. Saturated concentrated solutions of hygroscopic salts of calcium chloride and magnesium chloride have limited stability in various temperature ranges.
It has been discovered that for purposes of this invention, the most effective dust agent for the purpose of laying, collecting, or absorbing the dust and other like particles, is a liquid hygroscopic solution, an alkali or alkaline earth salt, preferably calcium chloride or magnesium chloride at a solution concentration ranging from about 10% by weight of the hygroscopic salt to about 35% by weight of the hygroscopic salt. The most preferred hygroscopic salt solution is a calcium chloride solution. The preferred solution concentration range is from 15% to about 35% solution of the hygroscopic salt and most preferably 29% with regard to the most preferred salt, that is calcium chloride solution. When a liquid hygroscopic solution of an alkaline earth salt, such as calcium chloride or magnesium chloride is used with a solution concentration within the range here expressed, the composition is stable over a wide range of temperatures varying from substantially below zero all the way up to 100° F. In particular, salt solution concentrations within those concentration ranges herein expressed, have salt freeze/thaw characteristics to provide stability from as low as - 53° F. up to 100° F. At the same time they have the correct concentration characteristics such that the solution is highly hygroscopic and also coacts with the solid carrier so that it is just as effective at dust collection as oil. In addition, because it is liquid, it actually enhances floor sweeping rather than sacrificing floor sweeping capability, as is the case with a dry pulverized salt.
In addition, hygroscopic liquid solutions of alkaline earth salts, such as magnesium chloride and calcium chloride, retain their effectiveness at dust collection in the presence of substantial amounts of sand. This is in contrast to oil which when mixed with high amounts of sand results in a substantial reduction in dust collecting ability, simply because much of the oil is used in its interaction with the sand. Put another way, the liquid solutions of alkaline earth salts do not interact with the sand as much as does the oil, instead leaving their hygroscopic characteristics for dust collection from the floor.
The weight ratio of the liquid hygroscopic alkali or alkaline earth salt to the floor sweeping composition will vary over a wide range depending upon the nature of the floor sweeping composition. Generally, the weight ratio of solid carrier composition to the liquid solution will be from about 1:.5 to about 4:1, most preferably from about 1:1 to 3:1 and best results are achieved with a weight ratio of 1:1.6, using a 29% calcium chloride solution.
The weight ratio of the liquid hygroscopic alkali or alkaline earth salt when incorporated with oil to be used in a floor sweeping composition will vary over a wide range depending upon the nature of the floor sweeping composition. Generally the weight ratio of the liquid hygroscopic solution to oil will be from 3:1 to 10:1, most preferably from about 2.5:1 to 8:1 and best results are achieved with a weight ratio 5.8:1, using a 29% calcium chloride solution. The mixing procedure would call for the addition of the calcium chloride solution to the carrier. After thorough mixing the oil is added to the mixture.
The following examples are illustrative of the practice of the present invention. They are intended to be illustrative and not limitations of the invention, since various embodiments can rarely be evolved or formulated and still provide the enhanced sweeping effectiveness.
Example 1
Seven samples of floor sweeping compositions were formulated using 29% calcium chloride solution, oil and sawdust. It is to be understood that other concentrations of calcium chloride liquid ranging from 10% to 35% could be readily substituted for the 29% liquor.
When mixing the samples containing both calcium chloride solution and oil, the calcium chloride solution is added first to the sawdust. The oil is added second. A salt water solution such as calcium chloride and oil will not mix. This action forces the oil to the outside of the solid carrier making the oil portion the first item to adsorb dust. When the oil portion is depleted in dust absorption the calcium chloride solution begins to absorb dust.
Sample #1 was mixed using 10 parts by weight of sawdust and 7.5 parts by weight of oil.
Sample #2 was mixed using 10 parts by weight of sawdust and 8.14 parts by weight of 29% calcium chloride liquor and 3.75 parts by weight of oil.
Sample #3 was mixed using 10 parts by weight of sawdust and 5/43 parts by weight of 29% calcium chloride liquor and 3.75 parts by weight of oil.
Sample #4 was mixed using 10 parts by weight of sawdust and 10.85 parts by weight of 29% calcium chloride liquor and 1.88 parts by weight of oil.
Sample #5 was mixed using 10 parts by weight of sawdust and 10.85 parts by weight of 29% calcium chloride liquor.
Sample #6 was mixed using 10 parts by weight of sawdust and 16.28 parts by weight of 29% calcium chloride liquor.
Sample #7 was mixed using 10 parts by weight of sawdust and 21.7 parts by weight of 29% calcium chloride liquor.
Example 2
The seven samples were tested for dust retention effectiveness by using powdered bentonite dust in air agitation in a closed vessel to maintain the dust in suspension. Sweeping compound was added to the bentonite dust mixture in the closed vessel until 100% of the dust was removed in a pre-weighed filter.
A measured amount of sweeping compound was added to the vessel and the dust and the sweeping compound was agitated with air. The dust was collected for ten seconds and the pre-weighed filter re-weighed. This testing process was carried out for seven different compounds at increments of 10 ml of sweeping compound from zero to 40 ml of addition. A blank sample with no sweeping compound was tested for each group of samples. Table I provides the data for each sample.
TABLE I______________________________________ Reduction in Dust______________________________________Sample #1Blank 0.004410 0.0015 65.91%20 0.0006 86.36%30 0.0 100.00%40 0.0 100.00%Sample #2Blank 0.002710 0.0026 29.73%20 0.0017 54.05%30 0.0003 91.89%40 0.0 100.00%Sample #3Blank 0.004210 0.0019 54.76%20 0.0010 76.19%30 0.0005 85.71%40 0.0 100.00%Sample #4Blank 0.005210 0.0018 65.38%20 0.0005 90.38%30 0.0001 98.08%40 0.0 100.00%Sample #5Blank 0.005310 0.0023 56.60%20 0.0011 79.24%30 0.0005 90.56%40 0.0 100.00%Sample #6Blank 0.004610 0.0020 56.52%20 0.0004 91.30%30 0.0001 97.83%40 0.0 100.00%Sample #7Blank 0.006510 0.0013 80.00%20 0.0011 83.08%30 0.0005 92.31%40 0.0 100.00%______________________________________
The collection time for the filter was measured as ten revolutions of the air circulating tube or ten seconds. The residue on the filter was weighed and the percent reduction of the dust was calculated. The dust collected as a blank is considered one hundred percent (100%) and the difference of the blank and the weighed filter is divided by the weight of the blank to determine the percent reduction. ##EQU1##
The results are shown graphically in FIG. 1 and FIG. 2.
All samples achieved 100% dust suppression at the 40 ml level. At the 30 ml level all samples performed satisfactorily with the highest sample at 100% dust suppression and the lowest sample at 85% dust suppression. At the 20 ml level sample #6 containing no oil and sample #4 containing reduced levels of oil in combination with a calcium chloride solution performed better than straight oil. At the 10 ml level all samples could be judged as inadequate with the exception of sample #7 which contained no oil.
The data clearly demonstrates that at various use levels, a sweeping compound made with a calcium chloride solution and a sweeping compound made with a calcium chloride solution and reduced quantity of oil will perform as well or better than oil base compounds alone.
In addition, the compositions are more effective than oil in the presence of substantial amounts of sand. Finally, it can be seen that the composition can be subjected to temperatures lower than zero and up to 100° and still retain its phase stability.
It can be seen that the compositions of the present invention are equal to and in some cases more effective than oil, can be disposed of without providing any risk of oil contamination, and can be used to fully replace oil or greatly reduce the oil content as a component of floor sweeping compositions, and yet function as effectively as oil for wetting or moistening agent used to control dust. | A floor sweeping composition including a floor sweeping solid carrier and a liquid hygroscopic alkali or alkaline earth salt solution, preferably selected from the group of magnesium chloride and calcium chloride. The liquid enhances the effectiveness of the sweeping composition and its ability to collect and remove fine dust materials. | 2 |
BACKGROUND OF THE INVENTION
A feature of the present invention is the provision of a loading device for a sewing machine.
During the processing of garments, such as sleeves, it is often desirable to sew the garments, such as hemming an edge of the sleeves by a suitable sewing machine. However, during processing of the sleeves for the sewing machine, it is normally desirable to align the sleeves during transport towards the sewing machine for sewing, and facilitate the loading of the sleeves for the alignment device and the sewing machine. Thus, if the operator places the sleeves too close together, they may obstruct each other during passage toward the sewing machine, and may be sewn together by the sewing machine which, of course, is undesirable. Also, the sleeves being too closely spaced could break parts of the sewing machine due to the double thickness, and cause downtime of the sewing machine until it is repaired. In addition, if the sleeves are too far apart during passage to the sewing machine, the sewing machine may sew a lengthy chain between the trailing and leading edges of the spaced garments which is undesirable.
SUMMARY OF THE INVENTION
A feature of the present invention is the provision of an improved device for loading a garment for a sewing machine.
The loading device of the present invention comprises, first means for moving the garments toward the sewing machine, second means downstream of the first moving means for moving the garments toward the sewing machine, means for changing the speed of the first and second moving means relative to each other to change the distance between adjacent moving garments.
A feature of the present invention is that the changing means changes the speed of the first moving means relative to the second moving means.
Another feature of the invention is that the changing means increases the speed of the first moving means relative to the second moving means in order to decrease the spacing between adjacent garments.
Yet another feature of the invention is that the changing means decreases the speed of the first moving means relative to the second moving means in order to increase the spacing between adjacent garments.
Thus, a feature of the present invention is that the loading device increases the spacing of adjacent garments to desired distances for passage to the sewing machine.
Still another feature of the invention is that the loading device decreases the distance between adjacent garments for passage to the sewing machine.
A feature of the present invention is that the device changes the distance between the garments in a simplified manner.
Still another feature of the invention is that the garments may be loaded on the loading device in a simplified manner.
Yet another feature of the invention is that the loading device is of simplified construction, and reduced cost.
A feature of the present invention is that the device has a loading station for the garments for placement on the first moving means.
Another feature of the invention is that the device has sensing means for sensing trailing and leading edges of the garments such that the changing means is responsive to the sensing means.
Still another feature of the invention is the sensing means is adjustable relative to the loading station.
A further feature of the invention is that the loading device is used in conjunction with an alignment device for the sewing machine.
Yet another feature of the invention is that in one embodiment the changing means may operate the moving means at a first fast speed and a second slow speed.
Another feature of the invention is that the changing means may operate the moving means at variable speeds.
A further feature of the invention is that the loading device may be controlled in a simplified manner.
Yet another feature of the invention is that the loading device improves the quality of the sewn garments by the sewing machine, and minimizes the possibility of damage to the sewing machine during use.
A feature of the present invention is that the distance between adjacent sleeves may be controlled according to programmed distance values.
Further features will become more fully apparent in the following description of the embodiments of this invention and from the appended claims.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a fragmentary plan view of a loading device of the present invention;
FIG. 2 is a fragmentary elevational view of the loading device of FIG. 1;
FIG. 3 is a schematic view of a control system for the device of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, there is shown a loading device generally designated 10 which is used in conjunction with an alignment device generally designated 12 and a sewing machine generally designated 14. The alignment device 12 may be of known construction, such as an alignment device disclosed in U.S. Ser. No. 405,704, filed Sep. 11, 1989, incorporated herein by reference, or U.S Ser. No. 07/514,827, filed Apr. 26, 1990, incorporated herein by reference. The alignment device 12 may have an endless conveyor belt 16 passing around a first rotatably mounted roller 18, a second rotatably mounted roller 20, and a third rotatably mounted roller 22. The alignment device 12 has a drive motor 24 which drives a pulley 26, with an endless belt 28 passing around the pulley 26 and the second roller 20 in order to drive the conveyor belt 16 about the rollers 18, 20, and 22. In a suitable form, the motor 24 may be an A. C. motor. The alignment device 12 may have a suitable alignment section 30, such as disclosed in said U.S. Ser. No. 07/514,827, located over the conveyor belt 16 in order to align the garments or workpieces, such as sleeves, for the sewing machine 14 during passage of the garments toward the sewing machine 14. Thus, the motor 24 drives the belt 16 in a direction for passage of the sleeves or garments through the alignment station 30 toward the sewing machine 14.
The loading device 10 has a plurality of laterally spaced endless belts 32 passing over a first rotatable roller 34, a second rotatable roller 36, and a third rotatable roller 38. As shown, the loading device 10 has a motor 40, such as a suitable D. C. drive motor, which drives a pulley 42. The loading device 10 has an endless belt 43 passing over the second roller 36 and the pulley 42 in order to drive the belts 32 in a direction moving the garments in a downstream direction toward the alignment device 12, with the belts 32 of the loading device 10 being driven faster than the belt 16 of the alignment device 12.
The loading device 10 has a longitudinally extending edge member 44 defining a longitudinally extending edge 46 adjacent one side of the belts 32. The loading device has a loading plate or station 48 located adjacent the other side of the belts 32 and defining a space, such as approximately 1 1/2", between the edge 46 and the loading plate or station 48. Thus, the sleeves may be stacked on the loading plate 48 preparatory to use by the operator.
As shown, the loading device 10 has an elongated rod 50 which is mounted between a pair of holding members 52a and 52b downstream of the loading plate 48. The loading device 10 has a sensor 54 secured to a flange 56 which is connected to a bushing 58 slidably mounted on the rod 50. The bushing 58 may be secured at a desired location on the rod 50 downstream from the loading plate 48 by a suitable bolt 60, passing through the bushing 58 and bearing against the rod 50, in order to adjust and releasably secure the bushing and sensor 54 at a desired location. With reference to FIG. 3, the sensor 54 is electrically connected to a central processing unit (C.P.U.), and the CPU is electrically connected to the motor 40 in order to control the motor 40. If desired, the CPU may also be electrically connected to the motor 24 of the alignment device 12, as will be further described below.
If desired, the loading device 10 may have a plate 62 extending laterally across the belts 32 and having a plurality of spaced fingers 64 located between a downstream part of the belts 32. The plate 62 permits passage of the sleeves from the belts 32 onto the conveyor belt 16 of the alignment device 12.
In use, the operator places the sleeves on the belts 32 of the loading device 10, with an edge or margin of the sleeves being located intermediate the edge 46 of the edge member 44 and the loading plate 48 on the belts 32, such that the sleeves pass in a downstream direction by the belts 32 beneath a sensor 54 and the sensor 54 detects the trailing and leading edges of the sleeves. Thus, the sensor 54 detects the trailing edge of a first sleeve, and a leading edge of a second sleeve, as adjacent sleeves pass sequentially beneath the sensor 54 and an electrical signal from the sensor 54 is received by the central processing unit CPU. In turn, the CPU determines the time or measures the time between the trailing and leading edges of the sleeves, and may readily determine the distance between adjacent sleeves due to the known speed of the belts 32. The CPU controls the motor 40 in order to slow down the belts 32, relative to the belt 16 in order to increase the spacing between adjacent sleeves a desired programmed distance by changing the speed of the motor 40 as the sleeves pass onto the conveyor belt 16 of the alignment device 12. In the event that the sleeves are placed on the loading device 10 at a greater distance than desired between adjacent sleeves, the signals as sensed by the sensor 54 between the trailing and leading edges of the adjacent sleeves is processed by the CPU, which speeds up the belts 32 relative to the belt 16 to decrease the spacing between adjacent sleeves as they pass onto the conveyor belt 16 of the alignment device 12. Thus, the operator may rapidly place the sleeves in a simplified manner on the loading device 10 upstream from the sensor 54 as the loading device automatically separates the sleeves in order to prevent them from bunching up as they pass to the sewing machine 14, which may otherwise cause sewing of the sleeves together and could break parts on the sewing machine due to the double thicknesses causing undesirable downtime and repair of the sewing machine 14. Also, in the event that the sleeves are too far apart, the loading device 14 automatically decreases the distance between the adjacent sleeves in order to minimize the thread chain sewn between adjacent sleeves with an undue length, which is undesired. The sleeves pass onto the alignment device from the loading device 10, and are aligned by the alignment station 30 for the location for passage to the sewing machine 14 and sewing as desired.
If desired, the central processing unit (CPU) of FIG. 3 may also control the motor 24 of the alignment device 12 in order to control the speed of the conveyor belt 16 relative to the belts 32 of the loading device 10. In this manner, both motors 24 and 40 may be controlled by the central processing unit in order to control the relative speed of the belts 32 and 16 to modify or change the distance between adjacent sleeves, either by increasing the distance between the sleeves or decreasing the distance, as previously described. In one form, the motor 40 may have a first fast speed and a second slow speed, as controlled by the CPU. However, if desired, the motor 40 may have a continuous range of change of speeds.
The foregoing detailed description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art. | A device for loading a garment for a sewing machine having a first device for moving the garment toward the sewing machine, a second device downstream of the first moving device for moving the garments towards the sewing machine, and a device for changing the speed of the first and second moving devices relative to each other to change the distance between adjacent moving garments according to programmed distance values. | 3 |
FIELD OF THE INVENTION
The present invention relates to a communication system for surveillance posts. More particularly, the present invention is related to a data transfer system that serves multiple surveillance posts each containing multiple surveillance devices and distributes the data among a plurality of network points.
BACKGROUND
Many surveillance stations employ multiple surveillance technologies. These technologies include passive and active detection systems, including acoustic, electric, image, image differential, seismic, thermal, to name a few. Many surveillance stations are built in places not readily accessible to human interference. For example, among borders containing relatively light population and desolate environmental conditions, electronic data gathering is crucial for continued surveillance activities.
In some situations, the data collection sensors are placed in a geographic area. These data collection sensors can feed information to a centralized transmission station, from which the data is relayed to an operations center. In the operations center, the data is observed and acted upon.
In many situations it is hard to reset alarm values for sensor readings, or communicate with the data gathering devices. Communication may be hard since many different sensors are involved, and the communication legs to the sensors may be haphazard, at best.
SUMMARY
Aspects of the invention are directed to a communication device for relaying data associated with a surveillance system. The communication device has a plurality of inputs that communicatively couple the communication device with a plurality of surveillance sensors. Each of the plurality of inputs is associated with one of a plurality of surveillance sensor data streams.
Also present is a wireless communication system. This inputs and outputs a data stream from or to the communication device, respectively. The data stream is directed to another remotely located wireless communication device. The data stream has the surveillance sensor data contained within it.
A communication junction is communicatively coupled to the wireless communication device and the plurality of inputs. This coalesces the data from the plurality of inputs into the data stream. The communication junction operates to retrieve the individual surveillance sensor data stream from the data stream, and directs the particular surveillance sensor data stream to the particular inputs.
In one aspect, the communication junction has a multiplexer. The multiplexer is communicatively coupled to the plurality of inputs, and multiplexes the plurality of surveillance sensor data streams into the data stream. The multiplexer can employ a time domain multiplexing algorithm.
The communication junction also has a demultiplexer. This demultiplexes the data stream into the plurality of surveillance sensor data streams.
In an exemplary aspect, the wireless communication system and the communication junction are coupled in a bi-directional manner. This can be accomplished through usage of dual cables. The communication device can deliver data between the communication junction and the wireless communication on a subcarrier frequency of a frequency associated with the output of the wireless communication device to the remote wireless communication device.
The received data stream can contain control messages for a particular surveillance sensor. In this manner, the sensor operation may be controlled from a remote source.
In one case, one of the inputs is associated with an acoustic message. Thus, radio communications can be delivered to the other remote surveillance units.
Aspects are also drawn to a device for monitoring incoming data associated with a plurality of remotely located sensors and outputting outgoing data associated with controlling the operation of the plurality of sensors associated with a surveillance post. This device has a wireless communication system for communicating the incoming and outgoing data. The device also has a communication junction that is communicatively coupled to the wireless communication device. This communication junction is operable to separate data associated with each of the sensors from the other sensors.
The monitoring device employs a user interface that is communicatively coupled to the wireless communication device. This monitoring device displays a representation of the incoming data associated with each of the sensors.
The monitoring device can employ a demultiplexer. This demultiplexes the incoming data into the plurality of surveillance sensor data streams.
An outgoing data stream can be made up of control messages. These control messages can be targeted for a particular surveillance sensor, a particular surveillance station, or a particular grouping of surveillance sensors by type.
The monitoring device can also have a user interface. The control messages can be generated through the interaction of an operator through the interface. The control messages can set operational aspects of the sensor or sensors, such as changing alarm levels, determining on/off cycles, or determining triggers based on data.
A surveillance system for detecting objects is also imagined. The surveillance system has a plurality of surveillance posts. Each of the surveillance posts has a plurality of sensors.
Each surveillance post also has a wireless communication system working in conjunction with a communication junction. This allows for inputting and outputting a data stream.
A surveillance system working in conjunction with the monitoring aspects is contemplated. The surveillance system is augmented with the addition of at least one monitoring unit. The monitoring unit has a wireless communication system for communicating the incoming and outgoing data with the surveillance posts. A communication junction, communicatively coupled to the wireless communication device at the monitoring unit, separates the data associated with each of the plurality of sensors from the others. The monitoring system also employs a user interface that is communicatively coupled to the wireless communication device. The user interface displays a representation of the incoming data associated with each of the plurality of sensors at each of the plurality of surveillance posts.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the detailed description, serve to explain the principles and implementations of the invention.
In the drawings:
FIG. 1 is a network diagram of an implementation of a communication scheme among remotely located surveillance posts.
FIG. 2 is an operational schematic view showing the coupling of an exemplary transceiver/wayside unit pair of FIG. 1 .
FIG. 3 is schematic representation of allowing combinations of analog communications associated with the wayside unit/transceiver pairs.
FIG. 4 is a schematic operational diagram of an exemplary monitoring device, as shown in FIG. 1 .
DETAILED DESCRIPTION
Embodiments of the present invention are described herein in the context of a System And Method for Monitoring Surveillance Signals from Multiple Units to A Number of Points. Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and is not intended to be in any way limiting. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts.
In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
In accordance with the present invention, the components, process steps, and/or data structures may be implemented using various types of digital systems, including hardware, software, or any combination thereof. In addition, those of ordinary skill in the art will recognize that devices of a less general-purpose nature may also be used without departing from the scope and spirit of the inventive concepts disclosed herein.
FIG. 1 is a network diagram of an implementation of a communication scheme among remotely located surveillance posts, according to the invention. A surveillance network 10 contains a plurality of wayside units, denoted by the units 16 a through 16 c . Each wayside unit 16 is communicatively coupled to a plurality of surveillance posts, denoted as 12 in FIG. 1 . Thus, in the case of the wayside unit 16 a , the surveillance post 12 a is communicatively coupled to it. Likewise, another surveillance net is depicted, one having the wayside unit 16 b coupled to the surveillance posts including the surveillance post 12 b.
Of course, the surveillance posts may be further delineated as having one or more surveillance sensors. Thus, the surveillance post 12 a contains the surveillance sensors 14 a , 18 a , and 22 a , and the surveillance post 12 b contains the surveillance sensors 14 b , 18 b , and 22 b . As noted before, these surveillance sensors may take many forms, such as acoustic, electric, image, image differential, seismic, thermal, or motion sensing apparatuses, to name a few. Of course, any type of sensor may be implemented.
The surveillance posts 12 are communicatively coupled to the associated wayside unit 16 . This coupling may take the form of a hard-wired coupling, or through the use of wireless technology. The data or other communications generated by the various sensors are relayed to the wayside unit 16 from each of the surveillance posts 12 associated with the particular wayside unit 16 . As such, the data generated, routine reports, diagnostics, or control communications are relayed between the associated wayside unit 16 and the particular surveillance post 12 . Further, particular messaging may be implemented on a sensor based communication schedule as well.
A wayside unit 16 c is also depicted. This wayside unit 16 c is coupled to a digital control unit 24 . The digital control unit 24 is operable to monitor the various surveillance posts and/or surveillance sensors associated with any of the other wayside units. The wayside unit 16 c may also have one or more surveillance posts communicatively coupled to it, as well as the digital control unit.
The wayside unit 16 is coupled to a radio transceiver 20 . This radio transceiver 20 allows communication by and between the various wayside units. Thus, communication links may be maintained between the wayside unit 16 a and the wayside unit 16 b , and the wayside unit 16 b and the wayside unit 16 c . These communications may be linked in a serial basis, such as having one wayside unit speak to two other wayside units, in a hub and spoke fashion, or in a broadcast fashion. Of course, the network topology may require various combinations, and this specification should be read to contemplate each of the aforementioned methods, as well as any combination thereof.
Thus, a communication web may be created between the various wayside units in a surveillance network. Further, communications at the wayside unit level may be directed to specific surveillance posts, or specific sensors. Further, communication may be directed on a class basis, such as talking to all the sensors having certain properties in a particular geographic area.
In an example, a centralized control may determine that thermal sensoring information is best collected at night, when the ambient temperature is below a certain point, or when the weather is one of rain. Thus, a command may be broadcast to the various wayside units through the associated radio transceivers to implement this. Additionally, assume that at some control station, a signal is sent at dusk and broadcast to the entire surveillance net. In this manner, the particular surveillance equipment may be toggled on an appropriate basis throughout the surveillance net 10 .
Also, various alarm levels may be set in a similar manner. Assume that the surveillance sensor 14 a originally is set to signal an alarm at a first threshold. The communication between the units allows the parameter to be set to any other threshold. Further, the threshold may be set on an individual, group, classification, or global scale.
Each of the surveillance posts 12 may operate under certain parameters. Assume that the surveillance post 12 a contains only a thermal imager, and as such, operates optimally at night. In this case, the post may be directed to an active state based upon environmental conditions. Or, each internal sensing device may operate under the same or related parameters. Or, a trigger may be defined where the alarm in one sensor triggers an operation in another.
In one implementation, a radio transceiver 20 c is communicatively coupled to a wayside unit 16 c . A digital control unit 24 is communicatively coupled to the wayside unit 16 d . In this manner, the state of any wayside unit, surveillance post, or surveillance sensor may be monitored and controlled. Also, the computing device may be operable to communicatively couple at any of the other wayside units, thus providing the ability to monitor and/or control the surveillance network 10 from any node on the surveillance network.
FIG. 2 is a detailed schematic view showing the coupling of an exemplary transceiver/wayside unit pair of FIG. 1 . The diagram also shows the coupling of the transceiver/wayside pairs with one another and with another transceiver/wayside unit pair in the surveillance net. First, a wayside unit 26 is directly coupled to an analog radio 28 . Correspondingly, a wayside unit 32 is directly coupled to an analog radio 30 , and the radios 28 and 30 are in communication with one another.
In one embodiment, the wayside unit 26 is coupled to the transceiver 28 through two coaxial cables. The wayside unit 26 is coupled to maintain multiple separate signals, transmitted and received, over the two coaxial cables. In this manner, the signals generated by the attached multiple surveillance posts are multiplexed for analog transmission over the transceiver 28 . In this manner, the data associated with the attached sensors may be broadcast from the analog radio 28 to other analog radios, such as the radio 30 . The wayside unit 26 output can be a subcarrier, and as such the signal can be used directly the radio 30 .
Conversely, incoming messages are received by the radio 28 and routed to the wayside unit 26 . The signals are demultiplexed and routed to the appropriate coupled surveillance post or surveillance sensor, as necessary. In the case where the wayside unit outputs a subcarrier to the radio, the subcarrier frequency is high enough to not interfere with the main radio inputs and/or outputs.
In one embodiment, all the inputs are digitized and combined into one output signal. Of course, many different methods may be used to send such signals, and should be contemplated by this disclosure.
In this manner, the wayside units operate in a bi-directional (full duplex) manner. Of course, other duplex modes may be utilized and should be construed to be included in this description.
Data can be transmitted between the various surveillance posts. This may be a preset timetable, on an as-needed basis, or on a dynamically variable timetable. Or, various combinations may be used with the surveillance posts, the surveillance sensors.
The wayside unit operates as a junction between the wireless communication between the radio transceivers and the sensor connections. Data flowing from the transceiver to the sensors is directed to the proper sensor by the wayside unit. The wayside unit also coalesces the data from the sensors to be broadcast by the radio transceiver.
In one exemplary embodiment, the wayside unit uses time division multiplexing (TDM) to combine the multiple inputs into a single subcarrier output. The multiple inputs are digitized before being multiplexed. In an exemplary embodiment, the subcarrier frequency operates at a frequency of 6.5 MHz. Of course, numerous other frequencies are envisioned. In conjunction with the TDM, a frame is generated for transmission. In one embodiment, framing bits are combined with the samples of the individual channels. The far-end wayside unit searches and finds the framing bits upon reception. These framing bits are used as markers to determine how to deconstruct the signal back into the individual channels.
In one exemplary embodiment, the wayside unit allows each input to be user configurable. The lines may be used for various sensors.
Additionally, an input line may be reserved to command functions and management purposes. Another line may be used to allow for the attachment of a headset, thus allowing operators at various nodes to remain in communication with one another.
FIG. 3 is schematic representation of allowing combinations of analog communications associated with the wayside unit/transceiver pairs. A first user is associated with a wayside unit/radio pair 36 . A second user is associated with a wayside unit/radio pair 38 . The wayside unit/radio pair 36 communicates to a wayside unit/radio pair 40 , and the wayside unit/radio pair 38 communicates to a wayside unit/radio pair 42 . A third user is associated with the wayside unit/radio pair 42 and the wayside unit/radio pair 40 .
The wayside unit/radio pair 42 and the wayside unit/radio pair 40 are communicatively coupled. This may be accomplished by such means as a bridging cable. In this manner, each of the three users may communicate amongst themselves.
FIG. 4 is a schematic operational diagram of an exemplary computing device, as shown in FIG. 1 . The computing device 48 contains a user interface 50 , a parameter monitor 52 , and a network monitor 54 . The computing device may be any standard computer, and may be implemented on such devices as mobile handheld computing units or the like.
In the user interface 50 , the various surveillance posts and surveillance sensors may be selected and displayed by an operator. The individual parameters, combinatorial triggers, or threshold alarms may be accessible and/or altered from the user interface 50 of the computing device 48 .
In one embodiment, clicking upon a specific sensor of a specific surveillance post brings a table of information to the user interface 50 . Such information may contain environmental data at the site, environmental data of the surveillance sensor or the surveillance post, threshold levels for alarms, trigger settings, and dynamic allocation of multiple or single alarm levels. In this manner, an alarm may be classified and prioritized according to various levels, various combinations of levels, or various combinations of individual sensor readings coupled with the sensor readings from other surveillance sensor. The alarm states can be user definable.
The user interface 50 may represent the units according to status. In one embodiment, the units are color coded. In this embodiment, green equates to normal operation, yellow to one or more alarms, and red to the absence of signal from the particular sensor or spot. Of course, other schemes may be envisioned wherein the color scheme depicts the various levels of alarm. The interface may also employ blinking outputs to alert operators.
Implemented in conjunction with the user interface 50 , a unit editor may be present. This allows the operator to remotely monitor and change the various settings associated with the surveillance post, the surveillance sensor, or any combination.
In a detail view, which can be obtained when clicking on the particular sensor, the various control and/or alarm signals can be displayed in a tabular format. The particular entries creating the alarm can be highlighted.
Further, in addition to sensor signals, the apparatus can track and diagnose internal problems. For example, the diagnostics of particular sensors may be displayed, and if the environmental conditions exceed a particular threshold, this may also cause an alarm to be displayed. As such, the various surveillance signals and/or operational signals may be monitored closely, and at any point in the system.
Additionally, the system may also store a history. In this manner, the events in the particular system and/or sensor may be preserved on an ongoing basis.
Thus, a system and method for transmitting and monitoring surveillance signals from multiple units to a number of points is described and illustrated. Those skilled in the art will recognize that many modifications and variations of the present invention are possible without departing from the invention. Of course, the various features depicted in each of the Figures and the accompanying text may be combined together. Accordingly, it should be clearly understood that the present invention is not intended to be limited by the particular features specifically described and illustrated in the drawings, but the concept of the present invention is to be measured by the scope of the appended claims. It should be understood that various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention as described by the appended claims that follow.
While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims. | A communication device for relaying data associated with a surveillance system is envisioned. The communication device has a plurality of inputs for communicatively coupling the communication device with a plurality of surveillance sensors, each of the plurality of inputs associated with one of a plurality of surveillance sensor data streams. Also present is a wireless communication system for inputting and outputting a data stream, the data stream being directed to another remote wireless communication device. This data stream contains the surveillance sensor data. The communication device also has a communication junction communicatively coupled to the wireless communication device and the plurality of inputs. The communication junction coalesces the data from the plurality of inputs into the data stream. The communication junction also retrieves individual surveillance sensor data from the data stream, and directs the particular surveillance sensor data stream to a particular one of the plurality of inputs. | 6 |
This is a continuation of U.S. patent application Ser. No. 714,233, filed Jun. 12, 1991, now abandoned.
DESCRIPTION
The invention relates to a driveshaft for use as a propeller shaft in the driveline of a motor vehicle, especially made of a fibre composite material in the form of a tubular shaft whose ends are provided with attaching regions containing coaxially arranged attaching elements which, at least in the circumferential direction, are form-fittingly connected to the tubular shaft, with at least one of the attaching elements being slidable into the tubular shaft from a predetermined axial force onwards.
DE-PS 30 07 896 proposes a driveshaft of the said type in the case of which the tube end is slid on to a sleeve provided with external teeth which cut into the tube surface. Externally, the connection is secured by an annular member securing the assembly.
DE 38 28 018 proposes a driveshaft in the case of which, again, a metallic attaching element with external teeth is pressed into the end of a fibre composite tube, with the teeth cutting into the composite material and with the tube end being radially expanded. In the region following the pressed-in sleeve which at the same time serves as a joint part the cross-section of the fibre composite tube is reduced.
Finally, U.S. Pat. No. 4,722,717 proposes a driveshaft where, between the open end of a fibre composite shaft and an attaching sleeve, there are provided complementary longitudinal and circumferential grooves on the inner face of the tube end and on the outer face of the sleeve inserted therein, which grooves are filled with a hardenable resin which may comprise short fibre particles. When the resin has set, there is obtained a connecting element achieving a form-fitting connection in the circumferential and axial direction.
The purpose in the latter case is to produce a connection between the tube end and the attaching element which cannot only be subjected to torque, but which is also axially fixed. Because of their individual design features, the two former connections may also be subjected to high circumferential and axial loads, at least as far as pressure forces are concerned.
Furthermore, it is known to destroy the driveshaft by tearing it with suitable means, i.e. a tearing wedge, if the permissible pressure forces are exceeded. In such a case, a high amount of energy is absorbed because the fibre composite material may be provided with an increased number of radial windings to be able to withstand circumferential tensile forces.
With modern motor vehicles, the deformation behaviour in the case of a frontal collision is predetermined by design measures in such a way that certain progressive characteristic deformation curves (deformation force as a function of the deformation travel) have to be achieved. ("On achieving different characteristic deformation curves", R. Hoefs, inter alia BMFT Project TV 80 35). If the above-mentioned driveshaft is used as a propeller shaft (cardan shafts) in motor vehicles with rear wheel or four wheel drive and if a frontal collision occurs, part of the energy to be absorbed is transferred to the rear of the vehicle. In such cases, fibre composite shafts or other lightweight shafts which as a rule, because of their low weight, do not require an intermediate joint, demonstrate a very high degree of stiffness. Under the influence of vehicle deformation, the. driveshaft is usually destroyed very quickly and prevents the kinetic energy from being introduced into rear of the vehicle as well as a specific energy absorption on the part of the driveshaft itself.
It is the object of the present invention to design a driveshaft of the said type for use in the longitudinal drive of a motor vehicle in such. a way that in the case of a collision improved absorption of the impact energy is ensured.
In accordance with the invention it is proposed that the tubular shaft should be adapted to the crash characteristics of the vehicle concerned in respect of energy absorption in the case of a collision, with energy absorption by the tubular shaft substantially being provided in those cases where the energy absorption by the vehicle has reached a minimum value, and that after a predetermined vehicle deformation travel, the level of energy absorption by the tubular shaft should be subjected to change.
Through knowing the deformation curve of a certain vehicle type it is possible to design the driveshaft and especially the propeller shaft in such a way that energy absorption by the propeller shaft itself substantially only takes place at that point in time when the energy absorption by the vehicle has reached a minimum value. In this way it is possible to achieve a more uniform energy absorption by the entire vehicle as a result of which passenger protection with reference to the occurring delaying forces is improved. After a predetermined deformation travel determined by the. energy absorption curve of the vehicle, the energy absorption of the tubular shaft itself assumes an extreme value.
In one embodiment of the invention, the tubular shaft comprises an attaching region which is connected to the inserted part of the attaching element, with the axial length of the attaching region being greater than the coaxially inserted part of the attaching element with the greatest internal diameter, and the axial pressure forces receivable by the tubular shaft in a non-destructive way are greater than the longitudinally acting adhesion and friction forces between the attaching element and the attaching region.
In order to prevent any changes in the propeller shaft connections at low impact speeds up to 5 km/h for example, the adhesion forces effective in the longitudinal direction between the tube end and the attaching sleeve my be calculated to be greater than the axial delaying forces occurring at the tubular shaft in the case of a non-destructive frontal collision of the vehicle in the area of "passenger protection" or "protection at low speeds".
By designing the driveshaft in the form of a releasable connection, produced by adhesion forces or possibly with a press-fit, between the attaching region and the attaching. element, higher axial forces cause the two driveshaft parts to be separated when the adhesion forces are exceeded, with any longitudinal forces occurring under normal operating conditions being accommodated to a limited extent in order to ensure the effect of conventional plunging joints adjoining the shaft, for example.
In order to achieve non-destructive insertion of the attaching element in a further embodiment of the invention for example, the internal diameter of the central tube region is greater than the internal diameter of the attaching region.
Alternatively, it is possible for the central tube region of the tubular shaft to have a smaller internal diameter as compared to the attaching region which is provided for bending or buckling the tubular shaft.
To prevent the shaft stiffness from exerting any adverse effects at a later stage of progressive vehicle deformation, shaft bending or buckling, for example, is introduced in the region with the smaller internal diameter.
According to an embodiment of the invention, the central tube region of the tubular shaft has a smaller internal diameter as compared to the attaching region, with energy absorption being higher in the region with the smaller internal diameter.
In order to prevent radial expansion of the driveshaft in the transition region between the two different external diameters of the central tube region and the attaching region, the transition region between the two different internal diameters of the tubular shaft is designed so as to be conical.
Because the attaching region of the tubular shaft is designed with a longer axial length than the coaxially inserted part of the attaching element it is possible to slide the attaching element into The tubular shaft, so that when the adhesion forces have been overcome, the resulting friction forces become effective, as a result of which a constant energy absorption by the end region of the tubular shaft is achieved.
To prevent the attaching element and supporting ring from being slid into the central region, the internal diameter of the central tube region is smaller than the internal diameter of the attaching region so that when the attaching element rests against the stop of the supporting ring, only the central region of the tubular shaft is subject to deformation.
Unfastening of the supporting ring is prevented in that the adhesion force between the supporting ring and the conical transition region of the tubular shaft is greater than the pressure forcing occurring in the longitudinal direction.
As a result of the friction forces occurring when inserting the attaching element into the attaching region of the tubular shaft, a preferably constant energy absorption curve is achieved. Inter alia, constant energy absorption is determined by the axial length of the attaching region. This provides a simple design solution permitting the transmission of the required amount of torque in a problem-free way.
According to the first design variant, energy absorption in the transition region decreases steadily down to zero when the attaching element is slid into and through the central region of the tubular shaft. In the case of the alternative solution, energy absorption intially increases further until it decreases to zero after the tubular shaft has been bent or buckled. In both cases, a non-rotating connection between the driveshaft and attaching element no longer exists. The friction forces occurring after separation of the connection between the attaching element and the attaching region determine a constant energy absorption.
To ensure transmission of high torques under normal vehicle operating conditions, the attaching element is provided with longitudinal teeth, with the tube end comprising a cylindrical counter face form-fittingly engaging the longitudinal teeth.
In a further embodiment of the invention, a connecting element is coaxially arranged between the attaching region and the connecting element.
The said connecting element may be provided in the form of a sleeve member which itself consists of a fibre composite material or suitable plastics or a resin material and which is glued into the tube end which, in turn, is slid on to the attaching element. For fixing the tube end and attaching element it may be advantageous for the connecting element to be provided with radial, preferably axially extending apertures which permit a limited, direct gluing contact between the tube and sleeve.
However, the connecting element may also be produced in situ if there are provided suitable collar regions at the attaching element and if the attaching element or tubular member is provided with supply and ventilation apertures for introducing a glue, especially a resin mixed with short fibres.
Embodiments of the present invention are illustrated in the drawings wherein
FIG. 1 is a section through a driveshaft having a first connection in accordance with the invention.
FIG. 2 is a section through a driveshaft having a further connection in accordance with the invention.
FIG. 3 shows a cross-section of a connection having an attaching element according to FIG. 1.
FIG. 3a is an enlarged detailed view of FIG 3.
FIG. 4 is a force/travel diagram showing the energy absorption curve extending through the tubular shaft according to FIG. 1.
FIG. 5 is a force/travel diagram showing the energy absorption curve extending through the tubular shaft according to FIG. 2 and
FIG. 6 shows a typical deformation curve of a vehicle involved in a collision.
FIG. 1 shows a tube end 2 of a tubular shaft 1 which may consists of a fibre composite material for example. The tubular shaft 1, with its attaching region 3, is slid on to an attaching element 4 and may be positioned on two collar regions 5, 6 for example or one centring element of the attaching element 4. Between the two collar regions 5, 6 the attaching element 4 is provided with outer teeth 7, with a connecting element 8 form-fittingly engaging the said teeth for example, and entering an adhesion-locking connection with the internally cylindrical surface of the tube end 2, as can be seen in FIG. 3. A characteristic feature of the tubular shaft 1 is the smaller internal diameter D e of the attaching region 3 as compared to the internal diameter D m of the central region 9 of the tubular shaft, with the transition region 10 having a conical shape.
The axial length of the tubular shaft end 2 with the smaller internal diameter D e may be freely selected and permits a constant energy absorption by the tubular shaft l as far as the transition region 10 during the insertion process.
After the separation of the glued connection between the connecting element 8 and the tube end 2, energy absorption is permitted as a result of the friction forces occurring between the tube end 2, the attaching element 4 and the connecting element 8, but under certain circumstances it is possible to do without the connecting element 8. FIG. 2 shows the tube end 2 of a further embodiment of the tubular shaft 1 which may also be made of a fibre composite material for example. A characteristic feature of the tubular shaft 1 according to FIG. 2 is the greater internal diameter D e of the attaching region 3 as compared to the internal diameter D m of the central region 9 of the tubular shaft, with the transition region 10 having a conical shape. Furthermore, an internally positioned supporting ring 13 having a stop 14 is glued into the transition region 10. The adhesion forces of the glued connection are greater than the axial forces required for bending or buckling in the case of a frontal collision in order to avoid a release or destruction of the tubular shaft 1 due to tearing in the transition region.
As in the previous embodiment, the axial length of the tubular shaft end 2 with the greater internal diameter D e may be freely selected and permits a constant energy absorption by the tubular shaft 1 until the attaching element 4 rests against the stop 14 of the supporting ring 13. After the attaching element 4 has contacted the stop 14, energy absorption first continues to increase until it drops to values close to zero after the tubular shaft 1 has been bent or buckled.
FIG. 3 shows the element end 12 having teeth 7, as well as the internally cylindrical tube end 2 between which two ends there is provided the hardened glue and the connecting element 8 which consists of fibre-reinforced resin, which is connected to the tube so as to form an adhesion-locking Connection and which is separated from the teeth 7 by a separating layer 11 in such a way that only a form-fitting connection occurs.
In FIG. 4, a force/travel diagram illustrates the energy absorption by the tubular shaft 1. Curve "A" refers to the tube end 2 to FIG. 1 in accordance with the invention and curve "B" to a tube end according to the state of the art, having two firmly clamped-in tube ends for example. In both cases, energy absorption starts with an approximately linear increase in axial force, and after the attaching element 4 has been torn off, a temporarily increased axial force according to curve "A" is accompanied by a constant energy absorption. The tubular shaft 1 in accordance with the invention is advantageous in that energy absorption by the tubular shaft 1 is constant as far as the transition region 10 and then decreases linearly in the transition region 10 until the rotatable connection between the tubular shaft 1 and the attaching element is separated as soon as the attaching element 4 is fully inserted into the central region 9 of the tubular shaft.
In FIG. 5, a force/travel diagram illustrates the energy absorption by the tubular shaft 1. Curve "A" refers to the tube end 2 to FIG. 1 in accordance with the invention and curve "B" to a tube end according to the state of the art, having two firmly clamped-in tube ends for example. In both cases, energy absorption starts with an approximately linear increase in axial force, and after the attaching element 4 has been torn off, a temporarily increased axial force according to curve "A" is accompanied by a constant energy absorption. The tubular shaft 1 in accordance with the invention is advantageous in that the destruction of the tubular shaft 1 is delayed in terms of time until the attaching element 4 rests against the stop 14 of the supporting ring 13, up to the point of final destruction of the tubular shaft 1 through subsequent bending or buckling of the central tube region 9.
FIG. 6 shows a typical deformation curve of a vehicle involved in a collision showing a negligible acceleration as a function of deformation travel. The embodiment of the tubular shaft 1 as proposed by the invention achieves an increase in energy absorption in the region of curve minima.
DRIVESHAFT
List of reference numbers
1 tubular shaft
2 tube end
3 attaching region
4 attaching element
5,6 collar region
7 Outer teeth of attaching element
8 connecting element
9 central region of tubular shaft
10 transition region
11 separating layer
12 element end
13 supporting ring
14 stop
D e internal diameter of tubular shaft end
D m internal diameter of central region of tubular shaft | A driveshaft using the longitudinal drive line of a motor vehicle has a tubular shaft with end portions and attachment elements which improve energy absorption in the event of a collision. The shaft is adapted to the crash characteristics of the vehicle in question with energy absorption by the shaft being provided in those cases where the energy absorption by the vehicle has reached a minimum value and after a predetermined vehicle deformation travel wherein the level of energy absorption by the tubular shaft is subject to change. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit and priority of provisional patent application No. 62/272,385 filed on Dec. 29, 2015, which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] (1) Field of the Invention
[0005] This inventive concept relates to the comfort and safety of toilet seats and particularly the comfort and safety of the means of attachment of the seat to a toilet bowl. Both commercial and residential toilet seats bear thousands of pounds of weight, cumulatively, on a daily basis. Whenever a person uses a toilet seat, the toilet seat imperceptibly shifts and slides relative to the toilet seat bowl. Conventional toilet seats, however, are not designed or equipped to handle the horizontal movement caused by such sliding and shifting. The horizontal movement causes the fasteners securing the toilet seat hinge to the toilet bowl to become loosened and/or damaged over time, thereby requiring replacement.
[0006] Eventually, the toilet seat can become completely detached and/or broken through excessive use. When a toilet seat is loose, it can slide completely off a toilet bowl, exposing an individual thereon to the unsanitary surface of a toilet bowl rim, and potential injury. Therefore, there is a need for a toilet seat stabilizing system which prevents the toilet seat from sliding horizontally relative to the toilet bowl, thereby creating a more secure commode seating seat and reducing the need to replace the seat except for wear and tear.
[0007] (2) Description of the Related Art, Including Information Disclosed Under 37 CFR 1.97 and 1.98.
[0008] US #2013/0019389 A1 (Jan. 24, 2013: A toilet seat securing device comprising: an elongated body, where the elongated body curves beneath a lateral portion of an underside of a toilet seat and where the elongated body is available as a pair, a single elongated body beneath each lateral portion of the toilet seat; a lip extending perpendicularly from a periphery of the elongated body, where the lip extends in an opposite direction from the toilet seat and where the lip is wider than the toilet seat to fit around an outer rim of a toilet bowl when the toilet seat is positioned atop the toilet bowl; and a plurality of fastening means attached to the elongated body, where the plurality of fastening means secure the toilet seat securing device to the underside of the toilet seat.
[0009] U.S. Pat. No. 8,316,472 BI (Nov. 27, 2012): A swiveling toilet seat device for attaching to a rim of a toilet bowl comprising a toilet seat-shaped first base pivotally attached to the back of the rim of the toilet bowl; a toilet seat-shaped second base disposed above the first base, wherein a plurality of wheels extend from the bottom surface of the second base and fit into a track disposed in the top surface of the first base; wherein the second base can rotate in a first direction and second direction atop the first base.
[0010] U.S. Pat. No. 6,052,838 (Apr. 25, 2000): A toilet seat aid consisting of a toilet seat aid body having a first sitting area and a second sitting area opposing each other. An operational opening is disposed substantially centrally within the seat body. The operational opening passes through the body, so as to interconnect the first and second sitting areas.
[0011] U.S. Pat. No. 5,212,840 (May 25, 1993): A device for stabilizing a toilet seat in its desired position atop a toilet bowl, comprising at least one restraint connectable to the bottom of the toilet seat for preventing lateral movement of the toilet seat relative to the toilet bowl, wherein the restraint extends downward into the toilet bowl so as to rest immediately adjacent to an upper inside rim of the toilet bowl when the toilet seat is in its lowered position. In a preferred embodiment the device includes a tapered configuration on the restraint to guide the toilet seat onto the toilet bowl, and an edge portion which is substantially parallel to the inside edge of the toilet bowl when the seat is in the lowered position, which serves to stabilize the toilet seat by preventing lateral movement.
[0012] U.S. Pat. No. 5,136,731 (Aug. 11, 1992) A toilet seat adaptor for the use of infants and children having two side panels in a U-shaped configuration joined together by a common hinge and separated from a toilet bowl upper rim surface by a plurality of U-shaped elevated contact members having disposable covers over outer portions of the contact members which contact the toilet bowl when the adaptor is positioned on the rim. The adaptor is foldable and minimizes surface contact thereby protecting the user from bacterial and/or viral infestation. Several embodiments of the contact members are disclosed.
[0013] U.S. Pat. No. 4,747,167 (May 31, 1988): Impact absorbing bumpers are contoured to be seated on the supporting surfaces of toilet bowl rims in cross-sectional alignment therewith at angularly spaced locations before attachment to the underside of a toilet seat. The toilet seat when hingedly mounted on the toilet bowl is displaced to its lowered position for attachment to the seated bumpers by adjustable attaching means.
BRIEF SUMMARY OF THE INVENTION
[0014] The inventive concept herein discloses a toilet seat stabilizing system and kit for eliminating or minimizing horizontal sliding or slippage of the toilet seat relative to the rim of the toilet bowl of a commode. The system includes at least two symmetrically-placed L-brackets, the longer length of each bracket of which is attached to the undersurface of the elongated sides of the toilet seat. The shorter length of each L-bracket is positioned so as to abuttingly engage the outer rim of the toilet bowl when the toilet seat is rotated downward into its position atop the toilet bowl.
[0015] The toilet seat stabilizing kit further includes at least one support spacer adapted to attach to the front undersurface of a toilet seat in order to better distribute the weight of a user. Additional support spacers may be used for attachment to the inner base of each L-bracket, thereby providing the toilet seat an evenly supported planar orientation atop the rim of the toilet bowl. The seat stabilizing kit further comprises one or more apertures in each L-bracket for receiving a threaded or other type of fastener to secure the L-brackets to the undersurface of the toilet seat.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
[0016] FIG. 1 shows a perspective view of the basic toilet seat stabilizing system 1 as attached to the undersurface of a toilet seat according to the basic embodiment of the present inventive concept.
[0017] FIG. 2 shows a perspective view of a toilet seat stabilizing system 1 in the process of being attached to the undersurface of a toilet seat having built-in spacers.
[0018] FIG. 3 depicts a view looking at a toilet seat from the right side upper surface, further showing the right L-bracket 25 .
[0019] FIG. 4 shows a close-up view of the right L-bracket 25 as attached to the toilet seat shown in FIG. 3 .
[0020] FIG. 5 presents a view of the left side of a toilet seat 3 having a left L-bracket 20 attached to the undersurface of the seat 3 .
[0021] FIG. 6 is a view of a left L-bracket 20 , and the aperture 31 to accommodate various types of fasteners.
[0022] FIG. 7 is a view of the typical locking screw 42 used to fasten the L-brackets to the undersurface of a toilet seat.
[0023] FIG. 8 depicts a commode, further having an air freshener 40 attached to the left L-bracket.
[0024] FIG. 9 shows a side spacer which may be fastened to the interior surface of an L-bracket, as necessary.
[0025] FIG. 10 shows a close-up view of the air freshener 40 shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] The objects, features, and advantages of the inventive concept presented in this application are more readily understood when referring to the accompanying drawings. The drawings, totaling ten figures, show the basic components and functions of embodiments and/or methods of use. In the several figures, like reference numbers are used in each figure to correspond to the same component as may be depicted in other figures.
[0027] The discussion of the present inventive concept will be initiated with FIG. 1 , which illustrates the basic embodiment of the toilet seat kit 2 . The view of FIG. 1 depicts the toilet seat kit 2 components as they are attached to the undersurface 4 of the toilet seat 3 . These components comprise a left L-bracket 20 , a right L-bracket 25 , and a front spacer 30 . The two L-brackets 20 , 25 may be attached by a variety of fasteners, including threaded screws, or by means of a long-lasting adhesive. Components of the toilet seat 3 shown include the left elongated side 8 , the right elongated side 9 , the seat front 4 , seat rear 11 , and the hinge attachments 12 .
[0028] The basic embodiment of the toilet seat stabilizing system 1 demonstrates that the two opposing L-brackets 20 , 25 are designed so as to attach to the opposing elongated sides 8 , 9 , of the undersurface 4 of the toilet seat 3 . From FIG. 1 , it can be appreciated that the present inventive concept provides a toilet seat stabilizing system 1 and kit 2 that are designed to ensure that the toilet seat 3 will not slide from side to side, relative to a toilet bowl 6 to which it is attached.
[0029] FIG. 2 depicts an embodiment of a toilet seat 3 having manufacturer's built-in seat support spacers 37 to provide an even distribution of the weight of a user upon the toilet seat 3 . The symmetrical spacing of the support spacers 37 also helps provide added weight support points between the left and right L-brackets 20 , 25 and the front 10 and rear 11 of the toilet seat 3 .
[0030] The L-brackets can be described in more detail by reference to FIG. 6 . By way of example, and for ease of explanation, a left L-bracket 20 will be the primary descriptive reference in this disclosure. The left L-bracket is also shown in the immediately preceding FIG. 5 . The left L-bracket 20 comprises a leg 21 , corresponding to the longer length of the left L-bracket 20 and a base 22 member which corresponds to the shorter length of the left L-bracket 20 . The leg 21 and base 22 are integrally joined in perpendicular orientation relative to each other.
[0031] The interior of the leg 21 is adapted to engage the outer rim 7 of a toilet bowl 6 , thereby securing the seat, horizontally, to the toilet bowl 6 , as is seen in FIG. 5 . The base 22 comprises an interior surface 23 and an exterior surface 24 (out of view in FIG. 6 ), wherein the exterior surface 24 is layered with an adhesive 32 . The adhesive 32 may be utilized to receive and adhere to the undersurface 4 of a toilet seat 3 , as necessary.
[0032] The interior surface 23 of each L-bracket is also adapted to receive a side support spacer 33 , if necessary to maintain the toilet seat 3 in a supported and level orientation from the rear 10 to the front 11 of the toilet seat 3 . The base 22 of the left L-bracket 20 further comprises at least one aperture 31 for receiving fasteners, such as screws, nails, or bolts, and provide more secure fastening of the left L-bracket 20 to the undersurface of a toilet seat 3 . The right L-bracket 25 (not shown in FIG. 5 ) is constructed in the same manner as the left L-bracket 20 and functions in an identical manner.
[0033] As stated above, the toilet seat stabilizing system 1 may further comprise a plurality of side support spacers 33 . FIG. 9 presents a view of a side support spacer 33 . The side support spacer 33 is constructed of width and length dimensions corresponding to the width and length of the interior surface 23 of the base 22 of the left L-bracket 20 . A side support spacer 33 may be attached to the interior surface 23 of the left L-bracket, and likewise to the right L-bracket 25 . This may be necessary to maintain the toilet seat 3 parallel to the plane of the toilet bowl rim 7 when the toilet seat 3 is placed down. The combination of the L-bracket 20 and the side support spacer 33 also serves to better distribute the weight bearing load of the toilet seat 3 .
[0034] FIG. 9 shows that the side support spacer 33 comprises parallel planar members defining a first side 34 and a second side 35 (not shown). The first side 34 may comprise a permanently-attached adhesive which will readily adhere to the interior surface 23 of the left L-bracket 20 of FIG. 6 . The side support spacer 33 also contains an aperture 31 in a location corresponding to the identical aperture 31 constructed in the interior surface of the L-bracket of FIG. 6 . The second side 35 of the side support spacer 33 is adapted to rest atop the rim 7 of a toilet bowl 6 when the toilet seat 3 is placed in the horizontal, down position.
[0035] FIG. 2 illustrates the manner and sequence of installation of the toilet seat stabilizing system 1 and seat kit 2 . Upon opening of a packet containing the seat kit 2 components, a user first attaches the exterior surfaces of the bases 22 , 27 of the opposing right and left L-brackets 25 , 20 to the undersurface 4 of the right and left elongated sides 9 , 8 of the toilet seat 3 . The two L-brackets should be symmetrically aligned, and then attached by means of inserting at least one fastener, such as a locking screw 42 , through the one or more apertures 31 in the bases of the legs 22 , 27 and into the undersurface 4 of the toilet seat 3 to secure the L-brackets 25 , 22 thereto. FIG. 7 is a view of a typical locking screw 42 which may be used to fasten the L-brackets 25 , 20 to the undersurface of a toilet seat 3 .
[0036] In a different embodiment, the L-brackets 25 , 22 may contain adhesive on the exterior of their bases 22 , 27 , the adhesive may serve to give additional fastening security of the L-brackets 25 , 22 to the undersurface 4 of the toilet seat 3 . As shown in FIG. 2 , the user then attaches one front spacer 30 to the undersurface 4 of the front 10 of the toilet seat 3 to assist in distributing the weight of a person sitting upon the toilet seat 3 . If necessary, the previously-disclosed side spacers 33 may be attached to the interior surfaces of the bases 22 , 27 of the L-brackets 25 , 20 .
[0037] FIG. 3 depicts a typical toilet seat 3 oriented as it would be if positioned atop a toilet bowl. The upper surface 5 of the toilet seat 3 is visible, along with the seat hinges 12 , the left elongated side 8 , right elongated side 9 , the front 10 of the toilet seat 3 , and the rear 11 of the toilet seat 3 . Also shown in FIG. 3 , in the isolated view A, is a right L-bracket 25 , one of the components of the toilet seat kit 2 . FIG. 4 presents a close-up view of the right L-bracket 25 as shown attached to the undersurface of the toilet seat 3 . Further shown is the leg 26 and part of the base 27 of the right L-bracket 25 .
[0038] With the seat kit 2 installed as shown, the leg 21 of the opposite left L-bracket 20 will be similarly oriented. This is illustrated in FIG. 5 , which depicts the left L-bracket 20 having been installed on the opposite side of the toilet seat 3 . Also shown in FIG. 5 is the base 22 of the left L-bracket 20 and the leg 21 , which is shown to engage the outer edge of the rim 7 of the toilet seat 6 . The lid 13 of the toilet seat 3 is shown in the up position.
[0039] As stated previously, the legs 21 , 26 of the opposing L-brackets 20 , 25 are in perpendicular orientation relative to the toilet seat 3 , such that they protrude downwardly from the toilet seat 3 . When the toilet seat 3 is closed and positioned atop the toilet bowl 6 , the legs 21 , 26 engage the outer rim 7 of toilet bowl 6 , as shown in FIG. 5 . The legs 21 , 26 effectively clamp the toilet bowl 6 , thereby securing the toilet seat 3 to the toilet bowl 6 and preventing the toilet seat 3 from moving side-to-side atop the toilet bowl 6 .
[0040] In referring to FIG. 8 , there is shown a perspective view of an air freshener 40 that is attached to the leg of the left L-bracket 20 in a different embodiment of the toilet seat kit 2 . In this version, the toilet seat kit 2 is modified to mount a detachable air freshener 40 device for deodorizing and creating a sanitary and comfortable bathroom environment. FIG. 10 shows that one surface of the air freshener 40 comprises an adhesive 43 that is protected by a peel-back sheet 44 and adapted to adhere to the exterior surface of the legs 21 , 26 of the L-brackets 20 , 25 . The air fresheners 40 are adapted to be replaced and replenished as desired by the user.
[0041] While preferred embodiments of the present inventive concept have been shown and disclosed herein, it will be obvious to those persons skilled in the art that such embodiments are presented by way of example only, and not as a limitation to the scope of the inventive concept. Numerous variations, changes, and substitutions may occur or be suggested to those skilled in the art without departing from the intent, scope, and totality of this inventive concept. Accordingly, it is intended that this inventive concept be inclusive of such variations, changes, and substitutions, and by no means limited by the scope of the claims presented herein. | Disclosed is a toilet seat stabilizing kit for preventing horizontal sliding or slippage of a toilet seat relative to the rim of the toilet bowl on which it rests. The kit includes at least two symmetrically-placed L-brackets. The longer length of each bracket is attached to the undersurface of the sides of the toilet seat, such that the inner surface of the shorter length of each L-bracket abuttingly engages the outer rim of the toilet bowl when the toilet seat is rotated into position atop the toilet bowl. The kit may further include a plurality of support spacers for attachment to the undersurface of the toilet seat in order to evenly distribute the weight of a user. The kit may comprise one or more apertures in each L-bracket for receiving a threaded or other type of fastener to secure the L-brackets to the undersurface of the toilet seat. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to vehicle speed controls and more particularly to such controls using electronic logic and fluid powered actuating means.
Vehicle speed controls have been known for some time and have been widely accepted. Because of their economics, reliability and accuracy, fluid actuated speed controls have become the dominant factor in this market. Such controls typically use vacuum from the vehicle engine manifold as the actuating force. The vacuum is applied to a bellows connected to the throttle linkage and thereby increases or decreases the throttle position to advance or retard the vehicle speed. The control for such a system compares actual vehicle speed with desired vehicle speed and adjusts the vacuum level in the bellows accordingly. Typically, the control is via a continuous modulated bleed of atmospheric air into the bellows. Such a bleed looks, to the engine, like a leak in the manifold gasketing and is somewhat detrimental to engine performance. This has not been a major problem in the past when typical vehicles having speed controls used large engines and were tuned in a range which allowed relatively wide latitude in fuel/air ratio.
Recently the average size of engines in vehicles equipped with speed controls has been decreasing. In addition engine tuning has been modified toward lean fuel/air ratios. Both of these factors have made it more critical to limit the amount of atmospheric bleed reaching the engine manifold. Because of their simplicity and wide acceptance, however, it remains desirable to use speed controls having operators utilizing engine vacuum for actuation.
Accordingly, it is an object of this invention to provide a vacuum actuated vehicle speed control which effects a minimum atmospheric bleed to the vehicle engine manifold.
It is a further object to provide such a speed control which is accurate to the high standards of previous units.
It is still a further object to provide such a speed control which includes a plurality of convenience and safety features for safe simple operation.
SUMMARY OF THE INVENTION
Broadly, the invention is an electronic control for the speed of a vehicle with an internal combustion engine or the like including a vacuum source, typically the engine intake manifold. In the conventional manner a vacuum actuation member such as a bellows is connected to the engine throttle linkage. The bellows is selectively in communication with either the vacuum source or atmosphere thereby increasing or decreasing, respectively, the throttle setting and vehicle speed. A dead-band is built into the control circuit to allow the actual vehicle speed to drift over a narrow range (e.g., + or - 1/2 M.P.H.) around the set point speed without any control action taking place. Such a system, compared with conventional proportional vacuum actuated systems allows much less atmospheric bleed into the vacuum source. This is especially important with small engines and/or in engines which are tuned to run "lean" as such engines are particularly sensitive to the effect of atmospheric bleed.
In a typical system, a pair of solenoid valves are provided. A charge valve allows selective communication between the bellows and the vacuum source and a dump valve allows selective communication between the bellows and atmosphere.
A speed signal generating means provides a signal, typically an analog voltage, indicative of actual vehicle speed. A speed set point signal generating means provides a signal, also an analog voltage in a typical circuit, indicative of the desired speed. The dead band is normally provided in association with either the vehicle speed signal generating means or, more commonly, with the speed set point generating means.
A comparator and control means compares the speed set point signal and the vehicle speed signal. If the actual speed exceeds the set speed the dump valve is energized. If the set speed exceeds the actual speed the charge valve is energized. As used herein, speed set point means, where appropriate, speed set point range; the latter term indicating a dead-band with an overspeed "set point" at one end thereof and an underspeed "set point" at the other end thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims which particularly point out and distinctly claim the subject matter forming the present invention, it is believed that the same will be better understood with the following description of the preferred embodiments taken in conjunction with the accompanying drawings in which:
FIG. 1 is a representation of the overall control system of the present invention installed in a motor vehicle;
FIG. 2, shown on the second sheet of the drawings, is a schematic control circuit of the present invention; and
FIG. 3, shown on the first sheet of the drawings, is a partial schematic representation of a variation of the circuit of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 of the drawings illustrates the overall speed control system of the present invention and generally indicates the physical location and association of parts.
A bellows is connected to the linkage joining the throttle pedal and carburetor and operates to increase the throttle position when in communication with vacuum source, typically the engine manifold. A charge valve provides selective communication between the manifold and the bellows and is opened by the control circuit when the actual vehicle speed is below the set speed. A dump valve provides selective communication between the bellows and atmosphere and is opened by the control circuit when the actual vehicle speed is above the set speed.
As will be described in more detail hereinafter, a dead-band is provided in the control circuit to provide a vehicle speed range of about + or - 1/2 M.P.H. over which no control action takes place. When the vehicle speed is in this dead band, both the charge and dump valves are closed. This system, it has been discovered, provides highly satisfactory vehicle speed control while greatly minimizing the amount of atmospheric air entering the engine manifold. For the sake of convenience herein the term set point speed is used. It should be understood, however, that a set point speed range is usually meant; i.e., the set point speed typically comprises a high and low limit to the dead-band. Alternatively, the dead band can be associated with the actual vehicle speed in which case this term is understood to mean the dead-band range within which this variable may vary without initiating control action.
There are five basic inputs to the control circuit of the present invention. A power supply is preferably taken from the load side of the brake light fuse. A brake signal, typically from the load side of the brake light switch, is used to disable the control system upon actuation of the brakes. A vehicle speed signal is provided, preferably in the form of a switch contact which has a closure frequency proportional to actual vehicle speed. In a preferred embodiment, the switch is a reed relay and a magnet rotating with the speedometer cable provides the closure thereof.
The control circuit is actuated by a command from the vehicle operator. For use with the preferred control circuit, an on-off switch is provided together with a momentary contact engage switch which can be integral with the on-off switch. The operator also selects the speed at which the vehicle is to travel. Any of the means known in the art can be used but the preferred means is via a rheostat which can, for instance, be mounted on the end of the vehicle turn signal operator lever along with and preferably integral with the aforementioned momentary contact switch. When a rheostat is used, it preferably does not include graduations correlating its position to vehicle set speed. As is known in the art, it is difficult to calibrate a vehicle speed control system to the varying conditions of the range of vehicles to which it will be applied and the use of a "blind" set point eliminates the need to attempt such calibration, yet provides fully acceptable control.
Preferably, the operator is provided with an "on" reminder light indicating that the circuit is in a condition allowing actuation and a "set" light indicating that the control is operative.
Turning now to FIG. 2, the preferred control system of the present invention is shown. Broadly, the control consists of six sub-circuits indicated by the dashed-line boxes. The basic sub-circuits are a master control means to turn the system on and off, a set point signal generating means, a speed signal generating means and a means comparing the set and speed signals and controlling the dump and charge valves. A dead-band is provided with appropriate circuitry within the set point, speed signal or comparator means to provide a narrow range of vehicle speed over which no control action takes place.
Preferably a throttle position feedback means is provided to anticipate the effect of changes in throttle position and thereby limit control overshoot. The feedback signal is algebraically added to the vehicle speed signal to provide the desired overshoot control.
To provide smooth operation and additional safety an underspeed lockout means is additionally provided. This prevents actuation of the control if the actual vehicle speed is substantially (about 10 MPH) below the set speed. In addition, the lockout provides a redundant back-up to the action of the brake switch to de-energize the control. Thus, if the brake switch were broken, preventing normal de-activation of the control, braking of the vehicle by about 10 M.P.H. would also de-activate the control.
Each of the sub-circuits will now be discussed in detail.
CONTROL POINT GENERATING CIRCUIT
The speed set point is established by varying the resistance of potentiometer R1. The associated control point generating circuit operates as follows. A voltage divider comprising resistors R2 and R3 and diode D1 is connected between the 8V supply and ground and provides the base voltage for transistor T1. That base voltage biases transistor T1 on and establishes a constant collector current I 1 therefrom. The diode D1 is chosen to have a threshold voltage and temperature characteristic comparable to the base to emitter junction of T1, thereby providing a temperature compensated circuit. I 1 , of course, will be a function of R2, R3, the emitter resistor R4 and to a small degree the gain of T1 and will preferably be about 0.1 ma. The circuit is generally designed so that an analog DC voltage of 0-8 corresponds to a speed range of 0-80 M.P.H.
Current I 1 provides a (minimum) set point speed voltage V 1 proportional to the sum of resistances of the minimum speed resistor R5 and the speed set resistor R1. Resistor R6 provides a dead-band associated with the set speed circuit and is in series with R5 and R1. To provide a dead-band of about + or - 1/2 M.P.H. (1 M.P.H. total) R6 will typically be 1000 ohms. Thus V 2 , the upper speed limit of the dead band, will be 0.1 volts above V 1 .
Preferably, a means is provided to limit the rate of vehicle acceleration when the set point potentiometer R1 is abruptly changed. Capacitor C1 provides this function by limiting the rate at which V 1 and V 2 can increase.
SPEED SIGNAL GENERATOR MEANS
Any suitable circuit or device can be used to provide an analog signal proportional to vehicle speed. As shown in FIG. 2 such a system is provided using the frequency of closing of switch S1 as the speed signal. S1 can, for instance, be a reed relay switch operated by a magnet rotating on or in synchronization with the speedometer cable.
Opening S 1 imposes +8V on the base of transistor T2 through resistor R7 and coupling capacitor C2. This biases T2 into conduction and brings the collector voltage V 3 thereof to virtual ground thereby discharging capacitor C3. T2 then turns off as a result of the discharge of C2 through grounding resistor R8. When T2 turns off V 3 , on the collector thereof, proceeds upward toward +8V at a rate determined by the RC constant of resistor R9 and capacitor C3 connected thereto. The typical wave form of V 3 is illustrated; the period thereof is, of course the period between successive openings of S1 while the shape thereof is dictated by R9C3. Capacitor C4 is provided in parallel with S1 to eliminate the potential effects of switch contact bounce. Diode D2 is provided to protect T2 from reverse voltage transients.
V 3 is applied to the negative (inverting) input of a comparator. The positive input of the comparator is held at +4V by the voltage divider comprising equal resistances R10 and R11 connected to the +8V supply. A capacitor C5 grounds electrical noise which would otherwise be present at the positive comparator input. The comparator is of the open collector output and provides a grounded output when the larger input is on the negative connection and a floating output when the larger input is on the positive input. Resistor R12 is connected to the +8V source and therefore provides an approximate +8V signal on the output of the comparator when the positive input is larger. The result of the sawtooth waveform V 3 on the negative input of the comparator is a square wave V 4 which varies between +8V and 0 and has an on time percentage proportional to R9C3 and the frequency of closure of switch S1; i.e., proportional to vehicle speed.
A small positive feedback is provided via resistor R13 to assure sharp reliable switching of the output of the comparator. A RC network comprising resistor R14 and capacitor C6 converts square wave V 4 to its DC average V 5 which, as mentioned previously, will vary from 0-8 VDC over a speed range of from 0-80 M.P.H.
COMPARATOR AND CONTROL MEANS
V 5 is applied through a high impedence input resistor R15 to the negative inputs of a pair of analog to digital comparators in the comparator and control circuit. Such comparators have a digital (on or off, open or closed) output which switches as the magnitude of the two analog inputs switches from one being greater to the other being greater. These comparators compare the actual vehicle speed (V 5 ) with the set point speed (V 1 and V 2 ). The dump valve is a normally (i.e., when de-energized) open valve and therefore provides a fail-safe system de-activation. It is normally energized and therefore closed when the vehicle speed is at or under the set speed by the following circuit. At or below the set point speed the negative input to the comparator associated with the dump valve is less than the positive input thereto from the set point circuit. Consequently the comparator output is open and current is allowed to flow via resistor R16 and diode D3 to the base of transistor T3 which, with transistor T4, provides a Darlington pair for high current gain. When the Darlington pair is conducting the dump valve is energized (closed). When the actual vehicle speed exceeds the (upper) set point speed the comparator output goes to ground thereby diverting the base current and turning the Darlington pair T3 and T4 off and opening the dump valve. The diodes D3 and D4 provide protection for the transistors T3 and T4 against base-emitter breakdown and from overvoltage spikes resulting from the field collapse of the dump valve.
A second comparator compares the actual speed with the (lower) set point speed and, when the former is lower than the latter, energizes (opens) the charge valve thereby placing the bellows in communication with the manifold vacuum and increasing the throttle setting. Specifically, this circuit comprises resistor R17, diodes D5 and D6 and transistors T5 and T6 arranged identically to those associated with the dump valve.
DEAD BAND CONSIDERATIONS
In the preferred embodiment of FIG. 2 as hereinbefore described it will be appreciated that the charge and dump valves are operated only when the actual vehicle speed is outside the deadband range established by R6 associated with the set point circuit. This is a particularly preferred embodiment inasmuch as the dead-band is constant irrespective of speed setting due to the constant current (I 1 ) circuit associated with R6. This provides optimum control over the entire speed range and in practice provides very satisfactory control with a minimum of atmospheric bleed to the engine manifold.
Although less preferred, other means can be used to provide the dead band for the control. One alternate system is shown in FIG. 3 which is a partial diagramatic schematic corresponding generally to a portion of FIG. 2. In the variation of FIG. 3 a resistor R' is associated with the actual speed signal and is provided between the two actual speed inputs to the comparators and therefore provides a dead band operation. As will be appreciated, the variation, as illustrated, does not provide a constant width dead band, not varying in width with vehicle speed, and therefore is less preferred.
POSITION FEEDBACK
Returning now to FIG. 2 a means is preferably provided to anticipate the effect of changes in throttle position and minimize or avoid overshoot of the controls. The preferred means is a throttle position feedback circuit. A potentiometer R18 is mounted, as illustrated in FIG. 1, to be moved by the bellows movement and to provide a linear resistance variation with bellows, and therefor throttle, position. Because of the non-linear characteristics of the vehicle speed versus throttle position curve a biasing resistor R19 is provided in series with potentiometer R18 to provide feedback voltage V 6 which is approximately linear with the steady-state vehicle speed associated with the actual vehicle speed.
As the throttle position increases in response to energization of the charge valve the wiper moves toward the positive end of the potentiometer. Capacitor C7 shunts the noise from R18 and its associated wiring to the ground. The increase in voltage on the wiper of R18 is seen by the comparators as an increase in actual vehicle speed because of the connection of R20 to the actual vehicle speed (negative) inputs thereof. Additionally, a transient increase in apparent (to the comparators) vehicle speed is provided through the lead network comprising resistor R21 and capacitor C8. As will be appreciated, the relative weight given to the actual speed signal (V 5 ) and the apparent speed signals (V 6 ) from the throttle position feedback circuit is a function of the relative sizes of R15, R18, R19, R20, R21 and C8 and can be adjusted to suit the dynamics of any particular vehicle system.
MASTER CONTROL MEANS
A master control means is provided to turn the system on and off upon the happening of any of several events. As a minimum, the master control must provide for the selective engagement of the system and for the automatic disengagement of the system upon actuation of the brakes.
Resistor R22, as will hereinafter be more fully described, is at virtual ground on its left hand side when the system is operational. In this condition, transistor T7 is switched on through the base voltage supplied by the voltage divider comprising R22 and resistor R23.
The system is energized as follows. The on-off switch S2 provides ground from the vehicle chassis ground G to the control system common ground. A momentary "engage" signal provides a ground to the switch side of resistor R24. While R24 is grounded a current exists through diode D7, T7 and the voltage divider comprising R24 and resistor R25 thereby biasing transistor T8 into conduction. Capacitor C9 provides a shunt across the base to emitter junction of T8 and prevents noise from accidentally biasing T8 into conduction.
When T8 conducts, it provides a current path through the coil of the lock in relay S3 and blocking diode D8 and through the low resistance path provided by the brake lights to ground. Current through this path locks relay S3 in through its own contacts and by passes T8 which stops conducting when the momentary engage contact is released. Diode D9 provides a path for shorting out the reverse current from the coil of S3 upon the deenergization thereof.
Transistor T9 is the system on-off transistor and is biased into conduction by current through T7, relay contact S3 and the voltage divider comprising resistors R26 and R27. As will be noted, conduction through T9 is required to provide a ground path for the dump and charge valves through their associated Darlington pairs of control transistors. T9 also provides the ground path to the "set" pilot light and its load resistor R28 to indicate to the operator that the control system is operating.
When T7 is conducting, but the system is not engaged, the "on" light is energized through resistor R29. When the system is energized the "on" light is shorted by diode D10 to the virtual ground provided by T9.
When the brake switch S4 is closed the brake lights function in the conventional manner. In addition, +12V is imposed through diode D11 on the base of T7 biasing it out of conduction and thereby dropping out relay S3, disabling the system regardless of the position of the "momentary" switch. In this connection, it should be noted that the function of D7 is to provide a voltage drop from +12V to the emitter of T7 equal to the voltage drop from +12V to the base of T7 by D11 thereby assuring that T7 will turn off. Closure of the brake switch S4 also imposes +12V on the ground side of the relay coil of S3 thereby insuring drop-out of that relay.
One very desirable safety circuit is one which prevents engagement of the system when the set point is substantially above the actual vehicle speed and to disable the system should the actual speed drop substantially below the set point. Such a system prevents the control from being engaged inadvertently when the vehicle is traveling at a low speed and provides a backup to the brake switch to disengage the system when braking. Additionally, this circuit drops out the controls should the set point be inadvertently adjusted upwardly abruptly by a substantial amount which could otherwise result in an undesired and potentially dangerous vehicle response.
The under speed disabling feature is provided by a comparator which sees, at its positive input, a fraction of the present set speed voltage V 1 as determined by the voltage divider comprising resistors R30 and R31. Normally these resistors will be in a ratio of about 1:4 so that the control action takes place at about 80% of the set speed. In addition R30 and R31 should be large compared to R1 and R5 so as not to load, to any significant extent, the speed set circuit. A capacitor C10 is provided to the set speed input of the under speed cutout to prevent transient noise from disabling the control. The negative input of the under speed disable comparator is connected to the actual vehicle speed signal V 5 through a resistor R32 which is preferably matched with R30.
A resistor R33 is preferably provided in the underspeed lockout circuit to provide reliable lock-in of the circuit at the limit of its range. If the actual vehicle speed is extremely close to the lower limit of the under speed disabling circuit it is possible to activate the system, receive confirmation thereof via the "set" light and have the under speed circuit system deactivate before the control increases the actual vehicle speed. To avoid this possible minor annoyance, R33 provides a limited drain on (and therefore lowering of) the set speed signal when the control is energized. Thus if V 1 is 5.0 volts before energizing the system it will drop to about 4.9 volts after energization thereby, in effect, locking in the control.
COMPONENTS
A voltage regulator provides the regulated +8 volt supply used in the set point signal generating circuit and the vehicle speed signal generating means. A Motorola MC7808 voltage regulator performs satisfactorily in this capacity. Capacitors C11 and C12 provide transient filtering on the input and output of the power supply.
The four comparators are all contained in a single Motorola MC3302 logic chip. While not shown, the logic chip also includes a ground connection and a +12V connection.
With the circuit shown, the following components provide a highly satisfactory control system:
Resistors OHMS R1 50 K R2 130 R3 1 K R4 20 K R5 62 K R6 1 K R7 1 K R8 10 K R9 100 K R10 10 K R11 10 K R12 2.7 K R13 220 K R14 47 K R15 100 K R16 4.7 K R17 4.7 K R18 10 K R19 10 K R20 560 K R21 820 K R22 2.7 K R23 10 K R24 4.7 K R25 10 K R26 470 R27 10 K R28 390 R29 390 R30 1 Meg. R31 3.6 Meg. R32 1 Meg. R33 4.7 Meg.
All resistors are 1/2 Watt
Capacitors microfarads C1 1 at 35V C2 0.12 C3 0.1 C4 0.1 C5 0.1 C6 22 at 25V C7 0.1 C8 5 at 25V C9 0.1 C10 0.1 C11 10 at 25V C12 100 at 25V
All Capacitors are 100V unless specified otherwise.
______________________________________Diodes Type D1 IN3064 D2 IN3064 D3 IN3064 D4 IN4001 D5 IN3064 D6 IN4001 D7 IN3064 D8 IN4001 D9 IN4001 D10 IN3064 D11 IN3064Transistors Type T1 2N3703 T2 MPS3704 T3 MPS3704 T4 2N3725 T5 MPS3704 T6 2N3725 T7 2N3703 T8 2N3703 T9 2N3725______________________________________
Valves -- 12 Volt, 150 ma
Relay S3 -- 12V, 20 ma
Indicator Lights -- Light Emitting Diodes
Texas Instrument FV-100
Many variations will occur to those skilled in the art, with reference to the foregoing disclosure. The embodiments described are intended to be illustrative and not limiting. | Disclosed is an electronic vehicle speed control with a fluid actuating means. Typically the actuating force is derived from the vehicle engine manifold vacuum applied selectively to a bellows operatively connected to the throttle mechanism. A dead-band type control is provided. When the actual vehicle speed is below the dead band range a valve is operated to allow the control fluid to increase the throttle setting. When the vehicle speed is above the dead band range a valve is operated to allow the control fluid to decrease the vehicle setting. In the preferred and specifically described circuit a circuit is provided to translate a contact closure rate into a D. C. voltage proportional to vehicle speed. A constant current source drives a series circuit including a speed set potentiometer and a dead-band setting resistor. The set speeds at either end of the dead band are compared to the actual speed and vacuum is "admitted" to or "dumped" from the bellows to return the actual speed within the dead band. Such a system provides very satisfactory control while affecting engine operation much less than a conventional vacuum powered vehicle speed control. Several novel safety and operational sub-circuits are also provided. | 1 |
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